E . L . J u l ya n
N1 PLUMBING HANDS
on!
© Future Managers 2013 All rights reserved. No part of this book may be reproduced in any form, electronic, mechanical, photocopying, or otherwise, without prior permission of the copyright owner. ISBN 978-1-77581-069-8 First published 1988 2nd edition 2013 To copy any part of this publication, you may contact DALRO for information and copyright clearance. Any unauthorised copying could lead to civil liability and/or criminal sanctions.
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Contents Module 1 Safety and housekeeping ...................................................................................... 1 1.1 1.2 1.3 1.4
Causes and prevention .......................................................................................................... 1 Workmen’s Compensation Act ............................................................................................ 2 Occupational Health and Safety Act ................................................................................... 3 Personal protective equipment ............................................................................................ 8 Exercises ............................................................................................................................... 10
Module 2 Tools and machines............................................................................................... 11 2.1 2.2
Tools ...................................................................................................................................... 11 Machines .............................................................................................................................. 26 Exercises ............................................................................................................................... 33
Module 3 Metals and materials............................................................................................. 35 3.1 3.2 3.3 3.4
Characteristics of metals .................................................................................................... 35 Metals used in the plumbing industry .............................................................................. 36 Characteristics and uses of other materials ..................................................................... 37 Reactions of metals ............................................................................................................. 39 Exercises ............................................................................................................................... 41
Module 4 Soldering and welding ......................................................................................... 43 4.1 4.2 4.3 4.4 4.5
Soft soldering ....................................................................................................................... 43 Hard soldering ..................................................................................................................... 45 Soldering mediums and fluxes for soft and hard soldering ........................................... 45 Gas welding .......................................................................................................................... 46 Welding works regulations ................................................................................................. 54 Exercises ............................................................................................................................... 56
Module 5 Cold water supply.................................................................................................... 57 5.1 5.2 5.3 5.4 5.5
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The properties of water........................................................................................................ 57 Water sources for human consumption ........................................................................... 57 Methods of joining fittings to pipes .................................................................................. 59 Other installations ............................................................................................................... 65 Fittings between fixed points ............................................................................................. 70 Exercises ............................................................................................................................... 74
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IV
Contents
Module 6 Hot water supply .................................................................................................... 77 6.1 6.2 6.3 6.4 6.5
The basic principles of heat transfer ................................................................................. 77 Hot water units .................................................................................................................... 77 Installation of a boiler-cylinder and supply tank ............................................................ 84 Causes, prevention and rectification of airlocks ............................................................. 86 Precautions when doing a hot water installation ............................................................ 87 Exercises ............................................................................................................................... 88
Module 7 Drainage .................................................................................................................... 89 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11
Standard sanitary and other abbreviations ...................................................................... 89 Drainage terms .................................................................................................................... 90 Drain/sewer pipe jointing methods .................................................................................. 90 Miscellaneous installations and constructions ................................................................ 94 Traps .................................................................................................................................... 103 Flush valves ........................................................................................................................ 106 Cisterns ............................................................................................................................... 108 Drainage installation ......................................................................................................... 110 Materials for sanitary fitments ......................................................................................... 117 Sanitary appliances ............................................................................................................ 118 Single-stack and stub-stack pipe systems ....................................................................... 128 Exercises ............................................................................................................................. 134
