WATER SUPPLYPLUMBING II

MOS 21K, SKILL LEVELS 1 AND 2

Subcourse EN5111

EDITION B

United States Army Engineer SchoolFort Leonard Wood, Missouri 65473-8929

11 Credit Hours

Edition Date: April 2005

SUBCOURSE OVERVIEW

This subcourse will enable you to join and install various kinds of pipes that can be used tocomplete the water supply system of a building. Made of different materials, these pipes must becut and the ends prepared for fitting connections to form leakproof joints. These connections aremade with threaded joints, fused joints, and compression joints, depending on the type of pipingmaterial used. As the water supply pipeline runs are installed, they must be supported withhangers and holders. Sometimes, the building structure must be cut into when installing the watersupply pipeline runs for the lavatories, sinks, and water closets. Once a rough-in water supplysystem is installed, it is tested for leaks. This water supply subcourse is presented in two lessons,each corresponding to a terminal learning objective.

Appendix C contains a metric conversion chart.

There are no prerequisites for this subcourse.

The lessons reflect the doctrine that was current at the time this subcourse was prepared. In yourown work situation, always refer to the latest official publications.

Unless this publication states otherwise, masculine nouns and pronouns do not refer exclusivelyto men.

TERMINAL LEARNING OBJECTIVE:

ACTION: You will learn to perform tasks related to preparing and connecting pipesand installing pipeline runs for a water supply system.

CONDITION: You will be given the materials contained in the subcourse.

STANDARD: To demonstrate proficiency, you must achieve a minimum score of 70percent on the subcourse examination.

i

TABLE OF CONTENTS

Subcourse Overview

Lesson 1: Water Supply System and Piping Materials

Part A: Identifying the Types of Piping Materials

Part B: Measuring the Pipes

Part C: Preparing the Piping Materials

Practice Exercise

Lesson 2: Rough-In Water Supplies and Water Supply Pipeline Runs

Part A: Installing Stops (Valves)

Part B: Using Fittings on Water Supply Pipeline Runs

Part C: Installing Water Supply Pipeline Runs

Part D: Supporting Water Supply Pipeline Runs

Part E: Testing the Water Supply System for Leaks

Practice Exercise

Appendix A: List of Common Acronyms

Appendix B: Recommended Reading List

Appendix C: Metric Conversion Chart

EN5111 Edition B Examination

ii

LESSON 1

WATER SUPPLY SYSTEM AND PIPING MATERIALS

Critical Task: 052-248-1002

OVERVIEW

LESSON DESCRIPTION:

This lesson covers the identification, measurement, and preparation of piping materials forinstallation into a water supply system. It also covers the identification of fittings and the use ofjoint connections. TERMINAL LEARNING OBJECTIVE:

ACTION: You will learn to describe the procedures used to prepare galvanized-steel/iron, plastic, and copper pipes for joint connections.

CONDITION: You will be given the material contained in this lesson.

STANDARD: You will correctly answer the practice exercise questions at the end of this lesson.

REFERENCES: The material contained in this lesson was derived from Field Manual (FM) 3-34.471 and Technical Manual(TM) 5-551K.

INTRODUCTION

A plumber must have the ability to join and install various kinds of pipes that can be used tocomplete the water supply system of a building. These pipes are made of different materials, andmany times they will have to be cut and their ends prepared for fitting connections to formleakproof joints. These connections are made with threaded joints, fused joints, and compressionjoints depending on the type of pipe.

PART A: IDENTIFYING THE TYPES OF PIPING MATERIALS

1-1. Piping Materials. The layout or repair of a water supply system requires that pipes aremeasured to specific lengths, cut, and the cut ends prepared to form joints. Pipe lengths can bemeasured in several ways. The measurement must allow for the pipe engagement into a fittingand the dimension of a fitting. Table 1-1 gives the pipe characteristics and uses in a plumbingsystem.

1-1

Table 1-1. Pipe Characteristics and Uses

SYSTEMTYPE OF PIPE RIGID FLEXIBLE WATER WASTE

Cast-iron soil pipe:Hub and spigotDouble hubHubless

***

***

Galvanized-steel/iron pipe * * *

Copper tubing:K1

L2

M3

DWV

****

**

***

*

Plastic pipe:PBPEPVCCPVC4

ABS

***

** *

**

*

*1 Thick wall2 Medium wall3 Thin wall4 CPVC is used for cold- and hot-water lines.

a. Galvanized-Steel/Iron Pipe. Galvanized-steel/iron pipe (Figure 1-1) can be usedfor hot- and cold-water supply distribution, certain drainage applications, and vent installations.It is made from mild carbon steel and is galvanized to prevent rust. It is joined with a threadedjoint in pipe-to-pipe or pipe-to-fitting connections. This pipe comes in three strengths: (1)standard, (2) extra strong, and (3) double extra strong. The definitions Schedule 40 and Schedule80 also describe pipe strengths. Schedule 40 standard is most commonly used in plumbing.Galvanized-steel/iron pipe should not be used underground and should be stored in a dry place. Ifthe pipe ends are threaded, they must be protected from damage. This pipe comes in 21-footlengths.

Figure 1-1. Galvanized-Steel/Iron Pipe

1-2

b. Copper Tubing. Copper tubing (Figure 1-2) is lightweight, easily joined, andcorrosion-resistant. It can be rigid or flexible and it is classified by its wall thickness. It is usedfor hot- and cold-water supply lines, certain drainage applications, and venting. Rigid coppertubing is hard-tempered and comes in 20-foot lengths. It does not bend, so changes in directionmust be made with fittings. Flexible copper tubing is soft tempered, easily bent for changes indirection, and comes in coils of 40 to 100 feet.

Figure 1-2. Copper Tubing

K is a thick-walled, rigid or flexible copper tubing available in 20-foot lengthsor 100-foot coils. Diameter sizes range from 1/4 inch to 12 inches.

L is a medium-walled, rigid or flexible copper tubing available in 20-footlengths or 100-foot coils. Diameter sizes are the same as K.

M is a thin-walled, rigid copper tubing available in 20-foot lengths. Diametersizes are the same as K.

