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SECTION 15060 - PIPES & PIPES FITTINGS

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1.01 RELATED WORK

A. Division 15 - Mechanical

1.02 SYSTEM DESCRIPTION

A. This section covers the general piping and fittings supply and installation required for the works.

1.03 REFERENCES

A. Reference Standards

The latest edition of the following standards:

1. American Society for Testing and Materials (ASTM):

a. ASTM A53B Welded and Seamless Steel Pipe for Ordinary Use, Specification for Black and Hot
Dipped Zinc Coated.

b. ASTM B88 Specification for Seamless Copper Water Tube.

2. American National Standards Institute (ANSI): Standards as specified herein.

3. Manufacturer's Standardization Society (MSS): Standards as specified herein.

4. American Welding Society (AWS): Standards as specified herein.

5. American Petroleum Institute (API): Standards as specified herein.

1.04 SUBMITTALS

A. Product Data:

Descriptive literature for each of the actual proposed material to be used including:
1. Operating Pressure Ranges
2. Pressure Losses.
3. Fluid Flows.
4. Test Reports.
5. Certificates of approval.

Grooved joint couplings and fittings shall be shown on drawings and product submittals, and shall be
specifically identified with the applicable style or series designation.

B. Shop Drawings

Shop drawings for each of the actual proposed systems shall include the following:
1. Working or manufacturing drawings.
2. Calculations
3. Installation details
4. Connections to other services
5. Accessories available indicating those included
6. System diagrams.

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1.05 QUALITY ASSURANCE

A. Qualify welding processes and operators for structural steel according to AWS D1.1 "Structural Welding
Code--Steel".

B. Qualify welding processes and operators for piping according to ASME "Boiler and Pressure Vessel Code",
Section IX, "Welding and Brazing Qualifications".

1. Comply with provisions of ASME B31 Series "Code for Pressure Piping".
2. Certify that each welder has passed AWS qualification tests for the welding processes involved and that
certification is current.
3. Submit welder certificated signed by the Contractor certifying that welders comply with the requirements
specified above.

C. All grooved joint couplings, fittings, valves, and specialties shall be the products of a single manufacturer.
Grooving tools shall be of the same manufacturer as the grooved components.

D. All castings used for coupling housings, fittings, valve bodies, etc., shall be date stamped for quality
assurance and traceability.

1.06 WORK INCLUDED ELSEWHERE

A. Section 15405: Soil, Waste, and Roof Drainage Piping Systems.

B. Sections related to External Site Utilities.

PART 2 - PRODUCTS

2.01 PIPES

A. Service Schedule

Service Pipe Material

1. Chilled Water ERW black steel pipes schedule 40 to ASTM A53 B up

to 12 inches/300mm and standard wall thickness for
sizes 12 inch/300mm and above.

2. Underground Cold Water. High Density Poly-Ethylene (HDPE)

3. Domestic Water (Hot & Cold) at PP-RCT to EN ISO 15874 / High Density Poly-
floor levels & Risers Ethylene (HDPE) for risers

4. Fire Protection Wet Standpipe Galvanized ERW steel to ASTM A795 or ASTM A53
System. schedule 40, grade B

5. Irrigation Water Pipes PP-RCT to EN ISO 15874

6. Refrigerant Pipes Copper Type L to ASTM B88

7. Fire Water Pipes ( Indoor) Seamless galvanized steel to ASTM A795 or ASTM
A53 grade B schedule 40.

8. Water Tank over flow and drain Pressure UPVC - 10 bar to BS 3505
pipes.

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9 FM200 Fire Protection Black malleable Steel Seamless Class 300, Sch.80.

10. Pool Pipes/Water Features UPVC Class E. (1) – 16 bar to BS 3505

11. Expansion Pipes Seamless Black Mild Steel, to ASTM A53 sch.40
12. Pipe Galvanizing ASTM A123
13. Domestic water at Roof Thermally Insulated Copper Pipe

B. Sizes

1. Unless otherwise specified pipework of 65 mm nominal bore and over shall be welded, or grooved
connections (in applicable systems), while 50 mm nominal bore and below the pipework shall be
screwed.

2.02 PIPING MATERIALS

A. Copper Piping

1. Pipework shall be Type “ L “ hard temper copper tubing conforming to ASTM B 88, or table “Y” to BS
2871 with PVC coating or tape.
2. Copper fittings shall be streamlined wrought copper solder type or grooved end of pattern to suit
requirements (ANSI B 16.22).
3. Flanges for copper pipes shall be cast bronze with raised ground face and bolt hole spot faced. Flanges
shall be rated for 1.5 MPa water working pressure.
4. Gaskets shall be of a material suitable for the fluid, temperature, and pressure for which they will be
used.
5. Lead-and antimony based solders shall not be used for potable water system. Brazing and silver
solders should be employed. Use 15 % silver rods for brazing.
6. Flange Adapter: Flat face, ductile iron housings coated with copper colored alkyd enamel, with
elastomer pressure responsive gasket, for direct connection to ANSI Class 125 flanged components,
rated for 2.0 MPa water working pressure.

a. Manufactured to copper-tube dimensions. (Flaring of tube ends to accommodate IPS sized flanges
is not permitted.)

B. Galvanized Steel Piping

1. Galvanized steel pipe fittings for 50 mm and smaller.

a. ANSI B16.3, 1MPa, galvanized malleable iron, threaded.

b. Threads, ANSI Bz.1.

