Plumbing N1 Hands-On!

7/23/2019 Plumbing N1 Hands-On!

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HANDS

on!

N1

PLU

MBI

NG

E.L.

Julyan


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Published by

Future Managers (Pty) Ltd

PO Box 13194, Mowbray, 7705Tel (021) 462 3572

Fax (021) 462 3681

E-mail: [email protected]

Website: www.uturemanagers.net

Future Managers 2013

All rights reserved. No part o this book may be reproduced in any orm, electronic,mechanical, photocopying, or otherwise, without prior permission o the copyright owner.

ISBN 978-1-77581-069-8

First published 19882nd edition 2013

To copy any part of this publication, you may contact DALRO for information and copyright

clearance.

Any unauthorised copying could lead to civil liability and/or criminal sanctions.

Telephone: 086 12 DALRO (from within South Africa); +27 (0)11 712-8000

Telefax: +27 (0)11 403-9094

Postal Address: P O Box 31627, Braamfontein, 2017, South Africa

www.dalro.co.za

FutureManagers

Plumbing N1.indb 2 2013/02/05 10:35 AM


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Contents

Module 1 Safety and housekeeping ..................................................................................... 1

1.1 Causes and prevention ......................................................................................................... 11.2 Workmens Compensation Act ........................................................................................... 2

1.3 Occupational Health and Saety Act .................................................................................. 3

1.4 Personal protective equipment ........................................................................................... 8

Exercises .............................................................................................................................. 10

Module 2 Tools and machines .............................................................................................. 11

2.1 ools ..................................................................................................................................... 11

2.2 Machines ............................................................................................................................. 26 Exercises .............................................................................................................................. 33

Module 3 Metals and materials............................................................................................ 35

3.1 Characteristics o metals ................................................................................................... 35

3.2 Metals used in the plumbing industry ............................................................................. 36

3.3 Characteristics and uses o other materials .................................................................... 37

3.4 Reactions o metals ............................................................................................................ 39

Exercises .............................................................................................................................. 41

Module 4 Soldering and welding ........................................................................................ 43

4.1 So soldering ...................................................................................................................... 43

4.2 Hard soldering .................................................................................................................... 45

4.3 Soldering mediums and uxes or so and hard soldering .......................................... 45

4.4 Gas welding ......................................................................................................................... 46

4.5 Welding works regulations ................................................................................................ 54

Exercises .............................................................................................................................. 56

Module 5 Cold water supply ...................................................................................................57

5.1 Te properties o water ....................................................................................................... 57

5.2 Water sources or human consumption .......................................................................... 57

5.3 Methods o joining ttings to pipes ................................................................................. 59

5.4 Other installations .............................................................................................................. 65

5.5 Fittings between xed points ............................................................................................ 70

Exercises .............................................................................................................................. 74



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IV Contents

Module 6 Hot water supply ................................................................................................... 77

6.1 Te basic principles o heat transer ................................................................................ 77

6.2 Hot water units ................................................................................................................... 77

6.3 Installation o a boiler-cylinder and supply tank ........................................................... 84

6.4 Causes, prevention and rectication o airlocks ............................................................ 866.5 Precautions when doing a hot water installation ........................................................... 87

Exercises .............................................................................................................................. 88

Module 7 Drainage ................................................................................................................... 89

7.1 Standard sanitary and other abbreviations ..................................................................... 89

7.2 Drainage terms ................................................................................................................... 90

7.3 Drain/sewer pipe jointing methods ................................................................................. 90

7.4 Miscellaneous installations and constructions ............................................................... 94

7.5 raps ................................................................................................................................... 103

7.6 Flush valves ....................................................................................................................... 106

7.7 Cisterns .............................................................................................................................. 108

7.8 Drainage installation ........................................................................................................ 110

7.9 Materials or sanitary tments ........................................................................................ 117

7.10 Sanitary appliances ........................................................................................................... 118

7.11 Single-stack and stub-stack pipe systems ...................................................................... 128

Exercises ............................................................................................................................ 134

Module 8 Sheet metal work ............................................................................................... 137

