Old’s Down the Drain

Advanced plumbing techniques are making inroads into the Indian market that was once considered resistant to change

With the advent of newer construction techniques there is an increasing emphasis on functionality along with aesthetics. It is inevitable that plumbing, which is an integral part and one of the most critical aspects of a building, will not remain untouched by this revolution. From water supply to its delivery and disposal of waste, advancements in design and installation techniques are changing the way plumbing is done in new age buildings. The entry of international players in the Indian market is further catalysing this change. Also, use of recyclable materials and products that conserve water and reduce maintenance costs is gaining ground. More and more builders, developers and contractors are now deploying such plumbing solutions in their projects.

GUPTA: Changing for the better

G C Gupta (gcgupta@deolalikar.com), general manager at Deolalikar Consultants and a senior plumbing expert, feels that the plumbing space is seeing a lot of positive development. “Things are definitely changing for the better. However, we are still a little resistant to change when it comes to adopting new technology. For example, if we talk about pipes, non-ferrous pipes like PP-R are replacing ferrous pipes only slowly. Similarly, thread joining is still widely used despite the presence of advanced clamp press systems,” he states. In recent years a number of European plumbing companies like Geberit, Viega, Tiemme, Kessel, Missel and Shwab have made inroads with products like pre-wall systems, syphonic drainage solutions, under-floor heating systems, sound insulation, new joining techniques, and multi-layer pipes, to name a few.

KHAMAR: Sustainability is the key

“Versatility is the need of the hour.Plumbing should not just make our lives easier but must aim at conserving water and other precious resources. Our pipes and fittings are manufactured from copper, bronze and stainless steel, and contain nearly 40% recycled material. When we talk about sustainable or green construction, plumbing is an important aspect and cannot be ignored. Our ProPress fittings eliminate the need for flames, solder and flux while joining pipes, and ensure the safety of the environment,” avers Shailesh B Khamar (shailesh.khamar@viega.in), Viega’s India head.

Safety, which did not feature in the priority list of plumbing till recently, is also being mulled upon these days. Fireprotected and leak-proof installations are now out of the ignore list. Attention is being paid to minute details, like insulating pipes and fittings from reverberating sound, and matching the finish of floor traps to the surface finish.

KHANNA: Time to adopt global standards

“Structure-borne sound that travels through walls, ceilings and floors can be reduced by using insulating systems. Fire protection is also important to meet modern building norms. It is high time that these products find a place in our plumbing installations,” reiterates Jatin Khanna (jatin.khanna@kessel.de), director of Plumtec, which has brought German plumbing brands like Kessel, Missel and Shwab to India.

However, experts feel that international brands need to strengthen their presence in the country and ensure dependable supply and good after sales service. “Plumbing contractors are hesitant to use foreign brands as they are sceptical about their after sales support. The availability of accessories and fittings is also an issue. If my client needs a small spare after say five years, and then comes to know that the company has wound up or no longer offers the product, he is left with no other option than to replace the entire installation,” feels Gupta.

Another crucial factor is training plumbers and making them aware of new products and installation techniques. According to Khamar, “Viega regularly conducts workshops for plumbers to educate them about its products and fitting techniques. It is in our interest that they become acquainted with them and do not hesitate to use them.”

Forward-looking businessmen in the plumbing trade are making their customers aware of latest trends, and gaining their respect as well as first-mover advantage. For them we bring a primer about concepts that no modern building can do without.

Plumbing New Depths

Here are some upcoming concepts that are likely to change the way plumbing is done in buildings

Dry Wall Systems
One of the most significant innovations in the construction arena is the concept of dry walls, which has very successfully been extended to the bathroom. This method of construction completely does away with masonry work. Instead, all the plumbing is fixed to GI frames, which are covered with decorative panels to give the look of sturdy walls. This method allows bathroom designers to experiment with layouts without compromising on functionality. Wash basins and WCs do not require solid walls for mounting; instead they can be fixed on dry walls to form islands in bathrooms. There is no chase cutting to embed pipes, no filling up of holes with wet cement, and no accumulation of rubble.

Before	After
Pre-wall installation frame with blocks for WC & Urinal

Taking this construction technique further, standard pre-wall modules (blocks) for wash basins, WCs and urinals simply fit into a drywall framework. The water inlet and outlet points as well as the waste outlets are pre-determined, and so are the positions for fixing the sanitaryware. The pipes need to be simply plugged into these points and their joints sealed. Once all plumbing is in place, the framework can be decorated with plasterboards and subsequently with tiles or other finishes. Access to the plumbing is easy as the panels are removable.

Drywall construction has further advantages; it facilitates the creation of free-standing walls of any height. Besides, decisions regarding placement of storage and shelves become easy, and the entire plumbing system can be made fire-resistant and sound-proof.