2. Galvanized steel pipe fittings for 65 mm and larger shall be flanged or grooved type coupling.

a. ANSI B16.9, standard weight galvanized.

b. Pipes shall be joined together using grooved fittings (UL and FM approval)

3. Flanges for galvanized steel pipes: ANSI B16.5, class 150.

4. Gaskets shall be of material suitable for the fluid temperature and pressure for which they are used.

5. All fittings shall comply with Standard of pipes.

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C. Black Steel Piping

All fire fighting pipes shall be galvanized seamless steel pipe schedule 40 as conform to NFPA standard and
ASTM A795 and galvanized of black steel pipe to ASTM A123

1. Black steel pipes shall be ERW steel conforming with schedule 40 to ASTM A53 B class or equivalent
international standard for steel pipes

a. Pipe fittings (tees, elbows, crosses, reducers, unions, flanges, etc...) shall be of the same weight and
quality as the pipe. Each black steel pipe shall conform to the following requirements:
b. Pipes and fittings up to 2" shall be suitable for threaded connections.
c. Fittings up to 2" shall be black malleable iron, banded with threaded connections.
d. Pipes and fittings larger than 2" shall be suitable for grooved mechanical coupling connections.
e. Pipe wall thickness and weight shall conform to ANSI standard.

D. UPVC Pressure Piping

1. Pipework:

The pipework and fittings shall be U.P.V.C. in accordance with BS 3505 Class E EN 1452, suitable for
pressure pipes (16 bar).

Fittings shall be in accordance with EN 1452.

The pipework and fittings shall be installed strictly in accordance with the manufacturer’s
recommendations, copies, of technical instructions on the laying of U.P.V.C. pipework shall be obtained
from the manufacturer’s Technical Service Department before work proceeds.

When jointing pipework the spigot and socket ends shall be supported clear of the ground to prevent dirt
deposits on the joint, solvent or lubricant. Only solvent and lubricant made by the manufacturer of the
pipe shall be used.

When making flanged joints the correct flanges and seal rings shall be used with seal gasket set square
between mating flange and all bolts secured evenly.

Where solvent joints are used a mechanical joint incorporating a seal ring shall be incorporated where
necessary to allow for thermal movement.

Test pressure shall be applied to the system after a period of not less than 24 hours.

Where joints are to be made between dissimilar materials a proper purpose made flanged adapter shall
be used.

No attempt shall be made to alter or manufacture U.P.V.C. fittings on site.

All underground UPVC pipes shall be encased with reinforced concrete

150mm thick.

2. Mechanical Joints:

When making a mechanical joint a check shall be made to ensure that the depth of entry mark is
indicated on every spigot before insertion into the socket, so that the spigot enters the socket within
13/25 mm of the bottom of the socket.

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The spigot end of the pipe shall be chamfered to half the wall thickness and made with suitable hand
tools provided by the manufacturer

When making a mechanical joint care shall be taken to ensure that the seal ring is not misplaced.
Due allowance shall be made for the control of thermal movement.

3. Solvent Joints:

When making a solvent joint the spigot and sockets shall be wiped clean and thoroughly degreased with
cleaner to remove oil, grease, etc, after which the spigot and socket shall have solvent adhesive
applied.

The sockets and spigots shall be assembled as quickly as possible after applying the adhesive and
within forty seconds after which it shall be held together for up to five minutes.

Special care shall be taken to prevent dirt and rubbish entering the open ends of pipes during erection.
Wrought iron screwed caps or plugs, or plastic covers only shall be used. Wood, rag or paper plugs
shall not be used. Failure to comply with this instruction shall mean that the Engineer shall have the
right to order the pipework to be dismantled for as far as considered necessary and the pipework to be
cleaned internally. Such work shall be carried out by the Contractor and all cost shall be borne by the
Contractor.

The Contractor is reminded that the valve fitted to the open end of a disconnected pipes is not
considered satisfactory to prevent the entry of rubbish. The open end shall be capped, plugged or
crimped.

D. PP-RCT Piping

1. PP-RCT pipes
All PP-RCT pipes shall be manufactured from approved Raw materials in accordance with EN 15874.
The material is a polypropylene random with enhanced crystalline structure and improved temperature
resistance (PP-RCT).

Produced pipes must be rated for Class 2 Wall thicknesses requirement of the project. Mechanical
Characteristics, Mean outside diameter and out of roundness together with their tolerances must comply
with EN15874-2.

Exposed pipe installations intended for transporting hot water must be rated Class 2 with aluminum foils
to better control the linear expansion process of the system, especially in riser’s applications.
Exposed pipe at roof level shall be provided with UV protection and mechanical protection to the
satisfaction of the Engineer.

Marking of Pipe - All pipes shall bear permanent identification markings that will remain legible during
the service life of the product. Marking on pipe shall include the following and shall be applied at
intervals of not more than 1.5 meters:

2. PP-RCT fittings
All PP-RCT fittings supplied under this scope of work must be pressure rated (Class 5) and
manufactured from the same material used to manufacture pipes and shall pass all tests required under
EN 15874-3.

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Fitting Inserts - All inserts used in the manufacturing of threaded fittings must be made of Nickel Plated
Brass CW617N EURO All threads must be made according to DIN 2999. All male threads must be
serrated to ease the application of sealing tape. Male threaded fittings must have PP-RCT coverage
extending to the tip of the insert (on the inner surface for fittings up to 63 mm outer diameter only).

Marking of Fittings- All fittings shall have permanent identification markings indicating the following:
1- Trademark, size and pressure rating of fitting (Class 5 acc. To EN ISO 15874).
2- Standard PP-r designation (i.e. PP-RCT).
3- Month and Year stamp indicating period of manufacturing.
4- Manufacturer's Quality Control.

3. Joining Polypropylene Pipes and Fittings

Socket Fusion Joining: This is the process used to join PP-RCT pipes to PP-RCT accessories. This
form of joining requires a heating tools and sockets. In this process a pipe end and a fitting are heated
simultaneously to fusion temperature (260 °C) using a heating bush and a heating spigot, and are then
pushed together. Thus, resulting in a homogeneous joint.