8.1 Diferent sheet metal joints ............................................................................................. 137

8.2 Sheet metal pattern development ................................................................................... 141

8.3 Installing and joining gutters .......................................................................................... 150

8.4 Roo ashings around ventilation pipes ........................................................................ 155

8.5 Non-metal ashings or proled sheet metal and tiled roos ..................................... 156

Exercises ............................................................................................................................ 165

Module 9 Calculations........................................................................................................... 1679.1 Measurement units ........................................................................................................... 167

Exercises ............................................................................................................................ 174

Sample exemplar paper .................................................................................................... 177



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Te aim o this volume is to assist the student who is keen to study in this particular

eld o the building trade.

Te contents are compiled to cover the prescribed syllabus, and as a basis or those who

intend studying urther in this eld to become proessional, licensed plumbers.

No text book or other work o reerence is ever complete. I thereore strongly

recommend that students seek out all available sources to obtain the maximum amount

o coverage on any particular topic, which would greatly enhance understanding o the

subject matter.

College lectures and text books simply provide a theoretical background. Practicalexperience and/or on site observation o works in progress are o vital importance to

complement the contents o these text books.

E.L. Julyan

Introduction



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2 Module 1 Safety and housekeeping

How to stack pipes

Neverthrowpipettingsfromonespottoanother,asyoumayspoilthethreadsof

the tting.

Donotstacksanitarywareontopofanother,asitcouldbreak. Anyacidoruxesshouldbestoredinaspecialroom.

1.2 Workmens Compensation Act

Te Act was ormulated to provide or compensation or disablement, caused by

occupational injuries or diseases sustained or contracted by employees in the course o

their employment, or death resulting rom such injuries or diseases, and to provide or

matters connected therewith.

Tis particular Act no. 130, dated 1993, or any amended, should be read as a whole tounderstand why it is necessary to have such a document. Te Act is part o the normal

Government Gazette issues obtainable rom any leading bookstore or directly rom the

Government Printers.

o administer the prescribed acts alls to a Commissioner and his staf, who have

the power to raise unds, have assessors and so on, and are run by an appointed

Compensation Board.

Te Act will not be discussed in detail. Te ew ew extracts below will show why it is

necessary to study the document as part o the prescribed work or the syllabus.

1.2.1 Claims for compensation

1. Notice o accident by employee to employer.

2. Notice o accident by employer to commissioner.

3. Inquiry by commissioner into accident.

4. Particulars in support o claim.

5. Employee to submit to medical examination.

6. Claim or compensation.

7. Prescription.8. Consideration o claim.

9. Appearance o parties.



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3Plumbing Theory N1

Te Act as published, or any adjustment in uture to it, deals with various topics related

to Compensation or Occupational Injuries and Diseases. o highlight only certain

clauses may not be wise. Each case according to the Act will be dealt on merit and or

this reason will it be best to study the latest document concerning the Act to suit the

circumstances o the particular case involved.

1.3 Occupational Health and Safety Act

It is recommended to consult the prescribed Government Gazette No. 14918 volume

337, dated 2 July 1993 or any amended since then. Below are a ew extracts rom the

particular volume (Act 85, 1993).

1.3.1 Duty to inform

Section 13: Without derogating rom any specic duty imposed on an employer by this

act, every employer shall:(a) As ar as is reasonably practical, cause every employee to be made conversant with

the hazards to his health and saety attached to any work that he has to perorm, any

article or substance that he has to produce, process, use, handle, store or transport

and any plant or machinery that he is required or permitted to use, as well, as with

the precautionary measures that should be taken and observed with respect to those

hazards:

(b) Inorm the health and saety representatives concerned beorehand o inspections,

investigations or ormal inquiries o which he has been notied by an inspector, and

o any application or exemption made by him in terms o section 40; and(c) Inorm a health and saety representative as soon as reasonably practical o the

occurrence o an incident in the workplace or section o the workplace or which

such representative has been designated.

