2009-06-15 AB-3P Technical Reference Manual R6

PATENTED ANTI-BACTERIA 3 LAYER WATER PIPE SYSTEM
TECHNICAL
REFERENCE MANUAL
REV. 6
FOR
HIGH IMPACT RESISTANT, ANTI-BACTERIA 3 LAYER PIPE
&
ITS ANCILLARY FITTING
AND ACCESSORIES
Address: www.meplas.com.my
No 124, Jalan Permata 2, Arab Malaysian Industrial Park, 71800 Nilai, Negeri Sembilan, Malaysia
Tel.No: + 60 (6) 799-5030 Fax.No: +60 (6) 799-5034 e-Mail: meplas@gmail.com
TABLE OF CONTENTS
1 INTRODUCTION 5
1.1 What is AB-3P? 5
1.2 How to make AB-3P? 5
1.3 No uPVC-phobia! Why? No backyard product. 5
1.4 Long time proven performance. 5
1.5 Certificate and Registration 6
1.6 System Solution 6
1.7 Superior Design 6
1.8 Color and marking 6
1.9 Real Lifetime, pipe for our descendant. 6
1.10 Super Fast Construction 7
1.11 Residual Chlorine and Bio-Film 7
2 AB-3P PROPERTIES 7
2.1 Ambient temperature and Pipe pressure rating 7
2.2 Chemical resistance 8
2.3 Behaviour in Fire 9
2.4 Abrasion Resistance 9
3 AB-3P/AB-DF PRODUCT FEATURES AND BENEFITS AB-3P PIPE 9

3.1.1 General 9
3.1.2 Certification and Test Criteria 9
3.1.3 Unique Spigot Rubber Ring Joint (Supa-Tite Bell-Mouth Joint) 10
3.1.4 Anti-Bacteria, Safety Proven Nano-Technology 11
3.1.5 Pressure Pipes with Very Low flow friction 11
3.1.6 Residual Chlorine Absorption 11
3.1.7 Bio-Film 11
3.2 AB-DF Epoxy Coated Ductile Iron Fittings for Underground Application 12
3.2.1 General 12
3.2.2 Certification complied to BS/EN 545 12
3.2.3 AB-DF GLAND DESIGN – ADVANTAGES 13
3.2.4 AB-DF GLAND DESIGN – Exposed Application 14
3.3 BRACO: Brass Compression fittings 14
AB-3P PIPE SYSTEM TECHNICAL REFERENCE MANUAL Revision 6 2

3.3.1 General
3.4 DOUBLE Omega Grip (DOG bite) 15

3.4.1 General
SEE JOINT AND FITTING EASY REFERENCE TABLE 15
4 PIPELINE DESIGN 16
4.1 Hydraulic design 16

4.1.1 Flow Calculation 18
4.1.2 Head Loss Calculation 18
4.1.3 Pipe INTERNAL Diameter Selection 18
4.1.4 Pressure class selection 19
4.1.5 Water hammer surges and cyclical effects 19
4.2 Structural Design 22

4.2.1 Minimum Cover Height 22
4.2.2 Thrust block for fittings 22
4.3 Above ground Installation 23

4.3.1 Protection against ultra violet (UV) 23
4.3.2 Heat Expansion & Contraction 23
4.3.3 Pipe movement 24
4.3.4 Exposed Pipe support 24
5 INSTALLATION 26
5.1 Transportation, Handling and Unloading 26
5.2 Storage 26
5.3 Fabrication, Cutting 28
5.4 Installation: Underground Trench Construction 28
5.5 Installation: Above Ground Exposed Construction 30

5.5.1 Protection against ultra violet (UV) 30
5.5.2 Heat Expansion & Contraction & Pipe movement 30
5.6 Jointing using “Supa-Tite” Rubber Ring Joints (Above and under ground) 30
5.6.1 Jointing Procedure (Factory Rubber ring inserted Pipe) 30
5.6.2 Jointing Procedure (Site Rubber ring insertion) 31
5.6.3 Various Method of Assembly for AB-3P Bell-Mouth Pipe 31
5.7.1 Assembly Procedure 34
5.7.2 Thrust block design for AB-DF Ductile Iron Fitting (Anchor Block) 36
5.18 Pre-Assembly and laying 46
5.19 Site Testing 47
6 REPAIRING 48

7 TRAINING PROGRAM 48
8 PRE-SALES SERVICE (PSS) & AFTER SALES SERVICE (ASS) 48
APPENDIX 1. GENERAL PROPERTIES OF AB-3P 50
APPENDIX 2. AB-3P INTERNAL DIAMETER, OUT-DIAMETER, THICKNESS REFERENCE

TABLE 51
APPENDIX 3. AB-3P CHEMICAL RESISTANCE CHART 52

AB-3P & AB-DF Pressure Piping System
Technical Reference Data
1 Introduction
1.1 What is AB-3P?
AB-3P stands for Anti-Bacteria 3 Layer pipe. This patented unique High impact resistance High
Tensile strength polymer pipes are manufactured from a kind of high quality PVC (Poly Vinyl
Chloride polymer) but with differently modified formula and characteristics for inner and outer
skin layer and center layer. This unique pipe is 2nd generation of Korean High impact resistant
water pipe called HI-3P®. HI-3P shows its excellent performance in Korea for last 16 years and
well accepted to Korean government authority. It basically meets and surpass all KS M3401
(HI-VP) standard and JIS K 6742 and shows better performance than Japanese HI-VI®.
1.2 How to make AB-3P?

AB-3P and HI-3P is produced using the Co-extrusion process. Normal PVC-U pipes are produced
with single extruder but AB-3P extrusion needs two extruders per each line. Normal PVC-U pipe
were introduced in Malaysia in the 1970's and are once widely accepted material for use in
water supply, irrigation and sewerage but tainted its reputation with bad quality by some of
manufacturers who produce non-quality substandard standard pipe mainly due to the harsh
price competition in the market.
1.3 No uPVC-phobia! Why? No backyard product.

However, AB-3P differs from conventional PVC-U since its structure is unique (3 layer) thus can
be easily identified. Furthermore, both AB-3P compound and AB-3P/HI-3P pipes are patented
due to its superior quality and strength as well as latest Nano-technology adopted to make
AB-3P pipe as Anti-Bacteria. Unlike any other polymer pipe, AB-3P Anti-Bacteria Pipe actively
sterilizes water while it passes through the pipe. This technology is the first time in the world
and the technology is proven to be safe by many government authorities including Korea, Japan,
Taiwan, Europe, America etc.
ME-Plas(M) Sdn Bhd owns exclusive license to produce AB-3P pipe in Malaysia and the first
factory in the world who can meets both KS, JIS as well as BS, MS relevant standard. Therefore,
there is no worry to have back-yard product or imitation product since it is very difficult to
imitate even without consideration of patents. AB-3P is made from the high quality of PVC
material and also use expensive Lead-Free and Zinc-Free additives thus non-toxic and no risk to
mix source unknown recycled material.
1.4 Long time proven performance.

The high impact resistant strength and tensile strength together with exceptional resistance
against corrosion and chemical attack as well as its unique active sterilization capability which
will strongly fight against bio-film problem makes these pipes ideal for important infrastructure
applications such as NRW, Irrigation, Internal plumbing as well as Sewerage project. Past 16
years experience has confirmed the long term durability and serviceability of AB-3P pressure
pipe system.
1.5 Certificate and Registration
AB-3P pressure piping systems meet the requirements of the relevant British and Malaysian
Standards. The pipes are certified and approved by SIRIM and KOTRIC Korea, and also
approved by SPAN and many States Water Authorities and Water Operators in Malaysia, Brunei,
and China etc.
1.6 System Solution

In addition to AB-3P, its ancillary fittings such as BRACO and AB-DF- the Hot Fusion Bonding
Epoxy Coated Ductile Iron Fitting solution makes perfect system which can be used for Pumping
main as well as gravity main application. HI-3P/AB-3P has been used for pumping main in many
water networks. AB-3P pressure pipes are suitable for the various applications such as Potable
water net works and reticulation mains, Industrial process pipelines, Pipelines for pumped
sewage and wastes, Irrigation systems as well as domestic plumbing system. In numerous
Malaysia and Korea Water Treatment Plants are using HI-3P/AB-3P pipe for the benefit of its
high chlorine resistance and reliable performance.
1.7 Superior Design

AB-3P has long time proven spigot bell mouth joint together with unique “Supa-tite” EPDM
rubber ring design and also user friendly self-locking gland AB-DF design surely guarantee the
best joint quality at site and ensure you the timely completion of project since this jointing
method can be done at any weather condition unlike conventional metal welding or
butt-welding or electro-fusion methodology or solvent cement fusion bonding. AB-DF use long
time proven K-type socket Mechanical joint with enhanced design.
1.8 Color and marking

Standard color is very light oyster grey (In between RAL 9001 and 9002). AB-3P follow standard
MS or BS marking and on client request, we could add some more identification marking such
as “JPP” or “ABC” in blue color on the center of pipe with Flow marking but with additional cost.
This will easily help people to identify the type of utility pipe when they excavate the ground.
Currently, MS standard does not allow to use other than light grey color but if client does not
want to tag SIRIM mark on the pipe, any color can be produced if order is in big volume.
1.9 Real Lifetime, pipe for our descendant.

The nominal working pressures given for AB-3P pipe are calculated to give continuous use over
50 years or more(Note: terms and conditions applied). In addition the excellent fatigue strength
of AB-3P allows for reasonable intermittent surges and reductions in flow pressure to be
accommodated. Furthermore, Anti-Bacteria suppress microbial to damage internal wall of pipe
unlike any other polymer pipe. Therefore, AB-3P is the only pipe to maintain its characteristics
without changing its internal diameter and also maintain external surface intact from various
attack of microbial erosion. If it is used for the treated water or raw water, factory provide
standard material warranty period for 10 years.

1.10 Super Fast Construction
Unlike all other welding or fusion bonding based pipe, the unique and error-free spigot joint
design and AB-DF design ensure you the much faster construction. So when you are in need of
fast track construction, do not let pipe laying works delay your other activities by using AB-3P
and AB-DF.
1.11 Residual Chlorine and Bio-Film

Many water operators have a headache to reduce chlorine cost and contents. In summary,
AB-3P absorbs less chlorine than other pipe such as Ductile Iron, Copper, Stainless steel, HDPE
etc. Furthermore, when dormant microbial sticks to pipe wall, it may regrow and form a bio-film
which eventually feed unwanted microbial into the portable water. AB-3P with its anti-bacteria
capacity, microbial can not survive when it sticks to AB-3P pipe wall. Within 24 hours, 99.9%
bacteria will be eliminated. FITI JIS Z2801 test report is available on request.
2 AB-3P Properties
The various properties of AB-3P are given in Appendix 1. Followings are other characteristics of
AB-3P pipe to assist you to design the water network.
2.1 Ambient temperature and Pipe pressure rating

AB-3P is generally suitable for service temperatures between 0°C and 60°C. However, if pipe
temperature is above 20°C then the derating factor shall be applied to the working pressure as
in Table 1 thus actual pressure rating shall be adjusted.
Table 1. Thermal derating factors
Maximum Service Multiplication Factor For
Temperature (°C) Pressure Derating
20 1.00
30 0.85
40 0.70
50 0.50
60 0.30
Example)
Nominal PN 9 pipe becomes PN 7.7 at 30 deg Celsius.
AB-3P was also tested under the temperature of 65 deg Celsius to use for hot spring water.
However, it shall not be used for more than 3 bar nominal pressure. If used in buried
underground application, ambient soil shall be solid so that pipe may dissipate its heat
efficiently. If it is used at outdoor, ambient temperature shall not be more than 40 deg
Celsius and proper support shall be provided to prevent pipe to be bend.
AB-3P is stronger in its tensile and impact strength than BS or MS requirement thus
depending on the various diameters, AB-3P has more safety margin than designed.
For example, 15mm PN15 which is the smallest size available for AB-3P will burst only at
95 bars in 20 deg Celsius. Therefore, even with 60 deg C, it will easily withstand 5 bar
which is normal pressure in domestic plumbing.
For pumping application, water hammering may cause pressure rise-up thus this
abnormal pressure fluctuation shall be also considered. However, AB-3P easily withstands
such a water hammering or pumping pressure fluctuation even in cyclic frequency without
showing any life time deterioration. However, consultant shall not skip surge arrestor.
Likewise, system approach is very important thus we recommend using AB-DF fittings and
trust block for AB-3P to be used for pumping main application as well as other application
for long-term safe operation. However, if Double Omega grip is used, thrust block can be
skipped.
Other jointing like solvent cement chemical fusion bonding joint or butt welding fusion
bonding usually can not be used for pumping main or where water hammering is
frequently incurred. Many water authority experienced that the conventional ductile iron
fitting with simple spigot insertion showed unreliable result in water treatment plant thus
only use stainless steel. However, new AB-DF design with proper support can be used
with reliability.
2.2 Chemical resistance

Generally speaking, AB-3P is suitable with most strong acids, alkalis and aqueous solutions.
AB-3P is unaffected by water, domestic sewage, or soil. It has excellent resistance against
attack from concentrations of alkalis and acids, aliphic hydrocarbons, except for strong
oxidizing agents at maximum or near maximum concentrations. If hydrochloric or Sulphuric
acids are being conveyed in pipes, standard pressure rating can be used even when acids are
concentrated.
However, in the case of nitric acid, it is recommended to go one class higher than indicated. As
for the alcohol or 10% sodium hydroxide, two classes higher than indicated is recommended.
The material is not recommended for use with aromatic and chlorinated hydrocarbons, ketones,
esters and ethers. The resistance of AB-3P pipe materials to a wide range of chemicals is listed
in Table 3 below. In addition, careful selection of rubber ring shall be made in case it is other
than the water.
We detail on the appendix a large number of reagent and their effects on AB-3P at 20 deg
Celsius and 60 deg Celsius. It must be understood that no guarantee can be given that actual
result obtained will, in every case, be exactly as shown.
The data should however, taken as guideline only and users are advised to carry out their own
tests when considering specific application or ask ME-Plas(m) to cooperate.