Electrofusion Joining: This technique is used strictly for repair and emergency work. In electrofusion,
the pipe and electrofusion fitting are heated by means of resistance wires and fused together. Power is
supplied through an automatic fusion control unit supplied by the manufacturer of fittings.

Heat Fusion Training Services: Upon request, the Manufacturer shall provide training in the
Manufacturer's recommended socket fusion and electrofusion procedures to the Contractor's installation
personnel, and to inspectors representing the Owner.

4. System Inspection and Testing

Upon completion of a section of or the entire water supply system, the system, or portion completed,
shall be inspected and proved tight under water pressure. The inspection must take place before
embedding or concealing the system under concrete or in walls.

For PP-RCT pipes, the inspection process is broken down in two sections: visual and operational.

Visual inspection:

A visual inspection should cover, but not limited to the following basic steps:

1- No pipe shall be secured to another pipe or used as a support for other pipes.
2- Pipes shall be laid as to prevent the formation of air locks or pockets. Where pipes are laid above
one another, cold water pipes shall be installed under hot water pipes to prevent condensation.
3- The supply pipes for each floor and those in individual flats shall be capable of being shut separately.
4- All inlets and outlets of completed pipe work shall be tightly closed with stoppers or caps to prepare
for operational phase of the system inspection.

Operational inspection: The visually inspected pipe work shall be filled with fresh water and completely
vented. The presence of air pockets in the system will lead to premature explosive failure of the system
with dangerous consequences to human life near the failure point.

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The operational phase of the inspection shall be carried out in two stages:

1- First stage: a test pressure equal to the permissible working pressure plus 10 bars shall be produced
twice within 30 minutes at 10-minute interval. Then it shall be checked whether, over an additional
period of 30 minutes, the pressure has dropped by more than 2.0 bars and leakage has occurred
(ambient and testing medium temperatures must be taken in consideration when performing this test,
consult with manufacturer for correction factors).

2- Second stage: It shall follow the first stage without interval and shall last 24 hours at a pressure of 15
bars. The system should hold a stable pressure with no variation. An overall drop of 2.0 bars is
acceptable if a stable pressure is achieved. Any other behavior indicates a leak.

Approved Manufacturer:

The pipe and fitting manufacturer shall have an established quality control program responsible for
inspecting incoming and outgoing materials. The manufacturer shall have a document control procedure,
which allows for traceability of manufactured products. It is mandatory for the manufacturer to be operating
and producing under ISO9001:2008 quality requirements.

2.03 PIPE FITTINGS AND SPECIALTIES

A. General

1. Refer to individual piping system sections for required pipe fittings and specialties not covered herein.

2. Fittings whether black, galvanized, copper or brass shall be compatible with the pipework system they
are connected to.

3. Grooved end fittings shall be generally of the ductile iron type; wrought steel full flow fittings may also be
used. Where ductile iron or wrought pattern is not available, factory-fabricated and tested fittings may be
used.

4. Iron fittings shall be generally of the malleable iron type: while steam and condensate services shall use
wrought iron fittings.

B. Elbows, Tees, Reducers

1. These fittings shall comply with ASTM and ANSI B16 as described in relevant sections of specifications.
The wall thickness shall at least be as specified for the straight pipes.

2. All fittings shall be factory made.

3. Unless otherwise stated, elbows shall be long radius bends with a radius of 1.5 times the nominal size,
and shall be smooth and not made of welded segments.

4. Tees up to and including an outside diameter of 323.9mm shall be of the pressed type.

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5. Unless otherwise specified, reducers shall be made with a length L = 3 (D-d), where L is the
construction length, D the outer diameter of the large end and d that of the small end. Unless otherwise
stated, the wall thickness of a reducer shall be the same as that of the adjacent large straight pipe.

6. Grooved end fittings shall be of the same manufacturer as the adjoining couplings.

C. Grooved Joint Couplings

1. Couplings shall consist of two ductile iron housings segments conforming with ASTM A536 Grade 65-
45-12, pressure responsive elastomer gasket conforming with ASTM D2000, and zinc electroplated
steel bolts and nuts conforming with ASTM A449 and A183.

a. 300mm and Smaller:

1) Rigid Type: Housings shall be cast with offsetting angle-pattern bolt pads to provide rigidity and
system support and hanging in accordance with ANSI B31.1 and B31.9.
a) 50mm through 150mm: ‘Installation-Ready’ for direct stab installation without field
disassembly.
b) 300mm and Smaller:
2) Flexible Type: For use in locations where vibration attenuation and stress relief are required.
Three flexible couplings may be used in lieu of a flexible connector. The couplings shall be
placed in close proximity to the source of the vibration.
3) Flange Adapter: Flat face, ductile iron housings with elastomer pressure responsive gasket, for
direct connection to ANSI Class 125 or 150 flanged components.

b. 350mm through 600mm: AGS series with lead-in chamfer on housing key and wide width gasket.
1) Rigid Type: Housing key shall fill the wedge shaped AGS groove and provide rigidity and
system support and hanging in accordance with ANSI B31.1 and B31.9.
2) Flexible Type: Housing key shall fit into the wedge shaped AGS groove and allow for linear
and angular pipe movement.
3) Flange Adapter: Flat face, ductile iron housings with elastomer pressure responsive gasket, for
direct connection to ANSI Class 125 flanged components.

D. Flanged Joints

1. Flanges shall, unless otherwise stated be welding neck over 100mm pipe or slip on weld for 100mm
pipe and under, with raised faces complying with ANSI B16-5. Screwed flanges can be used, but
welded flanges shall be preferable.

2. The material of the flange shall be compatible to the pipe and service the flange is connected to.

3. Galvanized flanges are to be screwed wherever possible. If this is not possible, black steel flanges are
to be welded to the pipework in the normal way and before final fitting, the whole prefabricated section
shall be proprietary hot dipped in a galvanized bath depositing the amount of zinc specified for the
galvanized tube.

