BlazeMaster Installation Manual
Transcription
BlazeMaster Installation Manual
Installation Manual Head Office 7 Ledgar Road, Balcatta, Western Australia, 6021 Tel +618 9200 2100, www.ampacsafety.net Global Solutions – Local Focus Promise Reliable Integration Distribution Evolution BlazeMaster® Installation Manual Contents Introduction .............................................................................................................................................................. 3 Combination of BlazeMaster® Products with Other CPVC and Solvent Cements ...................................................... 3 Where Can BlazeMaster® Fire Sprinkler Systems Be Used? ...................................................................................... 3 Temperature/Pressure Rating ................................................................................................................................... 4 Concealed Installations ............................................................................................................................................. 4 Sprinkler Head Temperature Ratings ........................................................................................................................ 4 Exposed Installations (Where Sprinklers are Required) ............................................................................................ 4 A. Standard Coverage and Residential Sprinklers .................................................................................................. 4 1. Listed Hazard or Residential Pendent Sprinklers ........................................................................................... 4 2. Light Hazard or Residential Horizontal Sidewall Sprinklers ........................................................................... 4 3. Light Hazard Upright Sprinklers ..................................................................................................................... 5 B. Light Hazard Extended Coverage and Residential Sprinklers ............................................................................. 5 1. Light Hazard Extended Coverage or Residential Pendent Sprinklers ............................................................ 5 2. Light Hazard Extended Coverage or Residential Horizontal Sidewall Sprinklers ........................................... 5 Combustible Concealed Installations ........................................................................................................................ 5 System Risers in AS2118.1, AS2118.4 and AS2118.5 Applications .............................................................................. 5 Underground Water Pressure Service ...................................................................................................................... 7 Thrust Blocking ......................................................................................................................................................... 7 Snaking of Pipe ......................................................................................................................................................... 7 Backfilling ................................................................................................................................................................. 8 Outdoor Installations ................................................................................................................................................ 9 Product Rating, Capabilities and Material Properties ............................................................................................... 9 Pressure Rating ..................................................................................................................................................... 9 Pipe Dimensions and Weights .................................................................................................................................. 9 Physical and Thermal Properties of BlazeMaster® CPVC ........................................................................................ 10 Hydraulic Design ..................................................................................................................................................... 10 C Factor .............................................................................................................................................................. 10 Pipe Friction Loss ................................................................................................................................................ 10 Fittings Friction Loss ........................................................................................................................................... 10 Thermal Expansion and Contraction ....................................................................................................................... 10 Thermal Expansion in Centimeters ...................................................................................................................... 11 Expansion Loop Formula ................................................................................................................................. 11 Page 1 BlazeMaster® Installation Manual Pipe Deflection ....................................................................................................................................................... 12 Handling and Storage ............................................................................................................................................. 13 Joining BlazeMaster® CPVC Pipe and Fittings with One-Step Solvent Cement ....................................................... 13 Cutting ................................................................................................................................................................ 13 Deburring & Beveling .......................................................................................................................................... 13 Solvent Cement Application................................................................................................................................ 13 Assembly ............................................................................................................................................................ 14 Set and Cure Times ............................................................................................................................................. 15 System Acceptance Testing (Hydrostatic Pressure Test) Warning: ......................................................................... 16 Estimating One-Step Solvent Cement Requirements .............................................................................................. 16 Cut-In Procedure for System Modification or Repairs ............................................................................................ 16 Minimum Cure Time Prior to Pressure Testing ................................................................................................ 17 Hangers and Supports ............................................................................................................................................ 18 Penetration of Studs and Joists............................................................................................................................... 19 Transition to Other Materials ................................................................................................................................. 19 Support ............................................................................................................................................................... 19 Threaded Connections ........................................................................................................................................ 19 Flanged Connections........................................................................................................................................... 19 Recommended Bolt Torque ............................................................................................................................ 20 Grooved Coupling Adapters ................................................................................................................................ 20 Other Design Criteria .............................................................................................................................................. 21 Chemical Compatibility ....................................................................................................................................... 21 Batt Insulation .................................................................................................................................................... 22 Antifreeze Solutions............................................................................................................................................ 