Drain, waste, and vent (DWV) copper tubing is available in 20-foot lengths.Diameter sizes range from 1 1/4 to 8 inches.

1-3

Rigid

Flexible

LK

LK M

c. Plastic Pipe. Plastic pipe (Figure 1-3) is lightweight and can be rigid or flexible. Itis easily joined and is corrosion-resistant. It can be used for water supply or waste systems. It isused for hot- or cold-water piping and for DWV piping. Plastic pipe is joined with solventcement. Plastic pipe is classified by the acronym for the type of material from which it is made.

(1) Polyvinyl chloride (PVC). PVC pipe is cream or white colored and usedonly for cold-waterlines, sanitary drainage, and venting. It comes in 10- and 20-foot lengths.Diameter sizes range from 1/2 to 6 inches.

(2) Chlorinated polyvinyl chloride (CPVC). CPVC pipe is light or creamcolored and used for hot-waterlines. It can also be used for cold-water lines. It comes in 10-footlengths. Diameter sizes are 1/2 and 3/4 inch.

(3) Acrylonitrile butadiene styrene (ABS). ABS pipe is black or gray and usedfor aboveground and belowground sanitary drainage and venting. It comes in 10- and 20-footlengths. Diameter sizes range from 1 1/4 to 6 inches.

(4) Polybutylene (PB). PB pipe is black or dark gray and used for cold-waterlines. It is available in 100-foot coils or more. Diameter sizes range from 3/4 to 2 inches. It iscostly, requires special fittings, and is not widely used.

(5) Polyethylene (PE). PE pipe is black and used for cold-water lines andsprinkler systems. It comes in 100-foot coils. Diameter sizes range from 3/4 to 2 inches.

NOTE: Check local plumbing codes to determine if the plastic pipe is authorized forinstallation.

Figure 1-3. Flexible Plastic Pipe

1-4

PB and PE

d. Engagements. A pipe engagement is the distance the pipe goes into a fitting. Thisdistance is determined by the nominal size diameter of the pipe. Table 1-2 shows the correct pipeengagement into a fitting based on the type of piping material and the nominal size diameter ofthe pipe.

Table 1-2. Pipe Engagement in Fittings

Type of Fitting Material Nominal Size Diameter(in inches)

Approximate PipeEngagement (in inches)

1/81/43/81/23/41

1 1/41 1/2

23

1/43/83/81/29/16

11/1611/1611/163/41

1/43/81/23/41

1 1/41 1/2

5/163/81/23/4

15/161

1/18

1/23/41

1 1/41 1/2

234

1/25/83/4

11/1611/163/4

1 1/21 3/4

23456

2 1/22 3/4

333

1-5

Steel, threaded (pipe-joint compound)

Copper (solder)

Plastic (solvent cement)

Cast-iron (oakum and lead)

e. Fitting Dimension. A fitting dimension is needed when determining the amount ofpipe required for installation. The fitting dimensions for all types of water supply fittings aredetermined in the same way. A fitting dimension is the distance from the center of the fitting tothe end of the fitting (Figure 1-4).

Figure 1-4. Determining a Fitting Dimension

1-6

Fitting dimension

PART B: MEASURING THE PIPES

1-2. Determining Pipe Measurements. Fittings are part of a pipe-run length. The total-lengthmeasurement must include the distance (engagement) a pipe goes into a fitting and the dimensionof the fitting. This part describes determinations and definitions of pipeline runs and plumbingmeasurements.

a. End-to-Center Measurement. An end-to-center measurement is the distancebetween the end of the pipe and the center of the fitting. Use the formula: the length of pipeequals the end-to-center measurement minus the fitting dimension plus the pipe engagement(Figure 1-5). Figure 1-6 provides an example of the computation used for an end-to-centermeasurement. This method is the same for all types of piping.

Figure 1-5. End-to-Center Measurement

End-to-center = 48"Minus fitting dimension = 48" – 1" = 47"Plus pipe engagement = 47" + 1/2" = 47 1/2"Length of pipe = 47 1/2"

Figure 1-6. Computation Example for an End-to-Center Measurement

1-7

Fitting dimensionEnd-to-center

Pipe engagement

1"

End-to-center

1/2"Pipe

Fitting dimension

Pipe engagement

48"

b. Center-to-Center Measurement. A center-to-center measurement is used whenpipe fittings are on each end of the pipe and is the distance between the centers of the fittings.Use the formula: the length of pipe equals the center-to-center measurement minus both fittingdimensions plus both pipe engagements (Figure 1-7). Figure 1-8 shows the computation used fora center-to-center measurement. This method is the same for all types of piping.

Figure 1-7. Center-to-Center Measurement

Center-to-center = 52"Minus both fitting dimensions = 52" – (1 1/4" + 1 1/4")Plus both pipe engagements = 49 1/2" + (1/2" + 1/2")Length of pipe = 50 1/2"

Figure 1-8. Computation Example for a Center-to-Center Measurement

1-8

Center-to-center

Pipe engagement

Fitting dimension

Pipe

Center-to-center

Pipe engagement

Fitting dimension

Pipe

1/2" 1/2"

52"

1 1/4" 1 1/4"

c. Face-to-Face Measurement. A face-to-face measurement is the distance betweenthe faces of each fitting. Use the formula: length of pipe equals face-to-face measurement plusboth pipe engagements (Figure 1-9). Figure 1-10 shows the computation used for a face-to-facemeasurement. This method is the same for all types of piping.

Figure 1-9. Face-to-Face Measurement

Face-to-face = 46"Plus both pipe engagements = 46" + 1/2" + 1/2"Length of pipe = 47"

Figure 1-10. Computation Example for a Face-to-Face Measurement

1-9

Face-to-face

Pipe engagement

Pipe

1/2" 1/2"

Face-to-face46"

Pipe engagement

PART C: PREPARING THE PIPING MATERIALS

1-3. Preparing Galvanized-Steel/Iron Pipe for a Joint Connection. The followingprocesses may be required to prepare galvanized-steel/iron pipe for installation: cutting,removing burrs, and threading of the pipe ends.

a. Cutting the Pipe. Table 1-3 explains how to cut a pipe, using a single-wheel pipecutter.