4. A corrugated brass rings for flanged joints shall match the pair of flanges they are gasketting and shall
be used between the flange faces to form the seal.

E. Blank Flanges and Gaskets

1. Blank flanges shall comply with ASTM & ANSI B16-5 and shall be of the same material as the
connecting pipework.

2. All flanges shall be gasketed whatever the size or system.

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F. Bolts and Nuts

1. Bolts, nuts and washers for flange connections shall be of hot dip galvanized steel.

2. Bolts and screws shall comply with ANSI B 18.2.1 specification ASTM A449.

3. Nuts shall comply with ANSI B 18.2.2.

4. The length of the thread protruding from the tightened nut in bolt couplings shall be equivalent to at least
half and at most once the bolt diameter.

5. Washers shall be placed under both nuts and bolt heads.

G. Unions

1. Unions in steel pipe other than steam piping shall be malleable iron and have female pattern, brass to
iron seat, and ground joint, for 65mm and smaller, and flanged connections for larger than 65mm.
Unions shall be rated for minimum of 1.5 MPa water working pressure. Threaded unions for steam &
condensate pipes shall be used for pipes up to 32 mm only.

2. Unions in copper piping shall be cast bronze, female pattern, brass to brass seat and ground joint
threaded end connections for 50mm and smaller, and flanged connections for larger than 50mm.
Unions shall be rated for minimum of 1.0 MPa water working pressure.

3. Unions are not required in installations using grooved mechanical joint couplings. (The couplings shall
serve as unions and disconnect points.)

2.04 HANGERS AND SUPPORTS

A. Mechanical Installation System

1. All installation material used for supporting and fixing mechanical pipe systems should be of a modern
flexible type that gives a tested and reliable supporting solution without the need for welding, drilling or
subsequent galvanizing for corrosion protection.

2. The system should provide for easy access and disassembly for future maintenance, and shall be
product of well-known manufacturer.

3. The Contractor should provide shop drawings and load calculations to verify the suitability of the system
for critical load applications as per the engineer’s requirement.

4. The system should consist of the following components:

a- C-channels should be used as the main item for supporting pipe and duct and runs and structures.
C-channel should be made in accordance with British Standards of width 41 mm, and height of
channel shall be selected according to load calculation, made of cold rolled steel strip of thickness
2.5 mm steel grade ST32-2 as per DIN 10025. The steel is Sendzimir galvanized to a thickness of
20 microns. The channel in ward side should include fine serrations that insure strong friction hold
of the assemble nuts and accessories. The channel inward side should be slotted for greater
flexibility and should include longitudinal swaging to increase rigidity and stiffness. Double channels
connected with tubular rivets shall be used where greater strength and stiffness is required.

Supporting distance and calculation of pipe loads for pipe nuts should be verified by channel design
in accordance with manufacturer recommendations.

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b- C-channel accessories as recommended by the channel manufacturer should be used for

assembly of various channel structures as appropriate for the application. These accessories
include fixing nuts with serration, angles, brackets and pipe ring saddles.

c- Pipe Ring Clamps: Galvanized, pre-engineered pipe ring clamps should be used for fixing all pipes
to channel system or directly to the concrete structure. The contractor should verify that the pipe
supported weight does not exceed the recommended maximum load of the clamp as provided by
the manufacturer. The clamps should consist of two half rings suitably connected with welded on
connection nut for fixing the clamp to the threaded rod. Where copper pipes, hot water and chilled
water steel pipes are used, the rings should provided with a pre-fitted rubber inlay with suitable
temperature resistance characteristics for the application.

d- Pipe Hangers for Sprinkler Fire Fighting Systems: Galvanized band hangers and screw clamping
pipe rings should be used for supporting fire-fighting system. The system should be approved for
loading as per UL, FM regulations for Fire Fighting Systems.

e- Threaded Rods used should be manufactured as per DIN 976 of Steel Grade 4.6, galvanized and
used to support pipe duct ring clamps onto the C-channel or directly to concrete anchors depending
on the application. The threaded rods, nuts and flat washers used should have a clean thread and
flawless galvanized condition.

f- Concrete Anchors: Internally threaded Anchors used for fixing threaded rods and pipe clamps
should be made from galvanized steel, anchors should have a flared end for accurate setting flush
with the surface, and should have an intelligent expansion selection that adapts to suit strength of
the base material. Concrete stud anchors should be used for fixing C-channels to the concrete
suitable for through in-place fattening with reliable fixing. All Concrete anchors used should be
provided with full load characteristics and used in accordance with manufacturer recommendations
with regards to application and setting details. Concrete Anchors should also be fire rated to verify
that they can withstand the required loads within the fire integrity limits of the supporting building
structure.

g- For riser pipes, Anchor Fixed Point Clamps should be used to support the weight of the riser pipe.
Fixed Point Clamps should be used in location as recommended by supporting system
manufacturer and approved by the Engineer.

5. In grooved installations, use rigid couplings with offsetting angle-pattern bolt pads, which permit support
and hanging in accordance with ANSI B31.1, B31.3, and B31.9.

B. Pipe Hangers, Upper Attachments

1. Individual or continuous preset concrete inserts.

2. Beam clamps and anchor bolts may be used for steel construction.

3. Self-drilling expansion shells for 75 mm pipe and smaller may be used in existing concrete structures.
See special details for larger piping.

C. Hanger Rods

1. Galvanized solid steel, all thread rods, with lock-nuts.( 10mm dia. Per pipe)

2. For trapez supports submit calculation for threaded hager rod diameter with at least 8 times load factor.

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D. Pipe Hangers, Lower Attachments

1. Lower attachments for individual runs of pipe shall be as follows, unless indicated otherwise:

a. steel piping up to 125 mm: steel clevis;

b. steel piping 150 mm and larger, not subject to thermal expansion: steel clevis;
c. steel piping 150 mm and larger, subject to thermal expansion: pipe roller support;
d. copper tubing, all sizes: copper-plated steel clevis, except where hanger is installed around the
outside of insulation, not in contact with pipe, where steel clevis hangers may be used;
e. cast iron pipe, all sizes: steel clevis.