Module 8 Sheet metal work ................................................................................................ 137 8.1 8.2 8.3 8.4 8.5
Different sheet metal joints .............................................................................................. 137 Sheet metal pattern development .................................................................................... 141 Installing and joining gutters ........................................................................................... 150 Roof flashings around ventilation pipes ......................................................................... 155 Non-metal flashings for profiled sheet metal and tiled roofs ...................................... 156 Exercises ............................................................................................................................. 165
Module 9 Calculations............................................................................................................ 167 9.1
Measurement units ............................................................................................................ 167 Exercises ............................................................................................................................. 174
Sample exemplar paper ..................................................................................................... 177
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Introduction The aim of this volume is to assist the student who is keen to study in this particular field of the building trade. The contents are compiled to cover the prescribed syllabus, and as a basis for those who intend studying further in this field to become professional, licensed plumbers. No text book or other work of reference is ever complete. I therefore strongly recommend that students seek out all available sources to obtain the maximum amount of coverage on any particular topic, which would greatly enhance understanding of the subject matter. College lectures and text books simply provide a theoretical background. Practical experience and/or on site observation of works in progress are of vital importance to complement the contents of these text books. E.L. Julyan
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MODULE
1 Safety and housekeeping 1.1 Causes and prevention As safety at work covers a wide field, it will not be possible to deal with all aspects of each item discussed. 1.1.1
Personal safety A plumber must take care of his own and the safety of those around him. Many accidents occur due to negligence, ignoring prescribed regulations in the workshop, or not following the operating instructions of a particular machine. Work should be done in a well-lit environment to avoid tripping over objects, and also to ensure the accuracy of the work. Below are a few guidelines. • • • • • •
1.1.2
Avoid working in direct sunlight. Wear the prescribed clothing. Do not wear loose or torn garments. Avoid wearing loose bracelets or other accessories. Wear the necessary safety gear, such as goggles, for the particular job. Be alert and plan in advance what has to be done for a particular job.
Safety regarding machines A machine is a capital investment that has to increase productivity. It should thus be maintained and cared for properly. • All electrical wiring should be according to the prescribed regulations. All cabling and switchgear must be fixed. • The areas around machines should clear of obstructions and the floor should clean and oil-free. • All machines driven by pulleys, belts or gearwheels shoiuld have the necessary safety guards. • Use a machine only for the purpose it was designed for. Never overload or force a machine. • Always clean and oil a machine when the job is completed and it is switched off.
1.1.3
Safety regarding materials Labour and material go hand in hand to determine the end product. • Care should be taken when handling sheet metal in windy weather, by using a board as backing, in order not to fold or bend the sheet unnecessarily.
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How to stack pipes
• Never throw pipe fittings from one spot to another, as you may spoil the threads of the fitting. • Do not stack sanitaryware on top of another, as it could break. • Any acid or fluxes should be stored in a special room. 1.2
Workmen’s Compensation Act The Act was formulated to provide for compensation for disablement, caused by occupational injuries or diseases sustained or contracted by employees in the course of their employment, or death resulting from such injuries or diseases, and to provide for matters connected therewith. This particular Act no. 130, dated 1993, or any amended, should be read as a whole to understand why it is necessary to have such a document. The Act is part of the normal Government Gazette issues obtainable from any leading bookstore or directly from the Government Printers. To administer the prescribed acts falls to a Commissioner and his staff, who have the power to raise funds, have assessors and so on, and are run by an appointed Compensation Board. The Act will not be discussed in detail. The few few extracts below will show why it is necessary to study the document as part of the prescribed work for the syllabus.
1.2.1
Claims for compensation 1. 2. 3. 4. 5. 6. 7. 8. 9.
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Notice of accident by employee to employer. Notice of accident by employer to commissioner. Inquiry by commissioner into accident. Particulars in support of claim. Employee to submit to medical examination. Claim for compensation. Prescription. Consideration of claim. Appearance of parties.
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The Act as published, or any adjustment in future to it, deals with various topics related to Compensation for Occupational Injuries and Diseases. To highlight only certain clauses may not be wise. Each case according to the Act will be dealt on merit and for this reason will it be best to study the latest document concerning the Act to suit the circumstances of the particular case involved. 1.3
Occupational Health and Safety Act It is recommended to consult the prescribed Government Gazette No. 14918 volume 337, dated 2 July 1993 or any amended since then. Below are a few extracts from the particular volume (Act 85, 1993).