Table 1-3. Cutting the Pipe Using a Pipe Cutter

Step 1. Determine the length of the pipe, and mark the spot for the cut.

Step 2. Lock the pipe tightly in a vise with the cutting mark about 8 inches from the vise.

Step 3. Open the jaws of the cutter by turning the handle counterclockwise.

Step 4. Place the cutter around the pipe with the cutting wheel exactly on the mark. The rollers will ensurethat a straight cut is made.

Step 5. Close the pipe cutter jaws lightly against the pipe by turning the handle clockwise.

Step 6. Give the handle a quarter turn clockwise when the cutting wheel and rollers have made contactwith the pipe.

Step 7. Apply cutting oil, and rotate the cutter completely around the pipe by making a quarter turn on thehandle for each complete revolution around the pipe. Continue the action until the pipe is cut.

NOTE: When a pipe cutter is not available, use a hacksaw and ensure that the cut is as square aspossible to simplify threading the pipe.

1-10

Pipe

Handle

Single-wheel pipe cutter

Cutting wheel

Measured mark

Vise

b. Removing Burrs. Table 1-4 explains how to remove burrs from the cut end of apipe.

Table 1-4. Removing Burrs

Step 1. Lock the pipe tightly in a vise or leave it in the vise from the cutting process.

Step 2. Push the reamer into the pipe.

Step 3. Turn the reamer clockwise in short, even strokes while keeping steady pressure against the pipeuntil all the inside burrs are removed from the cut end.

Step 4. Use a fine-metal file to remove burrs from the outside of the pipe.

1-11

Pipe reamer

Pipe

Vise

Gloves

c. Threading Pipe Ends. Table 1-5 explains how to thread pipe ends.

Table 1-5. Threading Pipe Ends

Step 1. Insert the correct size die into the diestock.

Step 2. Slide the diestock over the pipe, and apply pressure with one hand.

Step 3. Turn the stock handle slowly clockwise (using the other hand) until the die has taken a bite onthe pipe.

Step 4. Apply cutting oil to the die as the stock handle is given one complete clockwise turn and backedoff a quarter turn.

Step 5. Repeat this action until 1/4 inch of the pipe is beyond the diestock. The pipe is now threadedproperly.

Step 6. Turn the handle in a counterclockwise direction to remove the pipe.

NOTE: There are several types of threads, such as fine, course, and plumbing and pipefittingthreads, identified as national pipe threads (NPT). Pipe threads are cut at a taper. Identify pipedies as NPT to ensure that this is the type being used for pipe threading.

1-12

Vise

Steel pipe

Stock handle

Diestock

Gloves

1-4. Preparing Copper Tubing Ends for a Joint Connection. The following processesmaybe required to prepare copper tubing for installation: cutting; removing burrs; and preparingsoldered, flared, mechanical-compression, or swaged joints.

a. Cutting the Copper Tubing. Table 1-6 explains how to cut the tubing, using a tubecutter or a fine-tooth hacksaw (32 teeth per inch).

Table 1-6. Cutting the Copper Tubing

Step 1. Determine the length of copper tubing required, and mark the spot for the cut.

Step 2. Set the cutting wheel on the mark, and turn the cutter knob clockwise to get a bite on the tubing.

Step 3. Hold the tubing firmly with one hand, and turn the cutter clockwise around the tubing with theother hand until the tubing is cut.

Step 4. Use a fine-tooth hacksaw if a tube cutter is not available. This requires placing the copper tubingin a miter box to get a square cut.

1-13

Cutting wheelCopper tubing

Tube cutter

Hacksaw

Miter box

Copper tubing

Gloves

b. Removing Burrs. Push the reamer blade into the tubing, and turn the tubingclockwise with even strokes. Continue until all the burrs are removed from the cut end.

c. Preparing a Soldered Joint. Soldered joints are used to connect rigid coppertubing. Figure 1-11 displays the tools and materials needed.

Figure 1-11. Tools and Materials Needed for Soldered Joints

1-14

Emery clothSolder wire

Flux and brush

Propane torch

Wire brushSteel wool

FLUX

d. Preparing a Flared Joint. A flared joint is used with flexible copper tubing. Theflare on the end of the tubing can be made with a flaring tool or a flanging tool. Figure 1-12displays the tools needed to prepare a flared joint.

Figure 1-12. Tools Needed for a Flared Joint

1-15

Flaring toolFlanging tool

Flared fittingFlared end

e. Preparing a Mechanical-Compression Joint. A mechanical-compression joint isused to connect a fixture’s water supply tubing to the shutoff valves. Figure 1-13 shows amechanical-compression joint.

Figure 1-13. Materials Needed for a Mechanical-Compression Joint

f. Preparing a Swaged Joint. A swaged joint is used to connect two sections of rigidthin-walled copper tubing without using a fitting. The tools required are a swaging-tool set and aball-peen hammer. Figure 1-14 displays the tools needed to prepare the tubing for a swaged joint.

Figure 1-14. Tool Needed for a Swaged Joint

1-16

Fitting

TubingCompression ring

Compression nut

Swaging-tool set

Ball-peen hammer

1-5. Preparing Rigid and Flexible Plastic Pipes for Joint Connections. The followingprocesses maybe required to prepare plastic pipe for installation: cutting, removing burrs, andpreparing joints. Table 1-7 explains how to cut plastic pipe and remove burrs for jointpreparation.

Table 1-7. Cutting Plastic Pipe and Removing Burrs

Step 1. Determine the length of pipe required, and mark the spot for the cut.

Step 2. Place the pipe in a miter box. and cut the pipe with a hacksaw or fine-tooth handsaw. Use a miterbox to get a square cut.

Step 3. Remove burrs from both the inside and outside of the pipe with a pocketknife. Use sandpaper if apocketknife is not available.

1-17

Hacksaw Pipe

Miter box

Pocketknife

LESSON 1

PRACTICE EXERCISE

Instructions: The following items will test your grasp of the material covered in this lesson.There is only one correct answer for each item. When you complete the exercise, check youranswers with the answer key that follows. If you answer any item incorrectly, restudy that part ofthe lesson that contains the portion involved.