E. Vertical Pipe Supports

1. At intermediate floors use extension pipe clamps.

2. At top of risers, use hangers as specified above.

3. At base of risers, use stiff-leg pipe support immediately adjacent to elbow. For cast iron soil or storm
riser use solid concrete block.

F. Trapeze Hangers

1. Where numerous pipes are run in parallel to one another, they may be supported from a trapeze type
hanger arrangement. Rollers supports shall be used to support each run of piping on trapeze hangers to
permit independent movement of individual pipes.

2. Piping supports shall consist of channels, fittings, pipe brackets, pipe rollers, pipe clamps, post bases,
stud nuts, etc., as required to properly support and hang piping.

G. Stiff-legs or Stanchions

1. Stiff-legs or two-leg stanchion supports shall be provided in cases where support from overhead
structure is not possible. Pipe rollers shall be provided for pipe rigidly supported from floor.

H. Alignment Guides

1. Guides to be constructed with steel base and T-bar with teflon or graphite plates bonded to the steel
components to allow minimum static friction and self-lubrication for unlimited movement. Units shall be
factory painted. Guide base shall be welded to the pipe; like F & S "Unislide", Elcen, or equal.

I. Flexible Ball Joints

1. Units shall be carbon steel construction, screwed, flanged, or welded connection as required, suitable
for temperatures of 274 degrees C and pressure of 8.3 MPa;. Provide for 15 degrees angular flex and
360 degrees rotation.

J. Anti-Vibration Suspension Hangers

1. Combination type, shall have a double-deflection neoprene element in series with a steel coil spring;
deflection of 8 mm; steel coil spring shall be selected from a 25 mm static deflection series with a
minimum additional travel of 12 mm; spring diameter shall be large enough to permit 15 degree angular
misalignment of the rod connecting the hanger to the upper attachment without rubbing the hanger box.

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K. Spacing of Pipe Supports

1. Spacing Support Schedule:

The maximum spacing for pipe supports shall be as follows:

NOMINAL HORIZONTAL (m) VERTICAL (m)

BORE mm STEEL COPPER UPVC STEEL COPPER UPVC
10-12 - 1.0 - - 1.2 -
15 1.8 1.2 0.8 2.5 1.8 0.8
20-32 2.4 1.8 0.8 2.5 2.4 1.0
40-50 2.4 2.4 1.0 2.5 2.5 1.5
65-80 2.5 2.5 1.2 2.5 2.5 1.7
100 & above 2.5 2.5 1.2 2.5 2.5 1.7

Hangers and supports shall in no case be less than one (1) hanger per 2.5 m and at every change
indirection.

2. The spacing of pipe group supports shall be based on the smallest nominal bore pipe using the hanger,
in accordance with the spacing support schedule above. Alternatively intermediate supports can be
given to a particular pipe, if conditions permit.

2.05 PASSIVE FIRE PREVENTION SYSTEM

A. All openings through fire rated walls, ceilings and floors due to penetrations of mechanical installations as
well as those due to construction joints, should be sealed with fire rated products suitable for the specific
application as specified hereunder.

B. The product shall be capable of stopping the passage of fire, smoke, air and water through wall, floor and
ceiling penetrating, cladding and expansion joints. The product shall exhibit the minimum designed fire-
resistant properties.

C. The products shall be obtained from an approved, established and proven firm and quantities shall be
applied strictly in accordance with the written instructions of the manufacturer, international standards such
as UL, FM or BS, and to the approval of the Engineer.

D. The recommended treatments for various applications shall be as follows:

1. Metal pipe bare or insulated: the annular space around the pipe shall be packed with fire rated high
density backing material such as RockWool and the ends shall be filled and sealed with fire rated
intumescent mastic, or Elastic sealant according to UL, FM, or BS and manufacturer data to attain the
required rating. The size of the circular opening shall be maintained as the barest minimum as
recommended by the mastic manufacturer.

2. Non-metal pipe and conduit crossings less than 75 mm in diameter: The annular space around the
pipe shall be packed with fire rated foam or high density RockWool as backing material. The ends
should then be filled and sealed with intumescent, graphite based, fire rated mastic with expansion
pressure of minimum 6 bar, depth as per standard to attain the required fire rating. The circular
opening shall be maintained strictly as the barest minimum recommended by the mastic manufacturer.
For non metal pipes/conduits equal or more than 75mm in diameter, the pipe/conduit shall have fire
stop jacket installed flush on wall or floor or inside sleeve with fire rated mortor to fill the free volume of
the sleeve.

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2.06 FLASHING

A. Steel Flashing : 26 gauge ( 0.50 ) galvanized steel.

B. Lead Flashing : 24.5 kg/m2 (5lb/sq.ft.) sheet lead for waterproofing, 5kg/m2 ( 1 lb/sq.ft.) sheet lead to sound
proofing.

C. Safes: 24.5kg/m2 (5lb/sq.ft.) sheet lead or 0.20 mm (8mil) thick neoprene.

D. Caps: Steel, 22 gauge ( 0.80 mm) minimum, 16 gauge (1.50 mm) at fire resistance structures

2.07 SEALANTS

A. Sealant for Pipe Sleeves

1. All sealants materials shall be a single compounds, primerless, non-sagging type in neutral color.

2. Polysulfide: one part, gun grade.

3. Acrylic Latex: one part, gun grade, paintable, with a temperature range from -17 to +82 degrees C.

4. Butyl: one part, gun grade, suitable for both horizontal and vertical joints.

5. Fire rating compound similar to wall rating and as described under paragraph 2.05 of this section.

2.08 COMPENSATORS

A. General

1. All compensators shall be selected for the function it is to perform and the suitability for the fluid type;
pressure and temperature to be conveyed.

