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Quality Control for UPVC pipes and fittings

INTRODUCTION

Since the first days of formation and till today the basic purpose of "SMART HOME" is

producing according to requirements of the world standards with use of High Technologies,

in accordance with wishes of consumers.

Thanks to national technologies, we hope to produce in near future products which capture

not only domestic, but also the International market. Presenting to your attention new

quality products, we hope, that you’ll pay attention to difference of their quality from similar

products. In this booklet you will find all information that may be interesting to you, related

to release and exploitation of plastic pipes.

The definition “thermoplastic “of pipe means that the materials have plastic properties; they

can be repeatedly softened by heating and hardened by cooling through a temperature

range characteristic of the plastic. Besides that, in the softening state they can be shaped,

molded or extruded.

PVC AS VERSATILE MATERIAL

Polyvinylchloride (PVC) is the most widely used polymer in the whole range of plastic

Materials. The main reasons of the versatility of this thermoplastic material can be

summarized as:

1- Strength of the raw material.

2- Overall reasonably good Physical properties -Mechanical, optical and electrical.

3- Its range of useful properties may be extended by the use of additives.

4- In some respects PVC has outstandingly good properties, e.g. Fire resistance, abrasion

resistance.

5- Light weight, easy to handle.

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Quality

INTRODUCTION

We have been involved in the HDPE& U P V C industry & developed very strong relationship

with the valued Customers through conforming high quality with precision. As a top-class

maker of UPVC Pipes, We are ready for providing best quality products & services to our

customers.

Customer can be confident that "SMART HOME" has the full capacity & Capability to

manufacture pipes which not only comply with the relevant National, International and

British Standards, ES standards, ASTM standard but also meet its own strict criteria of

consistent high quality and performance.

To ensure high standards, "SMART HOME" follows a policy of using best quality raw

material formulations. This formulation is mixed in fully automatic hot & cold turbo mixer

with pneumatic & hydraulic control actuation and automatic feeding to the extruders. Thus,

gives an advantage to produce homogeneous, quality raw materials for the production of

High Standard Pipes without any hazards to human life. High Standard UPVC pipes are

manufactured under well skilled & trained operators, with supervision and full technical

support of engineers.

High Standard UPVC Pipes are vigorously inspected on line and tested. Quality Control and

Assurance is our Prime importance.

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QC/QA Program

General Description

Control Program is designed in EGIC to give producers the responsibility for controlling the

quality of product and to use the quality control information generated in the process of

receiving certification from specifying agencies. It requires producers to perform quality

control sampling, testing and record keeping on the product. It allows specifying agencies to

perform quality assurance sampling, testing and record keeping confirming the performance

of the producer’s quality plan as set forth herein. It is the intent of the program that

acceptance or rejection of product be based on the producer’s total quality program.

QA/QC Program Requirements

Basic Requirement

EGIC plant has a program with three basic elements

1. Quality control on (raw material, manufacturing process and finished product)

2. Approved Laboratories.

3. Quality Control Technicians.

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QUALITY CONTROL

Inspection & testing materials, semi products and final products according to the following

standards:

PVC Materials Manufacture Standards

• ASTM D2122 – Standard Test Method for Determining Dimensions of Thermoplastic Pipe

and Fittings

• ASTM D2412 - Standard Test Method for Determination of External Loading

• Characteristics of Plastic Pipe by Parallel-Plate Loading

• ASTM F1871 – Standard Specification for Folded/Formed Poly (Vinyl Chloride) Pipe Type

A for Existing Sewer and Conduit Rehabilitation

• ASTM D2444 – Impact Resistance

• ASTM D790 – Flexural Properties

• ASTM D638 – Tensile Properties

- ES 1717/2008 for PVC fitting & Extrusion.

PVC QUALITY CONTROL DEPARTEMENT

Quality control of row materials:

Testing the resin is the first step in the quality control program.

The test consists of:

Check of contamination.

Density

Tensile properties

K value

Particle size

Thermal properties

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QUALITY CONTROL OF PVC PIPES

Measurements in mm Pipes

Kg/m D

(mm)

S

(mm)

L

(m) DN .No

0.556 48 2.5 6 48

1

0.823 48 3.7 6 2

0.751 60 2.7 6 60

3

1.084 60 3.9 6 4

1.043 75 3 6

75

5

1.390 75 4 6 6

1.738 75 5 6 7

1.427 110 2.8 6

110

8

1.530 110 3 6 9

2.039 110 4 6 10

2.550 110 5 6 11

3.707 160 4 6 160

12

2.965 160 5 6 13

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Inspection of usable materials according to standards by applying the following tests:

VISUAL INSPECTION

LAB TESTS

1) Determination of free flow properties.

2) Determination of bulk density.

3) Determination of bulk density value.

4) Determination of moisture percentage.

5) Testing of powder granular size distribution.

6) Testing of heat stability.

7) Determination of stabilizer content.

8) Color metering.

PRODUCTION CONDITIONS

1) Screw speed.

2) MC. Speed.

3) Heat distribution.

4) Pressure.

5) Cooling.

INSPECTION OF FINAL PRODUCT

Visual inspection:

1) Pipes ends should be cut as square as possible to pipe axis.

2) Pipes should be free of any blisters and irregularities (including foreign matter) which

could affect their performance.

3) Pigmentation should be uniform throughout.

4) Pipes should be smooth both inside and outside

5) Printed data should be complete.

6) Dimensions(length, outside diameter, inside diameter thickness)

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LABORATORY TESTS

1) Methylene Chloride tests.

2) Dimensional stability and homogeneity test.

3) Microscopic investigation.

4) Determination of water absorption.

5) Determination of mechanical properties (tensile strength, yield strength, break

strength, elongation break force, impact force and hardness).

