CA2275793C

CA2275793C - Testing of plumbing installations and plumbing tool

Info

Publication number: CA2275793C
Application number: CA 2275793
Authority: CA
Inventors: John M. Mankins
Original assignee: Individual
Current assignee: Individual
Priority date: 1996-12-30
Filing date: 1997-12-30
Publication date: 2003-11-11
Anticipated expiration: 2017-12-30
Also published as: GB2335749B; WO1998029676A1; GB9913104D0; GB2335749A; US6390118B1; US5740830A; CA2275793A1; AU715649B2; AU5726298A; US6161563A

Abstract

A method and apparatus for testing a plumbing system (20) and for removing obstructions (70) in a plumbing line (44). During the rough-in plumbing phase of construction (Fig. 1), the drain pipe (44, 46, 48) from the plumbing system (20) in a building (22) to the main city sewer line (38) is positively sealed off by a test cap (70) welded in the pipe at the location of the clean-out (56), access to which is maintained through the clean-out (56). Pressurizing the rough-in plumbing to test proceeds. If any leaks occur, they are in the branch plumbing (26) on the building side of the test cap, and not at or in the test cap. Following successful completion of the initial test, the top-out plumbing is completed, leaving the test cap (70) welded in the clean-out (56) or drain pipe (44). After the roof vents are in, the second test of the plumbing system (20) is made. If the system shows any leaks, they are the result of a failure in the plumbing and not a failure of the test cap (70).
After final test and inspection, a special tool or apparatus (100) in accordance with the present invention is inserted down the clean-out (56) to penetrate and ream-out the test cap (70), so that the drain pipe is opened (174) and provides a passageway (180) through which the waste can flow to the sewer line (38).

Description

1 Description 3 Testing of Plumbing Installations and Plumbing Tool . 4 6 Technical Field 7 The present invention pertains to the testing of a plumbing installation and 8 more particularly to a method for testing the integrity of a newly installed plumbing 9 system and to a tool used in performing the method.
In residential house construction and as is well known, the plumbing is 11 basically installed in three stages, namely, the rough-in plumbing, top-out plumbing 12 and finish plumbing. The rough-in plumbing occurs prior to pouring of concrete.
13 Top-out plumbing follows framing the building and involves installing the pipes in 14 the walls and vent pipes that extend up through the roof of the structure.
Finish plumbing relates to setting toilets, sinks, and the like.
16 The rough plumbing includes laying a drain or waste pipe which leads from 17 building to the city sewer main normally in the access street or road adjacent to the 18 building. It is common practice to insert a clean-out in the drain pipe between the 19 pipes in the building and the section of the drain pipe that leads to the sewer line.
This clean-out may be located in a basement or, in a building without a basement, 21 outside the building and underground. If underground, the clean-out has a branch 22 extending to the surface of the ground for providing access to the drain pipe both 23 during construction and during use of the building. As is well known, in order to 24 pass the rigid inspection normally imposed by building codes, it is necessary to test the drainage part of the plumbing system after the rough-in and top-out stages are 26 finished.

28 Background Art 29 For this purpose, common procedures and devices are in use. The devices ' 30 include test caps and inflatable test plugs, so-called water-weenies. In use, the test 31 caps are sealed at the ends of all open and exposed branch pipes, and the inflatable 32 test plugs are used in the clean-out where the passageway plugged is not as SUBST1ME SHEEP (RUL.E 2~

1 accessible. After the tests, the exposed test caps are punched out with a hammer, and 2 the inflatable plugs are deflated and pulled out of the clean-out. Thus, the test plugs 3 and the inflatable plugs can be removed without disassembling and disturbing the 4 tested system.
As indicated, the test caps in above-ground, accessible locations are usually 6 knocked out with a hammer, whereupon the fragments are pried out with a 7 screwdriver or pliers. If a test cap is sealed in a clean-out, however, whether the 8 clean-out is relatively accessible in a basement or whether it is underground, it cannot 9 be punched out with a hammer and screwdriver without disassembling part of the system and thereby disturbing the tested system. Thus, test caps have not been used 11 to block the test pressure in the drain pipe.
12 Instead, during the rough-in plumbing stage, the inflatable weenie-shaped, 13 test plugs have been inserted in the clean-out, used for the tests, and subsequently 14 removed with a pull chain attached to the plug and extending out of the clean-out.
l 5 More specifically, to test the rough-in plumbing, the plug is inserted and inflated 16 thereby sealing the drain pipe. The plumbing on the building side of the plug is then 17 pressurized to check for leaks. After the top-out phase is completed, the plumbing is 18 again tested by again inflating the plug, and pressurizing the system, usually by 19 feeding water into the system through the vent pipes in the roof.
Use of such inflatable weenie plugs for the described testing has proved 21 unsatisfactory for several reasons. The essential problem is that the plugs often leak 22 although the plumbing may be entirely sound. Either the plug does not seal perfectly 23 circumferentially within the pipe or the plug is punctured as it is being slid in or out 24 of the clean-out and against the rough surfaces thereof. As a result, the test fails, not because of faulty plumbing, but because of a faulty plug. The plumbing crew will 26 then need to be called back to the job to attend to the problem, causing aggravation 27 and extra expense to the contractors and owners involved. Not only is there extra 28 labor cost involved, but the failed inflatable test plugs must be replaced at 29 considerable expense.
The patented art reveals other test devices that are intended for the purposes 31 discussed above but that are not in common use. The U.S. Pats. Nos.
4,936,350;
32 5,033,510; and 5,163,480 disclose special fittings and special baffles to plug the SUBSTITUTE SHEET (RULE 26~

1 drain line during testing of the plumbing system. After the test is completed, the baffles 2 are pulled out of the drain line through the clean-out by special cords attached to the 3 baffles. These devices are relatively expensive because of their special construction and 4 because they do not use standard test plugs. The Sullivan plug assembly in U.S. Pat.
No. 4,429,568 is even more complex, expensive, and nonstandard but operates on a 6 principle similar to the Huber devices. The art also includes plumbing tools such as so 7 called "snakes" or Roto-Rooters~ for removing blockages, but these are incapable of 8 penetrating and reaming out a test plug in relatively inaccessible but proximate 9 locations where it is necessary to bend the tool around a corner to access the plug, to penetrate the plug, and then to rotate the tool while bent and to apply force to ream 11 through the blockage.