1. Identify the type of piping that is not used in a water supply system.

A. Cast-iron

B. Copper tubing

C. Galvanized-steel/iron

D. Plastic

2. Refer to Table 1-8. What is the pipe engagement for 3/4-inch steel, threaded pipe?

A. 3/8 inch

B. 3/4 inch

C. 9/16 inch

D. 11/16 inch

Table 1-8. Pipe Engagement

Pipe Size(in inches)

Approximate Engagement Into a Hub(in inches)

3/81/23/41

1 1/4

3/81/2

9/1611/1611/16

1-18

Steel, threaded (pipe-joint compound)

3. Refer to Figure 1-15. What is the required length of pipe needed when using a face-to-face measurement?

A. 50 1/2 inches

B. 51 1/2 inches

C. 52 1/2 inches

D. 53 1/2 inches

Figure 1-15. Determining Length of a Pipe

4. Which fitting shown in Figure 1-16 shows a correct fitting dimension?

Figure 1-16. Fitting Dimension

1-19

A

B

C

D

Pipe

3/4" 3/4"

Face-to-face52"

Pipe engagement

5. When do you apply the cutting oil in threading a galvanized-steel/iron pipe?

A. Before you begin

B. After each complete turn

C. After each complete turn and backed off a quarter turn

D. After each complete turn and backed off a half turn

6. Refer to Figure 1-17. What is the length of pipe when you use an end-to-center measurement?

A. 47 3/4 inches

B. 45 3/4 inches

C. 44 3/4 inches

D. 43 3/4 inches

Figure 1-17. Determining Length of a Pipe

7. What tool is used to cut galvanized-steel/iron pipe?

A. Cross saw

B. Pipe saw

C. Pipe cutter

D. Rip saw

1-20

4"

1 3/4"

48"

8. What two tools are used to flare the ends of flexible copper tubing?

A. Swaging and flanging

B. Flaring and flanging

C. Swaging and flaring

D. Flanging and swatting

9. What tool is used to cut plastic pipe?

A. Knife

B. Hacksaw

C. Coping saw

D. Back saw

10. What type of plastic pipe can be used on both a water supply system and a waste system?

A. ABS

B. PB

C. PE

D. PVC

1-21

LESSON 1

PRACTICE EXERCISE

ANSWER KEY AND FEEDBACK

1. Identify the type of piping that is not used in a water supply system.

A. Cast-iron (Table 1-1)

B. Copper tubing

C. Galvanized-steel/iron

D. Plastic

2. Refer to Table 1-8. What is the pipe engagement for 3/4-inch steel, threaded pipe?

A. 3/8 inch

B. 3/4 inch

C. 9/16 inch (Table 1-2)

D. 11/16 inch

Table 1-8. Pipe Engagement

Pipe Size(in inches)

Approximate Engagement Into a Hub(in inches)

3/81/23/41

1 1/4

3/81/2

9/1611/1611/16

1-22

Steel, threaded (pipe-joint compound)

3. Refer to Figure 1-15. What is the required length of pipe needed when using a face-to-face measurement?

A. 50 1/2 inches

B. 51 1/2 inches

C. 52 1/2 inches

D. 53 1/2 inches (paragraph 1-2c and Figure 1-10)

Figure 1-15. Determining Length of a Pipe

4. Which fitting shown in Figure 1-16 shows a correct fitting dimension?

Figure 1-16. Fitting Dimension

1-23

A

B (paragraph 1-1e and Figure 1-4)

C

D

Pipe

3/4" 3/4"

Face-to-face52"

Pipe engagement

5. When do you apply the cutting oil in threading a galvanized-steel/iron pipe?

A. Before you begin

B. After each complete turn

C. After each complete turn and backed off a quarter turn (Table 1-5)

D. After each complete turn and backed off a half turn

6. Refer to Figure 1-17. What is the length of pipe when you use an end-to-center measurement?

A. 47 3/4 inches

B. 45 3/4 inches (paragraph 1-2a and Figure 1-6)

C. 44 3/4 inches

D. 43 3/4 inches

Figure 1-17. Determining Length of a Pipe

7. What tool is used to cut galvanized-steel/iron pipe?

A. Cross saw

B. Pipe saw

C. Pipe cutter (paragraph 1-3a and Table 1-3)

D. Rip saw

1-24

4"

1 3/4"

48"

8. What two tools are used to flare the ends of flexible copper tubing?

A. Swaging and flanging

B. Flaring and flanging (paragraph 1-4d and Figure 1-12)

C. Swaging and flaring

D. Flanging and swatting

9. What tool is used to cut plastic pipe?

A. Knife

B. Hacksaw (Table 1-7)

C. Coping saw

D. Back saw

10. What type of plastic pipe can be used on both a water supply system and a waste system?

A. ABS

B. PB

C. PE

D. PVC (Table 1-1)

1-25

LESSON 2

ROUGH-IN WATER SUPPLIES AND WATER SUPPLY PIPELINE RUNS

Critical Task: 052-248-1002

OVERVIEW

LESSON DESCRIPTION:

This lesson covers the installation of stops (valves) and fittings on water supply pipeline runs.This lesson also covers the installation and support of these pipeline runs during the buildingconstruction phase and testing the water supply system for leaks. TERMINAL LEARNING OBJECTIVE:

ACTION: You will learn to describe the procedures used to connect, install, and support a rough-in water supply system.

CONDITION: You will be given the material contained in this lesson.

STANDARD: You will correctly answer the practice exercise questions at the end of this lesson.

REFERENCES: The material contained in this lesson was derived from FM 3-34.471 and TM 5-551K.

INTRODUCTION

As the water supply pipeline runs are installed with fittings, they must be supported with hangersand holders. Many times, a plumber must cut into the building structure to place water supplypipeline runs to service lavatories, sinks, and water closets that are to be installed. The plumberalso tests the rough-in water supply system for leaks when it is completely installed.