1.3.1
Duty to inform Section 13: Without derogating from any specific duty imposed on an employer by this act, every employer shall: (a) As far as is reasonably practical, cause every employee to be made conversant with the hazards to his health and safety attached to any work that he has to perform, any article or substance that he has to produce, process, use, handle, store or transport and any plant or machinery that he is required or permitted to use, as well, as with the precautionary measures that should be taken and observed with respect to those hazards: (b) Inform the health and safety representatives concerned beforehand of inspections, investigations or formal inquiries of which he has been notified by an inspector, and of any application for exemption made by him in terms of section 40; and (c) Inform a health and safety representative as soon as reasonably practical of the occurrence of an incident in the workplace or section of the workplace for which such representative has been designated.
1.3.2
General duties of employees at work Section 14: Every employee shall at work: (a) Take reasonable care for the health and safety of himself and of other persons who may be affected by his acts or omissions; (b) As regards any duty or requirement imposed on his employer or any other person by this act, cooperate with such employer or person to enable that duty or requirement to be performed or complied with; (c) Carry out any lawful order given to him, and obey the health and safety rules and procedures laid down by his employer or by anyone authorised thereto by his employer, in the interest of health or safety; (d) If any situation, which is unsafe or unhealthy, comes to his attention, as soon as practical. Report such situation to his employer or to the health and safety representative for his workplace or section thereof, as the case may be, who shall report it to the employer; and (e) If he is involved in any incident which may affect his health or which has caused an injury to himself, report such incident to his employer or to anyone authorised thereto by the employer, or to his health and safety representative, when practical
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but not later than the end of the particular shift during which the incident occurred, unless the circumstances were such that the reporting of the incident was not possible, in which case he shall report the incident as soon as practicable thereafter. 1.3.3
Duty not to interfere with or misuse things Section 15: No person shall intentionally or recklessly interfere with, or misuse anything, which is provided in the interest of health or safety.
1.3.4
Functions of health and safety representatives Section 18(1): A health and safety representative may perform the following functions in respect of the workplace or section of the workplace for which he has been designated, namely: (a) Review the effectiveness of health and safety measures; (b) Identify potential hazards and potential major incidents at the workplace; (c) In collaboration with his employer, examine the causes of incidents at the workplace; (d) Investigate complaints by any employee relating to that employee’s health or safety at work; (e) Make representations to the employer or a health and safety committee on matters arising from paragraphs (a), (b), (c) or (d), or where such representations are unsuccessful, to an inspector; (f) Make representations to the employer on general matters affecting the health or safety of the employees at the workplace; (g) Inspect the workplace, including any article, substance, plant, machinery or health and safety equipment at that workplace with a view to the health and safety of employees, at such intervals as may be agreed upon with the employer, etc.
1.3.5
Offences, penalties and special orders of court Section 38(1)(p): Anyone who wilfully or recklessly does anything at a workplace or in connection with the use of plant or machinery which threatens the health or safety of any person, shall be guilty of an offence and on conviction be liable to a fine not exceeding R50 000 or to imprisonment for a period not exceeding one year or to both such fine and such imprisonment. Although a few extracts are given, it is highly recommended to read and study the whole-prescribed document.
1.3.6
The safe use of ladders Wooden ladders shall be constructed of straight grained wood that is free from defects, with the grain running in the length of the stile and the rung. It should not be painted or covered in any way, unless it has been established by the user that there are no cracks or other inherent weaknesses. Ladders could be oiled or covered with clear varnish or a wood preservative. The extension type ladder is best as it can be adjusted to the height of the work level. Ladders must always be set on a firm base to avoid slipping. A safe angle taken from the
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horizontal plane should be 75° or, at base, one-quarter of the working length away out from the building or support point.