There could be also other alternative solution to be used with not-recommend kind of fluid. In
other words, this list is by no means exhaustive and the fact that a reagent and their effects not
listed, please contact our technical personnel for consultation on the use of chemicals.
2.3 Behaviour in Fire

AB-3P does not support combustion and when the source of ignition is removed it is self
extinguishing. The principal doubt expressed with regard to the performance of PVC family
pipe-work during an internal fire is that it would burn away leaving access for the fire to enter
another part of the structure. This has been investigated by the Fire Research Station of the
Building Research Establishment. Special investigation report number 9116, Ad Hoc fire tests
on PVC services in buildings concluded that PVC pipes were found to soften and close forming
a carbonized mass that sealed the void. However as an added precaution we recommend that
where pipes pass through a fire stop that may give access to fire,
2.4 Abrasion Resistance

Due to the extremely low co-efficient of friction of AB-3P pipe it is particularly suitable for the
transportation of abrasive slurries. It is successfully proven in Power plant to convey coal slurry.
3 AB-3P/AB-DF Product Features and Benefits AB-3P Pipe

3.1.1 General
With its patented technology, AB-3P with its Nano-Tech skin layer and high tensile center
layer provides the strength and characteristics which single layer pipe can never provide. It
is tough and good quality pipe with good impact strength as well as high tensile strength.
Furthermore, ME-Plas(M) factory is manufactured under an stringent system of inspection,
testing, supervision and control in addition to its famous Total System Solution for water
main and domestic plumbing. Wall thickness of materials is formulated to achieve strength
that exceeds the performance of standards. High quality of finish with smooth internal and
external surface provides low coefficient of flow friction.
3.1.2 Certification and Test Criteria

With SIRIM and KOTRIC certifications, it provide an independent assurance to clients that
ME-Plas(M) products are manufactured under an stringent system of inspection, testing,
supervision and control in addition to its system solution for water main and domestic
plumbing. AB-3P is also approved by Malaysia SPAN water regulatory body.
In fact, AB-3P pipe is the only pipe which fulfills the strength and property requirements of
Korean Standard KS M 3401 (HI-VP), Japanese Standard JIS K6742 JWWA, British standard
BS 3505 as well as Malaysian Standard MS 628 – Part 1&2 altogether thanks to its superior
quality.
Furthermore, ME-Plas(M) Sdn Bhd has its own factory standard which is more stringent
than any of above standard by combining in better way. However, it shall be take noted
that since this pipe is world widely patented, no commercial standard will be specially
prepared for one patented pipe. We lead the standard.
When you choose this pipe, there is also no worry for your contractor to supply
non-standard or bad quality back yard product since this pipe is unique and can not be
imitated due to its high technology and patent as well.
So do not simply identify MS 628 or BS 3505 but identify the brand name of AB-3P and
make sure it is 3 layer with “supa-tite” unique bell mouth spigot design.
3.1.3 Unique Spigot Rubber Ring Joint (Supa-Tite Bell-Mouth Joint)

AB-3P pipes and its spigot jointing are innovatively
designed and formulated to consistently and reliably
exceed the performance aspects of standards complied,
especially on the hydrostatic pressure. For 80mm and
above, we give unique and extra safety spigot with
supa-tite Rubber ring design for straight joint and for
any other connection, we provide AB-DF, Hot fusion
epoxy coated ductile iron fitting solution which is
manufactured in accordance with BS EN545 with
unique self-locking gland design.
Compared with other rubber ring joint used by uPVC manufacturers, this rubber ring design
shows average 3~5 times higher pipe gripping power. (Below 100mm 3 bar, 100 mm and
above minimum 5 bar to slip out)
This design has been used in Korea for more than 16 years and shows its superiority over
any other spigot joint thus well accepted by government. This design also does not shows
problem when pipe is misaligned and pushed on which may cut rubber ring for DI pipe and
rubber ring rolls inside the pipe like conventional uPVC pipe case. This rubber ring is SIRIM
certified and made with EPDM material. However, do not expose under the direct sunlight
for long time more than 3 months to prevent natural degrade of synthetic rubber. If you
expect long term storage, please request us to deliver rubber ring separately so that you
can insert it before delivery to actual working site.
3.1.4 Anti-Bacteria, Safety Proven Nano-Technology

This technology is also patented and it was test in FITI Korea in accordance with JIS Z 2801
and proved that AB-3P pipe kill more than 99.9% of microbial such as E.Coli within 24 hours.
Similar technology is very popular now in many fields such as food packaging container,
refrigerator, kitchenware, water filter and many others. For more information, please
contact our technical team. The technology mainly targeted to kill the bacteria and virus
deposited at inner pipe wall in form of slime. This is also another root cause of drinking
water contamination. It also helps to protect pipe inner wall as its designed life since
bacteria also eats pipe inner wall such as lubricant etc. This is innovative and latest
Hi-technology which can be only found in AB-3P pipe. ME-Plas(M) Sdn Bhd has FITI test
certificate as well as UK Hundington Life Science Test Report for safety test.
3.1.5 Pressure Pipes with Very Low flow friction

With high quality control standard practiced in Korea, all dimensions and performance
surely meet and surpass the requirement of standards. This also guarantees the high
quality of finish with smooth internal bore and glossy and even external surfaces which
eventually provides low coefficient of flow friction. AB-3P has lower coefficient of friction of
0.00001 compared with Cast Iron 0.010 and Ductile Cast Iron Cement Lined Pipe 0.001. the
improved flow characteristics are maintained indefinitely due to non-corrodibility. No
encrustation of the bore means pumping efficiencies are maintained over the years and no
reduction in flow will occur.
3.1.6 Residual Chlorine Absorption

Certain level of Residual Chlorine shall be maintained to provide bacteria free water. So
chlorine absorption by pipe is also very important since chlorine is not cheap chemical.
Furthermore, to achieve required level of chlorine at the end of portable water pipe network,
it is unavoidable to supply overdosed chlorine water to the consumer who is nearer to water
treatment plant. So if pipe absorb less chlorine, overall dosing could be reduced thus
consumer near to water treatment plant also could enjoy less chlorine water.
It is reported by many researcher that Copper pipe absorb the most, then Stainless steel
pipe, Ductile Iron pipe, HDPE pipe and PVC family pipe absorb the minimum chlorine.
Furthermore, AB-3P also further assists to eliminate more microbial which may exist in the
supplying water.
3.1.7 Bio-Film
There are thousands of reports about bio-film formation on the portable water pipe wall.
Even if polymer pipe has minimum slime and no scale unlike other metal
pipe or metal pipe with cement lining, bio-film is found in slime and when
the dormant microbial stick on slime and re-grown then forms bacteria
consortium after 2 to 3 months. Surprisingly, there could be even some bacteria with
chlorine resistance. This has been a serious headache for water infrastructure operator. To
eliminate this, they used to dose more organic sterilizer and this organic sterilizer like
chlorine, the more they dosed and then all metal based pipes corrode even faster. AB-3P is
the only pipe where slime contact water pipe wall, bacteria can not grow thanks to its latest
patented Anti-Bacteria Nano-Technology. AB-3P pipe Anti-Bacteria functionality and
effectiveness is tested by FITI Korea with JIS Z 2801 using E.Coli bacteria and shown the
capability that 99.9% of Bacteria is exterminated after 24 hours.
3.2 AB-DF Epoxy Coated Ductile Iron Fittings for Underground Application
3.2.1 General
AB-DF jointing is long time proven
mechanical jointing method which is same
as mechanical coupling but with some
additional easy and error free installation
feature using innovative gland design.
The AB-DF Series, joint plain end AB-3P
pipe to flanged valves, fittings, pumps and
other equipment with integral flanged ends.
There is no need for threading, welding or grooving the pipe
end since AB-DF has built in thrust restraint.
The AB-DF is designed to eliminate the problems inherent with
pre-fabricated, pre-engineered piping systems. With the
AB-DF system, flanged piping can be fabricated on the job site,
eliminating the need for off-site suppliers and delays caused by inaccurate dimensional
details.
The working principles of the AB-DF are relatively simple. Cut the pipe to the length
required. Slide the flange over the plain end pipe and follow it with a standard mechanical
joint gasket and polymer washer and Lock ring (provided with Gland). When the AB-DF is
brought to mate against the existing flange and the flange bolts are tightened, a
compression type seal is created against the mating flange and onto the pipe surface. End
restraint is provided when the set screws around the hub of the AB-DF are tightened.
AB-DF Gland pioneered this time and field proven method of flanging pipe. Similar Gland
Adaptors have been in continuous use in thousands of installations for more than 15 years.
In addition, AB-DF Ductile Iron Fitting have passed the most stringent of laboratory tests
with third party certification of performance.
AB-DF offers the most complete line of adaptor flanges in the industry from 80mm through
400mm pipe sizes. Specify the leader in flange adaptors for your next project. AB-DF, Self
Locking Gland Design.
3.2.2 Certification complied to BS/EN 545

Ductile iron fittings & accessories are complied with EN 545:2002, are constructed in such
way so that they can be attached to the matching component which the dimensions &
tolerances to BS/EN 545.
This ensures the leak-tightness interconnectivity between all components, in order to
provide adequate joint performance required over their operating life.
3.2.3 AB-DF GLAND DESIGN – ADVANTAGES

z Job Site Fabrication Using Plain End Pipe:
AB-DF Gland eliminates the problems of pre-engineered, pre-fabricated piping
systems. Pipe fabrication can be performed at site using plain end pipe, a pipe
cutter and a wrench. No threading, welding or grooving is necessary. The AB-DF
Gland eliminates the need to rely on off-site fabricators and machine shops. It is
ideal for projects that involve retro fitting or renovation of existing piping systems.
The AB-DF Gland keeps the project moving…… DOWN TIME SAVINGS are
considerable.
z Eliminates Bolt Hole Alignment Problems:
AB-DF Gland Adaptors can bee freely rotated BEFORE AND EVEN AFTER the flange
bolts are inserted then align it properly and tighten it. This facilities bolt hole
alignment with the facing flange. Pre-fabricated piping systems do not offer this
installation advantage.
z There is no bolt like us:
AB-DF gland comes with Ductile Iron Hot Dip Galvanized Bolt which offers 170%
more tensile strength than normal Mild Steel Bolt. Furthermore, it comes with hot
dip galvanized thus life time is semi-permanent. In addition, to make installation
easier, innovatively design L-shaped head is automatically .engaged in the gland
hole and seat properly on edge of main body thus fitter need only one spanner to
tighten M18 nut. All bolt size is same regardless of pipe diameter but only numbers
of bolt, nut & washer are different depending on the pipe size. This standardized
bolt size eliminated workers error as well.
z Deeper Insertion and more option:
Compared to original Korean design, this design has a few more enhancement. It
has deeper insertion length thus provide more secure engagement between pipe
and fitting. It also has smoother inner bending to provide better water flow. We
also offer you more versatile coating option such as cold epoxy coating for special
emergency project where you need non-standard size. We also offers more
prestigious and expensive Rylsan Nylon Hot Fusion Bonded Epoxy Coating which
provides you stronger bonding to metal body and better sea-water resistant and
anti-abrasion than the ordinary Hot Fusion Bonded Epoxy Coating.
z Allows for Pipe misalignment:
Unlike conventional threaded or welded gland, the AB-DF Gland will allow for pipe
deflection during installation. This means the AB-DF Gland can “make the
connection” when other methods can’t.
z Built-In End Restraints:
The AB-DF Gland offers built-in end restraint with polymer washer and Lock Ring
grip. No tie rods or similar forms of anchoring is necessary.
z Future Maintenance Capabilities:
When future maintenance is required on gland equipment such as meters or valves,
the AB-DF Gland can be easily dis-assembled and slid back on the pipe. This allows
for removal of the gland equipment. When the equipments are to be replaced,
simply drop it and re-install the AB-DF Gland. Threaded and welded flanges do not
offer this feature.
3.2.4 AB-DF GLAND DESIGN – Exposed Application

In practice, no problems have been reported even under exposed application like Pumping
Station once properly supported. But for added security, we recommend the following:
z Wiring of set screws to prevent loosening.
z Apply ‘Loc-Tite’ to the set screws after they are tightened.
3.3 BRACO: Brass Compression fittings

3.3.1 BRACO fitting is Brass Compression Fittings which consists of 1a: Braco Fitting Body,
1b: Rubber-O-Ring, 1c: Washer, 1d: Lock Ring and 1e: Cap nut. The jointing is simple
and reliable and water can be supply immediately after installation without curing
period required.
1a 1b 1c 1d 1e

3.4 DOUBLE Omega Grip (DOG bite)
3.4.1 DOUBLE Omega Grip was designed for AB-3P Bell-Mouth joint and AB-DF Fittings.
No thrust block support is required after installed with DOG Grip. Same design of DOG
Grip will be use for Bell-Mouth Joint and AB-DF Fittings.
See Joint and Fitting Easy Reference Table