Press systems for joining pipes with a single tool

Pipe Materials & Joining Techniques
While plumbers remain stuck to conventional GI pipes and threading techniques, there is no denying the fact that newer and non-ferrous piping materials and joining techniques are fast gaining ground, particularly in new construction. PP-R is emerging as the most popular material, even in renovation projects, probably because it’s the most price friendly among the options; whereas copper, considered to be the best carrier of potable water, is still too expensive. However, GI is definitely on its way out.

While durability and hygiene are always the main considerations during selection of piping material, the cost of ownership cannot be overlooked. Long term ownership cost would include the cost and time of installation, maintenance, as well as expansion of the system.

Joining is another factor that is fast getting attention. Improper joining of pipes and fittings has always been the bane of traditional plumbing installations, so much so that customers have had to live with dripping and seepage that is caused by irreparable hairline cracks. This is now a thing of the past, what with techniques that no longer need the thread and safeda. Instead perfect joints are being forged by welding, soldering and chemicals solvents, and even crimping.

How different materials fare:

Property	Stainless	Copper	cPVC	PP-R
Dia range (in mm)	13-156	13-156	20-63	20-110
Service life (years)	10-30	10-30	30-40	above 50
Standard length (m)	6	5	5	3
Joining method	welded joint/ clamps or press	soldered joint	solvent cement	heat fusion
Joining time	few hours	few hours	few minutes	few seconds
Strength of joints	surface homogeneity	surface homogeneity	surface homogeneity	surface homogeneity
Line commissioning time	more than 4 hrs/half day	more than 4 hrs/half day	24 hours	immediate
Labour required	2 persons	2 persons	2 persons	1 persons
Brittleness characteristics	resistant	worrisome	non-resistant	resistant
Corrosion-resistance	good	very weak	resistant	very resistant
Chemical resistance	good	not to all chemicals	good	excellent
Ease of installation	not easy/easier with clamps & press	not easy	comfortable	excellent
Joining reliability	good	average	very good	excellent
Hygiene superiority	hygienic	unhygienic due to copper sulphate formation	solvent cement harmful to health	free from leeching chemicals, ideal for drinking water
Inner surface smoothness	semi-smooth	semi-smooth	smooth	very smooth
Wall thickness (OD 20mm)	2.6mm	1.5mm	1.9mm	3.4mm
When water freezes inside pipe	bursts	bursts	bursts	does not burst
Leak proof at connection	average	average	good	excellent
Eco-friendly	no	recyclable	no	yes

Joining a PP-R pipe by fusion jointing

 

PP-R: Polypropylene Random pipes are cost effective, suitable for potable water distribution, and are easy to install. They resist corrosion, weathering and expansion, and are suited for carrying hot water as their coefficient of heat conductivity is low. They can be installed almost instantly, and their fusion joining system is strong yet convenient. They have a life span of more than 50 years, if installed correctly.

Joining: PP-R pipes are usually put together using the technique of fusion jointing. The external surface of the pipe and the internal surface of the fitting are preheated, and the pipe is then inserted in the fitting, thus fusing the two surfaces. This type of welding can be carried out with inexpensive equipment. However, threaded metal inserts made of nickel-plated brass can also be used for joining.

 

 

Sweat soldering a copper pipe

Copper: Expected to be the next big thing in plumbing in India, copper pipes are widely used (nearly 80% of installations) in developed nations for water distribution.

Copper pipes are naturally corrosion resistant, leak-proof due to their malleable nature, and require little maintenance. They work well in hot water systems due to their negligible coefficient of linear expansion and ability to withstand high temperatures. Copper is 100% recyclable and according to the ICPCI, over 30% of global demand is met by recycled copper.
Joining: Copper pipes can either be sweat soldered, i.e. joined by hot solder flux, or they can be joined using compression couplers. Soldering is an old and reliable technique, but is messy because of the use of flame. Compression couplers have evolved into press- connectors which, with the help of a simple pressing machine and a connector, can ensure a lasting joint.

A stailess steel pipe being welded

Stainless Steel: Pipes made of this material are the most inert and perfect for distributing drinking water. Stainless steel offers good corrosion resistance, toughness and ductility. However, it is not widely used in domestic plumbing due to its high cost. However this price barrier is being broken with the elimination of nickel from the stainless steel alloy, which is responsible for the high price.
Joining: Stainless steel pipes can be joined by welding, which is an old but reliable method and ensures there is no leakage. Use of gun metal connectors through the press technique is also gaining ground.

 

Joining a cPVC pipe with solvent cement

cPVC: Chlorinated Poly Vinyl Chloride pipes have been used widely because of their flexibility and strength. They are cheaper when compared with metal pipes, and are light and easy to install. They remain free from corrosion and scaling or mineral deposits. Besides, they are more energy-efficient as they have improved thermal insulation properties, and cut down noise produced by the gush of water. However, cPVC pipes need to be placed away from sunlight and heat sources, as heat may cause them to release toxins. Also, the solvent cement used for joining these pipes is said to be harmful if it gets mixed with the water supply.
Joining: A special chemical known as solvent cement is used for joining cPVC pipes.