13 Disclosure of Invention 14 A method and apparatus for testing a plumbing system in a more dependable and cost-effective manner is provided and for removing obstructions in a plumbing 16 line. During the rough-in plumbing phase of construction, the drain pipe leading from 17 the plumbing system in a building to the city sewer main in the street is positively 18 sealed off by a test cap or plug welded in the pipe at the location of the clean-out.
19 Access to the test cap is maintained through the clean-out. Pressurizing the rough-in plumbing to test the same can then proceed knowing that if any leaks occur, they are in 21 the branch plumbing on the building side of the test cap and not at or in the test cap.
22 Following successful completion of the initial test, the top-out plumbing is completed, 23 leaving the test cap welded in the clean-out or drain pipe. After the roof vents are in, 24 the top-out test of the plumbing system is made, again knowing that if the system shows any leaks, they are the result of a failure in the plumbing work and not a failure 26 of the test cap. After the plumbing system has passed final test and inspection, a special 27 tool constructed in accordance with the present invention is inserted down the clean-out 28 to penetrate and ream-out the test cap, so that the drain pipe is at substantially its 29 normal inside diameter and provides a relatively full opening through which the waste can flow to the city sewer main in the street.
31 An object of an aspect of this invention is to provide an improved method for 32 testing a newly installed plumbing system and a tool used in performing the method.
33 Another object of an aspect of the invention is to provide a more cost effective 34 method for testing a newly installed plumbing system in a building.

1 A further object of an aspect of the invention is to avoid having to re-test a 2 plumbing system that would have passed the initial test but did not only because the 3 test plug failed.
4 An additional object of an aspect of the invention is to be able to test a newly installed plumbing system without using inflatable test plugs, so-called water weenies, 6 to seal off the drain pipe while doing the testing and thereby to avoid the expense of 7 frequently having to replace faulty plugs.
8 Yet another object of an aspect of the invention is to be able positively to seal 9 off a drain pipe in a plumbing system while pressurizing the system to test the system for leaks.
11 A still further object of an aspect of the invention is to be able to remove a test 12 plug that has been bonded in a drain pipe in a location that is accessible only through a 13 clean-out.
14 Another object of an aspect of the invention is to provide a tool that can be extended into a clean-out and can remove a plug or a portion thereof that has been 16 bonded in a fluid-tight manner in a drain pipe to which the clean-out is connected.
17 Another object of an aspect of the invention is to be able from a remote position 18 to maneuver and guide a penetrating and reaming head of a tool inside a clean-out and 19 into a position therein to penetrate and ream out a test cap welded in the clean-out.
Another object of an aspect of the invention is to provide a tool for cutting a test 21 cap out of a clean-out and that is adapted to attach cutting heads of different sizes for 22 different diameter pipes.
23 Another object of an aspect of the invention is to provide a test cap-removing 24 tool that is adapted to change its length depending on the distance between the test cap-to-be-removed and the location of the operation of the tool.
26 Another object of an aspect of the invention is to provide a test cap-removing 27 tool that cooperates with a clean-out to leverage the its operating head into an operating 28 position and then allows the head to penetrate and ream out the test cap.
29 A further object of an aspect of the invention is to enable a test plug that has been welded in fluid-tight relation in a drain pipe to be removed so that nearly the full 31 diameter of the drain pipe is available for conducting material therethrough after the 32 plug has been removed.
33 Therefore various aspects of the invention are provided as follows:
34 A method of testing a plumbing system in a building wherein the system is 1 connected to a sewer line by a drain line, comprising the steps of installing a test plug 2 in the drain line thereby to prevent flow through the line past the plug;
testing the 3 plumbing system by applying fluid pressure in the plumbing system on the opposite 4 side of the plug from the sewer line and against the plug thereby to test the plumbing 5 system for leaks; removing material from the plug while allowing the removed material 6 to remain in the drain line, thereby creating an opening through the plug while the drain 7 line remains connected to the sewer line, thereby allowing flow through the drain line;

8 and flushing the removed material down the drain line to the sewer line.