22 Painting .................................................................................................................................................................. 22 BlazeMaster® Pipe & Fitting Installations In Concrete ........................................................................................... 22 Maintenance .......................................................................................................................................................... 23 Penetrating Fire Rated Walls and Partitions ........................................................................................................... 23 Earthquake Bracing ................................................................................................................................................ 23 Summary ................................................................................................................................................................ 24 Dos and Don’ts ....................................................................................................................................................... 25 Dos ..................................................................................................................................................................... 25 Don’ts ................................................................................................................................................................. 25 Page 2 BlazeMaster® Installation Manual Introduction BlazeMaster® pipe and fittings are designed specifically for fire sprinkler systems. They are made from a specialty thermoplastic known chemically as post-chlorinated polyvinyl chloride (CPVC). BlazeMaster® pipe and fittings provide unique advantages in sprinkler installations including superior hydraulics, ease of joining, increased hanger spacing in comparison to other thermoplastics and ease of assembly. They also are based on a technology with a continuous and proven service history of more than 50 years. This installation manual provides instructions for handling and installing a BlazeMaster® fire sprinkler system as well as information regarding system design. It is intended as a supplement to basic, fundamental knowledge relating to the installation and/or repair of CPVC fire sprinkler systems. Before commencing installation, a user should understand and confirm applicable Australian Standards and local installation requirements for CPVC fire sprinkler systems. BlazeMaster® CPVC pipe manufactured by Paratech Co LTD and supplied by Ampac Safety in sizes 20mm through 80mm carries the markings of Underwriters Laboratories, Inc. (UL & C-UL). For additional information regarding the BlazeMaster® product line, please refer to the internet website, www.BlazeMaster.com. The most current product compatibility information, the BlazeMaster® Blaster newsletter, and other BlazeMaster® fire sprinkler systems information can be found at this site. Combination of BlazeMaster® Products with Other CPVC and Solvent Cements All BlazeMaster® pipe, fittings and solvent cements have been evaluated and are listed for combination regardless of the licensed manufacturer that produces the products. Ampac Safety recommends the use of FESCO solvent cements. The assembly and curing instructions referenced in this manual must be used. Where Can BlazeMaster® Fire Sprinkler Systems Be Used? BlazeMaster® CPVC pipe and fittings manufactured by Paratech Co LTD and are Listed by Underwriters Laboratories (UL & C-UL). BlazeMaster® pipe and fittings therefore are compliant with the requirements of AS 4118.2.1 for installation in accordance with AS 2118.9 – which permits the use of Blazemaster ® in residential systems to AS 2118.4, Domestic (Home sprinkler) systems to AS 2118.5 and Light Hazard systems to AS 2118.1 along with the mechanical plant, service and storage areas associated with these occupancies that are defined as Ordinary Hazard 1. BlazeMaster® can also be used as system risers in residential buildings up to four storeys in height, refer to AS 2118.4 and AS 2118.5 Refer also UL Fire Protection Equipment Directory, categories VIWT and HFYH. BlazeMaster® fire sprinkler systems shall be employed in wet-pipe systems. (A wet-pipe system contains water and is connected to a water supply so that the water will discharge immediately when the sprinkler is opened). BlazeMaster® CPVC pipe supplied by Ampac Safety must never be used in a system using compressed air or other gases. Australian Standards must be referenced and followed for design and installation requirements in conjunction with this design manual; AS 2118.1 Automatic fire sprinkler systems - General systems AS 2118.4 Sprinkler systems for accommodation buildings not exceeding four storeys in height AS 2118.5 Home fire sprinkler systems Page 3 BlazeMaster® Installation Manual Temperature/Pressure Rating BlazeMaster® pipe and fittings 20mm – 80mm are rated for continuous service of 1207kPa at 65°C. BlazeMaster® pipe and fittings are suitable for use in areas where ambient temperatures are within the range of 2°C to 65°C. BlazeMaster® pipe and fittings may be installed in an area, such as a concealed space, where the temperature will exceed 65°C if ventilation is provided or if insulation is used around the pipe to maintain a cooler environment. BlazeMaster® fire sprinkler systems must be laid out so that the pipe and fittings are not closely exposed to devices that generate heat in excess of 65°C such as light fixtures, ballasts and steam lines. If the installation is in an area subject to freezing temperatures, the sprinkler system must be protected from freezing. A frozen system will not only be deactivated, but the pressures that may build up can cause the sprinkler heads to open or damage the pipes. Concealed Installations In a concealed installation the minimum protection shall consist of: one layer of 9.5mm gypsum wallboard, or a suspended membrane ceiling with lay-in panels or tiles having a weight of not less than 1.7kg per square meter when installed with metallic support grids, or 12.7mm plywood soffits. For residential occupancies defined in AS2118.1, AS2118.4 and AS2118.5, the minimum protection may consist of one layer of 12.7mm plywood. During periods of renovation, appropriate steps must be taken to protect the piping from fire exposure if the ceiling is temporarily removed. Sprinkler Head Temperature Ratings BlazeMaster® pipe and fittings supplied by Ampac Safety shall be used in sprinkler systems employing sprinkler heads rated 107°C when installed concealed (protected) in accordance with the Listing. Sprinkler temperature ratings for exposed installations are indicated in the individual sections of this manual. Exposed Installations (Where Sprinklers are Required) Note: It is always acceptable to install BlazeMaster® products in areas where sprinklers are not required. As an alternative to the protection requirements, BlazeMaster® CPVC pipe and fittings may be installed without protection (exposed) when subject to the following additional limitations: A. Standard Coverage and Residential Sprinklers These installations shall be below a smooth, flat, horizontal ceiling construction and require the use of FESCO one step solvent cement. 1. Listed Hazard or Residential Pendent Sprinklers Listed quick response, 77°C maximum temperature rated, pendent sprinklers having deflectors installed within 203 mm from the ceiling or Listed residential, 77°C maximum temperature rated, pendent sprinklers located in accordance with their Listing and a maximum distance between sprinklers not to exceed 4.57m. The piping shall be mounted directly to the ceiling. 2. Light Hazard or Residential Horizontal Sidewall Sprinklers Listed quick response, 93°C maximum temperature rated, horizontal sidewall sprinklers having deflectors installed within 304 mm from the ceiling and within 152mm from the sidewall or Listed residential, 93°C maximum temperature rated, horizontal sidewall sprinklers located in accordance with their Listing and a maximum distance between sprinklers not to exceed 4.27m. The piping shall be mounted directly to the sidewall. Page 4 BlazeMaster® Installation Manual 3. Light Hazard Upright Sprinklers Listed quick response, 68°C maximum temperature rated, uprights sprinklers having deflectors installed101mm from the ceiling and a maximum distance between sprinklers not to exceed 4.57m. The maximum distance from the ceiling to the centerline of the main run of pipe shall not exceed 190mm and the distance from the centerline of a sprinkler head to a hanger shall be 76mm. B. Light Hazard Extended Coverage and Residential Sprinklers These installations shall be below a smooth, flat, horizontal ceiling construction, are limited to unobstructed construction, require the use of Schedule 80 fittings for sizes 32mm and greater, and require the use of FESCO one step solvent cement. For pendent sprinkler installations, the piping shall be mounted directly to the ceiling. For horizontal sidewall sprinkler installations, the piping shall be mounted directly to the sidewall. 