SPECIFICATIONS FOR DETACHABLE JOINTS AND VARIABLE ADAPTORS FOR DUCTILE IRON, upvc AND AC PIPES SPECIFICATION SAJH FT / DJ / 001 (Rev 2.0 / 09.2004) QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. BHD
SAJH Specification for Detachable Joints And Variable Adaptors For DI, upvc and AC Pipe CONTENT Page Contents 2-3 1.0 General 4 2.0 Type of detachable joint 4 3.0 Type of Variable adaptor 4 4.0 Working Pressure 4 5.0 Material 5 6.0 Effect of Non-metallic product on water quality 5 7.0 Casting 5 8.0 Dimensions and tolerances 5 9.0 Sleeve 5 10.0 Flange 6 11.0 Bolts, Stud, Nut and Washers 6 12.0 Gasket 6 13.0 Protection against corrosion 6 14.0 Sampling 6 15.0 Protection against damage in storage, transport and handling 6 16.0 Test & Inspection 7 17.0 Certification 7 18.0 Packing 7 19.0 Markings 7 20.0 Pre-delivery Inspection 8 Schedule of Stores 10-14 Tables Table 1 : Dimensions of Detachable Joint Type A Table 2 : Dimensions of Detachable Joint Type B Table 3 : Dimensions of Ductile Iron Collar Ductile Iron Pipe (Type C) Table 4 : Dimensions of Variable Adaptor for upvc and AC Pipe (Type D) 2
Appendixes Appendix A : Detachable Joint for upvc Pipe and AC Pipe (Long Collar) Type A & B Appendix B : Ductile Iron Collar for Ductile Iron Pipe Type C Appendix C : Variable Adaptor for AC & upvc Pipe Type D Appendix D : Detachable Joint for AC Pipe (Type A) & Dimensions of Detachable Joint for AC Pipe Type A Appendix E : Detachable Joint for upvc Pipe (Type B) & Dimensions of Detachable Joint for upvc Pipe (Type B) Appendix F : Ductile Iron Collar for Ductile Iron (Type C) & Dimensions of Ductile Iron Collar Ductile Iron Pipe (Type C) Appendix G : Variable adaptor for upvc and AC Pipe (Type D) & Dimensions of Variable Adaptor for upvc and AC Pipe (Type D) 3
SPECIFICATION FOR DETACHABLE JOINTS AND VARIABLE ADAPTORS FOR DI, upvc AND AC PIPES 1.0 General 1.1 This specification is applicable to all Detachable Joints and Variable Adaptors for water supply piping system and shall be read together with JKR 20200-0045-99, Standard Specification for Detachable Joints And Variable Adaptor for DI, upvc & AC Pipes. 1.2 This specification will provide necessary information on the product dimension and requirements for the supply of joints only. 2.0 Type of Detachable Joint Type, design and sizes for Detachable Joint as per drawing. 3.0 Type of Variable Adaptor 3.1 Type A : Variable Adaptor to suit asbestos cement complying to MS 712 and cement lined mild steel pipes complying with JKR Standard. 4.0 Working Pressure The fitting covered by this specification shall be of working pressure as stated in the table below: Type Class Nominal Size Working Pressure Type A 25 DN 80 600 16.0 bar Type B Mono Class DN 80 300 16.0 bar Type C K12 DN 100 300 DN 350 600 25.0 bar 16.0 bar Type D - DN 80-600 16.0 bar 4
5.0 Materials Component Materials Reference Grade or Designation (minimum) End Flange Ductile iron BS 2789 420-10 Sleeve Ductile iron BS 2789 420-10 Bolts, Nuts & Washers Hot dip galvanized carbon steel BS 4190 BS 970 - Gasket EPDM MS 672:99/AS 1646 Hardness 66 ~ 75 IRHD 6.0 Effect of Non metallic Products on Water Quality When used under the conditions for which they are designed, non metallic products in contact with or likely to come into contact with potable water shall comply with BS 6920 Part 1: 1990. 7.0 Casting All casting shall be homogeneous, smooth and shall be free from flaws, cracks, blow holes, cuts or other harmful defects. All surfaces in close proximity to the pipe and gaskets shall be smooth and free sharp edge. 8.0 Dimensions and Tolerances Detachable joints of various nominal sizes shall fit respective AC, upvc and ductile iron pipes of same nominal sizes. Joints tolerance of plus 1/50 nominal diameter shall be allowed for easy assembly. 9.0 Sleeve Dimensions may differ from one manufacturer to another. For the range of nominal sizes from 50mm to 600mm for each pipe material, dimensions shall be in accordance to the specification requirement describe in Table 1 to 4. 5