9 A method of using a tool to remove a circular center plate of a test cap for a plumbing system; wherein the test cap has a cylindrical body circumscribing the plate 11 and an annular flange extending radially outwardly from the body; wherein the 12 plumbing system has a clean-out with first and second branches positioned between 13 sections of a cylindrical drain pipe leading to a sewer line; wherein the test cap is 14 secured in fluid-tight relation to one of said sections of the drain pipe whereby the test cap creates a fluid-tight seal against passage of material through the drain pipe to the 16 sewer line, said first branch of the clean-out providing communication with the test cap;
17 wherein the clean-out has a third branch extending laterally from the drain pipe and 18 provides access to the center plate through the third branch and the first branch;
19 wherein the tool includes a rotary penetrating and reaming head, an elongated flexible shaft connected to the head, and means for rotating the shaft to rotate the head, 21 comprising the steps of inserting the head and the shaft into the third branch of the 22 clean-out until the head engages the first branch of the clean-out;
pressing axially on 23 the shaft to bend the shaft adjacent to the head and force the head into engagement with 24 the center plate of the test cap; axially thrusting the shaft downwardly thereby thrusting the head against and through the cap; and rotating the shaft and thus the head to cause 26 the head to ream the center plate out of the test cap and to create an opening in the test 27 cap substantially the same diameter as the body of the cap so as to provide fluid 28 communication through the drain pipe, whereby material intended to be moved through 29 the drain pipe to a sewer line is no longer blocked by the test cap.
A tool for creating an opening through a test cap that is secured in a drain line to 31 block flow therethrough and wherein a clean-out branch connected to the drain line 32 provides access to the cap after a plumbing test has been completed, comprising: a 33 penetrating and reaming head for reaming an opening through the test cap; a resiliently 34 flexible shaft connected to the head for extending the head into the clean-out branch 1 and into engagement with the test cap, said shaft being capable of flexing in the clean-2 out branch and a portion of the drain line to enable the engagement with the test cap;
3 and a handle connected to the shaft for axially thrusting and rotating the shaft while in 4 such flexed condition to rotate the head while axially forcing it against the test cap thereby to cause the head to penetrate and ream out an opening in the cap so that the 6 drain line is open and provides a passageway through which waste water can flow to a 7 sewer line.
8 A tool for removing the center plate of a test cap in a drain pipe that blocks flow 9 therethrough and wherein a clean-out connected to the drain pipe provides access to the cap after a plumbing test has been completed, comprising: an operating head including 11 penetrating and reaming blades thereon; a transversely flexible shaft having axial 12 rigidity and being connected to the head for extending the head into the clean-out 13 branch and into engagement with the center plate of the test cap within a portion of the 14 drain pipe, and a handle connected to the shaft for axially thrusting and rotating the shaft to rotate the head while axially forcing it against the center plate of the test cap, 16 thereby to cause the head to penetrate and ream out the center plate and to create the 17 opening therein; wherein the shaft has a longitudinal axis; wherein the shaft is 18 resiliently transversely flexible; wherein the shaft has a normally straight unstressed 19 condition but can be flexed out of the straight condition upon application of sufficient force; and wherein the shaft can transmit force axially thereof while in straight or 21 flexed condition whereby the head can be forced against and through the center plate of 22 the cap by applying force on the shaft axially thereof toward the head while rotating the 23 head.
24 A method of using a tool to penetrate and ream out a center plate of a test cap for a plumbing system; wherein the test cap has an annular body circumscribing the 26 plate; wherein the plumbing system has a clean-out element with a first section secured 27 between sections of a drain pipe; wherein the test cap is secured in fluid-tight relation 28 in and to one of said sections of the drain pipe whereby the test cap creates a fluid-tight 29 seal against passage of material through the drain pipe; wherein the clean-out element has a second section extending from the drain pipe and provides access to the center 31 plate through the second section after a plumbing test has been completed;
wherein the 32 tool includes a rotary cap penetrating and reaming head, an elongated transversely 33 flexible shaft connected to the head and being resiliently flexible from an unstressed 34 straight condition to a stressed curved condition, and a handle connected to the shaft to 1 rotate the head and axially thrust the shaft and head, said shaft possessing axial 2 rigidity lengthwise thereof from the handle to the head when in straight or flexed 3 condition, comprising the steps of: inserting the head and the shaft into the second 4 section of the clean-out element until the head engages the first section of the clean-s out element; pressing on the handle axially of the shaft to bend the shaft adjacent to 6 the head and force the head into engagement with the center plate of the test cap 7 within a portion of the drain pipe; pressing on the handle axially of the shaft to force 8 the head through the cap; and rotating the shaft and thus the head with the handle to 9 cause the head to penetrate and ream out an opening in the center plate of the test cap for establishing fluid communication through the drain pipe, whereby material 11 intended to flow through the drain pipe to a sewer line is no longer blocked by the test 12 cap.
13 A tool for creating an opening through a blockage in a drain line that is 14 blocking flow therethrough and wherein a passageway connected to the drain line provides access to the blockage, comprising: a penetrating and reaming head; a 16 normally straight, resiliently transversely flexible shaft having first and second ends, 17 the second end being connected to the head for extending the head into the 18 passageway and into engagement with the blockage, said shaft being capable of 19 transversely flexing in the passageway and a portion of the drain line to enable the engagement of the head with the blockage, said shaft possessing axial rigidity 21 lengthwise thereof from the first end to the second end when in its straight or flexed 22 condition; and a handle connected to the first end of the shaft for manually axially 23 pressing on and rotating the shaft while in such flexed condition to rotate the head 24 while axially forcing it against the blockage thereby to cause the head to penetrate the blockage and ream out the opening in the blockage so that the drain line is open and 26 provides a passageway perniitting flow therethrough.
27 These and other objects and advantages of the invention will become apparent 28 upon reference to the accompanying drawings and the following detailed description.
29 In accordance with another aspect of the present invention, there is provided a method of temporarily sealing a fluid carrying line in a plumbing system in order 31 to test the system for leaks, comprising the steps of:

7a 2 sealing the line with a fragmentable blockage, whereby the blockage has an 3 upstream side disposed toward the plumbing system and an oppositely facing 4 downstream side;
testing the system far leaks by exerting pressure against the upstream side of 6 the blockage;
7 after the testing step, fragmenting the blockage and unblocking the line;
and 8 flushing the fragments down the line.
9 In accordance with another aspect of the present invention, there is provided a method of testing a plumbing system including a drain line, comprising the steps of:
11 installing a test plug in the drain line thereby preventing flow through the line 12 past the plug;
13 testing the plumbing system by applying fluid pressure in the plumbing 14 system on the one side of the plug thereby to test the plumbing system for leaks;
applying fluid pressure farce against the plug lengthwise of the line in the 16 direction of the desired flow therethrough and following said testing sufficient to 17 create an opening through the plug, whereby flow can occur in the drain tine through 18 the plug and whereby parts of the plug are removed; and 19 flushing the removed parts of the plug along the line away from the location of the plug.
21 In accordance with another aspect of the present invention, there is provided 22 a tool for creating an opening through a. blockage in a drain line that is blocking 23 flow therethrough and wherein a passageway connected to the drain line provides 24 access to the blockage, comprising:
a penetrating and reaming head;
26 a shaft having a rigid portion and a resiliently transversely flexible having 27 first and second ends, the fast end being connected to the rigid portion and the second 28 end being connected to the head, the flexible portion from its first end to its second 29 end extending over a substantial part of the length of the shaft and being exposed externally of the tool throughout said substantial part of the length for extending the 31 head into the passageway into engagement with the blockage and for bringing the 7b 1 shaft being capable of transversely flexing in the passageway and a porkion of the 2 drain line to enable the engagement of the head with the blockage, said shaft 3 possessing axial rigidity lengthwise thereof from the first end to the second end when 4 in its straight or flexed condition; and a handle connected to the first end of the shaft for manually axially pressing on and rotating the shaft while in such flexed condition 6 to rotate the head while axially forcing it against the blockage thereby to cause the 7 head to penetrate the blockage and ream out the opening in the blockage so that the 8 drain line is open and provides a passageway perniitting flow therethrough.