4 Pipeline design
4.1 Hydraulic design
The capacity of flow in a pipeline can vary due to various
factors, which include the roughness of pipe bore,
influenced by the growth of scale and slime, roughening
due to abrasion and joint imperfections / fitting types and
configurations. Especially, it is well known fact that any
cement lined pipe is extremely vulnerable for scale and
also abrasion thus as time goes by, its coefficient value
drop drastically.
The flow data of AB-3P can be obtained from the charts

below. (Head Loss Nomogram)
Yet, for engineers who like to work with other formulae, the friction co-efficient of AB-3P pipes
are as below;
Absolute roughness For calculation of friction coefficient
Formula Up to size 300 Above 300
Colebrook 0.00001 m 0.00001 m
Darcy Weisbach - 0.03 ~ 0.06
Hazen-Williams 140 ~ 150 140
Flow capacity is calculated by using the Colebrook White Transition Equation and it is assumed
pipes are full bore discharge and velocity calculation. This equation takes into account, liquid
viscosity and pipe roughness, and is recognized as being one of the most accurate in general
use but requires an iterative solution. This equation also enables user to establish the
relationship between friction loss, discharge and velocity.
V=-2 x SQRT(2gDS) . log(k/3.7D + 2.51√ /D x SQRT(2gDS) where;
V = mean velocity in m/s

S = hydraulic gradient in m/m
D = pipe internal diameter in meters
g = gravitational acceleration, taken as 9.81 m/s
-6
√ = kinematic viscosity, taken as 1.01 x 10 m/s (at 20 deg C, 1.146 at 15 deg C)
k = pipe wall roughness, taken as 3x10-3 m
This value of the equivalent roughness coefficient "k" assumes the AB-3P pipeline is straight,
clean and concentrically jointed without fittings. Possible values ranging between 0.003 to
0.015 mm.
Type of pipe New After 50 Remarks

years
AB-3P 150 140 Hazen
Any pipe with Cement Lined 150 110 Scale factor not
Inside (Smooth bore) considered
Any pipe with Cement Lined 140 90 Scale factor not
Inside (Rough bore) considered
Steel Pipe without cement 140 40
Cast Iron without cement 130 40
Williams coefficient “C” for various 100mm pipes are listed for your information.
Table 2. Hazen Williams coefficient “C” for various 100mm pipes

4.1.1 Flow Calculation
For AB-3P flow calculation. You may use Hazen Williams Formula.
Q=AV
V= 0.84935 CR0.63I0.54
A=3.14D2 / 4
Q=0.27853 CD2.63I0.54
Where;
Q= Flow (m3/sec)
A= Pipe Cross-sectional Area (m2)
V= Velocity (m/sec)
C= Coefficient = 150
R= D/4 (m)
I= Water Route Slope (h/L)
D= Internal Diameter of Pipe (m)
4.1.2 Head Loss Calculation

Except head-loss by friction, all other loss factor can be disregarded since it is negligible
once total length of pipe become long.
hf= f L V2 / D 2g
f= 133.7 / D0.167C1.85V0.15
Where;
hf= Head-loss (m)
f= Pipe friction coefficient
g= gravity (m/sec2)
n=0.01.
4.1.3 Pipe INTERNAL Diameter Selection

Calculate water flow required and also slope.
ID=1.6258C-0.38Q0.38I-0.0205.
Example)
Want to deliver 30,000 m3/day from reservoir (Ground level=160m) to town (GL=100m).
The distance is 2 km. Calculate ID.
Q=0.347 m3/sec

I=60/2000=0.03
D=1.6258 x 150-0.38 x 0.3470.38x 0.03-0.0205 = 0.332 m (ID)
So in the Appendix 2 AB-3P Internal Diameter, Out-Diameter, Thickness Quick Reference
Table, 400mm PN12 is good enough and safe for this application.
4.1.4 Pressure class selection

The nominal pressure rating of a AB-3P pressure pipe is indicated by the PN, followed by a
2 number indicating the nominal pressure capacity.
For example, a PN12 pipe has a pressure capacity of 12bar at 20°C. This pressure should
not be exceeded through out the pipeline by the maximum operating pressure including
water hammer pressure surcharges.
See also Section 4.1.2 and 4.2 respectively for fatigue and structural considerations.
During the design, combined air release and anti-vacuum valves must be installed at local
high points in any section of a pipeline, so as to maintain full flow and prevent vacuum
conditions from occurring.
4.1.5 Water hammer surges and cyclical effects
Water hammer occurs in a pipe line when there is sudden fluctuation of flow caused by the
rapid start and stop of pump or opening and closing of valve.
Water hammer can cause a lot of problems such as damaging equipment, pipe bursting,
operation tuning difficulty and reduce system capacity.
Water hammer effects in AB-3P material is considerably low when compared with iron, steel
and concrete due to the much lower modulus of elasticity.
Where repeated pressure variations occur in AB-3P pipeline, say in the case of a pump
switching on and off in a rising main it may be necessary to consider the effect of fatigue
over the life time of the pipeline.
Design of pipeline should take into account the frequency of pressure fluctuations (cycles)
during the life of the pipeline and the amplitude of the pressure change between the
maximum and minimum steady state operating pressures plus water hammer effects.
This value when divided by the derating factor given in Table 4 should not exceed the
nominal pressure rating of the pipeline components. In practice the pressure changes in
water reticulation systems are seldom of sufficient amplitude and frequency for fatigue to
affect pipe class selection, but they can be an important consideration for pumping
systems.
AB-DF ductile iron fitting does not shows any problem on this aspect of cyclic fatigue
derating.
Table 3. Fatigue derating factors
Total cycles Fatigue derating factor, f
100,000 1.00
500,000 0.62
1,000,000 0.50
2,000,000 0.50
5,000,000 0.31
Note: A cycle is defined as one combined pump stop and start operation unless an
allowance is considered necessary to allow for attenuation of the surge wave. In this case
the cycle count should be twice the number of start/stop operations.
Examples:
1) A main pumping line is operating at the pressure of 7 bar. At the start and stop of pump,
the pressure fluctuates between 4 bar and 10 bar. The pump start/stop at 3 times and hour
and the design life is 50 years.
Therefore;
The pressure amplitude = 10 – 4 = 6 bar The whole life cycle = 3 x 24 x 365 x 50 =
1,314,000 From Table 4, the derating factor = 0.5
The minimum pressure rating (P) of the pipeline components (pipes, fittings, valve & etc)
is;
P = 6/0.5 = 12bar. Hence, a PN12 rated component is required at the operating pressure
of 7 bar.
However, for light application in domestic plumbing, Paling® PVC fittings present a
problem worthy of special consideration. Complex stress patterns in fittings can 'amplify'
the apparent stress cycle. An apparently harmless pressure cycle can thus produce a
damaging stress cycle leading to a relatively short fatigue life.
This factor is particularly severe in the case of branch fittings such as tees, where
amplification factors up four times have been noted.
The condition can be aggravated further by the existence of stress cycling from other
sources, for example bending stresses induced flexing under hydraulic thrust in improperly
supported systems.
Prudence therefore dictates that a suitable factor of safety be applied to fittings in

assessing class requirements. It is recommended that the following factors be applied to
the design dynamic pressure cycle for fittings:

Tees equal Dx3/4D Dx1/2D Dx1/4D
Safety Factor 4 3 2 1.5
Bends 90°short 45°short 90°long 45°long

Safety Factor 3 2 2 1.5
Reducers Dx3/4D Dx1/2D Dx1/4D

Safety Factor 1.5 2 2.5
Example:
A golf course watering scheme is designed to operate at 0.70 MPa. Balanced loading
will ensure no pump cycling during routine watering. However, the system is to be
maintained on standby with a jockey pump for hand watering purposes and this will
cut in and out at 0.35 and 0.75 MPa. With normal usage and leakage this may occur
every half hour on average for twelve hours a day. A twenty-five year life is required.
The total dynamic cycle is 0.4 MPa. The total life cycles predicted is 24 x 365 x 25 =
219,000. Referring to the chart, load factor is 0.8.
Therefore, P = 0.4/0.8 = 0.5 MPa (In this case, PN9 pipe is suitable)
For fittings;
Equal Tee; P = 0.4/0.8 = 0.5 MPa x Safety Factor = 0.5 x 4 = 2 Mpa Elbow; P =
0.4/0.8 = 0.5 MPa x Safety Factor = 0.5 x 3 = 1.5 Mpa
A PN15 equal tee may not have an acceptable life in this system, only PN15 elbow is
suitable.
Solution: Reduce the dynamic range or reduce the frequency or the periods on
standby.
Water hammer can be minimized by applying many control devices in the system. The
most influential parameters in selection of these devices such as air vessel, discharge tank,
surge tank and suitable location can be calculated with qualified consultant. The guideline
data is also available on request.
Also take note that above calculation does not consider extra strength and safety which
AB-3P can only provide. Therefore, with above design criteria, you will have minimum 10%
more safety than other uPVC pipe. But we still recommend following above criteria since it
will give more reliability to the whole system.

4.2 Structural Design
AB-3P are classified as "flexible" pipes, which means they have the ability to deform or deflect
diametrically within specified limits without structural damage or impairing the performance of
the pipes.
The external soil and live loadings imposed on flexible pipes may cause a decrease in the
vertical diameter and an increase in the horizontal diameter of the pipe. The horizontal
movement of the pipe walls in the soil material at the sides develops a passive resistance within
the soil to support the external load. Hence, the pipeline performance is influenced by the soil
type and density. The higher the effective soil modules at pipe depth, the less the pipe will
deflect.
Allowable deformation is up to 9% of its diameter and will not affect the pressure rating of the
pipe. A complete design approach is covered in BS EN 1295-1.
4.2.1 Minimum Cover Height

A minimum cover height of 450mm to the top of the pipe should be adopted for areas
without traffic loading. Under paved roadways the minimum cover height is 600mm or
750mm in unsealed roadways, and pipe embedment material should have a minimum
compaction Density Index of 65%. After pipes are laid and centered in the pipe trench, the
embedment material should be compacted in 80-100mm layers to the specified density.
The embedment should continue above the pipe to provide protection from the backfill.
That is a height above the pipe of 80-150mm may be required.
4.2.2 Thrust block for fittings

(This is not required if DOG bite is used.)
Where a pressurized pipeline system utilizes rubber ring joints, thrust will develop at
changes of size or direction of the pipeline such as at tees, elbows, reducers, valves and
closed ends. In buried installations, fittings shall be restrained by concrete blocks to be cast
at site. These thrust blocks should be formed and sized to effectively transfer the resultant
thrust at the fitting to the adjacent soil. The soil type and depth will influence the efficiency
of the thrust transfer. Thrust blocks must be of certain dimensions and shaped to distribute
the force to a plane surface of the undisturbed soil, normally perpendicular to the imposed
load. The interface area should be determined and the following equation can be used:
A = T/b x f 2
Where; A = area perpendicular to force (m )
T = hydrostatic thrust (kN) developed by the pipeline pressure on fittings
b = soil bearing capacity (kPa)
f = factor of safety

4.3 Above ground Installation
ME-Plas(M) AB-3P Piping system is suitable to be installed above ground or exposed. The
following measures however, are required to ensure the serviceability of the system;
4.3.1 Protection against ultra violet (UV)

AB-3P pressure pipes can be used above ground since it is quite strong against UV thanks
to its UVA additives which is only included in skin layer and also Nano-Silver implement
additional benefit. However, to secure its longer 50 years lifetime performance, one of the
following is recommended whichever is preference of end user.
z Use thin wall economical drainage pipe of similar OD and cut longitudinally and cover
the pipe. This thin wall pipe maybe bad quality and change its color or whatsoever but
it will never affect internal AB-3P. This is the best and economical method for tropical
country.
z Applying acrylic paint over the pipes.
z Use thin wall mild steel pipe or tin plate and paint it as usual. Even very thin pipe does
not really matter since it is simply cover of the pipe only.
z In the four season countries, they need to be well prepared for the winter time, they
normally use Styrofoam and tin sheet casing or similar to insulate pipe to protect
portable water from freezing. In such a case, it is completely safe from any UV.
4.3.2 Heat Expansion & Contraction

The expansion and contraction of plastic pipe is a function of the change in average
temperature of the pipe wall. This temperature depends on internal and external
environmental temperatures and whether the environments are gaseous (air) or liquid.
The most common case is a pipe conveying liquid surrounded by air.
The following simple equations may be used for calculation of expansion or contraction
under these conditions:
∆TL = Maximum temperature change in pipe contents
∆TA = Maximum temperature change of external air
∆T = Change in average temperature of pipe mid-wall
∆L = Change in length of pipe work section under consideration
k = Coefficient of linear expansion of pipe material, for AB-3P = 7 x 10–5 mm/mm/°C
L = Original length of pipe
To calculate pipe wall temperature change, use the equation
∆T = 0.65 ∆TL + 0.10 ∆TA
Using value of ∆T calculated, then calculate expansion using the equation
∆L= ∆T Δ L.k

4.3.3 Pipe movement
To accommodate the expansion and contraction without stressing the pipe, expansion loop
may be constructed with suitable length of unrestrained pipe (free leg length) as shown in
the graph below:
Example:
Determine the free leg length required to accommodate a change in length of 20 m of
90mm diameter pipe work caused by an increase in contents temperature from 20°C to
40°C, with the external air temperature also increasing from 5°C to 25°C.
1. To calculate pipe mid wall temperature change (∆T) apply the equation:
∆T= 0.65 ∆TL + 0.10 ∆TA Therefore ∆T = 0.65 (40–20) + 0.10 (25–5) i.e.
∆T = 0.65 Δ 20 + 0.10 Δ 20 = 15°
Note: The common error when calculating ∆T is to use extremes of temperature, in this
case 5°C for air and 40°C for contents. 35°C would then be used for ∆T in the next
calculation instead of the correct 15°C which would give more than double the true value.
2. To calculate expansion (∆L)
∆L= ∆T x L x k therefore ∆L = 15
x 20 x 7 x 10–5 mm/mm/°C =
0.0210m = 21mm
3. To calculate free leg length
using the value of ∆L/2, draw a
horizontal line on the graph from
the vertical scale to meet the 3in
or 90mm pipe gradient line. Drop
a perpendicular from the
intersection point to the
horizontal scale. The figure
obtained is the free leg length of
loop required, which in this case
is 1.03m.
As a rule of thumb, AB-3P pipes
will expand or contract by
0.6mm/metre for every 10°C
change in pipe wall temperature.
4.3.4 Exposed Pipe support

Support should not restrain the longitudinal movement of pipes. Where unyielding material
like steel is used to support pipes, a suitable compressible material (ie. rubber), with a
thickness of 3mm is used between the pipe and the clamp.

