ENGINEERS INDIA RESEARCH INSTITUTE

4/54, Roop Nagar, Delhi-110007 (India)

Phone: 9289151047, 9811437895, 9811151047
E-mail: [email protected]
Website: www.eiriindia.org

UPVC AND CPVC PIPE AND FITTING

[EIRI/EDPR/4755] J.C.: 2975XL

PVC (unplasticized polyvinylchloride) pipes and fittings exhibit excellent resistance

to aggressive environments both naturally occurring and as a result of industrial
activity. They are resistant to almost all types of corrosion, either chemical or
electrochemical in nature. Since PVC is a non-conductor, galvanic and electro
chemical effects do not occur in PVC pipes.

PVC Pipes are a often used in the following circumstances:

 For drinking water pipe distribution systems, both main and supply lines

 Sewer and discharge pipe systems

Due to its non-metallic nature, the material used is totally resistant to all forms of
metallic corrosion.

Aggressive water resulting from high sulphate soils and low hardness water will
not attack PVC pipes.

PVC pipes are therefore resistant to a wide range of industrial waters and
chemicals and offer an advantage in long-term systems life and manufacture
costs.

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 CONTENTS

INTRODUCTION 9
PROPERTIES OF UPVC PIPES & FITTINGS 11
CHLORINATED POLYVINYL CHLORIDE (CPVC) 13
BUREAU OF INDIAN STANDARDS SPECIFICATIONS PLASTIC PIPES
& FITTINGS 15
SPECIFICATION OF UPVC PIPES FOR POTABLE WATER 17
UNPLASTICIZED PVC PIPES FOR POTABLE WATER SUPPLIES
- SPECIFICATION 17
1 SCOPE 17
2 NORMATIVE REFERENCES 17
3 TERMINOLOGIES 18
4 NOTATIONS 23
5 CLASSIFICATIONS OF PIPES 24
6 COMPOSITIONS 25
7 DIMENSIONS 27
8 SEALING RINGS 34
9 PIPE ENDS 36
10 PHYSICAL AND CHEMICAL CHARACTERISTICS 37
11 MECHANICAL PROPERTIES 42
12 SAMPLING AND CRITERIA FOR CONFORMITY 43
13 MARKING 43
CPVC PIPES AND FITTING 44
TECHNICAL SPECIFICATIONS 45
CPVC PIPES & FITTINGS 46
MARKET OVERVIEW OF INDIAN PLASTIC PIPES 48
MANUFACTURERS/EXPORTERS 79
UPVC PIPE MANUFACTURERS/EXPORTERS RAW MATERIAL SECTION 84
PVC RESIN: 84
DIMENSION OF UPVC PIPE 85
PVC PIPE & FITTINGS DIMENSIONS (SCH 40 / SCH 80) 85
UPVC AND ITS BENEFITS 87
2.2 BENEFITS OF UPVC 88
COMPARISON BETWEEN CPVC AND PVC PIPES 89
BENEFITS OF CPVC 90
PHYSICAL PROPERTIES 90
HEAT RESISTANCE 91
MECHANICAL PROPERTIES 91

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PROPERTIES OF CPVC AND PVC 91
BONDING 92
FIRE PROPERTIES 92
COMPOSITION OF UPVC PIPE 93
ADVANTAGE AND SPECIFICATION OF CPVC PIPES AND FITTING 94
CPVC ADVANTAGES 95
CPVC APPLICATIONS 95
CPVC STANDARDS 96
SPECIFICATION OF CPVC PIPES AND FITTINGD 97
CPVC SCHEDULE 40 & SCHEDULE 80 PIPE SPECIFICATIONS 97
APPLICATION 97
SCOPE 97
CPVC MATERIALS 97
DIMENSIONS 98
THE MAXIMUM SERIVCE TEMPERATURE FOR CPVC IS 200°F. 101
GENERAL SPECIFICATIONS FOR STANDARD CPVC SCHEDULE 40
AND SCHEDULE 80 FABRICATED DRAINAGE FITTINGS 101
SCOPE 101
MATERIALS OF CONSTRUCTION 101
(CPVC) CHLORINATED POLYVINYL CHLORIDE 101
SOLVENT CEMENT AND WELDING ROD (CPVC) 102
ASSEMBLY AND CONSTRUCTION PROCEDURES 102
GENERAL SPECIFICATIONS FOR STANDARD CPVC SCHEDULE 40
& SCHEDULE 80 FABRICATED PRESSURE FITTINGS 103
SCOPE 103
MATERIALS OF CONSTRUCTION 103
(CPVC) CHLORINATED POLYVINYL CHLORIDE 103
SOLVENT CEMENT AND WELDING ROD (CPVC) 103
ASSEMBLY/CONSTRUCTION PROCEDURES 104
DIMENSIONAL SPECIFICATIONS 104
PRODUCT QUALITY 104
SEQUENCES IN UPVC PIPES MANUFACTURING 105
RAW MATERIAL PREPARATION: 105
MIXING AND BLENDING: 105
EXTRUSION: 105
SHAPING: 105