2. The compensator shall be the same size bore as the pipework it shall be connected to, and shall have
flanged connections for ease of maintenance.

B. Isolating Compensators

1. This type of compensator shall be to isolate a treated vibrating piece of equipment from the pipework
system. The compensator shall not allow for any expansion and contraction movement nor
misalignment of interconnecting flanges.

2. The single neoprene rubber convolution and rubber facing flange in a single moulding shall have a mild
steel backing flange.

3. The compensator shall be capable of a working pressure of 1.5 MPa and a temperature range of -15 to
90°C.

4. This type of compensator shall be suitable for vibration and noise control on LPHW, chilled water and
HWS systems.

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C. Axial Compensators

1. This type of compensator shall absorb movement under strict guiding in an axial direction only. No side
thrusts can be permitted.

2. The stainless steel convolutions of the number required to accommodate the determined movement
shall be protected internally and externally by a heavy mild steel sleeve for physical protection against
damage.

3. The compensator shall be capable of a working pressure of 2.5 MPa and a temperature range of -15 to
400°C.

4. Large expansion compensators capable of up to 200mm shall be considered to keep the number of
compensators to a minimum.

5. This type shall be suitable for LPHW, steam, condensate, chilled water, HWS in long straight runs such
as crawlways and service tunnels.

D. Angular Compensators

1. This type of compensator, similar to the axial, has a hinged restrain in one plane only. When used in a
controlled condition with more than one compensator together with natural pipe movement it shall allow
for large movement with minimum thrust upon the anchor points.

2. The stainless-steel convolutions shall be protected with an internal lining.

3. The compensator shall be capable of a working pressure of 1.5 MPa and a temperature range of -15 to
400°C.

4. This type of compensator shall be suitable for LPHW, steam, condensate, chilled water, and HWS
where the pipework can have natural 90° bends incorporated between anchor points.

E. Articulated Compensator

1. This type of compensator is a purpose made unit containing two axial compensator units contained
within a set of hinged tie bars which together with natural pipe curving movement permits a controlled
angular expansion movement with minimum internal pressure on the axial compensator and the least
external thurst upon the anchor point.

2. The stainless-steel convolutions shall be protected with an internal lining.

3. The compensator shall be capable of a working pressure of 1.5 MPa and a temperature range of -15 to
400°C.

4. This type of compensator shall be suitable for LPHW, steam, condensate, chilled water, and HWS
where the pipework can have natural 90° bends incorporated in a limited space with little thrust upon
pipe anchors, in cases such as equipment rooms adjacent to equipment connection.

2.09 THERMAL EXPANSION FIXED POINT SYSTEM

A. Where metal chilled pipes are subject to thermal expansion, particular attention should be given and pipe
runs should be studied and designed to compensate for the expansion forces and reduce the stress on the
pipes and supporting system.

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B. The contractor should provide sufficient shop drawings and load calculations to verify the suitability of the
system for critical thermal applications run as per the engineers’ requirement. Allowance for free thermal
expansion distance at pipe bends should be marked.

C. The following components should be used to control thermal expansion:

1. Slide Guides: Use side and Roll Connectors with integrated sliding components on all pipe runs subject
to high thermal movement. The guide should be used in accordance with manufacturer load limits and
movement limits. The slides should be resistant to operating temperatures of the supported pipes.

2. Anchor fixed Point Pipe Clamps: Where necessary and according to the thermal study, use fixed point
for a flexible and reliable fixing system against axial thermal expansion forces. The anchor points should
be used strictly in accordance with the manufacturer recommendations and loading characteristics and
in accordance with the calculated expansion forces provided by the thermal study.

3. Expansion compensators: For critical application and if expansion movement cannot be taken up by
free movement of the pipe bends, expansion compensators or bellows of the axial and/or angular type
should be used in conjunction with the fixed anchor points and in accordance with the thermal study.
Expansion compensators should be used in accordance with manufacturer recommendations.

4. Grooved End Expansion:

a. Packless, Gasketed, Slip, Expansion Joints: 350-psig maximum working pressure, steel pipe fitting
consiting of telescoping body and slip-pipe sections, PTFE modified polyphenylene sulfide coated
slide section, with grooved ends. Suitable for axial end movement to 3”.
b. Expansion joint consisting of a series of grooved end pipe nipples joined in tandem with flexible
couplings. Total joint movement dependent on the number of couplings and nipples used.
1. For water
systems, use adequate numbers of flexible couplings in header piping to accommodate thermal
growth and contraction, and for the elimination of expansion loops. (In accordance with Victaulic
instructions and as approved by the engineer.) Where expansion loops are required, use couplings
on the loops.

2.10 ACCESSORIES

A. Safety or Relief Valves

1. The relief valves shall be set to a maximum of 0.3 bar above the working pressure of the line in which
they are fitted or as indicated on drawings. Safety and relief valves shall be suitable for the operating
condition of the system.

2. They shall be of the totally enclosed spring-loaded type with padlock.

3. Safety valves and relief valves shall have a full-bore discharge connection. Where any law point occurs
in the discharge run, it shall be fitted with a 22 mm size copper waste pipe carried clear of the insulation
for drainage. The discharge and waste pipes shall be run to visible safe positions to be agreed.

4. Relief valves shall be ASME approved and labeled, size, capacity and setting as indicated.

B. Temperature and Pressure Test Pugs

1. Provide temperature and pressure test plugs.

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PART 3 - EXECUTION

3.01 PIPING INSTALLATIONS

A. General

1. Installation instructions contained in this Section pertain to most systems. For specific requirements for
installation of each system, refer to individual system specification sections.

