TRAINING MODULES
MODULE 1 – INTRODUCTION TO IS 12235
What is IS 12235?
IS 12235 contains testing methods for thermoplastic pipes and fittings.
Used for:
PVC Pipes
UPVC Pipes
CPVC Pipes
HDPE Pipes
Agriculture Pipes
Water Supply Pipes
Casing Pipes
MODULE 2 – LIST OF TESTS IN IS 12235
Part No Test Name
Part 1 Dimensions
Part 2 Vicat Softening Temperature
Part 3 Opacity
Part 4 Effect on Water
Part 5 Reversion Test
Part 6 Stress Relief Test
Part 7 Resistance to Sulphuric Acid
Part 8 Hydrostatic Pressure Test
Part 9 External Blow Test
Part 10 Flattening Test
Part 11 Impact Test
Part 12 Leak Tightness Test
Part 13 Tensile Strength
Part 14 Density
Part 15 Carbon Black Dispersion
Part 16 Longitudinal Reversion
Part 17 Thermal Stability
Part 18 Joint Test
Part 19 Socket/Assembly Test
MODULE 3 – DETAILED TEST PROCEDURES
PART 1 – DIMENSION TEST
Purpose:
To verify pipe size.
Equipment:
Vernier Caliper
Pi Tape
Micrometer
Measuring Tape
Checks:
Outer Diameter (OD)
Wall Thickness
Length
Ovality
Procedure:
OD Measurement:
Measure at 3 locations.
Take average.
Wall Thickness:
Cut sample ring.
Measure at 6 points.
Length:
Use measuring tape.
Acceptance:
As per relevant pipe standard.
PART 2 – VICAT SOFTENING TEMPERATURE
Purpose:
To know heat resistance of PVC.
Equipment:
Vicat Apparatus
Procedure:
Prepare flat specimen.
Apply needle load.
Heat oil bath at 50°C/hr.
Record temperature when penetration = 1 mm.
Requirement:
Usually ≥ 80°C / 110°C depending standard.
PART 3 – OPACITY TEST
Purpose:
To prevent sunlight penetration and algae growth.
Procedure:
Cut specimen from pipe.
Place in opacity tester.
Pass light through wall.
Measure transmitted light.
Result:
Light transmission must be within limit.
PART 4 – EFFECT ON WATER
Purpose:
To ensure no toxic effect on drinking water.
Procedure:
Wash pipe sample.
Fill distilled water.
Keep for specified time.
Test water for:
pH
Taste
Odour
Heavy metals
PART 5 – REVERSION TEST
Purpose:
To check shrinkage after heating.
Procedure:
Cut sample 200 mm.
Mark original length.
Heat in oven (150°C or specified temp).
Cool.
Measure final length.
Formula:
Reversion %=L0−L1L0×100\text{Reversion \%} = \frac{L_0-L_1}{L_0}\times100Reversion %=L0L0−L1×100
Limit:
Normally ≤ 5%
PART 6 – STRESS RELIEF TEST
Purpose:
To detect internal stress after extrusion.
Procedure:
Heat sample in oven.
Observe cracks, blisters, splits.
Result:
No visible cracks.
PART 7 – SULPHURIC ACID RESISTANCE
Purpose:
Chemical resistance.
Procedure:
Immerse sample in acid solution.
Keep specified time.
Inspect weight loss / damage.
PART 8 – HYDROSTATIC PRESSURE TEST
Most Important Test
Purpose:
To verify pressure carrying strength.
Equipment:
Hydrostatic Pressure Testing Machine
Procedure:
Cut pipe sample.
End cap fitment.
Fill water.
Remove air.
Apply required pressure.
Maintain temperature bath.
Hold for:
1 hour
165 hours
1000 hours
depending requirement.
Pass Criteria:
No burst
No leakage
No sweating
PART 9 – EXTERNAL BLOW TEST
Purpose:
Impact resistance in cold condition.
Procedure:
Condition sample at 0°C.
Drop striker from standard height.
Hit pipe several times.
Check crack.
Acceptance:
TIR within limit.
PART 10 – FLATTENING TEST
Purpose:
Pipe flexibility.
Procedure:
Place pipe between plates.
Compress slowly.
Observe cracks.
PART 11 – IMPACT TEST
Purpose:
Resistance to sudden shock.
Procedure:
Pendulum or falling weight used.
PART 12 – LEAK TIGHTNESS TEST
Purpose:
Joint sealing performance.
Procedure:
Assemble pipe + fitting.
Apply water pressure / vacuum.
Check leakage.
PART 13 – TENSILE STRENGTH
Purpose:
Material strength.
Procedure:
Prepare dumbbell specimen.
Use UTM machine.
Pull until break.
Formula:
σ=FA\sigma = \frac{F}{A}σ=AF
Where:
F = Load
A = Area
PART 14 – DENSITY TEST
Purpose:
Check raw material quality and filler control.
Procedure:
Cut sample.
Measure weight.
Measure displaced volume.
PART 15 – CARBON BLACK DISPERSION
Used in black HDPE pipes.
PART 16 – LONGITUDINAL REVERSION
Shrinkage in length after heating.
PART 17 – THERMAL STABILITY
Check decomposition resistance at high temperature.
PART 18 – JOINT TEST
Check socket joint strength.
PART 19 – ASSEMBLY TEST
Final fitment verification.
MODULE 4 – DAILY INSPECTOR CHECK SHEET
Test Frequency
OD Hourly
Thickness Hourly
Length Hourly
Weight/Meter Hourly
Visual Every Lot
Hydro As Plan
Impact Batch
MODULE 5 – COMMON DEFECTS
Defect Reason
Low thickness Die mismatch
Burst in hydro Poor material
Crack in impact Brittleness
Ovality Cooling issue
Black spot Contamination
Shrinkage high Processing stress
MODULE 6 – INTERVIEW QUESTIONS
Q1 What is most important test in pressure pipe?
Hydrostatic pressure test.
Q2 Why Vicat test done?
Heat resistance checking.
Q3 What is reversion?
Shrinkage after heating.
Q4 Why opacity required?
To block sunlight/algae growth.