1. Light Hazard Extended Coverage or Residential Pendent Sprinklers Listed light hazard, extended coverage, quick response, 68°C maximum temperature rated, pendent sprinklers having deflectors installed within 200mm from the ceiling, a maximum distance between sprinklers not to exceed 6.09m, and an 2 application density not less than 4.07 liter per min/m . Listed residential, 68°C maximum temperature rated, pendent sprinklers having deflectors installed within 200mm from the ceiling, a maximum distance between sprinklers not to exceed 2 6.09m, and an application density not less than 4.07 liter per min/m . 2. Light Hazard Extended Coverage or Residential Horizontal Sidewall Sprinklers Listed light hazard, extended coverage, quick response, 79°C maximum temperature rated, horizontal sidewall sprinklers having deflectors installed within 304mm from the ceiling and within 150mm from the sidewall, a maximum distance 2 between sprinklers not to exceed 4.87m, and an application density not less than 4.07 liter per min/m . Listed residential, 74°C maximum temperature rated, horizontal sidewall sprinklers having deflectors installed within 300mm from the ceiling and within 150 mm from the sidewall, a maximum distance between sprinklers not to exceed 2 5.48m, and an application density not less than 4.07 liter per min/m . Listed light hazard, extended coverage, quick-response, 74°C maximum temperature rated, horizontal sidewall sprinklers having deflectors installed within 300 mm from the ceiling and within 150mm from the sidewall, a maximum distance between sprinklers not to exceed 5.48m, and an application density not less than 4.07 liter per min/m 2. Listed light hazard, extended coverage, quick response, 68°C maximum temperature rated, horizontal sidewall sprinklers having deflectors installed within 300 mm from the ceiling and within 150mm from the sidewall, a maximum distance between sprinklers not to exceed 7.31m, and a flow not less than 152 L/min per sprinkler. Combustible Concealed Installations Specially listed sprinkler heads exist that are listed for use with BlazeMaster® products in combustible concealed spaces requiring sprinklers. When using BlazeMaster® products in these applications always follow the sprinkler head manufacturers’ installation guidelines. BlazeMaster® pipe and fittings must never be installed in combustible concealed spaces requiring sprinklers. Where AS2118.4 and AS2118.5 permit the omission of sprinklers from combustible concealed spaces and BlazeMaster® pipe and fittings may be installed in these areas when sprinklering residential occupancies according to these standards. System Risers in AS 2118.1, AS 2118.4 and AS 2118.5 Applications BlazeMaster® CPVC pipe and fittings may be used as system risers in accordance with AS 2118.1, AS 2118.4 and AS 2118.5 when subject to the following limitations: Page 5 BlazeMaster® Installation Manual 1. When installed protected (concealed), the minimum protection shall consist of either one layer of 9.5mm thick gypsum wallboard or 12.7mm thick plywood. 2. When installed without protection (exposed), the following limitations shall apply: Note: Only AS 2118.4 and AS 2118.5 applications may be installed without protection (exposed). a) The riser shall be installed below a smooth, flat, horizontal ceiling construction. A Listed residential pendent sprinkler is to be installed with its deflector at the distance from the ceiling specified in the sprinkler Listing. b) A Listed residential pendent sprinkler is to have a maximum temperature rating of 68°C and a minimum K-factor of 3.0 and is to be installed at a maximum horizontal distance of 300mm from the centerline of the riser. The system is to be designed based upon the Listed flows for the sprinkler selected except that the flow for a single sprinkler or for multiple sprinklers flowing is to be not less than 41.64lpm per sprinkler. c) The riser shall be supported vertically within 600mm of the ceiling or bottom of the joist. d) The minimum riser diameter shall be 25mm and the maximum riser diameter shall be 50mm. e) The maximum distance between the wall(s) and the outside surface of the riser pipe shall be 32mm. f) All solvent cement joints shall be made with BlazeMaster® One Step Solvent Cement. 3. The BlazeMaster® CPVC sprinkler pipe and fittings shall be installed per these installation instructions. 4. Risers shall be supported by pipe clamps or by hangers located on the horizontal connection close to the riser. Only Listed hangers and clamps shall be used. 5. Vertical lines must be supported at intervals, described in 7 & 8 below, to avoid placing excessive load on a fitting at the lower end. Do this by using riser clamps or double bolt pipe clamps Listed for this service. The clamps must not exert compressive stresses on the pipe. It is recommended that the clamps should be located just below a fitting so that the shoulder of the fitting rests against the clamp. If necessary, a coupling can be modified and adhered to the pipe as a bearing support such that the shoulder of the fitting rests on the clamp. Follow the recommended cure time. WARNING: Modified riser collar shall only be used to provide support to the riser and shall not be used to join two pieces of pipe. 6. Do not use riser clamps that squeeze the pipe and depend on compression of the pipe to support the weight. Page 6 BlazeMaster® Installation Manual 7. Hangers and straps shall not compress, distort, cut or abrade the piping and shall allow for free movement of the pipe to allow for thermal expansion and contraction. 8. Maintain vertical piping in straight alignment with supports at each floor level, or at 3.05m intervals, whichever is less. 9.CPVC risers in vertical shafts or in buildings with ceilings over 7.62m, shall be aligned straightly and supported at each floor level, or at 3.05m intervals, whichever is less. Underground Water Pressure Service Both pipe and fittings may be used in underground water pressure service installations per the following requirements: 1. AS 3500.1 and AS 2118.9. 2. The BlazeMaster® CPVC sprinkler pipe and fittings shall be installed a s per these installation instructions. Thrust Blocking If thrust blocks are utilized they should be designed per AS 3500.1. Note: BlazeMaster® fire sprinkler systems utilize a solvent cement joining method. As such, thrust blocks are not required with BlazeMaster® CPVC pipe and fittings in underground water pressure service. Reference AS3500.1. The trench should be of adequate width to allow convenient installation, while at the same time being as narrow as possible. Minimum trench widths may be utilised by joining pipe outside of the trench and lowering it into the trench after adequate joint strength has been achieved. (NOTE: Refer to the recommended set and cure time tables for solvent cement joints). Trench widths will have to be wider where pipe is joined in the trench or where thermal expansion and contraction is a factor. See section titled “Snaking of Pipe”. Water filled pipe should be buried at least 300 mm below the maximum expected frost line. It is recommended that BlazeMaster® piping be run within a metal or concrete casing when it is installed beneath surfaces that are subject to heavy-weight or constant traffic such as roadways and railroad tracks. The trench bottom should be continuous, relatively smooth and free of rocks. Where ledge rock, hardpan or boulders are encountered, it is necessary to protect the pipe from damage. Use a minimum of 100 mm of clean soil, sand, crushed stone or other approved material as referenced in AS 3500.1. Sufficient cover must be maintained to keep external stress levels below acceptable design stress. Reliability and safety of service is of major importance in determining minimum cover. Local, state and national codes may also govern. Snaking of Pipe After BlazeMaster® CPVC pipe has been solvent welded, it is advisable to snake the pipe according to the below recommendations beside the trench during its required curing time. BE ESPECIALLY CAREFUL NOT TO APPLY ANY STRESS THAT WILL DISTURB THE UNDRIED JOINT. This snaking is necessary in order to allow for any anticipated thermal movement that could take place in the newly joined pipeline. Page 7 BlazeMaster® Installation Manual Snaking is particularly necessary on the lengths that have been solvent welded during the late afternoon of a hot day, because their drying time will extend through the cool of the night when thermal contraction of the pipe could stress the joints to the point of pull out. This snaking is also especially necessary with pipe that is laid in its trench (necessitating wider trenches than recommended) and is back-filled with cool earth before the joints are thoroughly dry. Loop Offset in mm for Contraction: Maximum Temperature Variation, °C, Between Time of Solvent Welding and Final Use Loop Length 5° 10° 15° 20° 25° 30° 35° 40° 45° 50° 5 Meters 65 83 95 105 114 123 133 143 154 164 15 Meters 164 219 266 307 343 377 409 440 469 498 30 Meters 314 424 522 609 687 758 823 884 943 999 Backfilling Note: Underground pipe shall be thoroughly inspected and tested for leaks prior to backfilling. Backfill material should be placed over pipe sections only, leaving the joints