Marley Pvc Civils Technical Manual

Civils Technical Manual(PVC)

Contents

Introduction 2

PVC Pressure Pipe 3

Applications 3

Features and Benets 3

SABS Specication 3

Dimensions of Hydro-wall uPVC

Pressure Pipe 4

Dimensions of Aqua-Wall mPVC

Pressure Pipe 5

Joining 6

Fittings for Pressure Pipe 7

PVC Fittings 7

SG Iron Fittings 9

Resilient Seal Gate Valves 15

Physical Properties 16

General 16

The Stress Regression Line 17

Design Stress and Safety Factor

(service factor) 18

Effect of Temperature Change 18

The Effect of Ultra Violet Light 19

Chemical Resistance 19

Design Considerations 20

Pressure Considerations. 20

Temperature Considerations 23

Ultraviolet Light Considerations 23

Trench Load Considerations 24

Bending 29

Thrust Support 29

Flow Considerations 30

Quality Assurance 44

2Introduction

Marley Pipe Systems is one of South Africa's leading manufacturers and suppliers of plastic pipe reticulation systems, meeting the needs of the construction, civil, agricultural, industrial and petrochemical industries, primarily in South Africa, but also supplying into Africa, the Indian Ocean Islands, Europe and Australia.

Marley Pipe Systems was established in 1963 as Marley Plumbing, then part of the Marley SA group. Since then Marley Plumbing has become the market leader in the manufacture and distribution of plumbing products to the merchant trade.

In 1991 Marley Plumbing entered the pressure pipe market and now offers a range of uPVC and PVC pipe, as well as a range of pressure bends, tees, valves and other ttings.

In 1999 Marley international was bought by the Belgium based Etex group; already operating globally in the construction and piping industry.

In 2001 the Etex group acquired the global operation Glynwed Pipe Systems resulting in the merger of Glynwed Pipe Systems Africa and Marley Plumbing to form the new company Marley Pipe Systems. This new company offers pipe systems in uPVC, mPVC and High Density Polyethylene in a range of sizes from 16mm up to 630mm in diameter. In addition, a vast range of ttings and joining systems is also available from Solvent Weld ttings and integral Rubber Ring Joints to Buttwelding and electrofusion. Other mechanical joining systems are also available from top of the range metal clamping systems to an extensive range of compression ttings.

Employing some 400 personnel, Marley Pipe Systems has manufacturing facilities at Nigel in Gauteng Province as well as at Port Shepstone in KwaZulu-Natal. The distribution network encompasses 8 branches around the country as well as sales ofces in Namibia and Botswana, coupled with an active export division selling into Africa, the Indian Ocean Islands, Europe and Australia.

In June 2003 Marley Pipe Systems became part of the newly formed Belgium based Aliaxis group of companies. Specializing in plastic pipe reticulation systems, Aliaxis operates in 37 countries through over 100 companies, generating sales in excess of 1.7 Billion Euro.

3PVC (Polyvinyl Chloride)PVC Pressure Pipe

Applications

Marley Pipe Systems Hydro-Wall (uPVC Pressure Pipe SABS 966 Part 1) and Aqua-wall (mPVC Pressure Pipes SABS 966 Part 2) may be specied with condence for pumping mains and reticulation networks. They have, for many years, been successfully applied in civil, efuent, purication, irrigation and industrial applications.

Features and Benets

Low massEase of handlingReduced installation timeReduced transport costs

Corrosion resistance Long, maintenance free, life spanAbrasion resistance Excellent life span when pumping

slurriesSmooth bore Excellent ow characteristics

Lower pumping costsResilience Minimal handling damage

Minimal installation damageWavisafe Z-Lok@joint Easy, effective, dependable joints

SABS Specication

Hydro-Wall (uPVC) and Aqua-Wall (mPVC) pressure pipes are manufactured to, and carry the SABS Mark for SABS 966 Parts 1 and 2 respectively. Customers are therefore assured of consistently high quality pipes manufactured in an ISO 9001 accredited factory with a design life of 50 years and a substantial safety factor at the end of that period.

uPVC Pressure Pipe SABS 966 Part 1

mPVC Pressure Pipe SABS 966 Part 2

Features and Benets

4Dimensions of Hydro-wall uPVC Pressure Pipe

SABS 966 Part 1-Pipe DimensionsDesign Stress: 20mm-90mm sizes - 10 MPa 110mm - 500mm sizes -12.5 MPa All Sizes of Class 4 - 10 MPa

