STRONG NAHIN, ASTRAL STRONG!! TM

ENERGYSAVING

CHEMICALRESISTANT

RELIABLE FORDRINKING WATER

LOWINSTALLATION COST

For Agriculture Applications

LEAD-FREE

FIRST TIME IN INDIA -HEAVY METAL & LEAD FREE ASTRAL

COLUMN PIPES FOR SUBMERSIBLE PUMP(APPLIED FOR PRODUCT PATENT)

ASTRAL COLUMN PIPES & FITTINGS

Technical Manual

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01 Introduction ........................................................................ 01

Why uPVC For Column Pipes ? ............................................ 01

Why ASTRAL Column Pipes ? .............................................. 01

02 Silent Features .................................................................... 02

Unique Features.................................................................. 02

03 Column Pipe Key Properties............................................... 03

Field Of Applications ........................................................... 03

Column Pipe Sizes ............................................................... 03

04 Dimensions ......................................................................... 04

05 Comparison Chart With Other Material.............................. 06

06 Accessories.......................................................................... 07

07 Installation Procedures ....................................................... 08

08 Precautions ......................................................................... 09

Handling and Storage.......................................................... 09

09 Frequently Asked Questions About Astral Column Pipe ..... 10

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Index

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01www.astralcpvc.com

ASTRAL® have been relentless in its commitment to quality

and service. Through the years, ASTRAL® have broadened

and enhanced its product line to better serve the

customers. ASTRAL® was first to Introduced Flowguard™

Plus CPVC pipes and fittings, ASTRAL Aquarius® uPVC “Lead

Free” pipes and fittings, ASTRAL Foamcore® Pipes and

DWV® Click ring type fittings in Indian Market.

Repeting is tradition of introducing new products First Time

in Indian Market, ASTRAL® is proud to introduce “Lead

Free” and “Heavy Metal free” uPVC Column pipes in Indian

Market which is 100% safe for drinking water application.

INTRODUCTIONIn other term, ASTRAL Column Pipes keep the water clean

from the source itself and not contributing to any toxicity

to the water.

ASTRAL Column Pipes are available in 1” (33 mm OD) to 4”

(114 mm OD) with different class like V4‐12.5 Kg, ECO,

Medium, Standard, Heavy and Super Heavy with all

standard accessories like Top‐Bottom Adapters Sets, Pump

Guards, Lowering Jigs etc.

As the full line manufacturer of CPVC & uPVC piping system

for residential and industrial applications, ASTRAL® can be

your one stop source for all the plastic piping required for

lifetime piping solutions.

For many years, Metal pipes have been used with

submersible pumps to get the water from ground. These

pipes are corrode and scaled in their life span and giving

troubles to the owner in terms of qty of water and also the

pumping cost. PVC has excellent chemical and corrosion

resistance to a broad range of fluids. So PVC can give

trouble free service for many years.

WHY uPVC FOR COLUMN PIPES ?Secondly, among all thermoplastics also, PVC is the

material which can be compounded and modify keeping in

the mind of special characteristics required for pipes to be

used with submersible pumps. This versatility is not

observed with other thermoplastics like Polyethylene (PE).

Hence PVC contributes to major usage as piping material

globally.

ASTRAL Column Pipes have been developed as a result of

ASTRAL's constant endeavor to develop superior yet

economical piping solution for submersible pumps. The

compound has been developed at ASTRAL's R & D lab after

many trials and constant research with the help of

Japanese technology. ASTRAL's expertise in introducing

better compound in Indian Market, comes true yet another

time with introducing completely Eco Friendly – lead and

heavy metal free – column pipes.

WHY ASTRAL COLUMN PIPES ?The raw material such developed is processed in state of

the art machines which contribute to highest pipe quality

with most accurate dimensions. Then Pipes will be

threaded in very high tech CNC machines which are very

essential for performance of column pipes. The thread

geometry is such designed that it will give highest strength

against vertical column load as well as pressure developed

due to pump operation.