1 Brief Description of the Drawings 2 Fig. 1 is an isometric view showing a schematic representation of a plumbing 3 installation in a residential building construction that is intended to represent the 4 plumbing installation after the rough-in plumbing or first stage of the plumbing installation has been completed and during which a clean-out is installed in a drain 6 pipe leading from the building to a public sewer line.
7 Fig. 2 is an enlarged exploded isometric view of a part of Fig. l, showing 8 fragments of upper and lower sections of the drain pipe, showing the clean-out with a 9 branch thereof (partially broken away) to be connected to the lower section of the drain pipe, and showing a test cap to be connected to the lower section between the 11 section and the branch of the clean-out.
12 Fig. 3 is a still further enlarged view similar to Fig. 2 but with the parts 1.3 assembled, thereby showing the clean-out connected between the upper and lower 14 sections of the drain pipe and showing the test cap connected to the lower section between that section and the clean-out so as to block flow through the clean-out from 16 the upper section of the drain pipe to the lower section thereof.
17 Fig. 4 is a still further enlarged end view of the test cap shown in Figs.
2 and 18 3 as seen from the upstream end of the cap.
19 Fig. S is an exploded longitudinal diametrical section of the test cap taken on a plane indicated by line 5-5 of Fig. 4 but showing the test cap between the drain pipe 21 and the clean-out and illustrating how these three parts will interfit when assembled.
22 Fig. 6 is a view similar to Fig. 1 but on a reduced scale and intended to 23 represent the plumbing system after the second or top-out stage thereof has been 24 completed.
Fig. 7 is an isometric view of a tool used in carrying out the method of the 26 present invention and including an operating head, a flexible shaft, and handles.
27 Fig. 8 is an enlarged- end view of the operating head of the tool shown in 28 Fig. 7.
29 Fig. 9 is an enlarged, exploded, isometric view of the tool of Fig. 7 with the head and shaft being fragmentary and showing how the head is releasably connected 31 to the shaft.

1 Fig. 10 is an enlarged isometric view of the shaft showing the turns of the coil 2 spring construction of the shaft.
3 Fig. 11 is a reduced exploded isometric view of the tool of Fig. 7 and showing 4 how the handles are connected to the shaft.
Fig. 12 is an isometric view similar to and on the same scale as Fig. 3 with an 6 extension pipe connected to the clean-out, with the tool of Fig. 7 extended into the 7 clean-out, and with part of the clean-out broken away to show the head of the tool in 8 penetrating and reaming engagement with the center plate of the test cap.
9 Fig. 13 is an enlarged fragmentary, vertical longitudinal section of the clean-out and part of the lower section of the drain pipe and showing the tool with its head 1 I in engagement with the center plate of the cap.
12 Fig. 14 is a view similar to Fig. 12 but with the tool removed and with the 13 clean-out broken away to show how the head has completely removed the center 14 plate of the test cap thereby to open the drain pipe for movement of drain materials therethrough.

17 Detailed Description of the Best Mode for Carrying Out the Invention 18 Prior to describing the method and apparatus of the present invention, 19 reference will be briefly made to the environment in which the invention is used.
Thus, in Fig. 1, a plumbing system is schematically shown and generally indicated by 21 the numeral 20 in a residential building construction 22, with the plumbing system 22 being represented at the rough plumbing stage. Only the foundation area 24 and a 23 few of the interior pipes 26 of the plumbing system are shown thereby indicating that 24 only the basic pipes have been installed and that none of the finish plumbing is in nor are the appliances installed.
26 During the rough-in plumbing stage (Fig. 1), a drain pipe 36 is connected 27 between the interior plumbing 26 and a city sewer main or public sewer line 28 which usually runs underneath the street or road in front of the construction 22. The 29 drain pipe is typically made of a plastic such as ABS or PVC, but it may be cast iron or copper or other suitable material. For drainage purposes, the pipe usually has a 31 three- or four-inch diameter and is laid with enough slope to enable drainage. As is 32 well known, the ground 42 around the construction is excavated to provide a large 1 trench or open area 44 below normal ground level so the drain pipe can be connected 2 to the sewer line. The drain pipe has an upper section 46 connected to the interior 3 plumbing and a lower section 48 connected to the sewer line.
4 A three-way clean-out 56 (Figs 1, 2 and 3), usually of the same material as the 5 drain pipe 36, has inlet, outlet and clean-out branches 58, 60 and 62, each having a 6 collar 64 and an annular shoulder 66. The collars of the inlet and outlet branches are 7 respectively slid over and cemented to the upper and lower sections 46 and 48 of the 8 drain pipe with the shoulders of the clean-out normally abutting the ends of the pipe 9 sections. A riser 68 is connected to the clean-out branch and extends above the 10 surface of the ground 42, and a clean-out cover 69 is releasably connected to the riser 11 _ for sealing and closing this branch when necessary.

12 As is well-known, building codes typically require plumbing installations for 13 new construction to be tested for leaks twice: after the rough-in plumbing is in and 14 after the top-out plumbing is completed. It is currently standard practice to insert an inflatable plug, not shown, down the clean-out branch 62 and into the outlet branch 16 60, to inflate the plug, and thus to block the drain pipe 36 so the plumbing system can 17 be pressurized for leaks. Since such plugs have not been satisfactory as discussed 18 above, the principles of the present invention involve conducting the tests differently.
19 In accordance with the method of the present invention and as part of the rough-in plumbing phase (Figs. 1-5), a test cap or plug 70 of well-known 21 construction is fitted in and connected to the lower section 48 of the drain pipe 36, 22 and then the clean-out 56 is connected between and joins the upper and lower 23 sections 46 and 48 of the drain pipe. The test cap has an annular body 72, an annular 24 flange 74 extending radially outwardly from the body, and a circular center plate 76 filling the body.
26 Test caps or plugs, as 70 (Figs. 2 through 5), suitable for the purposes of the 27 present invention are sold by the PASCO Company of 11156 Wright Road, 28 Lynwood, CA 90262, as part Nos. 4844 and 4845. These caps are of plastic material 29 capable of being solvent-welded to ABS or PVC pipe, and are also commonly and herein referred to as knock-out plugs or discs . They are available in various sizes so 31 that their annular bodies 72 can be fitted in three- or four-inch diameter drain pipes 32 36.