exposed during testing. Ideally, backfilling should only be done early in the morning during hot weather when the line is fully contracted and there is no chance of insufficiently dried joints being subjected to contraction stresses. The pipe should be uniformly and continuously supported over its entire length on firm, stable material. Blocking should not be used to change pipe grade or to intermittently support pipe across excavated sections. Pipe is installed in a wide range of sub-soils. These soils should not only be stable but applied in such a manner to physically shield the pipe from damage. Attention should be given to local pipe laying experience that may indicate particular pipe bedding problems. Backfill materials free of rocks with a particle size of 12mm or less should be used to surround the pipe with 150mm to 200mm of cover. It should be placed in layers. Each soil layer should be sufficiently compacted to uniformly develop lateral passive soil forces during the backfill operation. It may be advisable to have the pipe under hydraulic pressure 103 – 172kPa during the backfilling. Vibratory methods are preferred when compacting sand or gravel. Best results are obtained when the soils are in a nearly saturated condition. Where water flooding is used, the initial backfill should be sufficient to insure complete coverage of the pipe. Additional material should not be added until the water flooded backfill is firm enough to walk on. Care should be taken to avoid floating the pipe. Page 8 BlazeMaster® Installation Manual Sand and gravel containing a significant proportion of fine-grained material, such as silt and clay should be compacted by hand or, preferably by mechanical tamper. The remainder of the backfill should be placed and spread in approximately uniform layers in such a manner to fill the trench completely so that there will be no unfilled spaces under or about the rocks or lumps of earth in the backfill. Large or sharp rocks, frozen clods and other debris greater than 100mm in diameter should be removed. Rolling equipment or heavy tampers should only be used to consolidate the final backfill. Outdoor Installations BlazeMaster® pipe and fittings are not listed for exposed, outdoor applications. Product Rating, Capabilities and Material Properties Pressure Rating BlazeMaster® pipe and fittings supplied by Ampac Safety, 20mm - 80 mm, are rated for continuous service of 1207kPa at 65°C. Pipe Dimensions and Weights BlazeMaster® pipe is produced in SDR 13.5 dimensions. SDR, or standard dimensional ratio, means the pipe wall thickness is directly proportional to the outside diameter. This results in all diameters carrying the same pressure capability. BlazeMaster® pipe is produced to the specifications of ASTM F 442. BlazeMaster® fittings are produced to ASTM F 437, F 438, or F 439 specifications depending on the size and configuration. ® BlazeMaster Pipe Dimensions and Weights SDR 13.5 (ASTM F 442) Nominal Average Size Average Pounds Kilograms ID OD Pounds Kilograms Per Foot Per Meter Per Foot Per Meter Inches mm Inches mm Inches mm Empty Empty H2O Filled H2O Filled ¾ 20.0 1.050 26.7 0.874 22.2 0.168 0.250 0.428 0.637 1 25.0 1.315 33.4 1.101 28.0 0.262 0.390 0.675 1.005 11/4 32.0 1.660 42.2 1.394 35.4 0.418 0.622 1.079 1.606 11/2 40.0 1.900 48.3 1.598 40.6 0.548 0.816 1.417 2.109 2 50.0 2.375 60.3 2.003 50.9 0.859 1.278 2.224 3.310 2 1/2 65.0 2.875 73.0 2.423 61.5 1.257 1.871 3.255 4.844 3 80.0 3.500 88.9 2.950 75.0 1.867 2.778 4.829 7.186 Note: The above average OD and average ID information is per ASTM F442. Page 9 BlazeMaster® Installation Manual Physical and Thermal Properties of BlazeMaster® CPVC Property CPVC ASTM Specific Gravity 1.53 D 792 IZOD Impact Strength (ft. lbs./inch, notched) 3.0 D 256A 4.23 x 10 Modulus of Elasticity, @ 73°F, psi 5 D 638 Ultimate Tensile Strength, psi 8,000 D 638 Compressive Strength, psi 9,600 D 695 .35 - .38 D 1598 Poisson’s Ratio Working Stress @ 73°F, psi 2,000 Hazen-Williams C Factor 150 Coefficient of Linear Expansion in./(in. °F) 3.8 x 10 D 696 -5 Thermal Conductivity BTU/hr./ft.2/°F/in. 0.95 C 177 Limiting Oxygen Index 60% D 2863 Electrical Conductivity Non Conductor Hydraulic Design C Factor Hydraulic calculations for the sizing of BlazeMaster® pipe and fitting shall be calculated using the Hazen-Williams C factor of 150. Pipe Friction Loss Pipe friction loss calculations shall be made according to AS 2118.1. Fittings Friction Loss The following table shows the allowance for friction loss for fittings, expressed as equivalent length of pipe. Allowance for Friction Loss in Fittings (SDR 13.5 Equivalent Pipe) 20mm 25mm 32mm 40mm 50mm 65mm 80mm Tee Branch 0.914m 1.52m 1.83 m 2.44m 3.05m 3.66m 4.57m Elbow 90° 2.13m 2.13m 2.44m 2.74m 3.35m 3.66m 3.96m Elbow 45° 0.305m 0.305m 0.610m 0.610m 0.610m 0.914m 1.220m Coupling 0.305m 0.305m 0.305m 0.305m 0.305m 0.610m 0.610m Tee Run 0.305m 0.305m 0.305m 0.305m 0.305m 0.610m 0.610m Thermal Expansion and Contraction BlazeMaster® CPVC pipe, like all piping materials, expands and contracts with changes in temperature. The coefficient of linear expansion is 0.000068 cm / cm °C. Lineal expansion is the same for all pipe diameters. A 4°C change in temperature will cause an expansion of 25mm for a 30.5m straight run of BlazeMaster® pipe. For most operating and installation conditions, expansion and contraction can be accommodated at changes in direction of the pipe run. However in certain instances, expansion loops or offsets may be required when installing long, straight runs of pipe. Page 10 BlazeMaster® Installation Manual Thermal Expansion in Centimeters Length of Run in Meters Temp. Change ∆ T °C 1 2 4 6 8 10 12 14 16 18 20 30 40 50 Thermal Expansion ∆ L (cm.) 10 0.07 0.14 0.27 0.41 0.54 0.68 0.82 0.95 1.09 1.22 1.36 2.04 2.72 3.40 15 0.10 0.20 0.41 0.61 0.82 1.02 1.22 1.43 1.63 1.84 2.04 3.06 4.08 5.10 20 0.14 0.27 0.54 0.82 1.09 1.36 1.63 1.90 2.18 2.45 2.72 4.08 5.44 6.80 25 0.17 0.34 0.68 1.02 1.36 1.70 2.04 2.38 2.72 3.06 3.40 5.10 6.80 8.05 30 0.20 0.41 0.82 1.22 1.63 2.04 2.45 2.86 3.26 3.67 4.08 6.12 8.16 10.20 35 0.24 0.48 0.95 1.43 1.90 2.38 2.86 3.33 3.81 4.28 4.76 7.14 9.52 11.90 40 0.27 0.54 1.09 1.63 2.18 2.72 3.26 3.81 4.35 4.90 5.44 8.16 10.88 13.60 45 0.31 0.61 1.22 1.84 2.45 3.06 3.67 4.28 4.90 5.51 6.12 9.18 12.24 15.30 50 0.34 0.68 of Elasticity Stress4.76 vs. Temperature 1.36 Modulus 2.04 2.72 3.40 &4.08 5.44 6.12 6.80 10.20 13.60 17.00 Temperature C 22.8 26.7 32.2 37.8 43.3 48.9 60.0 65.6 4.23 4.14 3.99 3.85 3.70 3.55 3.23 3.08 2,000 1,875 1,715 1,560 1,415 1,275 1,000 875 Modulus of Elasticity 5 “E” x 10 (psi) Working Stress “S” (psi) Expansion Loop Formula 𝐿= L E D S ∆L = = = = = √3 ED (∆L) 2𝑆 Loop length (mm) Modulus of elasticity at maximum temperature (psi) Outside diameter of the pipe (mm) Working stress at maximum temperature (psi) Change in length due to change in temperature (mm) Page 11 BlazeMaster® Installation Manual Hangers or guides should only be placed in the loop, offset or change in direction as indicated above. Piping supports should restrict lateral movement and should direct axial movement into the expansion loop. Pipe Deflection BlazeMaster® fire sprinkler piping is inherently ductile allowing it to be deflected, within permissible limits, around or away from objects during installation, which can reduce installation time. This ductility allows for greater freedom of design and lower installed cost. The maximum installed deflections for BlazeMaster® piping are as follows: Maximum Installed Deflections (One End Restrained) Pipe Length in Meters 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Permissible Bending Deflections SDR 13.5 (23°C) in cm 20mm 8.6 34.3 77.1 137.1 214.2 308.4 419.8 548.3 694.0 856.7 1,036.7 25mm 6.8 27.4 61.6 109.5 171.0 26.3 335.2 437.8 554.1 684.1 827.8 985.1 32m m 5.4 21.7 48.8 86.7 135.5 195.1 265.5 346.8 439.0 541.9 655.7 780.4 40mm 4.7 18.9 42.6 75.8 118.4 170.4 232.0 303.0 383.5 473.5 572.9 681.8 800.2 928.0 50mm 3.8 15.2 34.1 60.6 94.7 136.4 185.6 242.4 306.8 378.8 458.3 545.4 640.1 742.4 65mm 3.1 12.5 28.2 50.1 78.2 112.6 153.3 200.3 253.4 312.9 378.6 450.6 528.8 613.3 80mm 2.6 10.3 23.1 41.1 64.3 92.5 125.9 164.5 208.2 257.0 311.0 370.1 434.4 503.8 12 13 14 Maximum Installed Deflections (Both Ends Restrained) Pipe Length in Meters 1 2 3 4 5 6 7 8 9 10 11 Permissible Bending Deflections SDR 13.5 (23°C) in cm 20mm 2.1 8.6 19.3 34.2 53.5 77.1 104.9 137.0 173.4 214.1 259.0 308.2 361.8 419.5 25mm 1.7 6.8 15.4 27.4 42.8 61.6 83.8 109.5 138.6 171.1 207.1 246.4 289.2 335.4 32m m 1.4 5.4 12.2 21.7 33.9 48.8 66.4 86.7 109.7 135.4 163.9 195.0 228.9 265.4 40mm 1.2 4.7 10.6 18.9 29.6 42.6 58.0 75.7 95.8 118.3 143.2 170.4 200.0 231.9 50mm 0.9 3.8 8.5 15.2 23.7 34.1 46.4 60.7 76.8 94.8 114.7 136.5 160.2 185.8 65mm 0.8 3.1 7.0 12.5 19.6 28.2 38.4 50.1 63.4 78.3 94.7 112.7 132.3 153.5 80mm 0.6 2.6 5.8 10.3 16.1 23.1 31.5 41.1 52.1 64.3 77.8 92.6 108.6 126.0 Page 12 BlazeMaster® Installation Manual Handling and Storage BlazeMaster® CPVC is a tough, corrosion resistant material, but does not have the mechanical strength of steel. Reasonable care must be exercised in handling BlazeMaster® pipe and