1.3.2 General duties of employees at work

Section 14: Every employee shall at work:

(a) ake reasonable care or the health and saety o himsel and o other persons who

may be afected by his acts or omissions;

(b) As regards any duty or requirement imposed on his employer or any other person bythis act, cooperate with such employer or person to enable that duty or requirement

to be perormed or complied with;

(c) Carry out any lawul order given to him, and obey the health and saety rules and

procedures laid down by his employer or by anyone authorised thereto by his

employer, in the interest o health or saety;

(d) I any situation, which is unsae or unhealthy, comes to his attention, as soon

as practical. Report such situation to his employer or to the health and saety

representative or his workplace or section thereo, as the case may be, who shall

report it to the employer; and(e) I he is involved in any incident which may afect his health or which has caused

an injury to himsel, report such incident to his employer or to anyone authorised

thereto by the employer, or to his health and saety representative, when practical



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but not later than the end o the particular shi during which the incident occurred,

unless the circumstances were such that the reporting o the incident was not

possible, in which case he shall report the incident as soon as practicable thereaer.

1.3.3 Duty not to interfere with or misuse things

Section 15: No person shall intentionally or recklessly interere with, or misuse

anything, which is provided in the interest o health or saety.

1.3.4 Functions of health and safety representatives

Section 18(1): A health and saety representative may perorm the ollowing unctions

in respect o the workplace or section o the workplace or which he has been

designated, namely:

(a) Review the efectiveness o health and saety measures;

(b) Identiy potential hazards and potential major incidents at the workplace;(c) In collaboration with his employer, examine the causes o incidents at the workplace;

(d) Investigate complaints by any employee relating to that employees health or saety at

work;

(e) Make representations to the employer or a health and saety committee on matters

arising rom paragraphs (a), (b), (c) or (d), or where such representations are

unsuccessul, to an inspector;

(f) Make representations to the employer on general matters afecting the health or

saety o the employees at the workplace;

(g) Inspect the workplace, including any article, substance, plant, machinery or healthand saety equipment at that workplace with a view to the health and saety o

employees, at such intervals as may be agreed upon with the employer, etc.

1.3.5 Offences, penalties and special orders of court

Section 38(1)(p): Anyone who wilully or recklessly does anything at a workplace or

in connection with the use o plant or machinery which threatens the health or saety

o any person, shall be guilty o an ofence and on conviction be liable to a ne not

exceeding R50 000 or to imprisonment or a period not exceeding one year or to both

such ne and such imprisonment.

Although a ew extracts are given, it is highly recommended to read and study the

whole-prescribed document.

1.3.6 The safe use of ladders

Wooden ladders shall be constructed o straight grained wood that is ree rom deects,

with the grain running in the length o the stile and the rung. It should not be painted

or covered in any way, unless it has been established by the user that there are no cracks

or other inherent weaknesses. Ladders could be oiled or covered with clear varnish or awood preservative.

Te extension type ladder is best as it can be adjusted to the height o the work level.

Ladders must always be set on a rm base to avoid slipping. A sae angle taken rom the



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5Plumbing Theory N1

horizontal plane should be 75 or, at base, one-quarter o the working length away out

rom the building or support point.

Diferent types o ladder

Beore using a ladder, inspect the rame or any aws in the material, as well as all the

rungs and rung lock mechanisms. I any length o rope is part o the extension type, see

to it that it is o all-weather polypropylene rope without any loose strands.

Extension ladders should be erected in the closed position and extended when upright

against the wall. Make sure again that the locking device is well seated on its supporting

rung, beore extending the other hal. Never extend the remaining hal up to the last

rung; leave at least 25% o the top o the ladder as a support section.

Wherepossible,tryandsecurethetopparttoaconvenientanchorpointtominimise

sliding o the ladder against the wall or other material.

Facetheladderwhileclimbingordescendingfromit.

Neveroverloadyourselfwhenclimbingaladder;ratherusehoistingequipmentto

hoist the particular item to the specied height.

Nevererectaladderagainstanyglasssurfaceareas,PVCguttersorglazingbars.

Whencarryingaladder,carryitlengthways.Ifitexceedsalengthof3metres,getan

assistant to help carry the ladder to avoid accidents.