If AB-3P is installed in the vibrating area or
similar environment, you can still consider
Optional Ultra Grip. But also be reminded that
OUG is raking pipe surface thus more safety
factor is required. 155mm OUG can withstand
up to 15 bar.
The recommended distance between supports, vertical and horizontal, is tabulated below:
Table 5. Recommended Distance of Pipe Support

Distance between support for various water
temperature (PN12)
size vertical
horizontal pipes (mm)
(mm) (mm)
20 deg C 30 40 50 20 to 50
15 850 700 500 400 900
20 900 750 550 500 1000
25 1000 850 650 570 1200
32 1100 1000 800 700 1400
40 1250 1150 950 820 1600
50 1400 1300 1100 970 1800
65 1500 1400 1200 1070 2000
80 1650 1550 1350 1200 2200
100 1850 1750 1550 1370 2400
125 2000 1900 1750 1570 2450
155 2250 2150 2000 1850 2500
175 2400 2250 2200 2000 4400
200 2750 2500 2300 2100 4600
250 3100 2850 2600 2450 5200
300 3550 3300 3000 2700 6000
350 4000 3800 3500 3100 6000
400 4300 4200 4100 3500 6000

5 Installation
5.1 Transportation, Handling and Unloading
AB-3P pipes should only be transported on vehicles with a flat bed that provides adequate
support along the full length of the pipe. The bed of the vehicle must be thoroughly checked
before loading to ensure that it is free from sharp material that may damage the pipes. Where
side supports are required they should be smooth and not more than 1.5m apart. An
unsupported overhang at the rear of the vehicle should not exceed 1m. As with storage the
packs of pipe should be loaded with the heaviest at the bottom.
Pipe that arrives on site damaged should not be used and the incident should be advised to
ME-Plas(M) immediately.
AB-3P pipes are light (about 1/7 of the weight of Mild Steel Cement Lined Pipe) and easy to
handle. Installation time is very fast with bell mouth rubber ring joint and simple AB-DF design.
Nevertheless, careless handling may cause unnecessary damage.
Important notice for unloading:
z Do not throw from lorry. (Rolling properly, if you do not have forklift!)
z Do not unload by sliding from the tailboard of lorry
Pipes and fittings should not be dropped or thrown onto

sharp objects which could inflict deep scratches. AB-3P
pipes should not be allowed to slide across sharp edges.
During construction storage areas should be selected
which are free from surface irregularities such as stones,
or other sharp projections.
When you do not have any unloading equipment or
means, when unloading, if pipe is not bundled, you may
still unload it horizontally rolling down to the ground. But
put three shock absorbing material such as used tire at 2
meters interval. Then also put smooth timber or polymer
pipe to give maximum 45 degree slope to the ground.
When pipe rolled down, it shall not hit any sharp edges or metals around. Then when it rolls
down, it will bounce to tire and seated to ground safely. However, for AB-DF and fittings, never
throw or roll down. It shall be gently unloaded using either equipment or manually. AB-DF is
delivered with proper wrapping material to protect epoxy coating. Do not tear it off until you
install it at site.
5.2 Storage
AB-3P pipes may distort under high loads. Therefore stack heights should be kept to a
minimum for long term storage. (2 meters or below)

At elevated temperatures pipes may bow due
to uneven heating of individual pipe lengths.
Where this may be a problem during
installation they should be protected from
direct sunlight immediately prior to use. So
we recommend stacking in # shape and also
do not compress directly on to both of the
bell mouth spigot jointing end. i.e. Bell
mouthed pipes should be stacked in layers
with sockets placed at alternative ends of the
rack, and protruding, to avoid uneven stacks
and distortion. The sockets should not be
allowed to carry loads. We also recommend
storing AB-3P with proper cover to prevent
UV as well as dust. AB-3P is strong against UV effect but providing proper cover is always better.
Also excessive heating may deteriorate rubber ring. Even though this rubber ring is EPDM and
the one of the best quality, rubber ring is weaker than pipe itself thus proper ventilation to keep
the pipe less hot is always wise choice.
Important Notice
z Do not stack more than 1 meter if stacked in parallel.
z Do not stack more than 2 meters if stacked in # shape. (Best recommendation)
z Cover when you want to store for long time
z If exposed long time to sunlight, remove rubber ring and insert again only when deliver
to site.
Right is ideal storage of any polymer pipe. You can also nest small size pipe in the big size pipe.
However, when you stack like right figure as parallel manner, do not stack more than 1 meter
high.
When equipment such as fork lifts
or cranes is used on bundles,
adequate spreader and lifting
bars should be provided.
Wire slings must be kept clear of
the pipes. When unloading
alongside excavated trenches, it
is recommended that pipes be
placed on the opposite side of the
trench from excavated material.
AB-DF Fitting Rubber rings, Polymer Ring and Washer, jointing fluid, solvent cement and
priming fluid should be stored under cover until pipe installation starts.

5.3 Fabrication, Cutting
In case AB-3P pipe should be cut, use a fine tooth panel saw. It is important that the cut should
be square and to this end a mitre box or similar device is recommended. If this is not available
a square cut can be obtained by using a piece of paper wound around the pipe as shown in
figure. The outside edge of the pipe end should be chamfered to approximately 15° so that at
least 50% of the wall thickness is removed at the leading edge. After cutting, a chamfer of this
nature is essential for both solvent cement and rubber ring seal joints. a rasp or file can be used
for this operation.
Cutting the pipe Square
z Using a sheet of paper with square edges,
wrap it round the pipe.
z Ensuring that the paper is tightly wound
and ends are square, cut along edge of
paper
5.4 Installation: Underground Trench Construction

It is very important to take note that AB-3P pipes shall be immediately backfilled except joint
point exposed for testing verification. If this is not possible, cover the pipe even a little bit with
sand or similar before testing. During the installation of pipe, footing and sand bedding are vital
importance for higher safety of pipelines.
The reasons are as follows.
z Weaken the stress acting upon the pipe to increase its safety.
z Prevent the pipe from moving at the flowing of water to impede generation of heavy forces
which may temper the pipe.
z Protect the pipe to prevent occurrence of external damage by stone or rock and generation
of heavy stresses, and
z Form a uniform footing for longer retention of piping function.
z Execution of works in accordance with the following specification is therefore imperative.
Trenches should be constructed in accordance with the local authority requirements. They may
be as narrow as possible at the spring line of the pipe. The detail design of trench can be
obtained from BS EN 1295-1.
Adequate width of trench should be provided for compaction of the embedment material in the
side support
zone.

To make easier reference, following is recommended dimension on
the right Table 6. Recommended Trench
Minimum Width (W)
For minimum cover over the pipe (H), please refer to as follows;
Pipe Size W (mm)
- Private way No vehicle loading: 300 mm
15 42
- Private road, Paved: 600 mm 20 52
- Public Road: 900 mm 25 69
- Heavy Traffic road: 1200 mm 32 85
Note: Final depth shall be decided with Consultant engineer in 40 98
accordance with local regulation and practice. 50 122
65 152
ROAD CROSSING 80 178
For heavy traffic or heavy weight vehicle traffic road crossing, we 100 315
recommend to use one size bigger pipe (MS, or AB-3P) for sleeve 125 425
rather than concrete encasing to consider any possible maintenance 155 460
in the future and effective protection of the pipe. 175 477
200 500
It is also good practice to use DI pipe for road crossing part only 250 550
since DI pipe is very rigid and hardness is much stronger than 300 615
polymer pipe. 350 655
400 700
5.4.1 Bedding material

Unless otherwise specified, following material is recommended.
- Sand free from rock or hard and sharp objects which is larger than 13.2mm sieve.
- Crushed stone with approved grade which is normally smaller than 14mm. However,
AB-3P is not easily punctured or cracked unlike other polymer pipe but it is always
discrete not to have sharp material under the pipe.
- Compaction, as well as the type of natural soil of the trench wall, is important in
determining the ultimate performance of AB-3P. The trench bottom should be as
smooth as possible and to grade.
- Embedment material such as bedding, side support and overlay material should be of
non-cohesive granular material. Pipes should not be buried in contact with soil particle
sizes larger than 5% of diameter, with 20mm as maximum.
- Remove temporary supports such as bricks or timber be left under or in contact with
pipes. If the excavated material is not granular or friable, or does not comply with the
project specification, then suitable embedment must be imported.
- Jointing should be excavated in the bedding for pipe sockets to ensure the pipes are
evenly supported along the full length. In the absence of any specification and if the
pipe Classes are PN9, it is important that only non-cohesive or granular embedment be
used. Careful attention to the placement of embedment material to the specified

relative compaction with an absence of voids is recommended.
- If soil is very soft or swampy area, we highly recommend to use Optional ultra grip at
bell mouth joint and also proper full trust block or patent pending grooved fitting
connection method to ensure that push on joint part may not loose upon soil settlement.
Please consult with our distributor for the sleeper method if you have moving soil
due to the heavy water contents in the ground.
5.5 Installation: Above Ground Exposed Construction

5.5.1 Protection against ultra violet (UV)
AB-3P pressure pipes can be used above ground since it is quite strong against UV thanks
to its UVA additives which is only included in skin layer and also Nano-Silver implement
additional benefit. However, to secure its longer lifetime performance, following is
recommended whichever is preference of end user.
z Applying acrylic paint over the pipes.
z Use thin wall economical drainage pipe of similar OD and cut longitudinally and cover
the pipe. This thin wall pipe maybe bad quality and change its color or whatsoever but
it will never affect internally protected AB-3P.
z Use thin wall mild steel pipe or tin plate and paint it as usual. Even very thin pipe does
not really matter since it is simply cover of the pipe only.
z In the four season countries, they need to be well prepared for the winter time, they
normally use Styrofoam and tin sheet casing or similar to insulate pipe to protect
portable water from freezing. In such a case, it is completely safe from any UV.
5.5.2 Heat Expansion & Contraction & Pipe movement
To accommodate the expansion and contraction without stressing the pipe, expansion loop
may be constructed with suitable length of unrestrained pipe (free leg length) as shown in
the graph below: However, unless it is exposed to direct sunlight, if there is any supa-tite
rubber ring joint in the run, it usually absorb all mild natural pipe movement.
5.6 Jointing using “Supa-Tite” Rubber Ring Joints (Above and under ground)
ME-Plas(M) AB-3P pipes are supplied with “Supa-tite” rubber ring, pre-assembled at factory.
Approved lubricant should be used when jointing pipes to ease the insertion of spigot and is
supplied together with pipes.
5.6.1 Jointing Procedure (Factory Rubber ring

inserted Pipe)
The rubber ring joint should be assembled as
recommended by the pipe manufacturer. It is usually
pre-assembled at factory.
z Take out the end-cap on Bell mouth (female

pipe) side. Please return cap to water authority or properly dispose it to avoid
eyesore complaint.
z Check inside of belled parts and if there is any dirt, clean the Rubber Ring (but do
not pull out, clean as it is seated), the socket or the coupling interior, with a rag to
remove any dirt or foreign material before assembling.
z Apply approved AB-3P Lubricant on surface of Rubber Ring.
z Align it straight to chamfered spigot male pipe to belled pipe.
z Take off cap of chamfered male pipe.
z Clean the surface of male pipe for insertion.
z Apply lubricant from end to the HALF of insertion black marking line
z Align and push gently with jig for small size, for big size use excavator and push
other end of pipe using timber or similar material not to damage the pipe end.
z Make sure marking line is visible and well bordered with belled parts. If it is farther
than 5 mm, it is not properly engaged. Push a bit more.
5.6.2 Jointing Procedure (Site Rubber ring insertion)

In some special application, the EPDM rubber rings could be supplied separately in cartons.
If you need to install at site, in any cases;
z Clean the ring, the socket or the coupling interior, especially the groove area and
the spigot area with a rag or paper to remove any dirt or foreign material before
assembling.
z Inspect the ring, pipe spigot chamber, ring groove and sealing surfaces for
damages or deformation.
z When inserting the rubber ring, make it like heart shape and seat it into groove.
z Use only “Supa-Tite” rubber rings which are designed for AB-3P and supplied with
the pipe. Insert them as recommended by the ME-Plas(M) sdn bhd.
z Use only the lubricant supplied by ME-Plas(M) Sdn Bhd
z Remained procedure is the same as above.
5.6.3 Various Method of Assembly for AB-3P Bell-Mouth Pipe

z Crowbar method:
Complete entry of the spigot into the socket maybe obtained by pushing with crow-bar
or suitable level against the face of the socket of the entering pipe.
z Fork Tool Method:

For joint 80mm to 200mm, fork type tool may be used for assembly. The fork is placed
over and behind the socket of the last pipe laid. A wire rope sling is wrapped around the
spigot to be joined.

z Trench Excavator method
Where trench is prepared using excavator, this machine could be used for pushing the
pipe into the bell mouth. This method is very effective for large diameter pipe. Please
use timber to the edge of the pipe so that excavator bucket does not directly contact
the pipe.
z Wire Rope Puller method

For joint above 200mm, a wire rope or chain puller can be used as shown in diagram.
The puller is normally available in hardware shop.
AB-DF Ductile Iron Fitting Joint with AB-3P pipe usually does not need complicated tools.
It is mechanical joint type with innovative gland design. So pipe insertion is easy and does
not need any complicated tools.