Minimum wall thickness and Mass per 6 metre length

Outside Diameter

(mm)

Class 4 Class 6 Class 9 Class 12 Class 16 Class 20 Class 25

Working Pressure 400kPa







mm kg mm kg mm kg mm kg mm kg mm kg mm kg

20 1.50 0.79 1.90 1.01

25 1.50 1.01 1.90 1.25 2.30 1.53

32 1.50 1.31 1.60 1.55 2.40 2.03 2.90 2.46

40 1.50 1.65 1.80 1.96 2.30 2.47 3.00 3.16 3.70 3.94

50 1.50 2.06 1.60 2.48 2.20 3.00 2.80 3.77 3.70 4.88 4.60 6.12

63 1.50 2.63 1.90 3.31 2.70 4.64 3.60 6.09 4.70 7.80 5.80 9.73

75 1.50 3.15 2.20 4.57 3.20 6.56 4.30 8.67 5.60 11.07 6.90 13.78

90 1.60 4.53 2.70 6.73 3.90 9.56 5.10 12.34 6.70 15.69 8.20 19.67

110 2.20 6.77 2.60 8.14 3.90 12.11 5.10 15.67 6.70 20.29 8.20 24.46 10.00 29.33

125 2.50 8.91 3.00 10.66 4.40 15.53 5.80 20.25 7.60 26.15 9.30 31.55 11.40 37.87

140 2.80 11.19 3.30 13.19 4.90 19.37 6.50 25.41 8.50 32.75 10.40 39.51 12.80 47.73

160 3.20 14.64 3.60 17.36 5.60 25.32 7.40 33.10 9.70 42.76 11.90 51.73 14.60 62.31

3.9 22.40 4.70 26.92 7.00 39.68 9.20 51.62 12.10 66.92 14.90 81.24 18.20 97.46

250 49.00 35.33 5.90 42.46 8.70 62.66 11.50 81.12 15.10 105.03 18.60 127.58 22.80 153.55

315 6.20 56.44 7.40 67.28 11.00 99.04 14.50 129.29 19.00 167.12

355 7.00 72.19 8.40 86.55 12.40 126.57 16.30 164.83 21.40 213.49

400 7.90 90.90 9.40 109.40 14.00 161.41 18.40 210.21 24.10 271.22

450 8.90 115.20 10.60 139.39 15.70 204.60 20.70 266.65

500 9.60 140.97 11.60 172.59 17.40 252.34 22.90 327.84

5Dimensions of Aqua-Wall mPVC Pressure Pipe

SABS 966 Part 2 - Pipe DimensionsDesign Stress: 18 MPa

Minimum wall thickness and Mass per 6 metre length

Outside Diameter

(mm)