Remember, do not use a ladder longer than 9 metres; it is against the stipulatedregulations.

1.3.7 Safeguarding of openings

Holes, openings or any other sort o

excavation, on sloping or level ground,

should be screened of properly with

guard-rails or indicated with some type

o warning sign, to prevent grave injury to

pedestrians or a moving vehicle landing

up in an open trench. Excavated hole covered



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It is also extremely important to cover up openings made during the day to prevent

water entering the opening, as ooding a hole or trench brings about a saturation point.

Unnecessarylabourmustthenbeundertakentobailoutwater,ortocastconcreteon

any orm o unwanted earthwall overbreak.

Usuallyitisthecontractorsresponsibilitytoensurethatholes,trenches,andsoon,dugby his employees are screened of to avoid any legal action or negligence to saeguard

the public against mishaps.

1.3.8 Protection of excavations

As stated above, the contractor has an obligation to protect the public against accidents

caused by excavations in a public road, street or pavement.

Barrier as saety precaution

According to the Occupational Health and Saety Act, the builder or excavator should

ensure the ollowing regarding all excavations accessible by the public or adjacent to

public roads or thoroughares, where the saety o persons could be endangered.

Teexcavationshouldbeadequatelyprotectedbyabarrierorfenceatleast600mm

high, and as close to the excavation as practicable.

Itshouldbeprovidedwithredwarninglightsatnight.

1.3.9 Erection of scaffolding

Te erection o scafolding has become a specialised trade, where each type o scafold

has to meet the saety regulations or the workload and height o a particular structure.

Scafold in place



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7Plumbing Theory N1

It is important to study the saety regulations regarding the requirements or each type

o scafolding. A ew extracts o the prescribed regulations are given below.

Scaffold framework

1. Te user shall cause:

1.1 Scafold standards to be rmly supported and secured against displacement

and to be kept vertical, except in the case o putlog scafolds which shall incline

slightly towards the object on which work is perormed.

1.2 Standards to be spaced not more than 1,8 m; 2,4 m and 3 m apart in the case o

high, medium and low mass loads, respectively, i constructed o steel and not

more than 3 m apart i constructed o timber.

1.3 Ledgers to be spaced not more than 2,1 m apart vertically.

1.4 Putlogs or transoms to be spaced not more than 1,5 m; 1,8 m and 2,4 m apart in

the case o high, medium and low mass load respectively.

For the purpose o this regulation high, medium and low mass loads shall mean mass

loads o not more than 375; 250 and 125 kilogram/square metre respectively.

2. No user shall use, or cause to be used, any scafold unless it is:

2.1 Securely and efectively braced to ensure stability in all directions.

2.2 Secured at suitable vertical and horizontal distances to the object on which

work is being perormed unless the scafold is designed to be completely sel-

supporting.

2.3 So constructed that it has a actor o saety o not less than our.

2.4 Inspected by a competent person at least once a week and aer inclement

weather.

3. No user shall require or permit:

3.1 Scafolding, the supporting rame o which is constructed o timber, to exceed a

height o 25 metres.

3.2 Scafolding to be erected, altered or taken down other than by or under the

personal supervision o a competent person.

Scaffold boards

Te standard scafold board length is 3,900 m 228 mm 38 mm. Te quality thereore

must satisy the ollowing requirements:

1. Not more than one third of the width of the board in any one place shall be knot wood.

2. Te end shall not be split up more than 300 mm with the hoop iron xed.

3. Not more than hal o the depth shall be knot wood.

4. Te grain shall not cross rom ace to ace o the board in a distance o less than

300 mm.

5. It must not be twisted by more than 12 mm.



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1.3.10 Manual handling of loads

Beore starting a job, determine the type o material to be used. Look out or splinters

and jagged edges on sheet metal edges beore handling the material.

Fragile roof covering

Use crawling board

Ladder

Board to support ladder

Asbestos cement roof

Scaold board for workers

Sae-guarding methods

Beore carrying a load, make sure that you have an unobstructed path that is not

slippery.