5.7 AB-DF Epoxy coated Ductile Iron Fitting Installation
AB-DF jointing is mechanical jointing method which is same as mechanical coupling but with
some additional easy and error free installation feature using innovative gland design.
5.7.1 Assembly Procedure

5.7.1.1 AB-DF, Gland Design
z The most important part of AB-DF is Gland.
z Gland always comes with EPDM Rubber ring and
Polymer Lock Ring and Polymer Washer. Check 4 items
are not missing.
z Also check required numbers of M18 L-Shaped Bolts,
Nuts and Washers are with you.
z Make sure to bring suitable M18 spanner. (Wrench size
27mm)
z Place AB-DF at jointing part.
z Take off wrapping material just before joint. Insert
pipe to stop notch and pull out 5 mm and draw line to
outside of pipe.
z Insert Gland to pipe.
z Insert Polymer Lock Ring to pipe.
z Insert Polymer Washer to pipe.
z Insert AB-DF Rubber ring to pipe. (NOT “supa-tite”!).
z Push pipe into the AB-DF (No need lubricant)
z Tighten gland with L-shaped nut and washer using
M-18 spanner. (Wrench size 27mm).
z Check that bolt head is automatically engaged inside of
gland bolt hole and hook on the edge of fitting body.
z Tighten the nut a 80% only. (a bit loose to turn gland)
z Turn gland.
z Tighten the next nut.
z Repeat this until you tighten all the nut/washer/bolts
required.
z Align bolt position of gland to make easier final
tightening considering your working space.
z Tighten fully. But make sure that when you tighten one
bolt, the next bolt shall be opposite angle across the pipe center. It is same
principle when you tighten car tire bolt when repairing flat tire.
z Make sure that all 4 components are installed.
5.7.1.2 AB-DF Flange Connection Part

Some of the AB-DF fittings are designed to match with other devices such as valve or
Mild Steel Fitting/Pipe/Ductile Iron Fitting etc using mechanical flange such as Flange
Adaptor, Flange T Joint, Flanged blank-end (Endcap) etc. The most important part is
proper tightening when it comes to flange type connection.
5.7.1.2.1 Required equipment:
z Gasket Spanner size
Bolt size
z Bolts & Nuts (mm across flats)
z Torque Wrench M16 24
M18 27
z Oil / grease M20 30
z Spanner / Socket (table) M24 36
M27 41
5.7.1.2.2 Procedure M30 46
M33 50
As with all flange assemblies, M36 55
rubber gasket and faces of M39 60
flanges must be free of sand, M45 70
grit, grease or other matter. M52 80
Hold the gasket in correct position on a clean flange face aligns until faces
of both flanges meet.
Insert the upper and lower bolts, and then hand tightens the nuts. Insert
the remaining bolts and then hand-tighten the nuts.
Tighten the opposite sets of bolts in the sequence, ie. Start with bolts of the
upper and lower sides of the flange, followed by the right and left bolts.
Tighten all sets of bolts around the flange by achieving the recommended
bolt torque. Check and if necessary, re-tighten the bolts. Installation is
complete.
PN 16 Flanged
5.7.1.2.3 Bolting Torque Nominal Size
Bolting Torque
The chart indicates the approximate bolt DN Nm
torques required to seal flanged joints against 80 70
100 80
internal pressure. 150 120
Bolts must be tightened in the correct sequence 200 115
with sufficient circuits to ensure that the 250 165
300 180
required bolt torque is achieved on each bolt.
350 175
If your contractor does not have torque wrench, 400 220
please train them with normal spanner and
check with your torque wrench until he is familiar with the strength to apply with
spanner to achieve right torque value.
5.7.1.2.4 Bolting Details

The chart indicates the approximate bolt torques required to seal flanged joints
against internal pressure.
Nominal PN16 Flange
Diameter Length
No Dia
DN mm
80 8 M16 65
100 8 M16 65
150 8 M20 70
200 12 M20 70
250 12 M24 80
300 12 M24 85
350 16 M24 90
400 16 M27 95
5.7.2 Thrust block design for AB-DF Ductile Iron Fitting (Anchor Block)
(This is NOT applicable if DOG bite accessory is used)
(This is NOT applicable for Grooving AB-3P design or Jam-bolt design)
5.7.2.1 Purpose
The main purpose of thrust block is to prevent AB-DF fittings in the pipe line from
moving when pressure load is applied. The thrust blocks absorb the load from the
AB-DF fitting and transfer it to a wide load bearing area on the wall of trench. Thrust
blocks are required whenever pipelines;
z Change its direction
z Reduce its diameter
z Ends
z Connected to Valve
z Negotiate a curve where a soft soil condition is encountered.
5.7.2.2 Installation
It is very good practice to ensure that the pipe adjacent to the AB-DF fittings are firmly
secured before installation of thrust blocks. For buried pipe application, fittings are
usually restrained by concrete blocks cast at site. This is to ensure that neither the
AB-DF fittings nor the AB-3P/Other connected pipes will move when thrust block has
been installed. The thrust block should be positioned symmetrically along the line
through which the resultant thrust acts and rest firmly against the side of trench.
The soil type and depth will also affect the efficiency of the thrust transfer but to make
easier reference, here is some indicative thrust block size.

5.7.2.3 Typical Thrust Block
Sufficient support should be provided at AB-DF joint to ensure that the joints do not
move when subjected to internal hydrostatic pressure. You may find guideline
standard thrust block dimension in Appendix 4. However the dimension varies when
soil condition is changed like soft soil or hard rock. Please consult with professional
consultant.
Figure: Thrust Block

1. Gate valve using paddle flange 2. AB-DF Tapered Reducer
3.&4. AB-DF 45 deg Bends 5. AB-DF Blank Ends 6. AB-DF Equal Tee

(This is NOT applicable for Grooving AB-DF design or Jam-bolt design)

5.8 Double Omega Grip
Double Omega Grip is also called DOG bite since it strongly bite AB-3P pipe and hold against
any longitudinal movement. It is designed to be used as an accessories to hold pipe where;
• Bell mouth holding is required since pipe is not buried underground or buried but very
soft soil or exposed but gripping support is not easy and pressure is higher than 3~5
bar.
• AB-DF fitting is used but concrete thrust block is not easy or want to skip to save cost
and time.
• Conventional Bolted glanded DI fittings is used but concrete thrust block is not easy or
want to skip.
Installation Procedure
• DOG Grip Accessories for Fitting consist of: -
a) 4 sets of ¼˝x2˝ Bolts and Nuts.
b) 4 sets of ½˝ x 10˝ Tie Rods.
c) 2 sets of Gripping Flanges.
1a 1b 1c
Free
• Installation of Fitting and the DOG Grip Length
a) Insert the gland into the pipe.
2d 2e 2f
b) Insert the rubber ring into the pipe and connect to the fitting.
c) Adjust the position so that the bolt holes for bolt & tie-rod are properly align and can install easily.
d) Insert the bolts into the bolt holes and tighten and Nuts.
e) Insert the tie-rod into the bolt holes and tighten and Nuts.
f) After all the bolts and tie-rods at the fitting are completely tighten, align properly the DOG Grip
before insert the DOG Grip into the tie-rod.
g) Tighten the bolts & nuts between the DOG Grip.
h) Tighten the nuts at tie-rods, making sure that the tie-rods are evenly tightened and the free
lengths between the DOG Grip and the Gland are the same.
i) Install another set of DOG Grip on the other side of fitting.

AB-DF with DOG Grip fitting installation
DOG accessories can also be used to hold Bell mouth.
• Installation method is same.

• Useful for swampy area
• Useful for extremely soft soil.
• For exposed running and grip support is not easy to do as per
requirement.

5.9 Brass Compression Jointing
• BRACO Brass compression fittings are specially designed to suit AB-3P pipe.
• The jointing is very strong but the price will be a bit higher side compare with solvent
cement joint.
• The jointing is simple and reliable with a ring to hold and clip to the pipe when
tightened with a spanner.
• Make sure that Lock ring and rubber ring is in right direction.
1) Braco Fitting consists of:

(a) Braco Body, (b) Rubber-O-Ring, (c) Washer, (d) Lock Ring & (e) Gland.
1st 2nd 3rd 4th
2). Assembly Sequence 1st Insert Rubber-O-Ring into fitting.

2nd Insert Washer into fitting.
3rd Insert Lock Ring into fitting. (Small part up)
4th Insert Gland into fitting.
3
3) Jointing the Pipe.
(a) Make sure the pipe and fitting are clean before joint.
(b) Insert the pipe into the fitting and push it in until the end.
4 4) Tighten the Joint.

(a)Screw the Gland with a spanner clockwise until it is
tight.
(b) Check the joint by pulling the pipe from the fitting. If tighten
properly, the pipe cannot be
pulled out.

5.10 Solvent Cement Jointing
Following is the most important procedure to do proper solvent cement joint
z Recommended for Type of Solvent Cement for jointing of pipes:-
All sizes : IPS Weld-On® Solvent Cement with IPS Primer
z Recommended on BRUSH:-
Pipes with diameter 25mm (1”) and below – use dove or brush as accompanied and
fixed to can.
Pipes with diameter 32mm to 50mm (1 ¼” to 2”) – use separate 1” brush.
Pipes with diameter 75mm to 200mm (3” to 8”) – use separate 2” brush.
z Prepare factory approved Primer and Solvent
cement IPS Weld-On® only
Use 1 inch wide brush to apply solvent
cement which is faster to prevent curing
before actual joint insertion.
Pull out brush hairs with your finger and take
out all loosened hair so that it will not be
stuck on the pipe while applying it. Loosened
hairs of brush may cause leakage problem.
z Dry-fit pipe and fitting
z Fix pipe properly so that it will not move while
push in
z Apply ample primer to FITTING and immediately apply ample Solvent cement to FITTING.
z Apply ample primer to PIPE and immediately apply ample Solvent cement to PIPE.
Primer is to clean any oil on surface and soften to bond
Most of the joint failure came from insufficient solvent cement
z Push in fitting and turn until pipe reach to bottom of fitting
z Hold it for 10 seconds
z Clean excessive solvent cement spill out from joint with clothes
z Cure it for 24 hours (If water flows after 6 hours only, it takes longer time to get cured since
only external part can dry out. Excessive pressure which is more than PN rating shall not be
applied during curing time.)
For light application in the building etc, solvent cement jointing with PVC fittings can be also
used. To achieve strong joints in a pressure pipe works, the correct type of solvent cement
must be used. ME-Plas(M) insist to use IPS Weld-On® solvent cement with its primer which
is manufactured with a controlled amount of resin and solvents.
It must be emphasized that this is not a gluing process, instead an adhesion mechanism
achieved through the molecular bonding of resin solidification as the solvents evaporate which
is very similar like welding.
However, it shall be strongly emphasized that due to the dependency of workmanship which is
usually beyond control of end client, we strongly recommend to use Bell mouth Rubber Ring

joint and AB-DF Fittings unless it is impossible to avoid Solvent Cement Joint. “Supa-Tite”
Rubber Ring Joint method is much more reliable than any Solvent cement or Fusion welding or
even HI-3R:ABS injection molded fitting joint.
Also note that for bigger diameter pipe, the complete application of solvent cement also takes
some time. If you use quick drying type, you can not achieve proper connection.
We also recommend using blue or green colored solvent cement even if it is a little bit higher
cost. With colored solvent cement, worker can easily identify the even spreading and
application of solvent cement on the surface of pipe to be joined.
We can supply above solvent cement, 1 inch brush (For 100mm and above diameter) and clean
mope for primer application with more economical price than other retailed outlet.
If pipe is larger than 100mm, use 1 inch wide brush to apply solvent cement which is faster to
prevent curing before actual joint insertion. So choose proper brush and try to pull out brush
hairs with your finger and take out all loosened hair so that it will not be stuck on the pipe while
applying it. Loosened hairs of brush may cause leakage problem.
5.10.1 Above Ground Solvent weld jointing instructions

z Make a square cut using a mitre box and fine-toothed panel saw.
z Remove all burrs and swarf.
z Slightly chamfer the external pipe edge.
z Draw a line on the spigot to show the depth of socket.
z Clean the pipe and matching socket, using priming fluid to the manufacturer's pipe
recommendations.
z Keep the cleaned surfaces free of dirt and grease. Failure to do so could lead to
inadequate bonding and will result in joint failure.
NOTE: This is a very important step: the priming fluid not only cleanses the surface
but also prepares for a durable and long lasting joint.
z Apply primer to FITTING and immediately with the solvent cement to

the FITTING again.
z Apply primer to PIPE and immediately with the solvent cement to the
PIPE again. (Inside of the socket and again to the pipe spigot), over an area
corresponding to the socket depth.

z While the surface is still wet, push and twist the fitting
into the pipe.
z Hold the cemented joints for 10 seconds without
movement.
z Clean the excess of solvent cement with a clean
cloth.
z The pipe may be handled, but not unduly strained for1
hour. Wait 24 hours before testing or use.
5.10.2 Underground Buried Solvent Cement Jointing

In case of underground application, extreme care shall be
taken.
z Lay the pipe before making solvent welding.

z Follow the step of “5.7.1 Above ground jointing”
procedure.
z After jointing is done, immediately backfill the pipe trench.
This will reduce any excessive expansion or contraction
during the curing process of solvent weld joint.
z This joint will sustain the end thrust to which the pipe will
be submitted when under pressure. Care should be taken
that excess adhesive does not flow into the pipe bore.
z Wipe off any that has been expelled from the mouth of the
bell mouth socket.
z Do not disturb the joint for at least 30 minutes although the jointing may continue.
It shall be noted that ME-Plas(M) VERY STRONGLY INSIST to use “Supa-tite”
rubber ring joint and AB-DF fitting solution unless solvent cement joint is
completely unavoidable.
5.11 Expansion and Contraction