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LEAD FREE & HEAVY METAL FREE COMPOUND

ASTRAL Column pipes have been manufactured using Lead

free and Heavy Metal free compound – in other word

ASTRAL Column pipes are completely Eco Friendly. Pipes

will not pollute the ground water and will keep it safe for

leaching of carsegenic material like Lead.

SPECIAL COMPOUND

ASTRAL Column pipes are manufactured from “METAL

FREE” uPVC compound material especially developed by

using “JAPANESE TECHNOLOGY” to sustain best column

loads, pressure and also encounters the high impact

developed during handling, storage and installation. Due to

this special compound the TENSILE property of pipe

increase which is being tested rigorously using modern

testing equipment.

STUD LOCK SYSTEM

Every pipe is fitted with coupler having “Stud Lock” a

unique system developed by ASTRAL®, which ensures that

during installation, application or removal of system, the

coupler will never dethread from the pipe.

UNIQUE FEATURESDOUBLE LOCKING SYSTEM

ASTRAL® is the only company in India giving double locking

system which gives highest safety and reliability of the

system. Apart from stud pin lock system, pipes and

couplers are joined with special joining compound which

makes lifetime permanent joint without affecting the

thread dimensional stability in longer service life.

ANNEALING ON PIPES

Every pipe is annealed during manufacturing which is a

very special technique developed by ASTRAL®. This will

really enhanced the mechanical properties of pipes which

make sure that the pipes will perform best during

application.

100% HYGIENIC / SAFE FOR DRINKING WATER

Supply of drinking water is 100% hygienic and safe as being

pumped through ASTRAL uPVC Co lumn p ipes

manufactured from special METAL FREE compound right

from the origin of water source beneath under the earth at

maximum depth.

SQUARE THREADS

Unique square threads made on CNC machines provide

sufficient grip and additional strength against tensile load.

Thus the joint become fairly strong with sufficient factor of

safety to take care of load of entire assembly with pump

weight. These specially designed threads also make it

suitable for easy fitment.

THIN AND THICK PROCESS

The pipe ends are specially given the effect of additional

SALIENT FEATURESwall thickness by using Thin & Thick process to compensate

the strength and load bearing capacity caused due to

threading of pipes. The effect of Thin & Thick is given to all

sizes considering the working conditions & load factor.

EPDM 'C' RING

Specially designed "C" rings provided on the threads makes

the joints watertight and absorb pump vibrations. These

rings are made from EPDM rubber which is most suitable

for drinking water option.

02

STUD LOCK SYSTEMSTUD LOCK SYSTEMSTUD LOCK SYSTEM EPDM ‘C’ RINGEPDM ‘C’ RINGEPDM ‘C’ RING SQUARE THREADSQUARE THREADSQUARE THREAD

03www.astralcpvc.com

• Manufactured from high quality virgin PVC compound,

also reliable for drinking water

• Chemical and corrosion resistance

• Long life

• Exceeds the performance requirements of ASTM D 1785

standard specifications for uPVC pipes

• Smooth inner wall, no scale build up

• Low friction loss, resulting in energy saving, efficient

pumping

• 100% leak proof joint with two rubber 'C' rings per

coupler

• Light in weight, easy to transport

• Fast and easy installation

• Low installation cost. Does not require wrenches,

threading tools or solvent cement

• No curing period, immediate pump testing possible

• High impact resistance

COLUMN PIPE KEY PROPERTIES

Water rising for submersible pump, domestic and industrial applications. Ideally suitable for long term use in salty, sandy and chemically aggressive water.

FIELD OF APPLICATIONS

AVAILABLE SIZE :2• 1" : V4 (12.5 kg/cm ), Medium and Standard.2• 1‐¼", 1‐½" : V4 (12.5 kg/cm ), Medium, Standard and Heavy.

2• 2" : V4 (8 kg/cm ), Medium, Standard, Heavy and

Super Heavy.

• 2‐½" : Medium, Standard, Heavy and Super Heavy.2• 3" : ECO (10 kg/cm ), Medium, Standard, Heavy and

Super Heavy.

• 4" : Medium, Standard, Heavy and Super Heavy.