2-1

PART A: INSTALLING STOPS (VALVES)

2-1. Stops. A water supply service starts outside the building at the water main and then entersthe building. Tap the water main with a self-tapping machine, and lay a water service line withstops (valves) to enter the building in the basement or crawl space. The water supply servicewater line to a building has three stops: corporation, curb, and meter (Figure 2-1).

Figure 2-1. Corporation, Curb, and Meter Stops

a. Installing a Corporation Stop. Water mains are usually cast iron, 8 inches or morein diameter. If the main is less than 8 inches in diameter, the tap should be 2 inches or smaller.Table 2-1 explains how to tap into a water main and install a corporation stop, using a water-main self-tapping machine.

2-2

Curb stop

Shutoff (gate valve)

Meter stop

Building foundationCorporation stop

Stop box

Water main

RoadGrade

Table 2-1. Tapping a Water Main

Step 1. Dig to expose the pipe at the point where the tap is to be made. Dig as close to the top of thewater main as possible.

2-3

Ratchet handleBoring bar

Feed yoke

Friction collar

Cap

Cylinder

Flap-valve handle

Saddle

GasketWater main

Bypass

Combination drill and tap

Flap valve

Step 2. Clean all dirt and rust off the pipe at the point.

Step 3. Place the gasket of the water-main self-tapping machine on the pipe, and set the saddle of themachine on the gasket.

Step 4. Wrap the chain around the pipe, and tighten it to clamp the water main self-tapping machine to thepipe.

Step 5. Remove the cap from the cylinder of the machine, and place the combination drill and tap in theboring bar.

Step 6. Reassemble the machine by putting the boring bar through the cylinder and tightening the cap.

Step 7. Open the flap valve between the compartments.

Step 8. Start drilling the hole by applying pressure at the feed yoke and turning the ratchet handle until thedrill enters the main.

Step 9. Back off the feed yoke when the tap starts threading the hole to prevent stripping the threads.

Step 10. Continue to turn the boring bar until the ratchet handle can no longer be turned without extraforce.

Step 11. Remove the tap from the hole by reversing the ratchet. Then back the boring bar out by turning itcounterclockwise.

Step 12. Close the flap valve between the upper and lower compartments.

Step 13. Drain the water from the cylinder through the bypass.

Step 14. Remove the cap and drill tool. Place a corporation stop in the boring bar, ensuring that the stopis closed.

Step 15. Repeat steps 6 and 7.

Step 16. Turn the ratchet handle to thread the corporation stop into the pipe.

Step 17. Repeat step 13.

Step 18. Remove the cap from the cylinder, and unbolt the boring bar from the corporation stop.

Step 19. Remove the lower chamber from the pipe.

Step 20. Inspect for leaks.

Step 21. Tighten the corporation stop with a suitable wrench, if it leaks.

2-4

b. Installing a Curb Stop. Curb and meter stops control the water entering thebuilding. Table 2-2 explains how to install a curb stop.

Table 2-2. Curb Stop

Step 1. Position the curb stop in a suitable place between the curb and the building.

Step 2. Set the curb stop in a cast-iron stop box that has a variable telescopic length.

Step 3. Join the curb stop to the service piping with a compression joint when using copper tubing for thewater service.

NOTE: The curb stop provides a shutoff of the water supply outside a building.

2-5

Curb stop

BuildingEarth grade

CurbStreet

Stop box

Water service line

c. Installing a Meter Stop. After running the water service lines through the side ofthe building and closing the holes around the service pipe with waterproof cement, install thewater meter and meter stop. The meter stop is a ground-joint valve, which controls and shuts offthe flow of water into the building. Table 2-3 explains how to install a meter stop.

Table 2-3. Meter Stop

Step 1. Place the meter stop as near as possible to where the water service pipe enters the building.

Step 2. Position the water meter near the meter stop valve.

Step 3. Open the meter stop valve to measure the amount of water being used in the building.

2-6

Shutoff (gate valve)

Meter stop

Building foundation

PART B: USING FITTINGS ON WATER SUPPLY PIPELINE RUNS

2-2. Galvanized-Steel/Iron Fittings. This part shows threaded drainage fittings used forgalvanized-steel/iron pipes and explains how to make a threaded joint connection. Ts (Figure 2-2) are used when a water supply pipeline run branches at a 90-degree angle. Elbows(Figure 2-3) are used to change the direction of a water supply pipeline run. Couplings (Figure 2-4) are used to connect two lengths of pipe.

Figure 2-2. Ts

Figure 2-3. Elbows

2-7

Branch

Run Outlet

Branch BranchRun

OutletOutlet

Side-outlet T

Run

Reducing T (external) Reducing T (internal)

Standard T

NOTE: Branch and run can be reversed.

90 elbow 45 elbow

Y-elbow (or side-outlet elbow)

Reducing elbowStreet elbow

Figure 2-4. Couplings

2-3. Joint Connections. The threads of drainage fittings are at a slight angle (Figure 2-5).This angle causes horizontal drainage pipes to slope about 1/4 inch per foot. Table 2-4 explainshow to make a threaded joint connection.

Figure 2-5. Slope of Horizontal Drainage Pipes

2-8

Standard coupling Reducing coupling Eccentric reducing coupling

Extension piece

Fitting

1/4" slope per foot

90º angle

Pipe

Table 2-4. Making a Threaded Joint Connection

Step 1. Check the fitting threads for cleanliness and damage. If necessary, clean with a wire brush orreplace the fitting.

Step 2. Repeat step 1 for the pipe threads.

Step 3. Apply pipe joint compound or Teflon® tape to the pipe threads only.

Step 4. Screw the fitting on hand tight.

Step 5. Tighten the fitting, using two pipe wrenches. Use one pipe wrench on the fitting and theother on the pipe, turning clockwise.

2-9

Wrench

Pipe Joint Compound

Pipe threadsPipe Fitting

2-4. Copper Fittings. Various types of copper tubing fittings for soldered and compressionjoints are shown in Figure 2-6. The preparation for each type of joint will be described in greaterdetail.