Distortion can occur when laying pipes in direct sunlight. When one side of the pipe is hotter
than the other, it may develop a bent shape which may make jointing difficult.
However, this used to happen in polymer pipe such as PE, ABS or bad quality uPVC but AB-3P
has much less heat expansion rate than above. However, in any case if this happens, plastic
pipe will contract as it cools, after laying in hot weather. A 6 meter length of AB-3P will expand
or contract approximately 3~4mm for each 10°C rise or fall in temperature. In PE pipe case, it
will be 9mm, in case of ABS pipe, it will be 7 mm. So backfill each length, at least partially, as
laying proceeds to ensure that the heat expansion will not be so much. Refer Section 4.3.2 and
4.3.3. Rubber rings allow some movement of the pipeline during and after completion of the
laying operation to ensure that the joints do not slipped out. In fact, AB-3P’s unique rubber ring
design ensure water tightness than any other rubber ring design to ensure joint against

thermal changes. Therefore, even with freezing winter time and hot summer time, this joint
allows better performance for heat expansion and contraction as well as external and internal
vibration movement such as water hammering, earthquake.
5.12 Curved Installation

AB-3P unique “Supa-tite” Rubber ring joint of AB-3P pipe allows around 5°~8° of angular
deflection without AB-DF fittings depending on pipe diameter. Nonetheless, Joints should
always be made with the two pipes straight. Deflection should be made only after the joint is
made. Also AB-3P pipe itself is flexible at certain degree thus minor changes in direction can be
achieved by jointing and then deflecting a subsequent pipe. Also above figure considered
additional marginal safety factor as well.
AB-3P Pipes of smaller sizes are flexible enough to be easily deflected. The route of pipe should
be curved evenly along its length so that strain is not taken by the joint. The pipes should
always be joined directly in line before the curve is made. Radius of bending should not exceed
200 times the diameter of pipe. In principle, Local Water Authorities should be consulted on
whether or not curved AB-3P pipes are allowed to be drilled or fitted with tapping bands.
Sometimes, contractor also exercise to use AB-3P with almost 10 degree bend without fitting.
However, we highlight to firmly compact and support pipe on the curved outside perimeter so
that water pressure may not push out the pipe during the testing.
5.13 Concrete Encasement

AB-3P pipes may be encased in concrete. Where the concrete face cannot be located on a
socket, compressible material approximately 3mm thick and for a distance of about 100mm
from the face into the concrete should be used around pipes. By encircling the pipes at the
entry and exit points, any potential sharp edges will be prevented from bearing against the pipe
wall. The pipeline should not be pressurized with water until the concrete has developed
sufficient strength to resist tensile stresses. This could be used for heavy weight vehicle road
crossing instead of sleeve. For main highway, we recommend to use one size bigger pipe (MS,
or AB-3P) for sleeve rather than concrete encasing to consider any possible maintenance in the
future and protection of the pipe. It is also wise to use DI pipe for road crossing part only since
DI pipe is very rigid and hardness is much stronger than polymer pipe.
5.14 Backfilling
Mechanical joints, especially flanged joints of AB-DF and its ancillary devices, should be left
exposed if possible until the line is tested.
Pipes should be covered where there is a possibility of the trench filling with water due to rain,
etc. as flotation of the empty pipeline will occur unless it is backfilled to a height of at least one
and a half diameters above the pipe.
Before backfilling, pump any accumulated water from the trench.
Do not tip fill directly from dump truck into trench.

The method of placing the remainder of the trench backfill will depend on whether the pipeline
is located in an area with no traffic loading or under a roadway.
In a roadway it is normal practice to continue backfilling and compacting with good quality
embedment material up to pavement level. Heavy compaction of backfill should not commence
without at least 300mm of material covering the pipeline.
When assembly of pipe line is suspended, do not leave tools, cement, lubricants etc in the
trench or inside of piping. Also cover the open end of pipe line with proper Endcap supplied
with AB-3P pipe. It has small hole in the center thus can also breath and protect from mud and
debris to ingress into the pipe.
5.15 Pressurized and Non-pressurized Tapping

Before tapping, please contact local authority for permit. Check you have all proper equipment
to make tapping to polymer pipe. There are two types of tools for AB-3P pipe. It is exactly same
for PE or uPVC or ABS.
AB-3P also can tapping directly if it is not pressurized. However, this practice does not give
good result due to the bad workmanship mostly. Also contractor seldom have appropriate tools
and follow procedure stringently. So we strongly recommend to use tapping saddle for
applicable case. We also supply pressurized ductile iron tapping saddle as a part of AB-DF
system. We do not recommend using Cast iron Saddle since it is quite brittle and showed many
failures.
However, make sure to use saddles specially designed for polymer pipe. AB-DF saddle is
specially designed and in fact, has stronger gripping onto slippery polymer pipe surface with
latest design. You can see that internal rubber pad design is different with other saddle.
It shall have screwed groove inside of cutter to hold drilled pipe wall or another type is at the
tip of drill which is on the center of cutter, they have cut-pipe wall holding pin. See photos
below.
Screwed
cutter type Holding Pin
type Ductile Iron Tapping
Saddle with Convex Liner Grip

Precaution:
Please do not use any tapping saddle which does not has internal rubber ring to fight against
slip on the pipe surface. Without internal rubber, tapping may turn or even slipped along pipe
length.
General Tapping Procedure
z Mount the saddle
Fit the ferrule/strap on to the saddle. Fasten the saddle with bolt and nuts.
Place the flat washer over the ferrule stem.
Screw Tapping device on to the stem and open the valve in the body
Make sure the cock built in the ferrule is correctly open and all screws are tightened
before setting drill.
z Drilling
Rotate T or X bar to advance spindle until the cutter touch pipe wall
When it touches, slow down the feed.
Give additional feed to pierces the pipe wall. (1 cm or depending on pipe size)
Withdraw the spindle/cutter fully and close the valve.
Unscrew the complete head-works from the valve body
z Completion
After raising the drill, close the ferrule.
Make sure that your cutter hold cut pipe piece so that it will not go in the pipe and
stuck to water meter.
5.16 Connection to Water Meter and Stand pipes and vertical riser
For meter installation above the ground, the AB-3P Pipe should be terminated approximately 1
meter before vertical riser which is normally GI or Stainless steel pipe. However, you may also
use AB-3P for the vertical riser but in such a case, you shall support properly so that it will not
be easily damaged by the pedestrian abuser as well as holding firmly when internal hydro
stress may not move the riser. It is also wise to design it away from pedestrian walkway since
exposed vertical riser usually abused by malicious pedestrian or vehicle accident which any
kind of small size pipe can not tolerate the shock.
5.17 Prevention from Floating

Adequate measures shall be made to prevent floatation of pipe due to the ground water or
similar before backfilling is completed. However, unlike PE, AB-3P pipe material is heavier than
water (average density 1.38) thus you may partially backfill the pipe main body, not the joint
or fitting, than it will not float anymore.
5.18 Pre-Assembly and laying

Unless trench has a lot of existing communication pipes for electricity, water, gas etc, you can
pre-assemble bell-mouth rubber ring joint on the ground to make your connection easier if you

want. But, when you push pipes into the trench, make sure that there is no sharp material like
stone or nail which may damage AB-3P pipe.
However, AB-DF shall be joined in the trench. After push pre-assembled pipe in the trench,
make sure that rubber ring joint inspection line is still in position and does not comes out
beyond tolerance which is 5 mm. If GC type connection is used, make sure to use approved
tools to make proper groove.
5.19 Site Testing

The site testing requirements should be carried out according to the local Water Authorities. It
is recommended that the test is carried out at the pressure of 1.5 times the lowest rated
component of the pipeline.
Sample Procedure:
1. Pressure test as short a length of pipeline as possible.
2. Ensure that all air release valves are working properly. We found AVK® air valve is reliable
and many of other local brands do not show reliable and consistent result as of 2006.
3. Open filling valve very slowly and only about 10% of capacity to ensure gradual filling.
4. Allow pipeline to fill and pressurize to working pressure.
5. Allow two hours for pipeline to settle under pressure.
6. Pressurize as necessary back to working pressure as air slowly escaping out of water will
show a reduction of pressure.
7. Once satisfied that no leakage have monitored, then increase pressure gradually until test
pressure of 1.5 times working pressure. E.g. if working pressure is 7 bar maximum, then
increase to 10.5 bar, if 12 bar increase to 18 bar.
8. Maintain test pressure for 1 hour only.
9. When installing T such as scour and hydrant tees, it is important that the leg of tee is
blanked off then pressure tested to allow pipe movement to take place.
10. Once pressure test has been completed, the necessary thrust block must be installed.
The test usually performed for more than one hour. Water in the pipeline may require
replenishment depending on the pipe wall temperature due to expansion.
Solvent cement joints should be allowed to cure for at least 24 hours from the time of the last
joint made. All concrete works should be fully cured before carrying out pressure test.
It shall be noted that proper procedure shall be followed. Specially, make sure that air valve is
working properly and also fill in the water from lower part to upper part so that no air will be
trapped in the middle.
ME-Plas(M) Sdn Bhd has sample guideline site testing procedure and it is available on request.
It shall be also note that do not pressure pipeline to 1.5 times more than once as it will reduce
the life time span of AB-3P pipe. Since usual application of normal working pressure of pipe is

less than nominal pressure rating, AB-3P pipe and AB-DF can be used even longer than 50
years unless severe cyclic stress is continuously imposed.
6 Repairing
When AB-3P is damaged, you can easily repair it using short length of AB-3P pipe together with
two AB-DF Straight Couplings. However, you need to push in and out to give space on both side
of repair pipe. Therefore, when you order AB-DF Couplings for Repair, please advise them to
take off the Pipe stopping notch in the center of Coupling. Alternatively, you may also knock it
off by yourself but make sure that Cold Epoxy Touch-up Painting is very important afterward to
protect exposed metal part. See drawing attached. You may also use repairing kit to patch
minor punched part. Since AB-3P use push-on joint or k-9 bolted glanded joint, repair can be
done even under the water filled site or under the rain easily unlike PE fusion joint.
In the emergency case, you may use any uPVC repairing kit such as VJ joint
fittings since the OD is same as conventional uPVC pipe.
We emphasize compatibility and ease of maintenance.
7 Training Program
ME-Plas(M) Sdn Bhd provides very effective Contractor training program either at factory in
Nilai, Malaysia or at the Site at Malaysia.
We demonstrate how to connect pipe and also how they can perform construction works
effectively. Also we demonstrate using proper tapping equipment.
To avoid any clogging of the meter or branch pipe, Contractor shall use proper Polymer tapping
tool. In case contractor is too small to purchase the tools, please contact our distributor in each
region and they will offer very economical and attractive proposal to perform the works
professionally.
Please request ME-Plas(M) or AB-3P distributor “AB-3P & AB-DF Installation Quick Reference”
leaflets to distribute to your contractor so that they will know easily how to install pipe and
fitting. We highlight that AB-3P and AB-DF is very easy to install but for flange joint to connect
to other valve S-bend etc, please pay your attention and supervise thus let them follow
stringently the procedure.
8 Pre-Sales Service (PSS) & After Sales Service (ASS)

ME-Plas(M) is the only company who provides you patented latest proven system solution and
technology for its material as well as project management and site quality control.
We will gladly assist you to have cost effective and efficient design thus;
PLEASE INVOLVE US FROM THE DESIGN STAGE OF THE PROJECT.
We are the only manufacturer who also has a qualified Project Management Professional

certified by PMI USA as well as 20 years or more infrastructure construction project expert to
assist end client, particularly water network operator. So engage us from project initial design
stage until the life time of the project. We will be always besides you to assist.
In any time, you can contact our distributor and request for technical service whatsoever
problem you are facing during the site works. We do not blame the contractor for bad works
after works is done but rather establish good partnership and assist and cooperate with them
to achieve the best quality water network system for end client. So send us e-mail address then
we will send all training data for the education of contractor.
-- AB-3P and AB-DF ULTIMATE SYSTEM SOLUTION FOR WATER PIPE NETWORK --

Appendix 1. General Properties of AB-3P
Item Unit Typical Value
General Properties
Specific Gravity 1.38
Self extinguishing
Flammability
Not support combustion
Heat Reversion Less than 5%
Maximum continuous serviceable °C 60
temperature
Thermal Properties
Thermal conductivity w/m/*C 0.14
Specific Heat kj/g/*C 1.05
Coefficient of linear expansion Per *C 5 x 10
Vicat softening Temperature °C 80
Welding Temperature °C 180 ~ 185
mm/m/degree 0.07
Coefficient of thermal expansion
rise
Electrical Properties
Breakdown voltage k-volt 35 min on 1.8 mm
Volume Resistivity Ohm cm* 10
Dielectric Constant @106Hz - 3.5
Dielectric Strength kV/mm > 40
Dielectric Power Factor @106Hz - 0.02
Mechanical Properties
Modulus elasticity Gpa ~ 3.3
Hardness Rockwell R 120
Water Absorption mg/cm2 0.04 – 0.06
Tensile Strength MPa > 51
Elongation at Break % > 80
Compressive Strength MPa 66
Modulus of Elasticity MPa 2700
Izod Impact Strength kJ/m2 9