SHORTLY INTRODUCING:

• 5" : Standard, Heavy and Super Heavy

COLUMN PIPES SIZES

CORROSION RESISTANCECORROSION RESISTANCECORROSION RESISTANCE EASY INSTALLATIONEASY INSTALLATIONEASY INSTALLATION 100% LEAK PROOF100% LEAK PROOF100% LEAK PROOF LIGHT WEIGHTLIGHT WEIGHTLIGHT WEIGHT LONG LIFELONG LIFELONG LIFE

Lead Free

& Heavy

Metal Free

withstud pin

lock system

Design Patent

Pending

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Nominal Size(Inch)

Nominal Size(mm)

Type Wall Thickness (mm)

End Side Middle/Berral Side

Min Max Min Max

Average OutsideDiameter (OD)

(mm)

25 mm

32 mm

40 mm

50 mm

65 mm

80 mm

100 mm

1”

1 ¼”

1 ½”

2”

2 ½”

3”

4”

33.0 ± 0.10

42.0 ± 0.10

48.0 ± 0.10

60.0 ± 0.13

75.2 ± 0.13

88.0 ± 0.15

113.0 ± 0.15

2V4 (12.5 kg/cm )

Medium

Standard2

V4 (12.5 kg/cm )

Medium

Standard

Heavy2

V4 (12.5 kg/cm )

Medium

Standard

Heavy2

V4 (8 kg/cm )

Medium

Standard

Heavy2

Super Heavy (35 Kg/cm )

Medium

Standard

Heavy2

Super Heavy (35 Kg/cm )2ECO (10 Kg/cm )

Medium

Standard

Heavy2Super Heavy (35 Kg/cm )

Medium

Standard

Heavy2

Super Heavy (35 Kg/cm )

3.3

3.6

5.0

4.3

4.8

6.3

6.4

4.7

5.2

6.2

8.1

4.1

4.8

6.4

7.9

9.3

5.4

6.7

9.0

10.8

5.7

5.9

7.5

10.0

12.2

6.4

8.5

12.1

15.5

3.6

4.0

5.5

4.5

5.0

6.5

7.0

4.9

5.5

6.6

8.5

4.4

5.3

6.8

8.4

9.5

6.0

7.1

9.5

11.1

6.1

6.3

8.0

10.5

12.6

6.9

9.0

12.6

16.0

1.6

2.5

4.0

2.1

2.8

4.1

5.2

2.4

3.5

4.0

5.8

2.1

2.6

4.1

5.5

6.8

2.8

4.2

6.5

8.6

3.2

3.4

5.2

7.5

9.7

4.0

5.9

9.6

13.0

1.7

3.0

4.4

2.2

3.0

4.3

5.6

2.5

3.8

4.4

6.1

2.3

2.8

4.4

5.8

7.0

3.1

4.5

6.9

8.8

3.5

3.6

5.6

7.9

10.1

4.4

6.3

10.1

13.4

DIMENSIONS

05www.astralcpvc.com

Average OutsideDiameter (OD)

(mm)

Length of ThickPortion at Both

Side(mm)

NominalEffectiveLength(mm)

UltimateBreaking

Load(Kg)

Safe PullingLoad with

Chain Pulley(Kg)

Safe AllowableHydrostatic

Pressure2

(Kg/cm )

Safe TotalPump

Delivery Head(m)

33.0 ± 0.10

42.0 ± 0.10

48.0 ± 0.10

60.0 ± 0.13

75.2 ± 0.13

88.0 ± 0.15

113.0 ± 0.15

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

250 ± 20

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

3000 + 10

800

1450

1700

1340

2000

2600

3100

1760

2400

3000

4000

2150

2900

3800

5000

5600

3550

5300

7000

8600

4500

5100

7200

10600

11900

7500

10500

16000

19800

440

800

1250

740

1150

1500

1550

970

1250

1700

2000

1180

1550

2100

3030

3500

1930

2860

4200

4800

2500

2800

4110

6350

6600

4100

5800

9500

11000

12.5

16

30

12.5

15

25

35

12.5

15

26

35

8

13

20

27

35

10

16

26

35

10

11

17

26

35

10

15

26

35

125

160

300

125

150

250

350

125

150

260

350

80

130

200

270

350

100

160

260

350

100

110

170

260

350

100

150

260

350

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ASTRAL uPVC riser/drop/column pipes are perfect replacement to conventional Galvanized Iron pipes used in bore wells and

hold several critical advantages over conventional Mild steel or Galvanized steel pipes, which are