fittings. They must not be dropped or have objects dropped on them. If improper handling results in scratches, splits, or gouges, the damaged section shall be cut out and discarded. BlazeMaster® pipe must be covered with a nontransparent material when stored out of doors for extended periods of time. Brief exposure to direct sunlight on the job site may result in color fade but will not affect physical properties. BlazeMaster® fittings should be stored in their original containers to keep them free from dirt and reduce the possibility of damage. Caution should be taken not to over stack boxes of BlazeMaster® fittings in extreme temperature environments (>65°C). Joining BlazeMaster® CPVC Pipe and Fittings with One-Step Solvent Cement Notice: Read and understand all instructions prior to assembly. Follow all instructions. Failure to follow instructions during joining and testing may result in pipe failure, clogged waterways, or leakage. Cutting BlazeMaster® CPVC pipe can be easily cut with a ratchet cutter, a wheel-type plastic tubing cutter, a power saw or a fine toothed saw. Tools used to cut CPVC must be designed for plastic use and must be in good condition in accordance with the tool manufacturer’s recommendations. It is important to cut the pipe square. A square cut provides the surface of the pipe with maximum bonding area. Notice: Avoid splitting the pipe when using ratchet cutters. Failure to do so may result in pipe failure or leakage. Only use ratchet cutters that contain a sharp blade (blades dull quickly). Only use ratchet cutters at temperatures of 10°C or warmer. Only use well-maintained, good quality ratchet cutters capable of consistently cutting the pipe squarely. If any indication of damage or cracking is evident at the pipe end, cut off at least 50 mm beyond any visible crack. Deburring & Beveling Burrs and filings can prevent proper contact between pipe and fitting during assembly, and must be removed from the outside and the inside of the pipe. A chamfering/ reaming tool or a file is suitable for this purpose. A slight bevel (approximately 10° to 15°) shall be placed at the end of the pipe to ease entry of the pipe into the socket. This will minimize the chance that the edges of the pipe will wipe solvent cement from the fitting socket during the insertion of the pipe. Solvent Cement Application Caution: Prior to using approved BlazeMaster® fire sprinkler CPVC solvent cements, review and follow all precautions found on the container label. This material is hazardous according to health criteria of Safe Work Australia. Hazard Category: T Toxic Xi Irritant. Refer to the MSDS for safe handling precautions. Using a clean, dry rag, wipe loose dirt and moisture from the fitting socket and pipe end. Moisture can slow the cure time and at this stage of assembly, excessive water can reduce joint strength. The pipe should enter the fitting socket easily one-third to two-thirds of the way. Contact between the pipe and fitting is essential in making a good joint. This contact allows the solvent cement (which is applied in the next step) to effectively join the pipe and fitting. Page 13 BlazeMaster® Installation Manual Use a dauber that is properly sized for the pipe. For 20mm and 25mm pipe, use a dauber that is 12.7mm in size. For 32mm through 80mm pipe, use a dauber that is 19.1mm in size. Only use FESCO solvent cements that have been specifically formulated and listed/approved for use with CPVC fire sprinkler systems and approved by the pipe and fitting manufacturers. Vigorously apply a heavy, even coat of cement to the outside pipe end. Apply a medium coat to the fitting socket. Pipe sizes 32mm and above shall always receive a second cement application on the pipe end. FIRST APPLY CEMENT ON THE PIPE END, THEN IN THE FITTING SOCKET, AND, FINALLY, ON THE PIPE END AGAIN. Notice Too much solvent cement can cause clogged waterways or weaken the wall of the pipe or fitting and result in pipe failure or leakage. Do not allow excess cement to puddle in the pipe and fitting assembly. To prevent this puddling, apply a lighter coating of solvent cement to the inside of the fitting socket than the outside of the pipe. Wipe off excess cement on the outside of the joint. The solvents will evaporate, but the solvent cement inside the fitting will stay there. Special care shall be exercised when assembling CPVC fire sprinkler systems in temperatures below 4°C. In colder temperatures extra time must be allowed for the solvent cement to set and cure. Extra care should be taken to prevent damaging the pipe during handling. When solvent welding pipe and fittings in colder temperatures, make certain that the cement has not become lumpy or has “gelled”. Gelled cement must be discarded. At temperatures above 27°C make sure both surfaces to be joined are still wet with cement during assembly. Higher temperatures and/or wind accelerate the evaporation of the volatile solvents in the cement. Pipe stored in direct sunlight may have surface temperatures 10°C to 15°C above the air temperature. If possible store the pipe and fittings, or, at least, the ends to be solvent welded, out of the direct sunlight prior to cementing. The solvents will penetrate hot surfaces more deeply. In conditions like this it is very important to avoid puddling the solvent cement inside the fitting socket. Assembly After applying cement, immediately insert the pipe into the fitting socket, while rotating the pipe one-quarter turn until the pipe bottoms out at the fitting stop. Rotate the pipe as it is inserted into the fitting, not after it has bottomed out in the fitting. Properly align the fitting for the installation at this time. Pipe must bottom to the stop. Hold the assembly for 30 seconds to ensure initial bonding. A bead of solvent cement should be evident around the pipe and fitting juncture. If this bead is not continuous around the socket shoulder, it may indicate that insufficient cement was applied. If insufficient cement is applied, the fitting must be cut out and discarded. Cement in excess of the bead should be wiped off with a rag. Notice: Failure to allow sprinkler fitting joints to cure before installing sprinklers may result in cement in the sprinkler waterway. Install sprinkler heads only after all the CPVC pipe and fittings, including the sprinkler adapters, are solvent welded and allowed to cure for a minimum of 30 minutes. Do not install sprinklers in the fittings prior to the fittings being cemented in place. Exercise care when installing sprinklers. Allow sprinkler head fittings and previously joined fittings to cure for a minimum of 30 minutes prior to installing the sprinkler. When installing sprinklers, be sure to anchor or hold the pipe drop securely to avoid rotating the pipe in previously cemented connections. Page 14 BlazeMaster® Installation Manual Notice: Too much solvent cement can cause clogged waterways. Visually inspect sprinkler fittings to ensure that the waterway and threads are clear of any excess cement. Once the installation is complete and cured per Table I, II or III, hydrostatically test the system. Set and Cure Times Notice: Inadequate curing of solvent cement joints may cause pipe failure or leakage. Solvent cement set and cure times are a function of pipe size, temperature, relative humidity, and tightness of fit. Cure times should be increased when moisture is present such as during cut-ins to live sprinkler lines. (NOTE: A specific procedure for modifications or repairs to existing CPVC fire sprinkler lines is included in this manual.) The assembly must be allowed to set, without any stress on the joint, for 1 to 5 minutes, depending on pipe size and temperature. Following the initial set period, the assembly can be handled carefully, avoiding significant stresses to the joint. Refer to Tables I, II, and III for MINIMUM cure times prior to pressure testing. TABLE I 1552kPa Test Pressure (maximum) Ambient Temperature During Cure Period 16°C to 49°C 4°C to 15°C -18°C to 4°C 20mm 1 hour 4 hours 48 hours 25mm 1-1/2 hours 4 hours 48 hours 32 & 40mm 3 hours 32 hours 10 days 50mm 8 hours 48 hours Note 1 65 & 80mm 24 hours 96 hours Note 1 TABLE II 1379kPa Test Pressure (maximum) Ambient Temperature During Cure Period 16°C to 49°C 4°C to 15°C -18°C to 4°C 20mm 45 minutes 1-1/2 hours 24 hours 25mm 45 minutes 1-1/2 hours 24 hours 32 & 40mm 1-1/2 hours 16 hours 120 hours 50mm 6 hours 36 hours Note 1 65 & 80mm 8 hours 72 hours Note 1 TABLE III 690kPa Test Pressure (maximum) Ambient Temperature During Cure Period 16°C to 49°C 4°C to 15°C -18°C to 4°C 20mm 15 minutes 30 minutes 30 minutes 25mm 15 minutes 30 minutes 30 minutes 32mm 15 minutes 30 minutes 2 hours Note 1: For these sizes, the solvent cement can be applied at temperatures below 4.5°C, however, the sprinkler system temperature must be raised to a temperature of 4.5°C or above and allowed to cure per the above recommendations prior to pressure testing. Page 15 BlazeMaster® Installation Manual System Acceptance Testing (Hydrostatic Pressure Test) Warning: Never use air or compressed gas for system acceptance testing (hydrostatic pressure test). System failure when using compressed air or gas