Appendix 2. AB-3P Internal Diameter, Out-Diameter, Thickness Reference Table
AB-3P PN 9+ PN 12+ PN 15+
Norminal OD t ID t ID t ID
(mm) AVR Average AVR Average AVR Average AVR
15 21.4 Non-MS Non-MS 1.9 17.6
20 26.8 Non-MS Non-MS 2.2 22.4
25 33.6 Non-MS Non-MS 2.5 28.7
32 42.3 Non-MS Non-MS 2.5 37.4 3.0 36.4
40 48.3 Non-MS Non-MS 2.8 42.8 3.4 41.5
50 60.4 2.8 54.9 3.4 53.6 4.2 52.0
65 75.2 3.3 68.7 4.2 66.8 5.2 64.9
80 88.9 3.8 81.3 5.0 79.0 6.2 76.6
100 114.3 4.9 104.6 6.5 101.4 7.9 98.6
125 140.2 6.0 128.3 7.9 124.5 9.7 120.8
155 168.3 7.1 154.1 9.5 149.3 11.7 145.0
200 219.1 8.4 202.3 11.1 196.9 13.6 192.0
250 273.0 10.5 252.1 13.8 245.4 16.9 239.2
300 323.9 12.4 299.1 16.4 291.2 20.2 283.6
350 355.5 13.6 328.4 18.0 319.6 22.1 311.4
400 406.4 15.6 375.2 20.5 365.5 25.2 356.0

Appendix 3. AB-3P Chemical Resistance Chart
(O) Resistant and suitable (X) Not resistant so not-suitable
Chemical Concentration 20 Deg C 60 Deg C
Acetaldehyde 40% aqueous solution O X
100% X X
Acetic Acid 10% aqueous solution O O
60% aqueous solution O O
Glacial X X
Acetic anhydride X X
Acetone Traces X X
100% X X
Acetonitrile X X
Acetophenone X X
Adipic acid O ?
Aktivin (Chloramine) 1% aqueous O O
Alcohol. allyl ? X
Alcohol. amyl O O
Alcohol benzyl X X
Alcohol. butyl O ?
Alcohol. ethyl 40% w/w in water O ?
100% O ?
Alcohol. furturyl X X
Alcohol. hexyl O O
Alcohol. isopropyl O O
Alcohol. methyl 6% aqueous O O
100% O ?
Alcohol. nonyl O O
Alcohol. octyl O O
Alcohol. propargyl O O
Allyl chloride X X
Aliphatic hydrocarbons O O
Alum Saturated aqueous solution O O
Aluminium acetate Saturated aqueous solution O O
Aluminium fluoride Saturated aqueous solution O O

Aluminium hydroxide Saturated aqueous solution O O
Aluminium nitrate Saturated aqueous solution O O
Aluminium oxalate Saturated aqueous solution O O
Aluminium oxychloride O O
Aluminium potassium sulphate Saturated aqueous solution O O
Aluminium sulphate Saturated aqueous solution O O
Amber acid aqueous O O
Ammonia Dry gas O O
Liquid X X
Ammonium bicarbonate Saturated aqueous solution O O
Ammonium bifluoride Saturated aqueous solution O O
Ammonium carbonate Saturated aqueous solution O O
Ammonium chloride Saturated aqueous solution O O
Ammonium flupride Saturated aqueous solution O O
Ammonium hydroxide 0.88 S.G. aqueous solution O O
Ammonium metaphosphate Saturated aqueous solution O O
Ammonium nitrate Saturated aqueous solution O O
Ammonium oxalate Saturated aqueous solution O O
Ammonium persilphate Saturated aqueous solution O O
Ammonium phosphate Saturated aqueous solution O O
Ammonium sulphate Saturated aqueous solution O O
Ammonium sulphide Saturated aqueous solution O O
Ammonium thiocyanate Saturated aqueous solution O O
Amyl acetate X X
Amyl chloride X X
Aniline X X
Aniline hydrochloride X X
Aniline sulphate X X
Anisole X X
Anon See cyclohexane
Anthraquinone X X
Anthraquinone sulphonic acid O O
Antimony chloride O O
Antimony Trichloride O O

Apple acid Aqueous O O
Aqua regia O X
Arsenic acid Concentrated ? ?
Arylsulphonic acids X X
Barium chloride Saturated aqueous solution O O
Barium hydroxide Saturated aqueous solution O O
Barium sulphide O O
Beff tallow emulsion Usual commercial O O
sulphonated
Beer O O
Beeswas O O
Barium sulphide O O
Benzaldehyde Traces X X
100% X X
Benzene X X
Benzoic acid Saturated aqueous solution ? X
Benzoyl chloride X X
Benzyl acetate X X
Benzyl alcohol X X
Bisulphite See sodium bisulphite
Bismuth carbonate O O
Bleaching lye O O
Bone tallow X X
Borax Saturated aqueous solution O ?
Boric acid Saturated aqueous solution O ?
Boron trifluoride O
Brandies all types Usual commercial O O
Brine O O
Bromine Traces, gas ? X
100% (dry gas) X X
Liquid X X
Butadiene O O
Butane O O
Butanediol Aqueous up to 10% O ?
Butanol Up to 100% X ?

Butyl acetate X X
Butyl chloride X X
Butylraidehyde X X
Butoxyle O
Butyric acid 20% aqueous solution O O
Concentrated X X
Calcium chlorate aqueous solution O O
Calcium chloride aqueous solution O O
20% in methyl alcohol O O
Calcium hydroxide aqueous solution O O
Calcium nitrate aqueous solution O O
Calcium phosphate Saturated aqueous solution
Camphor oil O O
Carbon dioxide O O
Carbon disulphide X X
Carbon acid O O
Carbon monoxide O O
Carbon tetrarchloride X X
Castor oil O O
Caustic potash lye up to 40% O O
Chloracetic acid 60% aqueous solution O ?
Chloric acid 20% aqueous solution O O
Chlorine Dry gas (traces) O O
10% (moist gas) ? X
Chlorine trifluoride X X
Chlorine water Saturated solution ? X
Chlorobenzene X X
Chloroform X X
Chlorsulphonic acid Technically pure ?
Chrome alum Saturated aqueous solution O O
Chromic acid 50% aqueous solution O O
Cider O O
Citric acid Saturated aqueous solution O O
Clophenes usual commercial O O

Coal gas benzene free O O
Coconut tat alcohol technically pure O O
Copper chloride Saturated aqueous solution O O
Copper fluoride Saturated aqueous solution O O
Copper nitrate Saturated aqueous solution O O
Copper sulphate Saturated aqueous solution O O
Cuprous chloride saturated O O
Corn oil O O
Creosote X X
Cresols X X
Crotonaldehyde X X
Cumene technically pure ? ?
Cyanide of potash \ ? Tot 10%
Cyclohexanol X X
Cyclohexanone X X
Decahydronaphthalene technically pure O O
Densodrin W Usual commercial O O
Dextrin Saturated aqueous solution O O
Dextrose Saturated aqueous solution O O
Diamyl ether X X
Dibutyl phthalate X X
Dichlorodifluoromethane O
Dichlorethylene X X
Dichlorobenzene X X
Diesel oil O ?
Diethylene glycol O O
Diethyl ether X X
Diethyl ketone X X
Diglycolic acid 30% O ?
Dimethylamine X X
Dinonyl phthalate technically pure X X
Dioctyl phthalate X X
Dioxane X X
Disodium phosphate Saturated aqueous solution O O

Ethane O O
Ether X X
Ethyl acetate X X
Ethyl acrylate X X
Ethyl butyrate X X
Ethyl chloride X X
Ethyl formate X X
Ethyl lactate X X
Ethyl sulphate O ?
Ethylene bromide X X
Ethylene chlorhydrin X X
Ethylene chloride X X
Ethylene dibromide X X
Ethylene dichloride X X
Ethylene glycol O O
Ethylene oxide X X
Ferric chloride Saturated aqueous solution O O
Ferric nitrate Saturated aqueous solution O O
Ferric sulphate Saturated aqueous solution O O
Ferrous ammonium citrate Saturated aqueous solution O O
Ferrous chloride Saturated aqueous solution O O
Ferrous sulphate Saturated aqueous solution O O
Ferrous sulphate Saturated aqueous solution O O
Film developer Usual commercial O O
Flourine X X
Flousilicic acid O O
Formic acid 50% aqueous solution O ?
Frigen, 12 (Freon 12) 100% O
Fructose O O
Fruit pulp O O
Fuel oil O O
Furfural X X
Furfuryl alcohol X X
Gelatine aqueous all O O

Glucose Saturated aqueous solution O O
Glycerol O O
Glycerol monobenzyl ether X X
Glycolic acid O O
Grape sugar Saturated aqueous solution O O
Heptane O O
Heptane O O
Hexane O O
Hollander glue Working concentration O O
Hydrobromic acid 50% aqueous solution O O
Hydrochloric acid 10% aqueous solution O O
concentrated O O
Hydrocyanic acid O ?
Hydrofluoric acid 4% aqueous solution O ?
40% aqueous solution O ?
60% ? X
concentrated X X
Hydrogen O O
Hydrogen bromide anhydrous O O
Hydrogen flouride anhydrous O O
Hydrogen peroxide 4% (10 volume) O O
12% (40 volume) O O
30% (100 volume) O O
90% and above O O
Hydrogen phosphide O O
Hydrogen sulphide O O
Hydroquinone Saturated aqueous solution O O
Hydroxylamine sulphate Saturated aqueous solution O O
Hypochiorous acid ? X
Iodine Solution in potassium iodide X X
Isophorone X X
Jam Usual commercial O ?

Lactic acid 10% aqueous solution O O
100% X X
Lanoline O O
Lauric acid O O
Lauric acid O O
Lead acetate Saturated aqueous solution O O
Lead nitrate Saturated aqueous solution O O
Lead tetraethyl O O
Linoleic acid O O
Liseed oil O O
Magnesium chloride Saturated aqueous solution O O
Magnesium nitrate Saturated aqueous solution O O
Magnesium sulphate Saturated aqueous solution O O
Maleic acid 25% aqueous solution O ?
concentrated O ?
Malic acid Saturated aqueous solution O O
Manganese sulphate Saturated aqueous solution O O
Menthol ? X
Mercuric chloride X X
Mercuric cyanide Saturated aqueous solution O O
Mercurous nitrate Saturated aqueous solution O O
Mercury O O
Mersol D O O
Mesityl oxide X X
Methyl acetate X X
Methyl bromide X X
Methyl chloride X X
Methyl cyclohexanone X X
Methyl ethyl ketone X X
Methyl isobutyl ketone X X

Methyl methacrylate X X
Methyl sulphate O ?

Methy sulphuric acid 50% aqueous solution O O
Methylene chloride X X
Milk O ?
Mineral oils Without additives O O
Mixed acids Sulphuric acid/nitric acid/water O ?
Molasses O O
Monochlorbenzene X X
Morpholin X X
Naphtha X X
Naphthalene X X
Nekal BX Diluted O ?
Nickel chloride Saturated aqueous solution O O
Nickel nitrate Saturated aqueous solution O O
Nickel sulphate Saturated aqueous solution O O
Nicotine Saturated aqueous solution O O
Nicotinic acid Saturated aqueous solution O O
Nictric acid 5% aqueous solution O ?
70% aqueous solution ? ?
95% aqueous solution X X
Nitrobenzene X X
Nitropropane X X
Nitrous fumes moist ? X
Octane O O
Octyl cresol Technically pure X X
Oleic acid O O
Oleum 10% X X
Oxalic acid Saturated aqueous solution O O
Oxygen O O

Ozone O X
Paraffin oil O O
Pentane O
Perchloric acid X X
Petrol/Benzene mixture 80:20 ratio X X
Phenol Saturated aqueous solution O ?
Phenylhydrazine X X
Phenylhydrazine hydrochloride ? X
Phosgene gas O
Phosphoric acid 20% aqueous solution O O
Phosphorus pentoxide Decomposed water O O
Phosphorous trichloride X X
Phthalic anhydride Solution in ethyl alcohol O O
Picric acid 1% w/w in water O O
10% w/w in alcohol O O
Potassium acid sulphate Saturated aqueous solution O O
Potassium bicarbonate Saturated aqueous solution O O
Potassium bisulphate Saturated aqueous solution O O
Potassium borate Saturated aqueous solution O O
Potassium bromate Saturated aqueous solution O O
Potassium bromide Saturated aqueous solution O O
Potassium carbonate Saturated aqueous solution O O
Potassium chlorate Saturated aqueous solution O O
Potassium chloride Saturated aqueous solution O O
Potassium chromate Saturated aqueous solution O O
Potassium cuprocyanide Saturated aqueous solution O O
Potassium cyanide Saturated aqueous solution O O
Potassium dichromate Saturated aqueous solution O O
Potassium terricyanide Saturated aqueous solution O O
Potassium terrocyanide Saturated aqueous solution O O
Potassium hydroxide 1% aqueous solution O O
Potassium hypochlorite 10% aqueous solution O O

Potassium nitrate concentrated O O
Potassium perborate Saturated aqueous solution O O
Potassium permanganate Saturated aqueous solution O O
Potassium persulphate Saturated aqueous solution O O
Potassium phosphate Saturated aqueous solution O O
Potassium sulphate Saturated aqueous solution O O
Potassium sulphide Saturated aqueous solution O O
Potassium thiosulphate Saturated aqueous solution O O
Propane O
Propylene dichloride X X
Propylene glycol O O
Propylene oxide X X
Saccharose Saturated aqueous solution O O
Salicylic acid Saturated aqueous solution O O
Sea water O O
Selenic acid X X
Silicic acid, aqueous All O O
Silicone oil Technically pure X X
Silver acetate Saturated aqueous solution O O
Silver nitrate Saturated aqueous solution O O
Silver salts aqueous diluted O ?
Smelting, gases, dry Saturated aqueous solution O O
Soda Saturated aqueous solution O O
Sodium acetate Saturated aqueous solution O O
Sodium acid sulphate Saturated aqueous solution O O
Sodium aluminate Saturated aqueous solution O O
Sodium antimonate Saturated aqueous solution O O
Sodium benzoate Saturated aqueous solution O O
Sodium bicarbonate Saturated aqueous solution O O
Sodium bisulphate Saturated aqueous solution O O
Sodium bisulphite Saturated aqueous solution O O
Sodium carbonate Saturated aqueous solution O O
Sodium chlorate Saturated aqueous solution O O
Sodium chloride Saturated aqueous solution O O

Sodium chlorite aqueous diluted O ?
Sodium cyanide Saturated aqueous solution O O
Sodium terricyanide Saturated aqueous solution O O
Sodium terrocyanide Saturated aqueous solution O O
Sodium fluoride Saturated aqueous solution O O
Sodium hydroxide 1% aqueous solution O O
Sodium bicarbonate 10% aqueous solution O O
concentrated O O
Sodium hypochlorite 15% CL O O
Sodium hypochlorite aqueous diluted O O
Sodium hyposulphate Saturated aqueous solution O O
Sodium metaphosphate Saturated aqueous solution O O
Sodium nitrate Saturated aqueous solution O O
Sodium nitrite Saturated aqueous solution O O
Sodium perborate Saturated aqueous solution O O
Sodium phosphate Saturated aqueous solution O O
Sodium pyroborte Saturated aqueous solution O O
Sodium silicate Saturated aqueous solution O O
Sodium sulphate Saturated aqueous solution O O
Sodium sulphide 25% aqueous solution O O
concentrated O O
Sodium sulphite Saturated aqueous solution O O
Sodium thiosulphate Saturated aqueous solution O O
Soft soap Saturated aqueous solution O O
Spermaceti Usual commercial X X
Sperm-oil-alcohol Usual commercial O O
Spindle oil O O
Spinning bath acids cont CSz 100mg/1 O O
Starch soluble Saturated aqueous solution O O
Starch syrup O O
Steariic acid Saturated aqueous solution O O
Sucrose Saturated aqueous solution O O
Sugar syrup O ?