Figure 2-6. Fittings for Copper Tubing

2-10

Female adapterMale adapter Coupling

T45 elbow90 elbow

Male adapter Female adapter Coupling

45 elbow90 elbowT

Solder Fittings

Copper Compression Fittings

2-5. Joint Connections for Copper Tubing. There are several different types of joints forcopper tubing. A soldered joint is used to connect rigid copper tubing; a flared joint is used withflexible copper tubing; a mechanical-compression joint is used with flexible copper tubing toconnect the water supply tubing of a fixture to the shutoff valve; and a swaged joint is used toconnect two sections of rigid thin-walled copper tubing without using a fitting.

a. Soldered Joint. Soldered joint connections for copper tubing are made with flux,solder, and a heat source. The flux permits even spreading of molten solder over the surfacessoldered. The molten solder flows into the space between the fitting and the tubing. Table 2-5explains how to make a soldered joint.

Table 2-5. Soldered Joint

Step 1. Inspect the end of the tubing to be sure it is round, free of burrs, and cut square.

Step 2. Clean the outside end of the tubing and the inside of the fitting to a bright shine with emery cloth orfine steel wool.

Step 3. Apply a thin coat of flux to the shined end of the tubing and fitting.

Step 4. Push the fitting on the tubing, and give it a quarter turn to spread the flux evenly.

Step 5. Heat the connection with a torch, applying the flame on the fitting.

Step 6. Apply the solder to the joint when the flux is bubbling. The solder will flow into and completelyaround the joint.

Step 7. Clean the joint, using a clean rag.

NOTE: A well-soldered joint should have an even bead around the entire joint.

2-11

Flux

50-50 Solder

Torch

Fitting

b. Flared Joint. A flared joint is used with flexible copper tubing. The flare on theend of the tubing can be made with a flaring or flanging tool. Table 2-6 explains how to make aflared joint, using a flaring tool or a flanging tool.

Table 2-6. Flared Joint

Step 1. Inspect the end of the tubing to ensure that it is free of burrs and is cut square.

Step 2. Remove the flange nut from the fitting, and slide its unthreaded end onto the tubing first.

Step 3. Flare the end of the tubing with either a flaring tool or a flanging tool.

Flaring tool method. Loosen the wing nuts on the flaring tool, and place the tubing in thecorrect size hole. Make the tubing’s end even with the tool’s surface. Tighten the wing nuts.Turn the yoke cone down into the tubing until the flare fills the beveled pad of the hole.

Flanging tool method. Hold the flanging tool on the end of the tubing so it is centered andstraight. Tap the flanging tool, using a ball-peen hammer, until the flare fills the recess in theflanging nut.

Step 4. Slide the flare/compression nut up to the flared end, and screw it on the fitting hand tight, thentighten the flare/compression nut.

2-12

Nut wing

Flaring tool

Copper tubing

Ball-peen hammer

Flanging tool

Flange nut

c. Mechanical-Compression Joint. A mechanical-compression joint is used withflexible copper tubing to connect the water supply tubing of a fixture to the shutoff valve. Table 2-7 explains how to complete a mechanical-compression joint.

Table 2-7. Mechanical-Compression Joint

Step 1. Cut or bend the tubing to the required length.

Step 2. Slide the compression nut onto the tubing.

Step 3. Slide the compression ring onto the tubing.

Step 4. Screw the compression nut onto the fitting by hand.

Step 5. Tighten the nut. The ring compresses to form a sealed leakproof joint.

2-13

Fitting

TubingCompression ring

Compression nut

d. Swaged Joint. A swaged joint is used to connect two sections of rigid thin-walledcopper tubing without using a fitting. The connection is soldered to form a leakproof joint. Thetools required are a swaging-tool set and a ball-peen hammer. Table 2-8 explains how tocomplete a swaged joint.

Table 2-8. Swaged Joint

Step 1. Inspect the tubing end to make sure it is free of burrs and is cut square.

Step 2. Place the correct size swaging tool into the tubing (with one hand), centered and straight.

Step 3. Tap the swaging tool firmly with the ball-peen hammer to enlarge the end of the tubing.

Step 4. Connect the two sections of tubing, and solder the joint.

2-14

Swaged end

Swaging tool

Swaging tool

Copper tubing

Ball-peen hammer

2-6. Fittings for Rigid and Flexible Plastic Pipe. The various types of fittings for rigid andflexible plastic pipes are shown in Figure 2-7. The preparation for each type of pipe and fittingattachment will be described in greater detail.

Figure 2-7. Fittings for Rigid and Flexible Plastic Pipes

2-15

Solvent Weld

Slip

Sanitary Pipe

Long sweep TYVent TSanitary T

T 90 elbow Coupling Male adapter

Coupling45 elbow90 elbowT

a. Completing a Solvent-Cement Weld Joint. This joint is made by using a cleaningprimer and solvent cement on the pipe and fitting. Solvent cement consists of a plastic filler(same material for each type of plastic pipe) dissolved in a mixture of solvents. Use theappropriate solvent cement for the type of pipe being used. The solvent cement melts the plasticof the pipe and the fitting to weld them together. Since solvent cement sets fast, a plastic pipejoint is completed quickly. Table 2-9 explains how to join rigid plastic pipe with a solvent-cement weld joint.

Table 2-9. Solvent-Cement Weld Joint

Step 1. Inspect the pipe end for burrs and the fitting for cracks.

Step 2. Clean the pipe and the inside of the fitting with an authorized cleaning primer, using a clean rag.

Step 3. Coat the outside of the pipe end and the inside of the fitting with solvent cement.

Step 4. Push the pipe as quickly as possible into the fitting as far as it will go. A small bead of cement willbe visible.

Step 5. Give the fitting a quarter turn to spread the solvent cement evenly.

Step 6. Hold the joint connection for about 30 seconds to be sure it is solidly set.

Step 7. Wipe off all excess cement.

2-16

Solvent cement

FittingPipe

b. Completing an Insert Fitting Joint. This joint is made by sliding and clampingflexible plastic pipe onto an insert fitting. Table 2-10 explains how to join flexible plastic pipewith an insert fitting joint.

Table 2-10. Insert Fitting Joint

Step 1. Slide a clamp over the flexible pipe.

Step 2. Push the pipe onto the insert fitting to the last serration.