Different types of ladder
Before using a ladder, inspect the frame for any flaws in the material, as well as all the rungs and rung lock mechanisms. If any length of rope is part of the extension type, see to it that it is of all-weather polypropylene rope without any loose strands. Extension ladders should be erected in the closed position and extended when upright against the wall. Make sure again that the locking device is well seated on its supporting rung, before extending the other half. Never extend the remaining half up to the last rung; leave at least 25% of the top of the ladder as a support section. • Where possible, try and secure the top part to a convenient anchor point to minimise sliding of the ladder against the wall or other material. • Face the ladder while climbing or descending from it. • Never overload yourself when climbing a ladder; rather use hoisting equipment to hoist the particular item to the specified height. • Never erect a ladder against any glass surface areas, PVC gutters or glazing bars. • When carrying a ladder, carry it lengthways. If it exceeds a length of 3 metres, get an assistant to help carry the ladder to avoid accidents. Remember, do not use a ladder longer than 9 metres; it is against the stipulated regulations. 1.3.7
Safeguarding of openings Holes, openings or any other sort of excavation, on sloping or level ground, should be screened off properly with guard-rails or indicated with some type of warning sign, to prevent grave injury to pedestrians or a moving vehicle landing up in an open trench.
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Excavated hole covered
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It is also extremely important to cover up openings made during the day to prevent water entering the opening, as flooding a hole or trench brings about a saturation point. Unnecessary labour must then be undertaken to bail out water, or to cast concrete on any form of unwanted earthwall overbreak. Usually it is the contractor’s responsibility to ensure that holes, trenches, and so on, dug by his employees are screened off to avoid any legal action for negligence to safeguard the public against mishaps. 1.3.8
Protection of excavations As stated above, the contractor has an obligation to protect the public against accidents caused by excavations in a public road, street or pavement.
Barrier as safety precaution
According to the Occupational Health and Safety Act, the builder or excavator should ensure the following regarding all excavations accessible by the public or adjacent to public roads or thoroughfares, where the safety of persons could be endangered. • The excavation should be adequately protected by a barrier or fence at least 600 mm high, and as close to the excavation as practicable. • It should be provided with red warning lights at night. 1.3.9
Erection of scaffolding The erection of scaffolding has become a specialised trade, where each type of scaffold has to meet the safety regulations for the workload and height of a particular structure.
Scaffold in place
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It is important to study the safety regulations regarding the requirements for each type of scaffolding. A few extracts of the prescribed regulations are given below.
Scaffold framework
1. The user shall cause: 1.1 Scaffold standards to be firmly supported and secured against displacement and to be kept vertical, except in the case of putlog scaffolds which shall incline slightly towards the object on which work is performed. 1.2 Standards to be spaced not more than 1,8 m; 2,4 m and 3 m apart in the case of high, medium and low mass loads, respectively, if constructed of steel and not more than 3 m apart if constructed of timber. 1.3 Ledgers to be spaced not more than 2,1 m apart vertically. 1.4 Putlogs or transoms to be spaced not more than 1,5 m; 1,8 m and 2,4 m apart in the case of high, medium and low mass load respectively. For the purpose of this regulation ‘high’, ‘medium’ and ‘low’ mass loads shall mean mass loads of not more than 375; 250 and 125 kilogram/square metre respectively. 2. No user shall use, or cause to be used, any scaffold unless it is: 2.1 Securely and effectively braced to ensure stability in all directions. 2.2 Secured at suitable vertical and horizontal distances to the object on which work is being performed unless the scaffold is designed to be completely selfsupporting. 2.3 So constructed that it has a factor of safety of not less than four. 2.4 Inspected by a competent person at least once a week and after inclement weather. 3. No user shall require or permit: 3.1 Scaffolding, the supporting frame of which is constructed of timber, to exceed a height of 25 metres. 3.2 Scaffolding to be erected, altered or taken down other than by or under the personal supervision of a competent person.
Scaffold boards
The standard scaffold board length is 3,900 m × 228 mm × 38 mm. The quality therefore must satisfy the following requirements: Not more than one third of the width of the board in any one place shall be knot wood. The end shall not be split up more than 300 mm with the hoop iron fixed. Not more than half of the depth shall be knot wood. The grain shall not cross from face to face of the board in a distance of less than 300 mm. 5. It must not be twisted by more than 12 mm. 1. 2. 3. 4.
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1.3.10 Manual handling of loads Before starting a job, determine the type of material to be used. Look out for splinters and jagged edges on sheet metal edges before handling the material.