B. Piping Installation Generally

1. Conceal all pipe installations in walls, pipe chases, utility spaces, above ceilings, etc. unless other wise
indicated. Under slab piping shall be kept to the absolute minimum.

2. Install all piping free of sags or bends and with ample space between piping to permit proper
installation.

3. Install piping at right angles or parallel to building walls. Diagonal or bent piping will not be permitted.

4. Install piping tight to slabs, beams, joints etc. where possible and such that any removable ceiling
panels may be removed for access above ceilings.

5. Protect all piping from entrance of dirt or other foreign materials during the construction period. At the
completion of the project, all dirt and foreign matter in piping shall be removed completely.

6. Piping passing through exterior building walls shall be caulked weathertight.

7. Provide drain lines from all relief valves and condensate pans and run drain line full size to the nearest
floor or equipment drain.

8. All water piping shall have draining points at all low points. For mains, risers and branch lines there shall
be at least a 20 mm drain valve with a threaded hose connection for other points a15 mm drain valve
and hose and hose connection shall be provided.

9. Water piping shall be securely anchored to insure proper direction of expansion and contraction.

10. Expansion loops or expansion joints shall be provided as indicated and required, and shall be cold
sprung.

a. For water systems, use adequate numbers of flexible couplings in header piping to accommodate
thermal growth and contraction, and for the elimination of expansion loops. (In accordance with
Victaulic instructions and as approved by the engineer.) Where expansion loops are required, use
couplings on the loops.

11. Verify existing grades, inverts, and topographic conditions prior to any trenching, excavation, or
installations.

12. Horizontal piping shall slope uniformly without sags or humps to provide for complete drainage of
systems and elimination of air.

13. High points in closed piping systems shall be vented by Automatic air vents. Drainage piping shall slope
as required by code or as indicated. Steam and condensate shall slop down in direction of flow 12 mm
per 500 mm unless otherwise indicated. Slope water piping up in the direction of flow 12 mm per 500
mm.

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14. Piping shall be cut accurately to measurements established at the site, worked into place without
springing or forcing, and shall clear all windows, doors and other openings. Cutting or other weakening
or building structure to facilitate piping installation is not permitted, install to permit free expansion and
contraction without damage.

15. Swing joints at runouts to equipment and risers. Provide expansion loops at all other points for flexible
piping systems.

16. Drain piping from pump glands, relief valves, condensate drain pan etc., to spell over open sight drains,
floor drains, or other acceptable discharge points terminating drain line with plain end (unthreaded )
pipe.

17. Provide necessary temporary connections, valves, oversize flushing connections, pumps, etc., as
required to properly clean and test systems.

18. Coordinate piping installations with ductwork, structure, lighting, electrical conduit and all other materials
and equipment.

19. Use flexible pipe connectors for all inlet and discharge final connections to pumps (except in line pumps
) and other vibration producing equipment.

a. Three couplings may be used in lieu of a flexible connector for vibration attenuation and stress
relief. The couplings shall be placed in close proximity to the source of the vibration.

20. Provide flanges or couplings on all valves, apparatus, and equipment having 50 mm and larger
connections.

21. Reduction in pipe sizes except in drainage pipe, shall be made using eccentric reducer installed with the
level side up on water piping and level side down on steam and condensate piping.

22. Provide unions adjacent to each valve at the final connection to each piece of equipment of plumbing
fixture having 50 mm and smaller connections and where otherwise indicated.

23. Wherever wells are installed in piping for thermometers, pressure gages, probes, etc., pipe size shall be
increased by one pipe diameter to accommodate same.

24. Provide air chambers at the top of all hot and cold domestic risers, at the end of each water header in
utility spaces, at the end of each branch line, and at the top of all branches to fixtures. Provide shock
absorbers at each solenoid valve or piece of equipment that has a quick closing type valve. Air
chambers shall be a minimum of two pipe sizes larger than the terminating pipe and shall be equipped
with an accessible drain valve and air recharging petcock or installed at least 600 mm above fixture to
permit recharging by draining air chamber.

25. Use fittings for all changes in direction and all branch connections and take - off from mains. Changes in
direction and branch connection in welded piping shall conform to Section 15051 Welding.

26. Connect dissimilar piping material using dielectric unions or insulating flanges.

C. Hangers and Supports

1. Approved hangers and stiff leg support shall be installed in quantity and size as required to carry the
weight of pipe, contents, and insulation and shall be arranged to prevent vibration transmission to the
building and allow for pipe movement. All supports and hangers shall be factory fabricated such as
HILTI, Erico, or approved equal. Site fabricated supports and hangers are not approved.

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2. Support on pipework requiring a vapor barrier shall be installed on the outside of the insulation.
Approved material shall be provided between the pipe and the support to give adequate support and
thermal isolation. The vapor barrier will cover the chock.

3. Hangers spacing shall be as per clause 2.03 J1 of this section.

4. Hangers shall be supplied with lock nuts in sufficient number and location to lock all rod adjustments
permanently at the adjusted height. Two lock nuts shall be used unless the nut tightens against a
threaded socket. Minimum rod diameters shall be as follows:

NOMINAL PIPE SIZE ROD DIAMETER

12 mm through 50 mm 9 mm
60 mm and 75 mm 12 mm
100 mm and 125 mm 15 mm
150 mm 19 mm
200 mm through 250 mm 22 mm
300 mm & above 25 mm

5. Location of hangers shall be coordinated with light fixtures as shown on reflected ceiling plans. Piping
shall not be supported from ductwork, duct supports, or other piping. Hanger rods shall not penetrate
ductwork

6. Provide all necessary supplementary steel for support and attachment of hangers, and pipe , and duct
supports in shafts and between building structural members.

7. Piping at pumps, tanks, etc., shall be supported independently so that pipe weight will not be supported
by equipment. Each piece of pipework system shall be supported so that no stress shall be imposed on
equipment connections or flexible joints to equipment.