10.0 Flange Flanges shall be machined and drilled in accordance with BS 4504: Part 3.2, for working pressure of PN 16.For nominal pipe sizes in the range 50mm to 600mm the dimensions of variable adaptor shall be in accordance with Table 3 to 8. 11.0 Bolts, Stud, Nuts and Washers. i. Bolts shall be provided with a track head, which locates in a similarly shaped hole in the end ring, thus preventing rotation of the bolt and permitting tightening of the bolts using only one spanner. ii. The treads on bolts, studs and nuts shall comply with ISO metric series of BS 3643 Part 2. Threads lengths shall in every case be of sufficient length to permit proper tightening of the joints or variable adaptor to create the designed pressure seal without the nut reaching the end of the threaded section. 12.0 Gasket Gasket shall be free from porous areas, foreign materials and visible defects. Reclaimed rubber shall not be used. Gasket shall be such size and shape as to provide a pressure tight seal for the expectancy of the pipeline under the specified working, transient and test pressure conditions. 13.0 Protection Against Corrosion Detachable Joint and Variable Adaptor shall be protected against corrosion externally and internally by Fusion Bonded Epoxy powder FBE thickness shall be uniformly between 250µm to 350µm. 14.0 Sampling Sampling method shall comply with the minimum sampling requirement and any failure to the test piece will render the whole batch to be rejected. 15.0 Protection against damage in Storage, Transport and Handling Detachable joint and variable adaptor shall be protected against damage in storage, transport and handling by means of individual paper boxes and plastic-wrapped in batch of tens. 6
16.0 Tests and Inspection a. All tests and inspection will be carried out in accordance to the specification. b. It the responsibility of the Supplier to inform SAJH when the goods are being manufactured for inspection and testing prior to delivery, by which, failing to will allow SAJH reserves the right to refuse delivery. c. Tests shall be carried out in the premise of the supplier with all apparatus and equipment required be made available to perform all tests. d. Minimum of 10 percent of the fittings supplied will be tested prior to delivery. Any test, which fails, will render the whole batch rejected. e. The supplier shall deem to have included all costs for inspection and testing either done by SAJH or independent body appointed by SAJH. f. At any time, when requested, the supplier shall provide SAJH a sample of the product offered for evaluation purposes. All costs shall be borne by the supplier. g. If at any time the supplier fails to deliver the required sample, the product is deemed fail to meet the specifications. 17. Certification a. Manufacturer and/or supplier are required to provide a copy of the certificate and testing report from SIRIM, IKRAM or other recognised certification body. b. Tests report required should be those tests conducted within a year period. c. SAJH have the right to refuse offer or reject supply if the documents required are not enclosed. 18. Packing All Detachable Joints and Variable Adaptors shall be individually packed with proper methods and protected from damage during transit. 19. Markings All joints supplied shall embody the following markings: - a) Body material DI b) Nominal Size c) Class/working pressure (PN) d) Joint type, pipe type to be connected at each end, year manufactured. e) Gasket markings manufacturer, size, and mould number, material grade and code used. f) Manufacturer s name or trade mark g) Year of manufacture (last two digit) h) Lettering SAJH 7