Sulphur colloidal O O
Sulphur dioxide dry O O
Moist O ?
Liquid ? X
Sulphuric acid 10% aqueous solution O O
Sulphuric acid 50% aqueous solution O O
fuming X X
Sulphurous acid 10% aqueous solution O O
Tallow Technically pure O O
Tannic acid Saturated aqueous solution O O
Tartaric acid Saturated aqueous solution O O
Test benzine O O
Tetraethyl lead O O
Tetrahydrofuran X X
Tetrahydronaphthalene X X
Thionyl chloride X X
Tin (II) chloride, aqueous aqueous O ?
Toluene X X
Transformer oil Non-aromatic O O
Tributyl phosphate X X
Trichloroacetic acid O X

Trichlorethylene X X
Trichlorobenzene X X
Tricresyl phosphate X X
Triethylene glycol O O
Trimethylpropane O ?
Trioctyl phosphate X X
Turpentine O O
Urea O O
Urine O O
Vaseline X X
Vegetable Oils O O
Vinegar O O
Vinyl acetate X X
Water O O
Wax alcohol O O
Wines and spirits O O
Xylene X X
Zinc chloride O O

Appendix 4. Sample Thrust Block dimension guideline
z Determination of forces on fittings
The thrust in the direction of each leg is given by:
Fy = ρA
Where A = Cross sectional Area of pipe (mm)
ρ = Internal pressure (N/mm2)
Fx = ρA Cos α α = Angle of deviation of the pipe (degree)
F = thrust in Newton
The resultant outward thrust is the vector sum of the forces in both direction of the
pipe axis and is given by;
FR = 2 ρA sin α/2
AB-DF 45 deg Bend

(2G type)
For T branch and end cap, the

resultant outward thrust is given
by
FR = ρA AB-DF Endcap
ÆFR
AB-DF T-Branch
(2G1F Type)
Reducer, the thrust force is given by:-

FR = ρ(A1 – A2) = ρ π/4 (d12 – d22)
Where d1=Big pipe side Internal
diameter, d2=Small pipe side ID

Figure: Thrust force based on Internal pressure of 10 bar
Right figure shows the

approximate thrust force acting
on fittings with an internal
pressure of 10 bar.
For internal pressure of 6 bar,
the resultant thrust force can be
calculated by multiplying the
values obtained from figure by a
factor of 0.6.
z SAFE BEARING LOAD

We must ensure that the soil around the trenches where the pipeline is being laid is
capable of absorbing the load induced by the internal water pressure. Typical safe
bearing load values for soil in trenches where the soil cover over the pipe is 450mm or
more are given in the table below.
Table: Safe bearing load for different soil.
Material Safe Bearing Load
(kN/m2)
Peat, running sand, muck, ash 0
etc.
Soft clay 50
Medium clay; Sandy loam
Sand & gravel 100
Hard clay 150
Sand & gravel cemented with clay 200
Rock 240
z DETERMINATION OF THRUST BLOCK SIZE

Example:
Calculate the bearing area of a thrust block for a 400mm (external diameter) pipe with
a 45° bend on a AB-3P main in very hard clay. The internal pressure is 10 bars.
From above figure, the outward thrust acting on the 45° bend is about 75.30 KN.
From above table, the safe bearing load of hard clay is 150 kN/m
Bearing area of thrust block required,

F/ Safe bearing load of soil = 75.30/150 = 0.502m2
Figure: Bearing area
Referring to the minimum support

needed for bends where Be > De (see
the following page), the recommended
length w should be at least 1 meter long
and the minimum depth d shall be 0.5m.
Therefore, we suggested bearing area
dimension = d x w = 0.5 x 1.0 = 0.5 m2.
z THRUST BLOCK DIMENSION

Sufficient support should be provided at all AB-DF fittings to ensure that the joints do
not move when subjected to internal hydrostatic pressure including water hammering.
Basically, the minimum dimension required is:
Horizontal Bend
Bends: Be > De (minimum 150mm)
Branches:
Be1 > De + de/2, (minimum 200mm +
de/2)
Be2 > de + De/2, (minimum 200mm +
De/2)
Convex Vertical Bend Co

T-Branch Pipe-End
But at least,
Be1 = De + de/2 Be1 = 200mm + de/2 or
Be2 = de + De/2 Be2 = 200mm + De/2
To facilitate application for simple installation, please refer to attached drawing for
your due reference.

Please take note that this is only the guideline dimension varies when soil condition is changed like soft soil or hard
rock. Please consult with professional consultant. (Full size drawing available on request)

Notice
Copyright© 2004-2009 ME-Plas(M) Sdn Bhd and its licensors. All rights reserved. AB-3P, the AB-3P & ME-Plas(M)
logo, BRACO, AB-DF logo are either registered trademarks or trademarks of ME-Plas(M) Sdn Bhd, ABTP Marketing
Sdn Bhd & Gecom Korea. All other trademarks are the property of their respective owners.
Limitation of Liability:
The information contained herein has been compiled only as quick reference assistance to qualified contractors and
engineers. This book should not be used as a sole source of information as it does not refer to all aspects of pipeline
design and installation. Further reference should be made to established text books. So far as it may lawfully do so
ME-Plas(M) Sdn Bhd of Malaysia supplies this publication upon the basis and condition that it will incur no liability
whatsoever in respect of any loss or damage of any kind claimed to arise either directly or indirectly as a result of any
statement herein or in respect of any act cause matter or thing alleged to arise directly or indirectly as a result of the
contents of this publication and excludes all warranties and conditions statutory or otherwise as to quality or fitness for
any purpose and excludes all liability of itself, its servants and agents for all loss or damage in relation to the use of the
goods howsoever arising. Please note that overall responsibility lies solely with the user to ensure the currency and
validity of information or advice contained herein in the context of his circumstances. It is recommended that advice be
obtained from a Registered Consultant. No warranty is expressed or implied as to the content of the information or
results obtained by use thereof, and ME-Plas(M) Sdn Bhd will not be held liable for any costs, direct or indirect, that may
arise there-from.
Marketing Control Company

ABTP Marketing Sdn Bhd (AMS)
Tel.No: + 60 (3) 8994 9396 Fax.No: +60 (3) 8994 9196
e-Mail: ams.ab3p@gmail.com
Mr. Chin Yoke Lian: 016-212-3639, Ms. Jennifer 016-238 9950
Address:
No 8A, Jalan 17-155C, Bandar Bukit Jalil, 57000, Kuala Lumpur Malaysia
Authorized distributor
TransGenesis Marketing Sdn Bhd (TGM)
Tel.No: + 60 (3) 8994 9396 Fax.No: +60 (3) 8994 9196
e-Mail: transgenesismarketing@gmail.com
Mr. Ahmad Zaini: 012-2228716, Mr. Desmond: 012-3325033
Address:
AB3P Bumi Commerce Sdn Bhd (ABC)

Hj. Zakid: 019-4443926
Fax.No: (03) 8994 9003
e-Mail: bumicommerce@gmailcom
Address:

CMS Infra Trading Sdn Bhd (CMS)
Mr. Arbaeni Askam: 019-8861640
Tel No: (082) 348949 Fax No: (082) 348952
e-Mail: arbaenia@trading.cmsb.com.my
Address:
No. 2128, Sublot 2, Jalan Utama, Pending, 93450 Kuching Sarawak Malaysia
Southernhem Industries Sdn Bhd

Mr. Aim: 016-8636868
Tel: (082) 432155 / 791
Address:
Lot 1200, Block 7, MTLD, Jalan Demak Laut 5, 93050, Kuching, Sarawak, Malaysia
Bumi Angsana Trading Sdn Bhd (BAT)

Mr. Azmi: 012-3298111
Tel: (04) 7721995
e-Mail: bumiangsana@gmail.com
Unitrade Enterprise Sdn Bhd (UEP)

Mr. Cham Kiam Hui: 013-3980118
Fax No: (03) 80769110
Address: No. 62-2, Jalan Radin Tengah, Sri Petaling, 57000 KL Malaysia
e-Mail: unitradeenterprise@yahoo.com

2009-06-15 AB-3P Technical Reference Manual R6

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PATENTED ANTI-BACTERIA 3 LAYER WATER PIPE SYSTEM

1.1 What is AB-3P? 5

1.2 How to make AB-3P? 5

1.3 No uPVC-phobia! Why? No backyard product. 5

1.4 Long time proven performance. 5

1.5 Certificate and Registration 6

1.6 System Solution 6

1.7 Superior Design 6

1.8 Color and marking 6

1.9 Real Lifetime, pipe for our descendant. 6

1.10 Super Fast Construction 7

1.11 Residual Chlorine and Bio-Film 7

2.1 Ambient temperature and Pipe pressure rating 7

2.2 Chemical resistance 8

2.3 Behaviour in Fire 9

2.4 Abrasion Resistance 9

3 AB-3P/AB-DF PRODUCT FEATURES AND BENEFITS AB-3P PIPE 9

3.3 BRACO: Brass Compression fittings 14

AB-3P PIPE SYSTEM TECHNICAL REFERENCE MANUAL Revision 6 2

3.4 DOUBLE Omega Grip (DOG bite) 15

SEE JOINT AND FITTING EASY REFERENCE TABLE 15

4.1 Hydraulic design 16

4.2 Structural Design 22

4.3 Above ground Installation 23

5.1 Transportation, Handling and Unloading 26

5.3 Fabrication, Cutting 28

5.4 Installation: Underground Trench Construction 28

5.5 Installation: Above Ground Exposed Construction 30

5.18 Pre-Assembly and laying 46

5.19 Site Testing 47

AB-3P PIPE SYSTEM TECHNICAL REFERENCE MANUAL Revision 6 3

8 PRE-SALES SERVICE (PSS) & AFTER SALES SERVICE (ASS) 48

APPENDIX 1. GENERAL PROPERTIES OF AB-3P 50

APPENDIX 2. AB-3P INTERNAL DIAMETER, OUT-DIAMETER, THICKNESS REFERENCE

APPENDIX 3. AB-3P CHEMICAL RESISTANCE CHART 52

AB-3P PIPE SYSTEM TECHNICAL REFERENCE MANUAL Revision 6 4

1.2 How to make AB-3P?

1.3 No uPVC-phobia! Why? No backyard product.

1.4 Long time proven performance.

1.6 System Solution

1.7 Superior Design

1.8 Color and marking

1.9 Real Lifetime, pipe for our descendant.

AB-3P PIPE SYSTEM TECHNICAL REFERENCE MANUAL Revision 6 6

1.11 Residual Chlorine and Bio-Film

2.1 Ambient temperature and Pipe pressure rating

2.2 Chemical resistance

AB-3P PIPE SYSTEM TECHNICAL REFERENCE MANUAL Revision 6 8

2.3 Behaviour in Fire

2.4 Abrasion Resistance

3 AB-3P/AB-DF Product Features and Benefits AB-3P Pipe

3.1.2 Certification and Test Criteria

3.1.3 Unique Spigot Rubber Ring Joint (Supa-Tite Bell-Mouth Joint)

3.1.4 Anti-Bacteria, Safety Proven Nano-Technology

3.1.5 Pressure Pipes with Very Low flow friction

3.1.6 Residual Chlorine Absorption

3.2.2 Certification complied to BS/EN 545

3.2.3 AB-DF GLAND DESIGN – ADVANTAGES

3.2.4 AB-DF GLAND DESIGN – Exposed Application

3.3 BRACO: Brass Compression fittings

AB-3P PIPE SYSTEM TECHNICAL REFERENCE MANUAL Revision 6 14

See Joint and Fitting Easy Reference Table

AB-3P PIPE SYSTEM TECHNICAL REFERENCE MANUAL Revision 6 15

The flow data of AB-3P can be obtained from the charts