1 As above stated and during the rough-in plumbing stage, the test cap (Figs.

2 and 5) is fitted in the lower section 48 of the drain pipe with the body 72 received 3 within the pipe, the flange 74 engaging the end of the pipe, and the center plate 76 4 disposed transversely of and within the pipe. Prior to making this assembly, layers of a suitable bonding cement are applied as at 78 to the mating surfaces so as to solvent 6 weld the parts together in the described assembly. After the test cap is welded in 7 place (Fig. 13), the collar 64 of the outlet branch 60 of the clean-out is slipped over 8 and solvent-welded to the lower section of the drain pipe with the shoulder 66 of the 9 outlet branch abutting the radial flange 74 of the test cap. The resulting connection (Fig. 3) of the test cap in the drain pipe effects a fluid-tight seal that will block flow 11 through the pipe. Either before or after this connection, the inlet branch 58 of the 12 clean-out is connected to the upper section 46 of the drain pipe.
13 Following the described assembly (Figs. 1 and 3) of the test cap 70, the clean-14 out 56, and the upper and lower sections 46 and 48 of the drain pipe 36, the rough-in plumbing is subjected to a first pressure test. Such pressurization is accomplished in 16 a well-known manner that includes introducing water into the system through an 17 open end of a pipe in the interior plumbing 26. It is of course understood and well 18 known that all open ends of the pipes in the system 20 are plugged including 19 attaching the clean-out fitting 69 to the riser 68 of the clean-out branch 62. Such pressurization imposes fluid pressure on the upstream side of the test cap on the side 21 thereof opposite from the sewer line 38. Since the test cap is bonded in fluid-tight 22 relation within the drain pipe, no leaks will occur through or around the test cap. As a 23 result, if there is any loss of pressure in the plumbing system, it will clearly be in the 24 plumbing system itself and not in the plugging of the drain pipe by the test cap, as contrasted with the frequent leaks of the inflatable test plugs, as described above.
26 After the plumbing system 20 has passed the initial test at the rough-in 27 plumbing stage, construction of the building continues (Fig. 6) including completion 28 of the top-out plumbiilg job. This involves installation of one or more roof vents, as 29 86, extending up through the roof of the building, represented at 88. As part of finishing the construction, the ground 42 around the building is filled and graded, 31 leaving the riser 68 exposed above ground level to allow access to the clean-out 56.
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1 During the completion of the building 88 (Fig. 6), the test cap 70, the clean-2 out 56 and the drain pipe 36 are not disturbed and thus remain connected in the 3 described relationship (Fig. 3). After the top-out stage is completed, a second test of 4 the plumbing system 20 is conducted by again pressurizing the system 20 but this time typically by feeding water with a hose through an open roof vent, as 86.
Once 6 more, the test cap absolutely blocks flow through the drain pipe so that if there are 7 any leaks in the system, they will be in the system and not in the plug in the drain 8 pipe. If the system is sound, only one additional test is needed, but of course if there 9 are leaks, they must be repaired and the test repeated until all problems are corrected.
Following successful passage of the second or final test or tests, however, it is '11 of course necessary to remove the blockage caused by the test cap 70. 1n accordance 12 with the principles of the present invention, the blockage is removed by a special 13 plumbing tool 100 (Figs. 7-11). This tool includes an elongated flexible shaft 102, 14 preferably about four feet long and preferably about 3/4" in diameter, and having upper and lower ends 104 and 106. In the disclosed embodiment, the shaft is a 16 tightly wound coil spring 108 (Fig. 10) made of wire, the adjacent turns 110 of which 17 are in close engagement when the shaft is unflexed, thereby imparting a measure of 18 axial rigidity to the shaft notwithstanding its flexibility. Coil springs, as 108, suitable 19 for the shaft of the present invention are sold as part No. 9504 by the Marco Products Company of Sylmar, CA. Alternatively, other types of flexible shafts or cables with a 21 measure of axial rigidity can be employed.
22 The plumbing tool 100 (Figs. 7-11) also includes a penetrating and reaming 23 operating head 120 with a conical configuration releasably attached to the lower end 24 106 of the tool shaft 102. The head has a mounting ring 122 disposed perpendicularly of the axis of the shaft when the shaft is straight and unflexed as in Fig. 7, a 26 cruciform mounting bracket 124 secured within the ring, and a hub 126 extending 27 from the bracket axially of the ring. The outside diameter of the mounting ring is of a 28 dimension suitable for the size of clean-out 56 being used so that the ring will 29 slidably and rotatably fit within the clean-out (Fig. 13). A lower coupling 130 (Fig.
9) is connected to the lower end 106 of the spring shaft, is fitted over the hub, and is 31 fastened thereto by a set screw 132 on the coupling.