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COOLING AND SIZING: 106
SURFACE TREATMENT AND FINISHING: 106
QUALITY CONTROL: 106
PRODUCING UPVC PIPE 107
RAW MATERIAL PREPARATION: 107
MIXING AND COMPOUNDING: 107
EXTRUSION: 107
SIZING AND CALIBRATION: 107
COOLING AND COOLING TANKS: 108
MARKING AND PRINTING: 108
QUALITY CONTROL: 108
PACKAGING AND STORAGE: 108
PIPE EXTRUSION PROCESS 110
PIPE EXTRUSION PROCESS 110
MATERIALS: 111
PVC COMPOUNDING IS USUALLY CARRIED OUT IN TWO STAGES 113
CONVERTING CPVC INTO PIPES AND FITTING 114
CPVC EXTRUSION 114
CPVC INJECTION MOLDING 114
PROCESS FLOW DIAGRAM OF UPVC PIPE 115
MANUFACTURING PROCESS OF UPVC PIPES IN DETAILS 116
PVC COMPOUNDING 117
PVC COMPOUNDING IS USUALLY CARRIED OUT IN TWO STAGES 117
PVC PIPE FORMULATION: 117
PIPE EXTRUSION LINE: 117
PIPE EXTRUSION DIE: 117
SIZING EQUIPMENT: 118
COOLING WATER THROUGH: 118
PULLING MACHINES: 118
CONTROLS: 118
CUTTING DEVICE: 119
COILING DEVICE: 119
PVC PIPE 119
DETAILS OF PLASTIC EXTRUSION 120
SECTIONAL VIEW OF A SIMPLE PLASTIC EXTRUDER 120
TYPES OF EXTRUDERS 123
SINGLE SCREW EXTRUDER: 123
SIMPLE PLASTIC SINGLE SCREW EXTRUDER 123

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TWIN SCREW EXTRUDER: 124
TROUBLESHOOTING SHOOTING GUIDE FOR RVPC PIPE EXTRUSION 125
ADDRESSES OF PLANT & MACHINERIES SUPPLIERS 127
SUPPLIERS OF MOULDS FOR PIPE FITTINGS 130
SUPPLIERS OF HIGH SPEED MIXER 133
SUPPLIERS OF EXTRUDER 135
SUPPLIERS OF PLASTIC SCRAP GRINDER MACHINE 136
SUPPLIERS OF PLASTIC INJECTION MOULDING MACHINE 138
SUPPLIERS OF GENERATOR SET 139
SUPPLIERS OF RAW MATERIALS 142
SUPPLIERS OF PVC RESIN 142
SUPPLIERS OF CALCIUM STEARATE 143
SUPPLIERS OF LEAD STEARATE 144
SUPPLIERS OF PRECIPITATED CALCIUM CARBONATE 145
SUPPLIERS OF PIGMENT DYE 146

APPENDIX – A:
01. PLANT ECONOMICS A-1
02. LAND & BUILDING A-2
03. PLANT AND MACHINERY A-3
04. OTHER FIXED ASSESTS A-4
05. FIXED CAPITAL A-5
06. RAW MATERIAL A-6
07. SALARY AND WAGES A-7
08. UTILITIES AND OVERHEADS A-8
09. TOTAL WORKING CAPITAL A-9
10. TOTAL CAPITAL INVESTMENT A-10
11. COST OF PRODUCTION A-11
12. TURN OVER/ANNUM A-12
13. BREAK EVEN POINT A-13
14. RESOURCES FOR FINANCE A-14
15. INSTALMENT PAYABLE IN 5 YEARS A-15
16. DEPRECIATION CHART FOR 5 YEARS A-16
17. PROFIT ANALYSIS FOR 5 YEARS A-17
18. PROJECTED BALANCE SHEET FOR (5 YEARS) A-18

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 COST ESTIMATION

Plant Capacity 2.5 MT/Day

Land & Building (2000 sq.mt.) Rs. 2.75 Cr
Plant & Machinery Rs. 80.00 Lac
Working Capital for 1 Month Rs. 1.08 Cr
Total Capital Investment Rs. 4.85 Cr
Rate of Return 22%
Break Even Point 60%

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