Class 6 Class 9 Class 12 Class 16 Class 20 Class 25







mm kg mm kg mm kg mm kg mm kg mm kg

50 1.50 2.10 1.50 2.10 1.70 2.40 2.20 3.00 2.70 3.70 3.30 4.40

63 1.50 2.70 1.60 2.80 2.10 3.70 2.70 4.70 3.40 6.00 4.10 7.00

75 1.50 3.20 1.90 4.00 2.50 5.30 3.20 6.80 4.00 8.20 4.90 10.00

90 1.80 4.60 2.20 5.60 3.00 7.60 3.90 9.70 4.80 11.90 5.90 14.40

110 2.20 6.90 2.70 8.40 3.60 11.10 4.70 14.40 5.80 17.60 7.20 21.50

125 2.50 8.90 3.10 11.00 4.10 14.40 5.40 19.10 6.60 22.70 8.20 27.90

140 2.80 11.20 3.50 14.20 4.60 18.10 6.00 24.10 7.40 28.60 9.10 35.80

160 3.20 14.60 4.00 18.20 5.20 23.50 6.90 30.80 8.50 37.60 10.40 45.50

200 3.90 22.30 4.90 27.90 6.50 36.80 8.60 48.20 10.60 60.30 13.00 71,30

250 4.90 35.10 6.10 44.90 8.10 57.60 10.70 75.40 13.20 94.60 16.30 112.50

315 6.20 56.30 7.70 69.70 10.20 91.70 13.50 120.30 16.60 146.70

355 7.00 72.00 8.70 89.20 11.50 117.30 15.20 153.60 18.70 187.02

400 7.80 90.30 9.80 113.50 13.00 149.80 17.10 195.40 21.10 238.59

450 8.90 116.70 11.00 144.00 14.60 190.10 19.20 247.35 23.70 302.13

500 9.80 144.40 12.20 177.70 16.20 234.80 21.30 305.46 26.40 347.57

6Joining

The Wavisafe "Z-LOK" joint is integrally moulded on one end of the pipe. The joint incorporates a factory tted rubber sealing ring which is retained in position by a polypropylene lock ring. Each joint is capable of handling some expansion and contraction as well as angular deection. The seal ring is designed to provide a watertight joint at high and low pressures.

Each length of pipe has a "depth of entry" mark on the spigot end to ensure correct installation (see our Code of Practice Manual).

The seal rings ribbed prole reduces friction during assembly.

Rubber seal, rmly xed into the correct position with a polypropylene lock ring. This prevents accidental

displacement of the seal ring during jointing. Factory assembly ensures that the supplied joint is fully

functional. No more concern about joint failure due to the use of randomly sized or incorrectly placed seals.

7Fittings for Pressure Pipe

A wide range of complimentary ttings is available for use with Hydro-Wall and Aqua-Wall pressure pipes. For sizes up to 250mm diameter, there are PVC bends, sockets and adaptors as well as a wide variety of SG Iron ttings. Larger sizes can be catered for from a selection of plain ended fabricated steel ttings in conjunction with Viking Johnson couplings.

PVC Fittings

PVC BendsAll bends are made to suit either Class 9 or Class 16 applications and are available in 11, 22, 45 and 90 angles.

Outside Diameter A

(mm)

Overall Length B

(mm)Radius C

(mm)Mass (kg)

50 820 175 0.75

63 900 220 1.32

75 970 260 2.02

90 1085 315 3.22

110 1200 385 5.40

125 1330 440 7.65

140 1435 490 10.33

160 1610 560 15.08

200 1920 700 27.82

250 2220 875 50.23

Outside Diameter A

(mm)

Overall Length B

(mm)Radius C

(mm)Mass (kg)

50 820 175 0.75

63 900 220 1.32

15 970 260 2.02

90 1085 315 3.22

110 1200 385 5.40

125 1330 440 7.65

140 1435 490 10.33

160 1610 560 15.08

200 1920 700 27.82

250 2220 875 50.23

90 Pressure Bend

45 Pressure Bend

8Outside Diameter A

(mm)

Overall Length B

(mm)Radius C

(mm) Mass (kg)

50 640 175 0.59

63 670 220 0.98

75 700 260 1.45

90 755 315 2.25

110 800 385 3.60

125 670 440 5.00

140 920 490 6.62

160 1025 560 9.60

200 1190 700 17.24

250 1305 875 29.53

Adaptors PVC AC

PVCOutside Diameter A

(mm)

AC PipeNominal Size

(mm)

AC PipeActual outside

diameter C(mm)

50 50 69

63 50 69

75 75 96

90 75 96

110 100 122

125 125 150

140 125 150

160 150 177

200 200 232

250 250 286

Outside Diameter A

(mm)

Overall Length B

(mm)Radius C

(mm) Mass (kg)

50 640 175 0.59

63 670 220 0.98

75 700 260 1.45

90 755 315 2.25

110 800 385 3.60

125 670 440 5.00

140 920 490 6.62

160 1025 560 9.60

200 1190 700 17.24

250 1305 875 29.53

22Pressure Bend

11 Pressure Bend

The table below lists the available adaptors.

9PVC Double SocketsDouble Sockets are used to connect plain ended pipes. There are sometimes short lengths of plain ended pipes required before or after ttings, such as tees, bends, etc. In these cases the most economical method of connection is to use a double socket. The table below lists the available sizes.