Asbestos cement roof
Fragile roof covering Use crawling board
Scaffold board for workers
Ladder Board to support ladder
Safe-guarding methods Safe guarding methods
Before carrying a load, make sure that you have an unobstructed path that is not slippery. Six major points to remember when lifting heavy objects 1. Back must be straight 2. Hold chin in 3. Keep arms close to body 4. Keep feet slightly apart 5. Grip the object with palm of hands and not just the fingers 6. Bend the knees and lift by straightening the legs Most accidents happen when employees do not adhere to these points, especially a back injury. So, when lifting the object, lift with the thigh muscles by straightening the legs, lift in stages, from floor to knee level, and from knee to the carrying position. Also make sure that you can see over the load while carrying it. When you have to set the load down, reverse the lifting procedure. If you are not sure about the mass of an object, ask an assistant to help. 1.4
Personal protective equipment The employer, occupier or user should provide protective equipment, free of charge and in good condition, to any person working in a factory or where machinery is used. This includes the employee who is exposed to wet or dusty processes, to heat or any poisonous, corrosive or other injurious substance that could cause injury or disease or could unduly damage clothing. Adequate protective clothing and appliances include caps, goggles, gloves, leggings, footwear and protective ointment.
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Overalls
Any form of labour-intensive work requires that the body is protected against exterior mishaps. Overalls should be clean and fit properly.
Goggles
There are different types of goggles for different jobs. Clear goggles, which are lightweight and made of plastic, are normally used for grinding work, or where the person has to protect his or her eyes against flying objects.
Goggles
Dark-tinted goggles are used for any form of welding to protect the eyes against the bright light of the gas-welding flames and the sparks of the arc welding machine, which can cause severe damage to eyesight if the eyes are unprotected.
Ear-guards or protectors
Your ears must be protected against any high pitch decibels or unwanted sound. When working with a compressor or any other machine with similar noise levels, you should wear suitable ear-guards. Ear-guards are easy to use as they simply clamp over the head and are adjustable to suit the individual.
Masks
Where dust, spray work, polluted air or noxious gases are a risk, a mask is necessary to protect the lungs. Masks are essential in deep sewerage manholes, where methane gas may be present. Always wear a mask where any form of asbestos-cement sheeting is cut or cement powder is used. Failure to do this could affect your lungs in the long run.
Gloves
Do not risk injury to your hands and fingers by handling any loose pieces of metal, chemicals or heated objects.
Footwear
Footwear is important. A plumber must take note of signs that warn against any potential hazards. Footwear could prevent your feet skidding on slippery floor areas. Be cautious when wearing footwear with nails in it, especially near petroleum or explosive works.
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Safety boots
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Gauntlets
Gauntlets are essential where any form of gas welding (brazing) or arc welding is done. The gauntlets protect the front part of the legs of the welder against any hot sparks or flying flux pieces from the welding part of the object. They also protect the legs against excessive heat coming from the gas flames, which may burn the top layers of the skin.
Gauntlets
Hard hats Hard hats are prescribed by most building, civil and allied groups to be worn at construction sites. On the entrance gates of most reputable construction sites a signboard displays compulsory clothing, such as hard hats and footwear. Heavy penalties can be exacted if the regulations prescribed by the safety and health acts are not followed.
Hard hat
Exercise 1.1 1. Describe the aims of the Occupational Health and Safety Act. 2. What are the responsibilities of the employee to ensure safe working conditions? 3. Describe the safe use of ladders when performing the actions below. 3.1 Ascending or descending 3.2 Execution of a task 4. When excavating ground that is accessible to the public, or that is adjacent to pubic roads or thoroughfares, the safety of people could be compromised. Name three safety measures to be taken at the excavation to safeguard against this.
Exercise 1.2 1. Which law provides guidelines for the health and safety of persons at work against hazards arising out of or in connection with the activities at work? 2. For personal safety and protection, adequate safety clothing should be worn. Name three of these safety items. 3. Name four causes of accidents in a workshop. 4. Describe the following as applicable in the plumbing industry. 4.1 Safe use of ladders 4.2 Erection of scaffolding
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