6) Heat revision.

STORING

Pipes are stored horizontally on wood or Iron racks on a regular way.

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QUALITY CONTROL OF PVC FITTINGS

Measurements in mm

β=87.5 degree

Elbow 87.5o

Kg S H L D .No

0.110 4 30 72 48 14

0.170 4 35 92 60 15

0.280 4 40 109 75 16

0.675 6 45 147 110 17

1.490 6 70 208 160 18

Measurements in mm

β=45 degree

Elbow 45o

Kg S H L D .No

0.075 4 30 50 48 19

0.115 4 35 61 60 20

0.175 4 40 70 75 21

0.385 5.5 45 93 110 22

0.910 6 70 140 160 23

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Measurements in mm

β=87.5 degree

Elbow 87.5 o with access door

Kg Door S H L D .No

0.230 75 4 35 91 60 24

0.335 75 4.5 40 109 75 25

0.795 110 6 45 145 110 26

1.600 110 6 70 209 160 27

Measurements in mm

β=87.5 degree

Elbow 87.5 o with female

thread

Kg L S H thread D .No

0.120 59 4 30 1.25 48 28

0.112 58 4 30 1.5 48 29

0.107 58 3 30 1.5 50 30

Measurements in mm Socket

Kg S H L D .No

0.060 4 31 65 48 31

0.090 4 40 80 60 32

0.150 4.5 45 94 75 33

0.315 5.5 52 109 110 34

0.655 6 70 145.5 160 35

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Measurements in mm Floor drain

Kg S L2 L1 C2 C1 D

out

Din .

No

0.535 4 170 193 110 125 75 48 36

0.500 4 170 180 110 125 60 48 37

0.560 4 180 193 110 125 75 60 38

0.535 4 180 193 110 125 60 60 39

Measurements in mm

Vertical extension

Kg S C L H D .No

0.385 4 200 93 17 125 40

0.265 4 150 99 17 110 41

Measurements in mm

Cleaning insert with access door

Kg Door S H L D .No

0.115 75 4 43 68 60 42

0.145 75 4.5 50 80 75 43

0.320 110 5 50 80 110 44

0.600 110 6 78 117 160 45

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Measurements in mm Siphon

Kg C S H L D .No

1.155 305 6 45 195 110 46

Measurements in mm

Vent

Kg S H L D .No

0.090 3 46 102 75 47

0.175 4 52 102 110 48

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Measurements in mm Reducer

Kg Type L H2 H1 D2 D1 .No

0.06 III 45 30 36 48 60 49

0.11 III 52 38 42 60 75 50

0.26 II 61 38 50 60 110 51

0.245 II 61 38 50 75 110 52

0.55 I 77 56 65 110 160 53

Measurements in mm

β=87.5 degree

Tee 87.5 o

Kg C S H L D .No

0.150 127 4 30 71 48 54

0.230 153 4 35 86 60 55

0.365 189 4.5 40 100 75 56

0.940 243 6 45 142 110 57

1.840 345 6 70 346 160 58

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Measurements in mm

β=45 degree

Tee 45 o

Kg C S H L D .No

0.165 142 4 30 86 48 59

0.278 165 4 35 103 60 60

0.420 202 4.5 40 128 75 61

1.070 281 6 45 182 110 61

Measurements in mm

β=87.5 degree

Reduced tee 87.5 o

Kg L S2 S1 C H2 H1 D2 D1 .No

0.300 96 4 4.5 167 34 40 60 75 62

0.555 105 4.5 6 180 36 45 60 110 63

0.620 121 4 6 196 40 45 75 110 64

1.360 169 6 6 288 45 71 110 160 65

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Measurements in mm

β=45 degree

Reduced tee 45 o

Kg L S2 S1 C H2 H1 D2 D1 .No

0.72 140 4 6 222 37 45 60 110 66

0.87 155 5 6 260 40 46 75 110 67

Measurements in mm Cross

Kg C2 C1 S H L D .No

1.33 245 293 6.5 45 145 110 68

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Measurements in mm

β=87.5 degree

Tee 87.5 o with access door

Kg Door S C H L D .No

0.295 75 4 154 36 86 60 69

0.420 75 4.5 189 40 100 75 70

1.110 110 6 234 45 141 110 71

1.995 110 6 345 71 203 160 72

Measurements in mm

β=87.5 degree

Reduced tee 87.5 o

with access door

Kg Door S2 S1 L C H2 H1 D2 D1 .No

0.355 75 4 4.5 96 65 35 40 60 75 73

0.68 75 5 6 107 185 35 45 60 110 74

0.755 75 6 6 122 199 36 45 75 110 75

1.50 110 6 6 214 288 45 71 110 160 76

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Small Drain

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Open cover for vertical extension

Closed cover for vertical extension

Measurement in mm

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Measurements in mm

Part 1: Reducer 110/75 with zero thickness

Kg S2 S1 L D2 D1

2 3 39.5 75 110

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Measurements in mm

Part 2:

kg S2 S1 L3 L2 L1 D1

7 4 45 154 154 110

Measurements in mm

Part 3:

Kg S3 S2 S1 A L2 L1

7 5 9 43 163.5 175

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LAB TESTS

Hydrostatic test (EGIC lab contains two tanks, hot and cold; hydrostatic pressure

touch screen control panel up to 150 bar)

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EGIC Lab

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Density equipment MFR equipment

Tensile equipment Elongations equipment

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Microtome equipment Microscope equipment

Milling machine (CNC)

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The thermal stability of polyethylene material shall meet the

requirement of ISO 4427

The thermal stability can be measured in EGIC lab by using DSC

Differential Scanning Calorimeter