COMPARISON WITH OTHER MATERIALS

06

Property Requirement forDrop/Riser/Column Pipes

ASTRAL uPVC COLUMN Pipes Mild Steel or Galvanized Steel Pipes

Long life ASTRAL uPVC Column pipes do not react with acidic or alkaline water and have a long life in the bore wells.

Steel pipes are prone to rust, corrosion & ultimately get damaged and need to be replaced quickly.

Light weight Pipes are Light in weight and are easy to handle, install and remove.

Pipes are heavy and a great effort is required for installation or maintenance. Difficult to handle.

Smooth Internal Surface Internal surface is smooth, Therefore low head loss due to friction & results in higher discharge of water.

Rough internal surface and head loss is high resulting in less discharge of water.

Leak proof joints Rubber seals are provided with the thread at every joint ensuring 100% leak proof.

Not pressure tight, No rubber seal & hence NOT Leak proof.

Strong threaded joints Specially designed square Threads, which DO NOT corrode, rust or deteriorate.

Threads are prone to rust and corrosion easily.

07www.astralcpvc.com

ACCESSORIES• V4

• ECO

• Medium

• Standard

• Heavy

• Super Heavy

uPVC COLUMN PIPE

1” to 4”

TOP BOTTOM ADAPTER SET

1” to 4” CI & SS Both

PUMP GUARD SET

1½” to 4”

SIGRI (LOWERING JIG)

2” to 4”

‘C’ RING

1” to 4” ALL SIZE

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INSTALLATION PROCEDURES

INSERT MS FLANGE

111 Insert one MS Flange to Bottom Adaptor from bottom side

FIX THE ADAPTOR

Fix the Adaptor to Pump with wrench support, tightly 222WASH WITH SOAP & CLEAN WATER

Wash PVC SM Piece male and female Threads with plain water and insert in Adaptor Square Threads.333

CONNECT FLANGES WITH SS RODSPlace 2nd MS Flange on top of PVC SM Piece coupler and connect both Flanges with SS RODSNote: Maintain minimum play between both Flanges while tightening the bolts to rods. 444

INSERT PIPES

Clean the male and female Threads with plain water and insert pipe to pipe till last pipe.555

FIX WITH PUMPS

Drop the pump with one after another pipe with a support of

LOWERING ZIG and manpower. 666FIX WINDING WIRE

Tie the cable to pipe outer walls, with a winding wire loosely, with an extra length of one foot approximately to each pipe to sustain the Vibration jerks.777

FIX TOP ADAPTOR FOR USAGE

Fix TOP ADAPTOR to final pipe coupler, adjust with GI coupler

and bend for regular usage. 888

09www.astralcpvc.com

PRECAUTIONS

HANDLING AND STORAGESTORAGE If possible, pipe should be stored inside. When this is

not possible, the pipe should be stored on level ground

which is dry and free from sharp objects. If different

schedules of pipes are stacked together, the pipe with the

thickest walls should be at the bottom.

The pipe should be protected from the sun and be in

an area with proper ventilation. This will lessen the effects

of ultraviolet rays and help prevent heat built‐up.

If the pipe is stored in racks, it should be continuously

supported along its length. If this is not possible, the

spacing of the supports should not exceed three feet (3’).

When storage temperatures are below 0°C (32°F),

extra care should be taken when handling the pipe. This will

help prevent any problems which could be caused by the

slightly lower impact strength of uPVC pipe at temperature

below freezing.

The pipe should be handled with reasonable care.

Because Column Pipes are much lighter in weight than

metal pipe. There is sometimes a tendency to throw it

around. This should be avoided.