I More specifically, the lower coupling 130 (Fig. 9) has a female sleeve 134 2 that slips over the hub 126. The hub has a hole 128 that is aligned with and receives 3 the set screw 132 to secure the coupling to the mounting ring 122. The lower 4 coupling also has a threaded male stub 135 that threads into the lower end 106 of the S spring shaft 102 thereby to secure the coupling to the shaft. It will be understood that 6 the coupling 130 allows different sizes of heads 120 to be connected to the tool shaft 7 depending on the diameter of the drain pipe involved.
8 The operating head 120 (Figs. 7, 8, and 13) also has a plurality of triangular 9 cutting or reaming blades 136 rigidly secured to and projecting endwardly from the mounting ring 122 and bracket 124. Four blades are used in the disclosed 11 embodiment and are positioned in the four quadrants of the mounting ring and 12 bracket with the base edges of blades welded to the mounting ring and bracket and 13 the altitude edges of the four blades welded together along the axis of the ring. The 14 blades have axial guiding edges 137 and cutting edges 138 converging to a sharp point or tip 140 of the head. The base edges are set radially inwardly (Figs.
8 and 13) 16 of the outside diameter of the mounting ring to leave an annular stop rim 17 circumscribing the blades adjacent to the mounting ring for a purpose to be 18 described. When the tool shaft 102 is straight and unflexed (Fig. 7), the tip of the 19 head projects endwardly from and in coaxial alignment with the shaft.
In addition, the plumbing tool 100 (Figs. 7 and 11) has a handle 150 that 21 includes a crankshaft 152 connected to the upper end 104 of the tool shaft 102 and a 22 crankhandle 154 projecting from the crankshaft. The crankshaft is connected to the 23 tool shaft. by an upper coupling 130 and set screw 132 in the same manner as the 24 cutting head 120 is connected to the tool shaft, as described above. The handle also includes a holding sleeve 156 rotatably received on the crankshaft between the upper 26 end of the upper coupling and the crankhandle.
27 It is to be noted that the length of the tool shaft 102 can be changed by 28 connecting sections of springs, as 108, for example each about two feet in length, 29 together by intermediate couplings, not shown, but similar to the upper and lower couplings 130. As contrasted with the upper and lower couplings, however, the 31 intermediate couplings have threaded male stubs at both ends for threading into 32 adjacent open ends of adjacent springs. Thus, by having a supply of the spring 1 sections and the intermediate couplings, the shaft can be made longer or shorter to 2 suit particular jobs. Also, although the shaft in disclosed embodiment is a single 3 length of spring preferably about four feet long, it may be made up of shorter lengths 4 of springs (for example, and as above noted, each about two feet long) equaling four feet or any other desired length.
6 The plumbing tool 100 (Fig. 7) is held by grasping the sleeve 156 in one hand 7 and the crankhandle 154 in the other hand. The tool shaft 102 and thus the operating 8 head 120 are rotated by turning the crankhandle while holding the sleeve.
Also, the 9 tool shaft has sufficient rigidity to allow force to be transmitted through and axially of the shaft to the tip 140 by grasping the sleeve in one hand and the crankhandle in 11 the other and thrusting the tool axially of the tool shaft. Such rotation and axial 12 thrusting can be accomplished at the same time whether the tool shaft is straight or 13 flexed.
14 The plumbing tool 100 is used to carry out the method of the present invention after all necessary pressure tests have been successfully completed.
To this 16 end, the cover 69 (Fig. 6) is removed and the operating head 120 of the tool is 17 inserted in the riser 68 (Fig. 12) and lowered down into the clean-out 56.
The 18 mounting ring 122 slidably engages the interior of the riser and the clean-out branch 19 62 and guides the operating head 120 down the clean-out until it exits the clean-out branch and strikes the base 59 of the clean-out (Fig. 12). Axial thrust is then imparted 21 to the tool shaft 102 to cause the head to tip over from a generally vertical attitude, 22 not shown, into the generally horizontal attitude shown in Fig. 12, with the mounting 23 ring engaging the base of the clean-out and the tip 140 pointing toward the test cap 24 70. Such tipping is facilitated by the flexibility of the shaft and the engagement of the shaft with the clean-out branch along area 170, but also by the downward slope of the 26 drain pipe 36.
27 When in this generally horizontal position (Figs. 12 and 13), further axial 28 pressure on the tool shaft 102 causes the operating head 120 to move axially 29 downwardly of the drain pipe 36 toward the outlet branch 60. Because of the combined transverse flexibility and axial rigidity of the tool shaft and the leveraging 31 effect of the shaft bearing against the clean-out branch 62 and/or the riser 68 at region 32 170, this axial pressure on the tool shaft causes the tip 140 of the head to move into . CA 02275793 2000-03-08 1$
1 engagement with the center plate 76 of the test cap 70. 'Then, the shaft is thrust 2 sharply downwardly to force the tip of the head to penetrate the plate, creating an 3 initial hole 174 (Fig. 12) in the plate.
4 Thereafter, while continuing to apply axial downward pressure on the tool $ shaft 102 (Fig. 13), the tool shaft and the operating head 120 are rotated with the 6 crankhandle 1$4 to begin cutting away or reaming out the center plate. The 7 mounting ring 122 is soon rotatably slidably received in the outlet branch 60 and 8 thereafter guides movement of the head axially along the outlet branch. As the 9 reaming action continues, the guiding edges 137 move within the annular body 72 of the test cap 70 to guide and center the head. When the stop rim 142 strikes the radial 11 flange 74, the cutting blades will have substantially completely cut or reamed out the 12 center plate 76 from within the annular body 72 of the test cap to provide a large 13 opening 180 (Fig. 14) in the test cap. This opening 180 is the about the same 14 diameter as the inside diameter of the body since the diameter of the head at the 1$ guiding edges 137 is the about the same diameter as the inside diameter of the body.
16 In turn, the inside diameter of the body is just slightly less than the inside diameter of 17 the drain pipe, so that creating the opening 180 will allow waste material to move 18 essentially unimpeded through the pipe.
19 After the opening 180 has been created, the tool 100 is pulled back out of the outlet branch 60 and thence out of the clean-out branch 62 and riser 68.
Because the 21 stop rim 142 contacts the radial flange 74 of the test cap 70, the operating head 120 22 does not hang-up or become locked in the clean-out. It is also to be noted that the 23 removed material, i.e., the cut fragments, not shown, of , the center plate are 24 subsequently flushed down the lower section 48 of the drain pipe to the sewer line 2$ 38.
26 From the foregoing it will be understood that an improved method for testing 27 a newly installed plumbing system has been provided including a tool 100 for 28 carrying out the method. The method is more cost-effective because it avoids having 29 to re-test a plumbing system 20 that would have passed the test but did not only because the test plug failed. Since the method does not use inflatable test plugs to 31 seal off the drain pipe 36 while doing the testing, the common failure of the inflatable 32 plug does not cause a failed test. Instead, the method involves use of a test cap which 1 positively seals the drain pipe and allows an accurate test of the plumbing system.
2 The test cap and its positive seal can be employed because the method also uses the 3 tool 100 that can be extended into the clean-out and operated from a remote position 4 to create an opening 180 in the cap and remove the blockage from the pipe.
It will be recognized that although the method and tool have been described and shown with an 6 underground clean-out, they can be used equally as well when the clean-out is in a 7 basement or otherwise above ground.
8 Although a preferred embodiment of the present invention has been shown 9 and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be 11 understood that the present invention has been described by way of illustration and 12 not limitation.