for system acceptance testing may result in property damage, serious injury, or death. Once an installation is completed and joints are properly cured per the above recommendations, the system should be pressure tested with water to the requirements of AS 2118.1, AS 2118.4 or AS 2118.5 as applicable. See table I, II and III for curing conditions for different hydrostatic test pressures. Table should not be interpolated for other pressures. Use the next highest hydrostatic test pressure table. When pressure testing, the sprinkler system shall be slowly filled with water and the air bled from the highest and farthest sprinkler heads before pressure testing is applied. Air must be removed from piping systems (plastic or metal) to prevent it from being locked in the system when pressure is applied. Entrapped air can generate excessive surge pressures that can result in bodily injury and/ or property damage, regardless of the piping materials used. If a leak is found, the fitting must be cut out and discarded. A new section can be installed using couplings or a union. Unions should be used in accessible areas only. Estimating One-Step Solvent Cement Requirements The following guidelines are provided to allow estimation of one-step solvent cement quantities needed. Fitting Size Number of Joints Per Litre 20mm 285 25mm 190 32mm 137 40mm 106 50mm 74 65mm 53 80mm 42 Cut-In Procedure for System Modification or Repairs At times it may become necessary to make modifications to existing CPVC fire sprinkler systems. This can be done safely when the proper procedures are followed. The following procedure has been developed to assure that the modifications are done successfully. Prior to making system cut-ins on existing systems, care should be used to review proper joining procedures and to FOLLOW CUT-IN CURE SCHEDULES to ensure the highest system integrity. Several methods can be utilised to tie into an existing system using a socket style tee fitting in combination with the use of socket unions, grooved coupling adapters, and flanges. Regardless of the method used, the following points must be followed to ensure the highest integrity: Using proper tools, the cut-in should be made on the smallest diameter pipe section (that is capable of adequately supplying the system changes) in close proximity to the modification being made. This approach will expedite cure times prior to pressure testing. The cut-in connection to the existing system should be made first, prior to proceeding with additional work. Page 16 BlazeMaster® Installation Manual Existing lines must be drained adequately prior to solvent cementing. Use a Drain Vac unit to be sure all water is removed from the system (moisture can slow the cure time and reduce joint strength). One method to verify that the water has been drained from the system is to remove the sprinkler heads on each side of the cut-in and allow any remaining water to drain. Carefully review and follow the solvent cementing procedures for proper joining techniques prior to commencing with cut-in (pipe must be cut square to proper length, deburred, beveled and dry to ensure proper insertion depth and highest integrity). Carefully measure and cut pipe to proper length to ensure complete insertion during assembly (check the interference fit of the components being joined). Note: During assembly of the cut-in tee (and other components) it is important to make a one-quarter turn when inserting the pipe into the fitting per the assembly instructions, particularly on 32mm pipe sizes and larger. This may require the use of several components assembled in combination with the cut-in tee to create a short spool piece assembly. This can be accomplished by using socket unions, flanges, or grooved coupling adapters that will ensure that a onequarter turn can be obtained on all pipe connections being joined. Prior to applying the solvent cement, use a clean dry rag to wipe moisture and dirt from the fitting socket and the pipe end (the presence of moisture on the joining surfaces will reduce joint integrity). Use a new can of solvent cement when making cut-in connections (verify expiration dates stamped on can prior to use). After all work is completed, the cut-in joints must be allowed to cure properly prior to pressure testing as shown in the table below. After work is completed and cut-in cure times are met, inspect work for proper alignment and hanger placement prior to pressure testing. After cut-in cure times are met, the system must be slowly filled with water and the air bled from the furthest and highest sprinkler heads before test pressure is applied (refer to the installation instructions regarding Hydrostatic Testing). After cut-in cure times are met and the air is bled from the system, it is recommended that portion of the sprinkler system containing the cut-in tee be pressure tested. Prior to pressure testing, the system must be sectioned off to its smallest area using floor valves, etc., to isolate the cut-in area. It is further recommended that the test pressure applied should not exceed 50 psi over the system pressure. This approach will minimize the potential for water damage should a leak occur. WARNING: AIR OR COMPRESSED GAS MUST NEVER BE USED FOR PRESSURE TESTING Minimum Cure Time Prior to Pressure Testing Ambient Temperature During Cure 15°C to 50°C 4°C to 15°C -20°C to 4°C 20mm" Pipe Size 1 hour 4 hours 48 hours 25mm 1-1/2 hour 4 hours 48 hours 32 & 40mm 3 hour s 32 hours 10 days 50mm 8 hour s 48 hours * 65 & 80mm 24 hours 96 hours * * Solvent cement can be applied at temperatures below 4.5°C for pipe 50mm in size and larger, however the temperature of the system must be raised to 4.5°C or higher and allowed to cure per the above recommendations prior to pressure testing. W hen bringing cement, pipe or fittings in from the outside, be sure they are brought up to room temperature before using the 15°C to 50°C cure schedule. Page 17 BlazeMaster® Installation Manual Hangers and Supports Because BlazeMaster® pipe is rigid, it requires fewer supports than flexible plastic systems. The support spacing is shown in the following table. Pipe Size Maximum Support Spacing 20mm 1.7m 25mm 1.8m 32mm 2.0m 40mm 2.1m 50mm 2.4m 65mm 2.7m 80mm 3.0m The pipe hangars must comply with the requirements of AS 2118.9. Most hangers designed for metal pipe are suitable for BlazeMaster® pipe. Do not use undersized hangers. Hangers with sufficient load bearing surface shall be selected based on pipe size, i.e. 32mm hangers for 32mm pipe. The hanger shall not have rough or sharp edges that come in contact with the pipe. The pipe hangers must comply with the requirements of AS 2118.9. For Quick Response upright sprinkler heads, rigid hangers secured to the ceiling shall be used. Horizontal runs of BlazeMaster® pipe shall be braced so that the stress load (caused by bending the pipe) will not be placed on a fitting or joint. See the Pipe Deflection section and tables. When a sprinkler head activates, a significant reactive force can be exerted on the pipe. With a pendent head, this reactive force can cause the pipe to lift vertically if it is not properly secured, especially if the sprinkler drop is from small diameter pipe. The closest hanger shall brace the pipe against vertical lift-up. Any of a number of techniques can be used to brace the pipe. Four acceptable approaches would be to use a standard band hanger positioning the threaded support rod to 1.6mm above the pipe, a split-ring hanger, a wrap-around U hanger, or a special escutcheon which prevents upward movement of the sprinkler through the ceiling. Table A Spacing Distance In Line Sprinkler Head Drop Tee Pipe Size Less than 690 kPa More than 690 kPa 20mm 1.22m 0.91m 25mm 1.52m 1.22m 32mm 1.83m 1.52m 40 – 80mm 2.13m 2.13m Table B Maximum Support Spacing Distance End Line Sprinkler Head Drop Elbow Pipe Size Less than 690 kPa More than 690 kPa 20mm 229mm 152mm 25mm 305mm 229mm 32mm 406mm 305mm 40 – 80mm 610mm 305mm Page 18 BlazeMaster® Installation Manual Penetration of Studs and Joists Wooden Studs and Joists It is acceptable to cut holes in wood studs for support. The holes should be oversized to allow for movement. Metal Studs BlazeMaster® pipe and fittings should be protected from sharp edges when passing through metal studs. Transition to Other Materials Support Additional support should be added at the metal side of a BlazeMaster® CPVC-metal transition to support the weight of the metal system. Threaded Connections BlazeMaster® CPVC male and female threaded adapters or flanges are listed for connecting a BlazeMaster® fire sprinkler system to other materials, valves, and appurtenances. A thread sealant shall be used in making threaded connections. TFE (Teflon®) thread tape is the recommended sealant. Some thread sealants other than TFE thread tape contain solvents or other materials that may be damaging to CPVC. Always consult with the manufacturer of the material for compatibility with BlazeMaster® CPVC pipe and fittings or reference the Chemical Compatibility and FGG/BM/CZ™ System Compatible program sections of www.lubrizol.com/BuildingSolutions/BlazeMaster.html for additional information. Care shall be exercised when transitioning between BlazeMaster® pipe and fittings and metal. Care must be taken to avoid over-torquing. Flanged Connections Flange Make-Up: Once a flange is joined to pipe, the method for joining two flanges is as follows: 1. Piping runs joined to the flanges must be installed in a straight line position to the flange to avoid stress at the flange due to misalignment. Piping must also be secured and supported to prevent lateral movement that can create stress and damage the flange. 