The pipe should never be dragged or pushed from a

truck bed. Pallets for pipe should be removed with a fork

lift. Loose pipe can be rolled down timbers, as long as the

pieces do not fall on each other or on any hard or uneven

surface. In all cases, severe contact with any sharp objects

(rocks, angle irons, forks on forklifts, etc.) should be

avoided.

HANDLING

• A safety cable or rope should be used to prevent

dropping of pump in the well either during operation or

withdrawal. The rope can be of steel or nylon or

polypropylene.

• If lubrication is needed to ease the joint assembly, plain

water or soapy water can be applied to the threads prior

to assembly.

• Use of good quality reflux valves on the delivery side is

recommended for preventing water hammer, upthrust

and back spin in the pumping system.

• It is advisable to use safety device such as pump

protection relay to prevent dry running of pump or pump

shut‐off head condition.

• Do not apply grease, oil or any other oily substance on

the threads.

• Use new rubber seals for every reinstallation of

submersible pump.

• In bore wells, without full casing pipes, it is advised that

at the time of removal of pumps from bore wells, if the

pump gets stuck up due to silt/sticky mud or entrapped

stone, proper flushing of the bore well should be done

and only then pulling load should be applied to the pipes

for pump removal.

• Do not over tighten the pipes as it will result in crushing

of rubber sealing thereby leading to leakage/pipe failure.

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FREQUENTLY ASKED QUESTIONS ABOUT ASTRAL COLUMN PIPE

1. Why Lead Free Column Pipes?

Lead is a metal with no known biological benefit to humans. Too much lead can damage various systems of the body including the nervous and reproductive systems and the kidneys, and it can cause high blood pressure and anemia. Lead accumulates in the bones and lead poisoning may be diagnosed from a blue line around the gums. Lead is especially harmful to the developing brains of fetuses and young children and to pregnant women. Lead interferes with the metabolism of calcium and Vitamins D. High blood lead levels in children can cause consequences which maybe irreversible including learning disabilities, behavioral problems, and mental retardation. At very high levels, lead can cause convulsions, coma and death. Lead can be dissolved in water when lead pipes are used for transportation of water. So use of such pipes may be harmful to human being. So, lead free column pipes are for drawing recommended pure and safe water from bone wells.

2. Why ASTRAL Column Pipes?

ASTRAL® is pioneers in India for introducing new plumbing systems since its inception. ASTRAL Column Pipes comprises of life long trouble free service with its unique features like Lead free, Stud Pin Lock, Double Locking with Special Adhesive, Annealing on pipes etc. ASTRAL Column Pipes are most advanced column pipes available in Indian Market today.

3. What is the expected life of ASTRAL Column Pipes?

ASTRAL Column Pipe system design & standards incorporate significant engineering safety factors which should translate to a long service life ASTRAL Column Pipe System have a design service life span up to 50 years. ASTRAL Column Pipe System is not susceptible to corrosion, scale build up or electrolysis in areas where water, solid and / or atmospheric conditions are aggressive. ASTRAL® firmly believes that the system will provide a service life as long or longer than alternative materials in the market.

4. What is the benefit of stud pin lock system in ASTRAL Column Pipes?

STUD PIN LOCK SYSTEM will give more grips to pipe and coupler while installing and retrieval time. By joining the coupler it makes one end male Thread and other end Female Thread. This system is user friendly and EXTRA safety in long run.

5. Is unique feature of ASTRAL Column Pipe?

Especially designed THIN AND THICK process for more safety of threads, “LEAD AND METAL FREE” product made in India for the 1st time, also exported to abroad.

6. Why Column Pipe is not made in 6 mtr length?

Depends on gravitational calculations and bendable radius of pipe considered and not made in 6 mtrs length.

7. How do you say that this is better than the traditional GI pipes?

This is lesser in weight, easy installation, low manpower required, no rust after any number of years, this will give long run and generations will use the pipe, economy, regular availability of raw material, no friction loss, this will support motor, take less load and give expandable life, no electro leakage and finally users can use in full depth also with full confidence.

8. Are you sure that plastic pipe will take a full load of motor and pump including water inside the pipe?

Yes, this uPVC column pipes are made with specially designed square threads, a new technology to sustain the load and pressure at full capacity.