Claims

1. A method of testing a plumbing system in a building wherein the system is connected to a sewer line by a drain line, comprising the steps of: installing a test plug in the drain line thereby to prevent flow through the line past the plug;
testing the plumbing system by applying fluid pressure in the plumbing system on the opposite side of the plug from the sewer line and against the plug thereby to test the plumbing system for leaks; removing material from the plug while allowing the removed material to remain in the drain line, thereby creating an opening through the plug while the drain line remains connected to the sewer line, thereby allowing flow through the drain line; and flushing the removed material down the drain line to the sewer line.

2. The method of Claim 1, wherein the removing step involves penetrating and reaming out the plug.

3. The method of Claim 1, including the further step of causing the plug to be inaccessible except through an access opening leading to the plug whereby access to the plug can be achieved without disconnecting the drain line from the plumbing system or the sewer line; and wherein the removing step involves extending a tool through the access opening for engaging the plug and causing said material to be forced into the drain line on the opposite side of the plug from the tool.

4. The method of Claim 3, wherein the tool includes an elongated flexible shaft having opposite ends, a penetrating and reaming head attached to one end of the shaft, and an operating handle attached to the opposite end of the shaft, and wherein the removing step involves extending the head and the shaft through the access opening to move the head into penetrating engagement with the plug and thereafter rotating the head against the plug by turning the handle thereby to ream out the plug.

5. The method of Claim 4, wherein the removing step involves reaming out the plug so that the opening through the plug is of substantially the same diameter as the drain line and provides for substantially smooth movement of drainage material through the drain line.

6. The method of Claim 1, wherein the plug is of plastic material; wherein the steps include installing a first stage of the system including the drain line;
wherein the installing step includes welding the plug in fluid-tight relation in the drain line during installation of the first stage; wherein the testing step includes applying a first test of fluid pressure in the plumbing system after the first stage is installed;
wherein the steps further include installing a second stage of the plumbing system;
wherein the testing step further includes applying a second test of fluid pressure in the plumbing system to test the plumbing for leaks after the second stage is installed; and wherein the removing step includes removing said material from the plug only after the second test pressure has been removed.

7. The method of Claim 6, wherein the steps further include leaving the portion of the drain line that contains the plug exposed during said first stage; covering the portion of the drain line that contains the plug during said second stage while providing an access opening to the plug without disconnecting the drain line from the plumbing system or the sewer line; and wherein the removing step involves removing said material from the plug through the access opening.

8. The method of Claim 7, wherein the drain line includes a drain pipe having an upper section connected to the remainder of the plumbing system and a lower section adapted to be connected to the sewer line; wherein the steps further include joining the upper and lower sections of the drain pipe with a clean-out that has inlet and outlet branches respectively attached to the upper and lower sections of the drain pipe and constituting part of said drain line and a clean-out branch in fluid communication with the inlet and outlet branches; wherein the installing step involves welding the plug in the drain line adjacent to the lower section of the drain pipe before the outlet branch of the clean-out is connected to the lower section; wherein the plug is accessible from outside the plumbing system through the clean-out branch; and wherein the removing step is performed through the clean-out branch of the clean-out.

9. A method of using a tool to remove a circular center plate of a test cap for a plumbing system; wherein the test cap has a cylindrical body circumscribing the plate and an annular flange extending radially outwardly from the body; wherein the plumbing system has a clean-out with first and second branches positioned between sections of a cylindrical drain pipe leading to a sewer line; wherein the test cap is secured in fluid-tight relation to one of said sections of the drain pipe whereby the test cap creates a fluid-tight seal against passage of material through the drain pipe to the sewer line, said first branch of the clean-out providing communication with the test cap; wherein the clean-out has a third branch extending laterally from the drain pipe and provides access to the center plate through the third branch and the first branch;
wherein the tool includes a rotary penetrating and reaming head, an elongated flexible shaft connected to the head, and means for rotating the shaft to rotate the head, comprising the steps of: inserting the head and the shaft into the third branch of the clean-out until the head engages the first branch of the clean-out; pressing axially on the shaft to bend the shaft adjacent to the head and force the head into engagement with the center plate of the test cap; axially thrusting the shaft downwardly thereby thrusting the head against and through the cap; and rotating the shaft and thus the head to cause the head to ream the center plate out of the test cap and to create an opening in the test cap substantially the same diameter as the body of the cap so as to provide fluid communication through the drain pipe, whereby material intended to be moved through the drain pipe to a sewer line is no longer blocked by the test cap.

10. The method of Claim 9, wherein the head has a diameter about equal to the inside diameter of the drain pipe, wherein the rotating step is continued until the head engages the inside diameter of the drain pipe whereby the center plate and the body of the test cap are substantially completely removed thereby to provide a substantially uniform diameter through the drain pipe.

11. A tool for creating an opening through a test cap that is secured in a drain line to block flow therethrough and wherein a clean-out branch connected to the drain line provides access to the cap after a plumbing test has been completed, comprising: a penetrating and reaming head for reaming an opening through the test cap; a resiliently flexible shaft connected to the head for extending the head into the clean-out branch and into engagement with the test cap, said shaft being capable of flexing in the clean-out branch and a portion of the drain line to enable the engagement with the test cap; and a handle connected to the shaft for axially thrusting and rotating the shaft while in such flexed condition to rotate the head while axially forcing it against the test cap thereby to cause the head to penetrate and ream out an opening in the cap so that the drain line is open and provides a passageway through which waste water can flow to a sewer line.

