Post on 03-Feb-2022
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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