9. What is the capacity on plastic threads?

The threads are designed in square to give more sustaining capacity, depends on the lowering depth. The breakable load and safe chain pulley load etc. are considered on depth and pressure rating of the pipe. Any HP Motor and Pump can be installed according to this formula scientifically, Technological Methodology.

10. How the selection of the Pipes to be done ?

The pipes can be selected based on the depth of the bore well, pump delivery head and maximum allowable pressure of the pipes. ASTRAL® manufacture different pressure class pipes for different lowering depths which mostly cater all different requirements worldwide. ASTRAL® range of pipes is successfully installed up to 1100 ft. Contact out Sales Team / Technical support team for further details.

11. Will ASTRAL Column Pipes Save me Money?

Yes, ASTRAL Column Pipes are much cheaper than Metal pipes. Also these pipes offer superior performance due to its higher Hazen William Factor (C= 150). It is not susceptible to corrosion, scales build up and hence gives 20‐25 % more water e v e n i n l o n g service of life. In other terms it also saves money f o r p o w e r consumption on pumps.

12. If situation demands is it advisable rethreading at site?

No, it is not allowed to cut or rethread the pipes on site. These pipes are threaded on highly sophisticated CNC machines with highest dimensional accuracy. This type of perfection is not possible at site. Also ASTRAL® has complete range of pipes with different lengths of pipe so in most of the cases such operations are not required at site.

13. Is it necessary to provide Full casing in the bore for column pipes?

It is not compulsory to provide the full casing to the ASTRAL Column Pipes in normal conditions. But technically it is always better to provide full casing to Column Pipes which helps the system performed better. Especially in the areas where loose stones or bolders or loose soils are prevalent, full casing will help to prevent the failure of bore.

14. Is it possible to recover water pump from borewell, in case of bone failures?

It is possible to recover the pump and pipes by applying the force equal or less than the ultimate breaking load. In the cases where the higher forces are required, it is not possible to recover the pipes or pumps.

Note:

Educate customer to DEMAND for TWO SIDES PIN LOCK SYSTEM (STUD PIN LOCK SYSTEM) to prevent conversion to other Column Pipes by multi product /brand sellers.

11www.astralcpvc.com

AFG/PC/005REV:07/11/14

desi

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spec

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advt

.in

All information contained in this manual is given in good faith and believed to be accurate and reliable. But because of many factors which are outside our knowledge and control and affect use of product, no warranty is given or is to be implied with respect to such information, nor we offer any warranty of immunity against patent infringement. No responsibility can be accepted for any error, omissions or incorrect assumptions. Any specification can change without prior notice.

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Authorised Distributor :

CIN : L25200GJ1996PLC029134

REGISTERED & CORPORATE OFFICE:

207/1, Astral House, B/h. Rajpath Club,

Off. S.G. Highway, Ahmedabad-380 059,

Gujarat, India.

Phone : +91 79 6621 2000

Fax : +91 79 6621 2121

E-mail : info@astralcpvc.com

Website : www.astralcpvc.com

ASTRAL POLY TECHNIK LIMITED

ASTRAL IS ISO 9001:2008REGISTERED COMPANY

BRANCH OFFICES:Mumbai : Phone : (022) 2686 2227 E-mail : mumbai@astralcpvc.comNew Delhi : Phone : (011) 2616 8156 E-mail : delhi@astralcpvc.comBengaluru : Telefax : (080) 2661 7236 E-mail : bgloffice@astralcpvc.comHyderabad : Telefax : (040) 2790 0023 E-mail : hyderabad@astralcpvc.comChennai : Phone : (044) 4350 6384 E-mail : chennai@astralcpvc.comJaipur : Phone : (0141) 2360 236 E-mail : jaipur@astralcpvc.com Lucknow : Phone : (0522) 2728 844 E-mail : lucknow@astralcpvc.comKochi : Phone : (0484) 3328 156 E-mail : kochi@astralcpvc.com

STRONG NAHIN, ASTRAL STRONG!! TM

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