2. With gasket in place, align the bolt holes of the mating flanges by rotating the ring into position. (Consideration should be given to alignment of one-piece flange prior to joining with pipe.) 3. Insert all bolts, washers (two standard flat washers per bolt), and nuts. 4. Make sure the faces of the mating surfaces are flush against gasket prior to bolting down the flanges. Page 19 BlazeMaster® Installation Manual 5. Tighten the nuts by hand until they are snug. Establish uniform pressure over the flange face by tightening the bolts in 6.8 Newton-m increments according to the sequence shown in Figure 8: Bolt Tightening Sequence following a 180° opposing sequence. 6. Care must be taken to avoid “bending” the flange when joining a flange to a “raised face” flange, or a wafer-style valve. Do not use bolts to bring together improperly mated flanges. Caution: Over-torquing will damage the flange. Torque given is for dry, non-lubricated bolt, standard washers, grade E EPDM 3.18mm thick full face gasket. If lubricant (non-petroleum based) is used, torque levels may vary. Actual field conditions may require a variation in these recommendations. Recommended Bolt Torque Flange Size Bolt Diameter Torque 20– 40mm 12.7mm 13.6 – 20.3 Newton-m 50 – 80mm 15.9mm 27.1 – 40.7 Newton-m Grooved Coupling Adapters The following procedures are recommended for proper assembly of the Grooved Coupling Adapter. READ THESE INSTRUCTIONS CAREFULLY BEFORE BEGINNING INSTALLATION. 1. Inspect the fittings and pipe to insure that they are sufficiently free from indentations, projections or roll-marks on the gasket seating areas of the fitting and pipe. The pipe should be squarely cut with any loose scale, paint, and/or dirt removed from the groove and seating surface. Use a standard grade E*, EPDM compound that is suitable for wet fire sprinkler service. A flexible coupling shall be used with grooved coupling adapters. Caution: Use of rigid style couplings may damage the grooved coupling adapter. Consult the coupling manufacturer for proper selection. *See manufacturer for temperature ratings. 2. Make sure the gasket is clean and free of any cracks, cuts or other defects which may cause leaks. Lubricate the gasket with a vegetable soap-based gasket lubricant. Caution: Use of petroleum based lubricants will damage the gasket and adapter resulting in stress failure of the CPVC adapter. A gasket/joint lubricant is recommended to prevent pinching the gasket and to assist in seating the gasket during the alignment process. Apply the appropriate lubricant to the gasket lips and exterior surface of the gasket. Page 20 BlazeMaster® Installation Manual 3. Place the gasket over the metal pipe ends, being sure gasket lip does not overhang the pipe end. Insert the CPVC grooved coupling adapter into the gasket. Make sure that the gasket is centered between the two grooves. No portion of the gasket should extend into the grooves. Caution: Make sure the gasket is not pinched between the pipe and the fitting. 4. Place the metal housing over the gasket, making sure the metal housing key is into the grooves on the metal pipe and the CPVC coupling adapter. Insert the bolts and hand tighten. Tighten the bolts alternately and equally until the bolt pads are touching metal-to-metal. In completing a proper joint, the gasket is also slightly compressed, adding to the strength of the seal from the gasket’s durometer. 5. Inspect the joints before and after pressure testing. Look for gaps between the bolt pads and for housing keys that are not inside the grooves. Other Design Criteria Chemical Compatibility CPVC domestic water, fire sprinkler, and industrial piping systems have been used successfully for more than 50 years in new construction, re-pipe and repair. CPVC products are ideally suited for these applications due to their outstanding corrosion resistance. Occasionally, however, CPVC can be damaged by contact with chemicals found in some construction products (and site preparations). This may result in damage to property, people, or the BlazeMaster® CPVC fire sprinkler system. Reasonable care needs to be taken to insure that products coming into contact with CPVC systems are chemically compatible. Ampac Safety recommends that chemical compatibility with CPVC be confirmed with the manufacturer of the product in contact with CPVC piping systems. If chemical compatibility with CPVC is in question, Ampac Safety recommends isolating the suspect product from contact with CPVC pipe or fittings. Lubrizol maintains a list of products that have been shown to be UNACCEPTABLE for (unprotected use) contact with CPVC systems. Chemically incompatible products are added to this list as they are brought to our attention. For the most current list of chemically incompatible products, contact Lubrizol or refer to the Chemical Compatibility Section at www.lubrizol.com/BuildingSolutions/BlazeMaster.html. A product's absence from this list does not imply or insure CPVC chemical compatibility. The FGG/BM/CZ™ System Compatible program identifies products that have been determined to be compatible with CPVC compounds supplied by Lubrizol, such as BlazeMaster® CPVC. Products included in this program carry the FGG/BM/CZ™ System Compatible logo on their label. Additional information on this program can be found on the internet at www.lubrizol.com/BuildingSolutions/BlazeMaster.html. ALWAYS CHECK THE PRODUCT MANUFACTURER'S RECOMMENDATION IN THIS REGARD. A Note on Microbiologically Influenced Corrosion (MIC) In areas where water supplies are known to have contributed to MIC metallic fire sprinkler system water supplies should be tested and appropriately treated. This testing and treatment is not required when using BlazeMaster® CPVC products. BlazeMaster® CPVC is not susceptible to MIC because: 1. CPVC surfaces discourage the adherence of the bacteria associated with MIC. In metallic systems, colonies form around the bacteria that entrap organic acids against the wall, causing the pitting which is common with MIC. 2. As the bacteria associated with MIC cannot adhere to the inner surface of CPVC, the bacteria will not propagate as rapidly. 3. The organic acids produced by the MIC bacteria promote the oxidation of metals but do not affect CPVC. In fact, the compounds that comprise BlazeMaster® pipe and fittings are known to be unaffected in extreme acid environments far more severe than those environments associated with MIC. Note: Metal components within non-metallic fire sprinkler systems are not immune to MIC. Page 21 BlazeMaster® Installation Manual Batt Insulation If batts are to be used for freeze protections, they should be used in accordance with a published guideline or calculations to indicate the minimum thickness to be used and any other application criteria. Antifreeze Solutions Where installations are subject to freezing, the criteria in AS 2118.1 may be consulted. AS 2118.4 recommends the use of a dry system for freezing conditions which precludes the use of CPVC pipe. If required, utilising CPVC pipe in freezing conditions will be best undertaken utilising an alternative solution relying on the design criteria in NFPA 13 and further information available on request Painting Painted BlazeMaster® CPVC pipe and fittings have not been evaluated by UL and are outside the scope of the UL and cUL Listing. Water-based acrylic latex paint is the preferred and recommended paint to use on BlazeMaster® CPVC pipe and fittings. Oil or solvent-based paints may be chemically incompatible. Certain types of oil or solvent-based paints may, however, be used provided that it is a light coating that dries quickly. These paints should not be allowed to puddle or pool on the surface. Application of solvent-based paints must be individually reviewed as there are certain types of paints and stains that contain drying oils and should not be used at all on CPVC. BlazeMaster® Pipe & Fitting Installations In Concrete BlazeMaster® CPVC pipe and fittings are acceptable for use when embedded in concrete. Direct contact with concrete does not have any adverse effect on BlazeMaster® materials. The installation of BlazeMaster® CPVC pipe and fittings in concrete has not been evaluated by UL and is not covered under the scope of the UL Listing. Note that embedding of any type of pipe in concrete is prohibited by AS 2118.1, AS 2118.4 and AS 2118.5. Embedding of pipe and fittings would therefore be subject to an alternative solution. Typical recommended installation practices should be followed. following guidelines. In addition, particular care must be paid to the 1. As the BlazeMaster® pipe is laid out be certain that it does not come in contact with sharp objects or edges, such as rocks, metal, or structural members. 