20. Pre delivery inspection a. It is the responsibility of the tenderer to inform SAJH for inspection purposes during manufacturing and before delivery. SAJH reserve the right to inspect and witness the testing of product offered. b. The cost for the above tests shall be borne by the manufacturer/supplier. Table 1 : Dimensions of Detachable Joint Type A Flange (mm) Sleeve (mm) No.Of Bolt Dia.Of Bolt DN D1 D2 d h1 D3 D4 h2 (mm) 50 79±1 94±1 11±1 22±1 79±1 89±1 40±1 4 9 80 100±1 116±2 14±1 22±1 100±1 111±2 40±1 4 12 100 126±1 143±3 14±1 28±1 126±1 138±3 50±2 4 12 125 154±1 172±3 14±1 28±1 154±1 166±3 50±2 4 12 150 182±1 201±3 14±1 28±1 182±1 195±3 50±2 4 12 175 209±2 229±3 14±1 32±2 209±2 223±3 60±2 4 12 200 237±2 258±3 18±2 32±2 237±2 252±4 60±2 4 16 225 264±2 286±4 18±2 32±2 264±2 379±4 60±2 4 16 250 292±3 315±4 18±2 32±2 292±3 308±5 60±2 4 16 300 352±3 376±4 18±2 40±2 352±3 369±5 75±3 5 16 350 406±3 431±4 18±2 40±2 406±3 424±5 75±3 6 16 375 433±3 459±5 18±2 46±2 433±3 452±6 85±3 6 16 400 460±3 488±5 18±2 46±2 460±3 480±6 85±3 7 16 450 518±3 547±5 18±2 50±2 518±3 539±6 95±3 8 16 500 572±3 602±6 22±2 50±2 572±3 594±6 95±3 9 20 600 678±3 710±6 22±2 50±2 678±3 702±6 95±3 10 20 Table 2 : Dimensions of Detachable Joint Type B Flange (mm) DN D1 D2 d h1 D3 Sleeve (mm) D4 h2 No. Of Bolt 80 93±1 109±1 14±1 28±1 93±1 104±1 100±1 4 12 100 117±1 134±1 14±1 31±1 117±1 129±1 110±1 4 12 150 173±1 192±1 14±1 32±1 173±1 186±1 130±1 4 12 200 224±2 245±2 18±2 36±2 224±2 239±2 150±2 4 16 250 278±2 300±2 18±2 414±2 278±2 294±2 165±2 4 16 300 329±2 353±2 18±2 42±2 329±2 346±2 170±2 5 16 Dia. Of Bolt (mm) 8
Table 3 : Dimensions of Ductile Iron Collar Ductile Iron Pipe (Type C) Pipe Size D1 D2 D3 H H1 H2 t1 t2 PCD d Bolt Size 100 122±1 147±1 163±1 36±1 4±1 18±1 7.0±1 8.0±1 181±1 18±1 M16 4 150 174±1 199±1 216±1 38±1 4±1 19±1 8.0±1 8.0±1 234±1 18±1 M16 4 200 226±1 251±1 269±1 38±1 4±1 19±1 8.5±1 8.5±1 287±1 18±1 M16 6 250 278±2 304±2 323±2 40±2 5±2 20±2 8.5±2 8.5±2 341±2 18±2 M16 6 300 330±2 356±2 376±2 40±2 5±2 20±2 9.0±2 9.0±2 395±2 18±2 M16 8 350 383±2 412±2 432±2 42±2 5±2 21±2 9.0±2 9.0±2 450±2 18±2 M16 8 No. Of Holes Table 3a : Dimension of Sleeve for D1 Collars Pipe Size H H1 D1 D2 D3 D4 100 100±1 10±1 122±1 132±1 137±1 141±1 150 100±1 10±1 174±1 185±1 190±1 194±1 200 110±1 12±1 226±1 238±1 243±1 248±1 250 130±2 12±2 278±2 290±2 296±2 302±2 300 150±2 13±2 330±2 344±2 350±2 356±2 350 165±2 15±2 383±2 397±2 404±2 412±2 Table 3b : Dimensions of Rubber Gasket for D1 Collars Pipe Size T D1 D2 H1 H2 H3 H 100 13±1 110±1 136±1 6±1 6±1 19±1 31±1 150 13±1 162±1 188±1 6±1 6±1 19±1 31±1 200 13±1 214±1 240±1 6±1 6±1 19±1 31±1 250 13±2 265±2 291±2 6±2 6±2 19±2 31±2 300 13±2 317±2 343±2 6±2 6±2 19±2 31±2 350 15±2 369±2 401±2 6±2 6±2 20±2 33±2 Table 4 : Dimensions of Variable Adaptor For upvc and AC Pipe (Type D) DN Top Flange (upvc) (mm) Sleeve (mm) Bottom Flange ( AC ) (mm) D1 D2 d1 h1 D3 D4 h2 D7 D6 D5 D6 d2 h2 80 94±1 111±1 14±1 22±1 94±1 106±1 100±1 100±1 112±1 100±1 117±1 14±1 22±1 4 12 100 118±1 136±1 14±1 28±1 118±1 131±2 110±2 127±2 140±2 127±2 145±2 14±1 28±1 4 12 150 174±2 193±2 14±1 28±1 174±2 188±2 130±2 182±2 196±2 182±2 202±2 14±2 28±1 4 12 200 225±2 247±2 18±2 32±1 225±2 241±3 150±3 238±3 254±2 238±3 260±3 18±2 32±1 4 16 250 281±2 304±3 18±2 32±1 281±2 298±3 165±3 291±3 308±2 291±3 314±3 18±2 32±1 4 16 300 330±2 354±3 18±2 40±2 330±2 348±3 170±3 352±3 370±2 352±3 376±3 18±2 40±2 5 16 Bolt. No. Bolt Dia. (mm) 9