Step 3. Slide the clamp over the pipe, and tighten the clamp with a screwdriver.

PART C: INSTALLING WATER SUPPLY PIPELINE RUNS

2-7. Water Supply Pipeline Runs. Install the water supply pipeline runs during the buildingconstruction. The following steps will make it easier to rough-in water supply pipeline runs withfittings, support these pipeline runs, and test the rough-in water supply system joints for leaks.The water supply pipeline runs consist of distribution lines, branch lines, and riser lines that willservice the fixtures or equipment.

a. Main Distribution Lines. Install this waterline, with all fittings required for thebranch lines, between or through the floor joist from the meter stop. The pipe size will be thesame as the water service line.

2-17

Clamp

Flexible pipe

Insert fittingClamp

b. Branch Lines. From the fittings on the distribution line, install the branch linesbetween or through the floor joist to those fixture points that the fixture riser lines will service.

c. Fixture Riser Lines. Table 2-11 shows how the different waterlines connect tocomplete the water supply system and explains how to install fixture supply pipe risers.

Table 2-11. Main Distribution, Branch, and Fixture Riser Lines

Step 1. Install fixture supply pipe risers from the branch line fittings by drilling holes through the sole plate orfloor.

Step 2. Set the risers with fittings to connect the water supply.

Step 3. Set the air chamber to control the pipe noise.

2-18

Cold-water distribution line from meter stop

Cap

Air chamber

T

Wall stud

Sole plate

Fixture riser line

T with nipple and a 90° elbow

Branch line

Floor joist

90° elbow

Hot-water distribution line from water heater

2-8. Water Supply Pipeline Runs.

a. Installing Water Supply Pipeline Runs Through a Floor Joist. Table 2-12 explainshow to install rough-in water supply pipeline runs through a floor joist.

Table 2-12. Installing Water Supply Pipeline Runs

Step 1. Determine which water supply pipeline runs require installation through the floor joist.

Step 2. Find the center of the floor joist.

Step 3. Drill a hole through the center of the joist. The hole cannot be larger than 1/4 of the depth of thejoist. For example, if you are using a 2- by 8-inch joist, the hole cannot be any larger than 2 inches.

2-19

Hole

Floor joist

b. Notching and Bracing a Joist. Notches can be at the top or bottom of a joist. Thenotch width should be slightly larger than the outside diameter of the pipe. Table 2-13 explainshow to cut a notch in a joist and to brace the joist.

Table 2-13. Notching and Bracing a Joist

Step 1. Determine the width of the notch.

Step 2. Cut both sides of the notch to the proper depth with a handsaw. The notch depth can be no morethan a quarter of the joist depth. For example, if the joist depth is 8 inches, then the maximum notch depthwould be 2 inches (1/4 of 8 = 2)

Step 3. Use a hammer and a sharp wood chisel to cut away the wood between the notch cuts.

Step 4. Place a 2- by 2-inch board on each side of the joist when the notch is on the top.

Step 5. Center boards under the notch and nail in place.

Step 6. Center a steel plate over the notch when it is on the bottom of the joist.

Step 7. Nail the plate into place.

2-20

Handsaw2" x 8" floor joist

Wood chiselWidth of the notch

Depth of the notch

2" x 2" boards

Steel plate

c. Cutting and Bracing a Wall Stud. Table 2-14 explains how to cut and brace a wallstud.

Table 2-14. Cutting and Bracing a Wall Stud

Step 1. Cut the notch from the top or bottom half of the stud. A notch cut from the top cannot be greaterthan 1/2 of the depth of the stud. A notch cut from the bottom cannot be greater than 1/3 of the depth ofthe stud.

Step 2. Ensure that the width of the cut-out notch is able to take the pipe size to be installed.

Step 3. Measure the depth of the wall stud before cutting notches.

Step 4. Brace all notch cuts in the wall studs with water supply pipeline runs.

Step 5. Ensure that the studs with the notch cuts have a steel plate centered over the notch.

Step 6. Nail the plate into place.

2-21

Wall stud

Depth of stud

Width of the notch based on pipe size

Depth of notch

Brace steel plate

Pipeline run

PART D: SUPPORTING WATER SUPPLY PIPELINE RUNS

2-9. Pipe Supports. Horizontal and vertical water supply pipeline runs with fittings must besupported. The length of the pipeline runs, their locations, and the joints will determine where toplace the pipe supports. There are many types of pipe supports designed to hang or support thepipeline run (Figure 2-8). The building material and types of pipes will, in many cases, determinethe kind of supports to use.

Figure 2-8. Pipe Hangers

2-22

Pipe strap

Wall hanger

Adjustable hanger

Common hanger

Common hanger

a. Supporting Horizontal Water Pipes. Use tube clamps, U-hooks or self-nailinghooks, perforated bands, and one-hole clamps to support a horizontal water supply pipeline runto a joist. Figure 2-9 shows these types of pipe supports.

Figure 2-9. Supporting Horizontal Water Pipes

2-23

Tube clamp

One-hole clamp

Pipe

Joist

b. Supporting Vertical Water Pipes. Use wood blocking to attach the pipe supports(Figure 2-10). The pipe supports that can be used to support a vertical water piping run are tubeclamps, one-hole clamps, and perforated bands.

Figure 2-10. Supporting Vertical Water Pipes

2-24

Stud

Sole plate

Pipe

Wood blocking

Tube clamp

PART E: TESTING THE WATER SUPPLY SYSTEM FOR LEAKS

2-10. Water Supply System Test. Once the rough-in water supply system is completed, testthe system for leaks, using the water test or air test. Locate and repair any leaks at once, andretest the system.

a. Water Supply System Test. Table 2-15 explains how to test a system with water.

Table 2-15. Water Supply System Test

Step 1. Seal the branches and vent lines, and place a test plug in the test T.

Step 2. Fill the system with water, and check for a drop in the water level.

Step 3. Check each joint for leaks if the water level drops noticeably. The test is satisfactory if the waterlevel does not fall more than 4 inches in a 30-minute period.

Step 4. Make leaking joints watertight, and replace any defective material.