8. Provide anchors, guides, and bracing as indicated to prevent lateral movement

9. Where an excessive number of fittings or accessories are installed between hangers, provide additional
hangers or adequate support.

10. Rods for trapeze hangers supporting several pipes shall be sized for the equivalent load.
11. Hangers’ rods shall be attached to structural members of the building.

12. Provide additional hangers or anchoring devices necessary for support of piping at corners, tops of
risers, etc.

13. Anchors shall consist of rigid members clamped or welded to the pipe to prevent pipe movement at that
point. Attach anchors to structural members of the building.

D. Joints

1. Any leaking joints shall be completely disassembled and remade with new materials.

2. Caulked joints in drainage piping shall be made using spun oakum to within 25 mm of hub and the
remaining space filled with poured pure pig lead and swigged.

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3. Ends of all copper tubing and the interior of the cup of the fitting shall be thoroughly cleaned and
polished prior to the application of the flux and solder. The flux shall not be used as a substitute for
proper joint preparation.

4. All pipe shall be carefully reamed. Threaded pipe shall have full-length clean-cut threads.

5. Grooved joints shall be installed in accordance with the manufacturer’s latest published installation
instructions. Grooved ends shall be clean and free from indentations, projections, and roll marks in the
area from pipe end to groove. Gaskets shall be of an elastomer grade suitable for the intended service,
and shall be molded and produced by the coupling manufacturer. The grooved coupling manufacturer’s
factory trained representative shall provide on-site training for contractor’s field personnel in the use of
grooving tools and installation of grooved joint products. The representative shall periodically visit the
jobsite and review contractor is following best recommended practices in grooved product installation.
(A distributor’s representative is not considered qualified to conduct the training or jobsite visit(s).)

6. All sockets and pipe end of PVC shall be cleaned and solvent cement applied for full circumferential
cover.

E. Pipework Expansion

1. The contractor shall supply and fix expansion devices, anchors and guides to adequately allow for the
expansion and contraction of the pipework. The minimum number considered necessary are shown on
the contract drawings.

2. Whenever possible, such as brunch take-offs, natural expansion shall be used within the configuration
of the pipework system.

3. Pipe work expansion shall be carefully controlled to prevent damage to the pipework system,
equipment, structure, etc.

4. Special consideration shall be given to steam, condensate, LTHW and hot water services.

5. Chilled water and cold water pipework generally where installed in the services building, main services
duct, equipment rooms and other areas where relatively high ambient temperatures may occur, and
where movement cannot be absorbed naturally, shall incorporate flanged joints of the type which allow
expansion, contraction and some measure of lateral movement. These joints shall be a mechanical pipe
coupling consisting of a center sleeve, and flanges wedge shaped rubber sealing rings and nuts and
bolts. The main components shall be constructed from high quality malleable or cast iron for sizes up to
80 mm diameter and steel above this size. All nuts and bolts shall be galvanized. Sealing rings shall be
suitable for the liquid type, temperature and pressure range. Sizes up to 345 mm diameter shall be
supplied preassembled. Larger sizes shall be supplied unfitted for ease of handling. Coupling shall allow
for a setting regularity of + 6 up to 600 mm + 5for 600 mm to 750 mm and 4 for 750 to 900 m. Each
coupling shall allow for a repeated maximum pipe movement of 9.5 mm and sufficient couplings shall be
installed on this basis.

6. All expansion devices shall be suitable insulated to prevent accident to personnel, but does not restrict
the movement of the pipework

7. All expansion devices and natural expansion pipework systems shall be installed with 50 % cold draw of
the total movement.

8. Anchor points shall be provided as shown on the drawings. The anchor shall be capable of resisting the
maximum stresses that be applied. The contractor shall ensure that the structure, that the anchor is
attached to, shall also be capable of withstanding the same stresses.

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9. The method of anchoring the pipework to a secured point shall be:

a. Mild Steel - Welding

b. Cast Iron - Two wrought iron stirrups acting as clamps,

bolted, with sufficient thread for tightening, to a
secured cast iron chair

c. Copper - A wide copper strap, undersized to give

sufficient grip, when bolted together around the
pipe shall be attached to the secured point.

10. Care shall be taken when installing and positioning guides to ensure that the amount of free play in the
pipeline is kept to an absolute minimum and that the resulting thrust of expansion is taken up in the
designed manner. Means for Lubrication shall be provided where necessary . Guides for pipework over
50 mm shall be of the type incorporating re-inforced PTFE in order to allow reduced frictional resistance
to movement. Guides and skid supports shall be provided in accordance with the manufacturers
recommendations and shall form part of the submission.

3.02 ACCESSIBILITY

A. Locate all equipment that must be serviced, operated , or maintained, in fully accessible positions. Minor
deviations from the drawings may be allowed for better accessibility at written approval.

B. Allow ample space for removal of parts that may require replacement or service in the future.

C. Extend all grease fittings to an accessible location.

3.03 MECHANICAL CUTTING AND PATCHING

A. Contractor shall be responsible for all cutting, fitting, or patching of his work which may be required to make
its several parts come together properly and fit it to receive, or be received, by work of other trades. Cutting
of structural members shall not be done without written approval.

B. Any cost caused by defective or ill-timed work shall be borne by the contractor, as determined by the
Engineer. Contractor shall not endanger any work, persons, or construction by cutting, digging or otherwise.

C. Place sleeves through all walls, floors, and ceilings during the initial construction where it is necessary for
piping to go through. When this is not done, do all cutting and patching required for the installation of the
work. Any damage caused to the building by this cutting and patching, shall be corrected at no additional
cost.

D. Patching of all openings for new installations and all openings resulting from the removal or relocation of any
installations shall be done by craftsmen skilled in the particular trade effected, with materials of like type
adjoining openings.

END OF SECTION 15060

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