12. A tool for removing the center plate of a test cap in a drain pipe that blocks flow therethrough and wherein a clean-out connected to the drain pipe provides access to the cap after a plumbing test has been completed, comprising: an operating head including penetrating and reaming blades thereon; a transversely flexible shaft having axial rigidity and being connected to the head for extending the head into the clean-out branch and into engagement with the center plate of the test cap within a portion of the drain pipe, and a handle connected to the shaft for axially thrusting and rotating the shaft to rotate the head while axially forcing it against the center plate of the test cap, thereby to cause the head to penetrate and ream out the center plate and to create the opening therein; wherein the shaft has a longitudinal axis; wherein the shaft is resiliently transversely flexible; wherein the shaft has a normally straight unstressed condition but can be flexed out of the straight condition upon application of sufficient force; and wherein the shaft can transmit force axially thereof while in straight or flexed condition whereby the head can be forced against and through the center plate of the cap by applying force on the shaft axially thereof toward the head while rotating the head.

13. The tool of claim 11, wherein the head has an axis of rotation and includes a plurality of blades radially extending from the axis in circumferentially spaced relation to each other, said blades converging toward the end of the head.

14. The tool of Claim 11, wherein the head has means for guiding it axially within the clean-out.

15. The tool of Claim 11, wherein the head has means for guiding it axially of the test cap while the head is reaming out the opening.

16. The tool of Claim 11, wherein the shaft is releasably connected to the cutting head.

17. The tool of Claim 11, wherein the head has means for limiting movement thereof within the test cap while the head is reaming out the opening.

18. The tool of claim 11, wherein the handle includes a crank secured to the shaft and a sleeve rotatable relative to the shaft.

19. The tool of claim 11, wherein the shaft is about four feet in length.

20. The tool of claim 11, wherein the flexible shaft is a coil spring.

21. The method of Claim 1, wherein said fluid pressure is relieved before the removing step occurs.

22. A method of using a tool to penetrate and ream out a center plate of a test cap for a plumbing system; wherein the test cap has an annular body circumscribing the plate;
wherein the plumbing system has a clean-out element with a first section secured between sections of a drain pipe; wherein the test cap is secured in fluid-tight relation in and to one of said sections of the drain pipe whereby the test cap creates a fluid-tight seal against passage of material through the drain pipe; wherein the clean-out element has a second section extending from the drain pipe and provides access to the center plate through the second section after a plumbing test has been completed;
wherein the tool includes a rotary cap penetrating and reaming head, an elongated transversely flexible shaft connected to the head and being resiliently flexible from an unstressed straight condition to a stressed curved condition, and a handle connected to the shaft to rotate the head and axially thrust the shaft and head, said shaft possessing axial rigidity lengthwise thereof from the handle to the head when in straight or flexed condition, comprising the steps of: inserting the head and the shaft into the second section of the clean-out element until the head engages the first section of the clean-out element; pressing on the handle axially of the shaft to bend the shaft adjacent to the head and force the head into engagement with the center plate of the test cap within a portion of the drain pipe; and pressing on the handle axially of the shaft and rotating the shaft and thus the head with the handle to cause the head to penetrate and ream out an opening in the center plate of the test cap for establishing fluid communication through the drain pipe, whereby material intended to flow through the drain pipe to a sewer line is no longer blocked by the test cap.

23. The tool of Claim 11, wherein the shaft has a section for bearing against the clean-out thereby to guide and leverage the head into engagement with the cap.

24. The tool of Claim 11, wherein the handle is connected to the shaft at the opposite end thereof from the head.

25. A tool for creating an opening through a blockage in a drain line that is blocking flow therethrough and wherein a passageway connected to the drain line provides access to the blockage, comprising: a penetrating and reaming head; a normally straight, resiliently transversely flexible shaft having first and second ends, the second end being connected to the head for extending the head into the passageway and into engagement with the blockage, said shaft being capable of transversely flexing in the passageway and a portion of the drain line to enable the engagement of the head with the blockage, said shaft possessing axial rigidity lengthwise thereof from the first end to the second end when in its straight or flexed condition; and a handle connected to the first end of the shaft for manually axially pressing on and rotating the shaft while in such flexed condition to rotate the head while axially forcing it against the blockage thereby to cause the head to penetrate the blockage and ream out the opening in the blockage so that the drain line is open and provides a passageway permitting flow therethrough.

26. The method of claim 1, wherein the plug is a standard test plug.

27. The method of claim 4, wherein the removing step further includes imposing axial pressure against the shaft by pressing on the handle thereby axially thrusting the head against the plug.

28. A method of temporarily sealing a fluid carrying line in a plumbing system in order to test the system for leaks, comprising the steps of:
sealing the line with a fragmentable blockage, whereby the blockage has an upstream side disposed toward the plumbing system and an oppositely facing downstream side;
testing the system for leaks by exerting pressure against the upstream side of the blockage;
after the testing step, fragmenting the blockage and unblocking the line; and flushing the fragments down the line.

29. A method of testing a plumbing system including a drain line, comprising the steps of:
installing a test plug in the drain line thereby preventing flow through the line past the plug;
testing the plumbing system by applying fluid pressure in the plumbing system on the one side of the plug thereby to test the plumbing system for leaks;
applying fluid pressure force against the plug lengthwise of the line in the direction of the desired flow therethrough and following said testing sufficient to create an opening through the plug, whereby flow can occur in the drain tine through the plug and whereby parts of the plug are removed; and flushing the removed parts of the plug along the line away from the location of the plug.

30. A tool for creating an opening through a. blockage in a drain line that is blocking flow therethrough and wherein a passageway connected to the drain line provides access to the blockage, comprising:
a penetrating and reaming head;
a shaft having a rigid portion and a resiliently transversely flexible having first and second ends, the first end being connected to the rigid portion and the second end being connected to the head , the flexible portion from its first end to its second end extending over a substantial part of the length of the shaft and being exposed externally of the tool throughout said substantial part of the length for extending the head into the passageway into engagement with the blockage and for bringing the flexible portion into engagement with the passageway, said flexible portion of the shaft being capable of transversely flexing in the passageway and a portion of the drain line to enable the engagement of the head with the blockage said shaft possessing axial rigidity lengthwise thereof from the first end to the second end when in its straight or flexed condition; and a handle connected to the first end of the shaft for manually axially pressing on and rotating the shaft while in such flexed condition to rotate the head while axially forcing it against the blockage thereby to cause the head to penetrate the blockage and ream out the opening in the blockage so that the drain line is open and provides a passageway permitting flow therethrough.