Size (mm) Length (mm)

50 300

63 300

75 300

90 330

110 330

125 380

140 450

160 450

200 540

250 615

SG Iron Fittings

SG Iron Equal Tees

Nominal Size (mm)

C (mm) D (mm) Mass (kg)

50 124 132 2.4

63 145 150 3.3

75 150 151 4.3

90 161 175 5.4

110 177 192 6.5

125 205 205 18.1

140 227 229 22.5

160 229 230 13.2

200 265 259 24.8

250 318 315 44.2

10

Specications PCD (mm) No. of HolesDiameter of Hole (mm)

3 1/2 Table C BS10 165.1 4 18.0

3 Table D BS10 146.0 4 18.0

80mm Table 10 SABS 1123 160.0 8 18.0

80mm Table 16 SABS 1123 160.0 8 18.0

Table of available drilling patterns for SG Iron Hydrant Tees

SG Iron Scour Tees

Nominal Diamter

(mm)C (mm) D (mm) Mass (kg)

110 180 175 9.8

160 207 197 14.1

200 218 230 21.1

250 254 253 34.2

Table of available drilling patterns for SG Iron Scour Tees

Specications PCD (mm) No. of Holes Diameter of Hole (mm)

4 Table D BS10 177.8 4 18.0

100mm Table 10 SABS 1123 180.0 8 18.0

100mm Table 16 SABS 1123 180.0 8 18.0

Nominal Size (mm)


75 150 155 6.1

90 163 160 7.2

110 175 170 8.3

160 193 225 13.8

200 214 217 19.2

250 251 243 27.6

SG Iron Hydrant Tees

11

SG Iron Reducing TeesA full range of reducing tees from 63mm - 250mm is available in SG iron. Certain sizes consist of two components, eg. A 160mm x 50mm reducing tee is made up of a160mm x 90mm reducing tee plus a 90mm x 50mm reducer which ts into the branch of the reducing tee as shown in the diagram. The '*' denotes two part reducing tees in the table below.

Nominal Size (mm)


63x50* 130 160 4.3

75x50 150 152 4.0

75x63 150 152 4.3

90x50* 154 189 6.0

90x63 154 152 5.0

90x75 159 158 5.5

110x50* 176 210 7.8

110x63 176 173 6.8

110x75 176 175 6.6

110x90 166 181 7.1

125x50* 205 335 24.7

125x63* 205 298 25.0

125x75* 205 293 25.0

125x90* 205 315 25.4

125x110* 205 264 22.7

140x50* 227 320 30.1

140x63* 227 283 30.4

140x75* 227 278 30.4

140x90* 227 300 30.4

140x110* 227 249 28.1

140x125* 227 250 26.1

160x50* 180 230 10.9

160x63 180 193 9.9

160x75* 180 255 13.3

160x90 193 212 11.4

160x110 204 216 11.2

160x125* 204 294 23.2

160x140* 204 272 22.2

200x50* 242 301 19.9

200x63* 242 264 20.2

200x75* 242 259 20.2

200x90* 242 281 20.3

200x110 242 230 17.9

200x125* 250 288 31.8

200x140* 250 266 31.8

200x160 250 253 21.6

250x50* 253 516 40.1

250x63* 253 417 40.4

250x75* 253 472 40.4

250x90* 253 494 40.5

250x110* 253 443 38.3

250x125* 253 443 83.0

250x140* 253 421 48.5

250x160* 253 408 43.0

250x200 253 295 30.8

12

SG Iron ReducersThere are two types of reducers available, namely socketed both sides and spigot and socket. Both are used for in-line reduction of pipe size. However, the spigot /socket reducer has an advantage when used in conjunction with a tting. The spigot end can be tted into any of the sockets on these ttings.

Nominal Size (mm) C (mm) Mass (kg)

75x63 222 2.4

90x63 224 3.1

90x15 250 3.5

110x63 270 8.0

110x75 270 4.4

110x90 226 4.3

160x90 334 8.3

160x110 334 8.1

200x110 339 12.9

200x160 336 12.8

250x160 338 17.3

250x200 440 18.8

Nominal Size (mm) C (mm) D (mm) Mass (kg)