Insert fitting for joining composite pipes

Composite Pipes: They offer the best of both worlds by combining plastic and aluminium. A layer of aluminium is sandwiched between two layers of crosslinked polyethylene. The resultant pipes are light weight, strong and corrosion resistant, as well as flexible and frost resistant just like plastic pipes. The presence of the metal layer prevents thermal expansion and makes them impermeable, thus reducing the chances of mixing. They can be easily bent around turns and do not lose their shape. Composite pipes can handle more pressure and do not burst easily, when compared to normal plastic pipes. They have a lower coefficient of thermal expansion.
Joining: O-ring based insert fittings are used to joint pipes. Once the fitting is inserted, a nut is tightened over the pipe to hold fitting in place. Usually no tools are needed.

Pipes laid on sub-floor followed by a layer of concrete & floor tiles

Underfloor Heating
Underfloor radiant heating has proven to be an efficient and economical concept. Widely used in cold regions of the world, it is now finding acceptance in India, both for homes as well as commercial spaces.

Underfloor heating, which is based on hot water being circulated through pipes embedded in floors, is more effective than the traditional convectional heating using blowers and radiators. Heated floors warm up space and the human body more at the lower level and less at the upper, unlike convectional heating equipment which does the opposite, thereby creating a more comfortable environment. A well laid out piping system will ensure that the entire space is uniformly heated, and no hot or cold spots are created as is the case with convectional heating. Since a floor offers a larger surface area, the air in the room heats up faster, even at low temperatures. Naturally, such a system also saves the space from ingress of dust as there are no ducts involved. Interestingly, the same system can be used for cooling during summers by running cold water through the underfloor pipes.

An underfloor heating system is usually made up of flexible polybutene (PB) or cross linked polyethylene (PEX) pipes, which are laid into grooves in the concrete sub-floor with due care being taken for expansion and contraction. The sub-floor is then finished as usual with tiles, laminate flooring or any other material. Fossil fuel or oil-based boilers, or even solar heaters, can be used for heating the water that is to flow into the pipes. Heat from the pipes is radiated up through the floor into the room, while the water is re-circulated to maintain the desired temperature. The temperature and flow for each zone of the building can be controlled. Though these systems have a higher installation cost, they prove to cost less in terms of long term ownership.

A shower channel drain with double colour trap sealing collars & stainless steel grate

Drainage
Drainage is an extremely critical element of a building’s plumbing system. A drain’s basic function is to collect and dispose waste water in areas that are exposed, and prevent them from flooding and subsequently from damage due to water logging. These areas include bathrooms, roof, balconies, yards and basements.

Roofs require heavy-duty drainage. Traditionally, larger the roof, more the number of down pipes as well as direction of slopes needed. However newer drainage concepts require fewer down pipes, practically no slopes, and yet empty out the water faster, and in this way drastically cut down construction costs. This offers greater flexibility in the use of roofs, as spots earlier blocked by drain outlets can now be utilised.

Sound proofing drain pipes and WC systems with insulating jackets

The syphonic drainage system, which works on the principle of negative pressure, sucks in water to drain it out rapidly instead of waiting for enough to collect and run down due to gravity. As for the placement of the outlets, this system suggests that instead of placing them around the perimeter they should be placed towards the centre and the roof be made inward sloping. This will significantly decrease the number of collector pipes required.

Indoor drainage, particularly in bathrooms, is also getting a facelift. Traditional CI drains, once embedded in the floor, can never be removed for cleaning or replacement when they get corroded over the years. The jaali, or drain cover, sits on the trap awkwardly and needs to be cemented if it has to stay in place. However, new age drains are modular in design. They come in composite materials that withstand water attack, and can easily be removed and replaced. What’s more, their smart covers are designed to fit in neatly, sit flush with the floor, and even match with the floor finishes.

Another innovation in bathroom drainage is the shower channel, which enables better water outflow due to its rectangular design. It can be adjusted according to the floor level, sits flush with the surface finish, and helps integrate the shower area with the bathroom to attain a continuous floor.

Sound proofing drain pipes and WC systems with insulating jackets

Sound Insulation
With increasing use of drywall and hollow brick construction in buildings, where pipes are no longer embedded in brick or mortar, the problem of structure-borne sound is becoming a major cause of worry. Sound is produced in stereo quality when water flows through pipes into basins, bath tubs, cisterns and other fixed elements. The sound of water gushing is amplified and reverberated through walls, floors and ceilings to other areas of the building. This noise can lead to dissatisfaction and frustration amongst the occupants and affect their daily lives.

Sound insulating systems can be installed with pipes to prevent this problem. Multi-layer composites consisting of fibre, foil and mesh are now being increasingly used in modern buildings for effective sound insulation. They are tear-resistant and much more effective than the conventionally used plain vanilla foam wrappings.