Six major points to remember when lifing heavy objects

1. Back must be straight

2. Hold chin in3. Keep arms close to body

4. Keep eet slightly apart

5. Grip the object with palm o hands and not just the ngers

6. Bend the knees and li by straightening the legs

Most accidents happen when employees do not adhere to these points, especially a back

injury. So, when liing the object, li with the thigh muscles by straightening the legs,

li in stages, rom oor to knee level, and rom knee to the carrying position. Also make

sure that you can see over the load while carrying it.

When you have to set the load down, reverse the liing procedure.

I you are not sure about the mass o an object, ask an assistant to help.

1.4 Personal protective equipment

Te employer, occupier or user should provide protective equipment, ree o charge

and in good condition, to any person working in a actory or where machinery is used.

Tis includes the employee who is exposed to wet or dusty processes, to heat or any

poisonous, corrosive or other injurious substance that could cause injury or disease orcould unduly damage clothing. Adequate protective clothing and appliances include

caps, goggles, gloves, leggings, ootwear and protective ointment.



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Overalls

Any orm o labour-intensive work requires that the body is protected against exterior

mishaps. Overalls should be clean and t properly.

Goggles

Tere are diferent types o goggles or diferent jobs. Clear goggles, which are

lightweight and made o plastic, are normally used or grinding work, or where the

person has to protect his or her eyes against ying objects.

Goggles

Dark-tinted goggles are used or any orm o welding to protect the eyes against the

bright light o the gas-welding ames and the sparks o the arc welding machine, which

can cause severe damage to eyesight i the eyes are unprotected.

Ear-guards or protectors

Your ears must be protected against any high pitch decibels or unwanted sound. When

working with a compressor or any other machine with similar noise levels, you should

wear suitable ear-guards. Ear-guards are easy to use as they simply clamp over the headand are adjustable to suit the individual.

Masks

Where dust, spray work, polluted air or noxious gases are a risk, a mask is necessary to

protect the lungs. Masks are essential in deep sewerage manholes, where methane gas

may be present. Always wear a mask where any orm o asbestos-cement sheeting is cut

or cement powder is used. Failure to do this could afect your lungs in the long run.

Gloves

Do not risk injury to your hands and ngers by handling any loose pieces o metal,

chemicals or heated objects.

Footwear

Footwear is important. A plumber must take note o signs

that warn against any potential hazards. Footwear could

prevent your eet skidding on slippery oor areas.

Be cautious when wearing ootwear with nails in it,especially near petroleum or explosive works.

Saety boots



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Gauntlets

Gauntlets are essential where any orm o gas welding

(brazing) or arc welding is done.

Te gauntlets protect the ront part o the legs o the

welder against any hot sparks or ying ux piecesrom the welding part o the object. Tey also protect

the legs against excessive heat coming rom the gas

ames, which may burn the top layers o the skin.

Hard hats

Hard hats are prescribed by most building, civil and allied

groups to be worn at construction sites. On the entrance gates

o most reputable construction sites a signboard displays

compulsory clothing, such as hard hats and ootwear.

Heavy penalties can be exacted i the regulations

prescribed by the saety and health acts are not ollowed.

Exercise 1.1

1. Describe the aims o the Occupational Health and Saety Act.

2. What are the responsibilities o the employee to ensure sae working conditions?

3. Describe the sae use o ladders when perorming the actions below.

3.1 Ascending or descending

3.2 Execution o a task

4. When excavating ground that is accessible to the public, or that is adjacent to

pubic roads or thoroughares, the saety o people could be compromised. Name

three saety measures to be taken at the excavation to saeguard against this.

Exercise 1.21. Which law provides guidelines or the health and saety o persons at work

against hazards arising out o or in connection with the activities at work?

2. For personal saety and protection, adequate saety clothing should be worn.

Name three o these saety items.

3. Name our causes o accidents in a workshop.

4. Describe the ollowing as applicable in the plumbing industry.

4.1 Sae use o ladders

4.2 Erection o scafolding

Gauntlets

Hard hat

Plumbing N1 Hands-On!

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