2. Although CPVC pipe has some degree of flexibility, in laying out the pipe it is best to use straight runs of pipe. It is possible for CPVC pipe to be snaked when it is laid out. This can be useful in some installations when an offset from a straight run can be helpful in avoiding various construction obstacles. Straight runs of pipe will minimise any stress that is exerted on the pipe. When the pipe is embedded in concrete there is no opportunity to relieve any stress once the concrete is poured. Therefore, it is important to layout the piping such that the stress is minimised from the time of installation. 3. Avoid the contact of BlazeMaster® pipe and fittings with construction materials that are incompatible with CPVC. Verify the suitability of a particular product for use with CPVC with the manufacturer of the particular construction material. BlazeMaster® CPVC pipe and fittings have been successfully installed encased in concrete for many years. Neither Lubrizol (the manufacturer of BlazeMaster® CPVC material) nor Ampac Safety is aware of any problems that have been caused by chemical incompatibility between BlazeMaster ® pipe and fittings and concrete or any chemicals that have been added to concrete. As new construction materials are introduced to the market it is advisable to contact the manufacturer of the construction material to confirm its chemical compatibility with BlazeMaster® CPVC. Page 22 BlazeMaster® Installation Manual 4. Steps must be taken to prevent the wire mesh or reinforcing bars from causing any abrasion damage to the BlazeMaster® pipe and fittings. This is mostly of concern prior to pouring the concrete. It is not recommended that BlazeMaster® pipe and fittings be installed in concrete that is to be post tensioned. The post tensioning process can create excessive forces which can damage the BlazeMaster® pipe. 5. When there are pipe joints that will eventually be covered in concrete, the installation must be pressure tested prior to pouring the concrete. If there will not be any joints covered by concrete, there is no need to pressure test the system prior to pouring the concrete. 6. Prior to the pouring of the concrete, the BlazeMaster® pipe should be intermittently secured to prevent movement during this process. Nonabrasive, plastic fasteners are good choices for this application. 7. Care should be taken so that the BlazeMaster® pipe and fittings are not damaged by the tools and equipment used to pour and finish the concrete. BlazeMaster® pipe and fittings should not come in contact with equipment such as tampers and agitators. 8. As the concrete is poured, assure that the pipe has not moved from its intended position. 9. Thermal expansion and contraction is not an issue for BlazeMaster® pipe and fittings that are embedded in concrete. Those forces are relieved in a manner that does not affect the pipe or fittings. However, expansion and contraction must still be incorporated in the design of those sections of pipe that are not embedded in concrete. Failure to adequately allow for stress at these points may result in damage to the pipe where it enters and exits the concrete. 10. In order to allow easier access to the sprinkler head adaptor it is recommended that the adapter not be encased in concrete. Provisions should be made prior to pouring the concrete so that the concrete does not encase the sprinkler head adapter and the pipe immediately attached to this fitting. Protective coverings may be utilised to prevent the concrete from surrounding the sprinkler head adapter and the pipe supplying it. This will allow easier access to the fitting should modifications be required to the system. Maintenance Maintenance of a BlazeMaster® fire sprinkler system shall be in accordance with the Standard for Inspection, Testing and Maintenance of Water Based Extinguishing Systems as defined by AS 1851. Penetrating Fire Rated Walls and Partitions Consult relevant building codes before penetrating fire rated walls and partitions,. Several classified through penetration firestop systems are approved for use with CPVC pipe. Consult Ampac Safety for further information. Warning: Some firestop sealants or wrap strips contain solvents or plasticizers that may be damaging to CPVC. Always consult the manufacturer of the firestop material for compatibility with BlazeMaster® CPVC pipe and fittings. To avoid compatibility issues, reference the Chemical Compatibility and FGG/BM/CZ™ System Compatible program sections of www.lubrizol.com/BuildingSolutions/BlazeMaster.html for additional information. Earthquake Bracing Since BlazeMaster® CPVC pipe is more ductile than metallic sprinkler pipe, it has a greater capacity to withstand earthquake damage. In areas subject to earthquakes, BlazeMaster® fire sprinkler systems shall be designed and braced in accordance with local codes. BlazeMaster® CPVC fire sprinkler pipe has the flexibility to meet this criteria. The permissible bending deflection values for BlazeMaster® CPVC pipe can be found in the tables in the Pipe Deflection section of this manual. When it is required to earthquake brace BlazeMaster® piping, it is important to use fittings, fasteners or clamps that do not have sharp edges or apply compressive forces sufficient to distort the pipe. Page 23 BlazeMaster® Installation Manual Summary BlazeMaster® pipe and fittings, designed specifically for fire sprinkler systems, provide unique advantages. Long-term performance of a BlazeMaster® system will be maximised if it is properly installed and maintained in accordance with applicable Australian Standards. Page 24 BlazeMaster® Installation Manual Dos and Don’ts While not a complete list, the following is intended to highlight many of the “Dos” and “Don’ts” addressed in this manual. Dos Install product according to these installation instructions. Follow recommended safe work practices. Make certain that thread sealants, gasket lubricants, or fire stop materials are compatible with BlazeMaster® CPVC. Use only latex-based paints if painting is desired. Keep pipe and fittings in original packaging until needed. Cover pipe and fittings with an opaque tarp if stored outdoors. Follow proper handling procedures. Use tools specifically designed for use with plastic pipe and fittings. Use proper solvent cement and follow application instructions. Use a drop cloth to protect interior finishes. Cut the pipe ends square. Deburr and bevel the pipe end before solvent cementing. Rotate the pipe 1/4 turn when bottoming pipe in fitting socket. Avoid puddling of solvent cement in fittings and pipe. Make certain that solvent cement does not run and plug the sprinkler head orifice. Follow these recommended cure times prior to pressure testing. Fill lines slowly and bleed the air from the system prior to pressure testing. Support sprinkler head properly to prevent lift up of the head through the ceiling when activated. Keep threaded rod within 1⁄16" of the pipe. Install BlazeMaster® CPVC pipe and fittings in wet systems only. Use only insulation and/or glycerin & water solutions for freeze protection. Allow for movement due to expansion and contraction. Renew your BlazeMaster® CPVC pipe and fittings installation training every two years. Don’ts Do not use edible oils such as Crisco® as a gasket lubricant. Do not use petroleum or solvent-based paints, sealants, lubricants or fire stop materials. Do not use any glycol-based solutions as an anti-freeze. Do not mix glycerin and water solution in contaminated containers. Do not use both Teflon® tape and thread sealants simultaneously. Do not use solvent cement that exceeds its shelf life or has become discolored or gelled. Do not allow solvent cement to plug the sprinkler head orifice. Do not connect rigid metal couplers to BlazeMaster® CPVC grooved adapters. Do not thread BlazeMaster® CPVC pipe. Do not use solvent cement near sources of heat, open flame, or when smoking. Do not pressure test until recommended cure times are met. Do not use dull or broken cutting tool blades when cutting pipe. Do not use BlazeMaster® CPVC pipe that has been stored outdoors, unprotected and is faded in color. Do not allow threaded rod to come in contact with the pipe. Do not install BlazeMaster® CPVC pipe in cold weather without allowing for expansion. Do not install BlazeMaster® CPVC pipe and fittings in dry systems. Page 25 BlazeMaster® Installation Manual BlazeMaster® pipe and fittings meet and exceed global performance and manufacturing standards for CPVC fire sprinkler systems–making it the most specified non-metallic system in the world. BlazeMaster Fire Sprinkler Systems are specially engineered to provide exceptional flame and smoke resistance, high impact and temperature resistance, lower total installed costs and a safe and reliable joining system. BlazeMaster Fire Sprinkler Systems are recommended for use in residential and light commercial applications. ® BlazeMaster is a registered trademark of The Lubrizol Corporation, a Berkshire Hathaway Company. FGG/BM/CZ™ System Compatible is a trademark of The Lubrizol Corporation, a Berkshire Hathaway Company. Page 26