SCHEDULE OF STORES 10
SAJ Holdings Sdn. Bhd. SCHEDULE OF STORES For Supply And Delivery Of Detachable Joints And Variable Adaptor For Asbestos Cement Pipes To Specification SAJH FT/DJ/001 For The Period of. Year(s) No Description Detachable Joint To Suit BS 534 Cement A Lined Mild Steel Pipes 1 80mm detachable joint 2 100mm detachable joint 3 150mm detachable joint 4 200mm detachable joint 5 250mm detachable joint 6 300mm detachable joint 7 350mm detachable joint 8 400mm detachable joint 9 450mm detachable joint 10 500mm detachable joint 11 550mm detachable joint 12 600mm detachable joint Ductile Iron Detachable Joint To Suit MS B 712 A.C Pipes 1 80mm 2 100mm 3 150mm 4 200mm 5 250mm 6 300mm 7 350mm 8 400mm 9 450mm 10 500mm 11 550mm 12 600mm Prov. Qty Rate (RM) Amount (RM) (Ringgit: ) Signature of Tenderer:. Signature of witness: Name: Name:.. In the capacity of:.. Adress:. Tenderer s Seal or chop:.. Date:.. Date:. 11
SAJ Holdings Sdn. Bhd. SCHEDULE OF STORES For Supply And Delivery Of Detachable Joints And Variable Adaptor For Asbestos Cement Pipes To Specification SAJH FT/DJ/001 For The Period of. Year(s) No Description Ductile Iron Variable Adaptor To Suit MS C 712:81 Asbestos Cement Pipes 1 80mm 2 100mm 3 150mm 4 200mm 5 250mm 6 300mm 7 350mm 8 400mm 9 450mm 10 500mm 11 550mm 12 600mm Prov. Qty Rate (RM) Amount (RM) (Ringgit: ) Signature of Tenderer:. Signature of witness: Name: Name:.. In the capacity of:.. Adress:. Tenderer s Seal or chop:.. Date:.. Date:. 12
SAJ Holdings Sdn. Bhd. SCHEDULE OF STORES Supply And Delivery Of Detachable Joints And Variable Adaptor For Ductile Iron Pipes To Specification SAJH FT/DJ/001 For The Period of.. Year(s) No Description Ductile Iron Detachable Joint To Suit BS D EN 545 or BS 4772 1 80mm detachable joint 2 100mm detachable joint 3 150mm detachable joint 4 200mm detachable joint 5 250mm detachable joint 6 300mm detachable joint 7 350mm detachable joint 8 400mm detachable joint 9 450mm detachable joint 10 500mm detachable joint 11 550mm detachable joint 12 600mm detachable joint Prov. Qty Rate (RM) Amount (RM) (Ringgit: ) Signature of Tenderer:. Signature of witness: Name: Name:.. In the capacity of:.. Adress:. Tenderer s Seal or chop:.. Date:.. Date:. 13
SAJ Holdings Sdn. Bhd. SCHEDULE OF STORES Supply And Delivery Of Detachable Joints And Variable Adaptor For upvc Pipes To Specification SAJH FT/DJ/001 For The Period of.. Year(s) No Description Ductile Iron Detachable Joint To Suit MS E 628 Part 1 upvc Pipes 1 80mm detachable joint 2 100mm detachable joint 3 150mm detachable joint 4 200mm detachable joint 5 250mm detachable joint 6 300mm detachable joint 7 350mm detachable joint 8 400mm detachable joint 9 450mm detachable joint 10 500mm detachable joint 11 550mm detachable joint 12 600mm detachable joint Ductile Iron Variable Adaptor To Suit MS F 628 Part 1 upvc 1 80mm detachable joint 2 100mm detachable joint 3 150mm detachable joint 4 200mm detachable joint 5 250mm detachable joint 6 300mm detachable joint 7 350mm detachable joint 8 400mm detachable joint 9 450mm detachable joint 10 500mm detachable joint 11 550mm detachable joint 12 600mm detachable joint Prov. Qty Rate (RM) Amount (RM) 14
Appendix A Detachable Joint for upvc Pipe and AC Pipe (Long Collar) Type A and B
Appendix B Detachable Joint for Ductile Iron Pipe Type C
Appendix C Variable Adaptor for AC and upvc Pipe Type D
Appendix B Detachable Joint for AC Pipe (Type A)
Appendix E Detachable Joint for upvc Pipe (Type B)
Appendix F Ductile Iron Collar for Ductile Iron Pipe (Type C)
Appendix G Variable Adaptor for upvc and AC Pipe (Type D)