2-25

Cap

All T openings are capped during the test

Wall stud

Sole plate

T with nipple and a 90° elbow

From meter stop

Floor joist

90° elbowFrom water heater

b. Air Test. A special plug, through which air is pumped into the watersupply system, is required for this test. Perform an air test, using the following steps:

Step 1. Apply an air pressure of about 5 pounds per square inch (measured by agauge).

Step 2. A drop in the mercury column on the gauge shows a leaky joint. In asatisfactory test, the line should hold 5 pounds per square inch for 15 minutes.

Step 3. Listen for the sound of escaping air to help locate leaks. If no sound isheard and pressure is falling, apply a soap solution to the joints in the area of theleak. If there is a leak, bubbles will form.

2-26

LESSON 2

PRACTICE EXERCISE

Instructions: The following items will test your grasp of the material covered in this lesson.There is only one correct answer for each item. When you complete the exercise, check youranswers with the answer key that follows. If you answer any item incorrectly, restudy that part ofthe lesson that contains the portion involved.

1. Identify which of the following is not a stop for a service water line to a building.

A. Building stop

B. Corporation stop

C. Curb stop

D. Meter stop

2. Which of the following stops shuts off the water supply outside of the building?

A. Building stop

B. Corporation stop

C. Curb stop

D. Meter stop

3 Where is the pipe joint compound applied for a threaded drainage fitting joint forgalvanized-steel/iron pipe?

A. Fitting threads only

B. Pipe threads only

C. Pipe and fitting threads

D. All threads

4. Where is the heat applied to make a soldered joint for copper tubing?

A. Pipe

B. Flux

C. Fitting

D. Solder

2-27

5. Identify which of the following is not a type of copper tubing joint connection.

A. Soldered joint

B. Flared joint

C. Mechanical-compression joint

D. Solvent-cement weld joint

6. What is the largest-sized hole that can be drilled though the center of a 2- by 8-inch floorjoist for a pipeline run?

A. 1 inch

B. 2 inches

C. 3 inches

D. 4 inches

7. What is the maximum depth that a notch can be cut in a floor joist?

A. 1/4 of the joist depth

B. 1/3 of the joist depth

C. 1/2 of the joist depth

D. 2/3 of the joist depth

8. What is the maximum depth that a notch can be cut at the bottom of a wall stud?

A. 1/4 of the depth of the stud

B. 1/3 of the depth of the stud

C. 1/2 of the depth of the stud

D. 2/3 of the depth of the stud

2-28

9. What is used to brace the bottom of a joist or the lower half of a wall stud?

A. Steel plate

B. Wood blocking

C. Pipe strap

D. Plastic plate

10. What is the number of minutes water is kept in a rough-in water supply system during awater test?

A. 15

B. 20

C. 25

D. 30

2-29

LESSON 2

PRACTICE EXERCISE

ANSWER KEY AND FEEDBACK

1. Identify which of the following is not a stop for a service water line to a building.

A. Building stop (paragraph 2-1 and Figure 2-1)

B. Corporation stop

C. Curb stop

D. Meter stop

2. Which of the following stops shuts off the water supply outside of the building?

A. Building stop

B. Corporation stop

C. Curb stop (Table 2-2)

D. Meter stop

3 Where is the pipe joint compound applied for a threaded drainage fitting joint forgalvanized-steel/iron pipe?

A. Fitting threads only

B. Pipe threads only (Table 2-4)

C. Pipe and fitting threads

D. All threads

4. Where is the heat applied to make a soldered joint for copper tubing?

A. Pipe

B. Flux

C. Fitting (Table 2-5)

D. Solder

2-30

5. Identify which of the following is not a type of copper tubing joint connection.

A. Soldered joint

B. Flared joint

C. Mechanical-compression joint

D. Solvent-cement weld joint (paragraphs 2-5 and 2-6a)

6. What is the largest-sized hole that can be drilled though the center of a 2- by 8-inch floorjoist for a pipeline run?

A. 1 inch

B. 2 inches (Table 2-12)

C. 3 inches

D. 4 inches

7. What is the maximum depth that a notch can be cut in a floor joist?

A. 1/4 of the joist depth (Table 2-13)

B. 1/3 of the joist depth

C. 1/2 of the joist depth

D. 2/3 of the joist depth

8. What is the maximum depth that a notch can be cut at the bottom of a wall stud?

A. 1/4 of the depth of the stud

B. 1/3 of the depth of the stud (Table 2-14)

C. 1/2 of the depth of the stud

D. 2/3 of the depth of the stud

2-31

9. What is used to brace the bottom of a joist or the lower half of a wall stud?

A. Steel plate (Tables 2-13 and 2-14)

B. Wood blocking

C. Pipe strap

D. Plastic plate

10. What is the number of minutes water is kept in a rough-in water supply system during awater test?

A. 15

B. 20

C. 25

D. 30 (Table 2-15)

2-32

APPENDIX A

LIST OF COMMON ACRONYMS

ABS acrylonitrile-butadiene-styrene

CPVC chlorinate polyvinyl chloride

DWV drain, waste, and vent

EN engineer

FM field manual

MOS military occupational specialty

NPT national pipe threads

PB polybutylene

PE polyethylene

PVC polyvinyl chloride

TM technical manual

A-1

APPENDIX B

RECOMMENDED READING LIST

The following publications provide additional information about the material in the subcourse.You do not need this material to complete the subcourse.

FM 3-34.471. Plumbing, Pipe Fitting, and Sewerage. 31 August 2001.

TM 5-551K. Plumbing and Pipefitting. 29 July 1971.

B-1

APPENDIX C

METRIC CONVERSION CHART

This appendix complies with current Army directives which state that the metric system will beincorporated into all new publications. Table C-1 is a metric conversion chart.

Table C-1. Metric Conversion Chart

US Units Multiplied By Metric Units

Feet 0.30480 Meters

Inches 2.54000 Centimeters

Inches 0.02540 Meters

Inches 25.40010 Millimeters

Metric Units Multiplied By US Units

Centimeters 0.39370 Inches

Meters 3.28080 Feet

Meters 39.37000 Inches

Millimeters 0.03937 Inches

C-1