63x50(B) 137 100 1.0

75x50(B) 141 106 1.1

75x63(B) 141 106 1.2

90x50(B) 144 112 3.0

90x63(B) 144 112 1.7

90x75(B) 155 112 1.9

110x50(L) 255 120 2.0

110x63(L) 156 122 2.3

110x75(B) 151 122 2.3

110x90(B) 113 122 2.4

125x110(B) 181 128 4.6

140x110(B) 150 130 5.6

140x125(B) 151 130 4.2

160x90(L) 310 141 4.8

160x110(B) 115 140 5.0

160x125(B) 115 140 10.0

160x140(B) 153 140 9.0

200x110(L) 345 155 1.3

200x160(B) 215 155 7.5

250x160(L) 395 179 12.2

250x200(B) 218 179 12.8

Female reducers (socketed both sides)

Male/Female reducer (spigot and socket)

13

SG Iron Flange Adaptors

SG Iron End Caps

Nominal Size (mm)

C (mm) D (mm) E (mm) T (mm) Mass (kg)

50 105 150 47 19 2.2

63 135 165 55 19 2.8

75 124 200 70 19 3.4

90 155 200 80 20 4.3

110 158 220 90 20 4.7

125 160 255 110 22 14.0

140 154 255 130 22 14.0

160 185 280 140 22 9.1

200 177 340 180 25 14.8

250 210 405 230 28 23.8

Outside Diameter

(mm)

Flange Size (mm)

Flange Size (mm)

BS 10 Table D SABS 1123 Table 10 SABS 1123 Table 16

PCD (mm)

No. of Holes

Diameter of Holes

(mm)PCD (mm)

No. of Holes

Diameter of Holes

(mm)PCD (mm)

No. of Holes

Diameter of Holes

(mm)

50+63 50 114.3 4 18 125 4 18 125 4 18

75 65 127.0 4 18 145 4 18 145 4 18

110 100 177.8 4 18 180 8 18 180 8 18

125 125 209.6 8 18 210 8 18 210 8 18

140 125 209.6 8 18 240 8 22 240 8 18

160 150 235.0 8 18 240 8 22 240 8 22

200 200 292.0 8 18 295 8 22 295 12 22

250 250 355.6 8 22 350 12 22 355 12 26

Nominal Size (mm)

C (mm) Mass (kg)

50 117 0.9

63 121 1.5

75 128 1.8

90 129 2.5

110 135 2.7

160 154 5.7

200 228 8.6

Table of available drilling patterns for SG Iron Flange Adaptors

14

SG Iron SaddlesSaddles are manufactured from SG iron, have four galvanised bolts and nuts, two straps and a rubber gasket which seats in a recess under the saddle. The standard drilling and tapping is 25mm BSP. Tappings up to 40mm BSP can be ordered. Marley Pipe Systems also manufacture a range of Magnum Polypropylene Saddles which are ideal for use with PVC pipes.

SG Iron Repair CouplingsThese sleeve couplings are used for repairing breaks in pipelines.

Nominal Size (mm) C (mm) D (mm) Mass (kg)

63 76 133 1.6

75 76 142 1.6

90 76 160 1.7

110 76 180 2.0

160 76 230 2.4

200 76 270 2.8

Nominal Size (mm) C (mm)

63 220

75 232

90 250

110 272

160 320

200 345

250 438

15

Resilient Seal Gate ValvesFor waterworks purposes, double-socketed, non-rising spindle, Class 16.

DNPipe

Diameter External

(mm)

A (mm)

L (mm)

H (mm)

F (mm)

C (mm)

E (mm)

Mass (Kg)

40 50 103 270 236 14 64 44 7

50 63 103 286 241 14 80 52 8

65 75 108 298 271 17 82 58 9

80 90 115 315 297 17 85 68 13

100 110 118 336 334 19 100 79 18

125 125 115 348 375 19 118 87 24

150 160 130 400 448 19 140 107 40

200 200 135 426 562 24 156 130 56

200 225 151 452 562 24 150 142 58

250 250 161 474 664 27 152 157 80

250 280 166 504 664 27 172 174 95

300 315 172 548 740 27 204 193 123

400 400 185 596 950 32 226 240 246

MaterialsBody and bonnet Ductile iron, GGG-50, to DIN 1693 (BS 2789 grade

500 - 7)

Coating*Electrostatically applied epoxy resin to DIN 30677 - internally and externally

Stem Stainless steel, DIN X 20 Cr 13

Stem sealingNBR wiper ring, 2 NBR O-rings inside and 2 outside a plastic bearing, EPDM rubber manchette

Wedge

Ductile iron, GGG-50, core fully vulcanised with intergral wedge nut of dezincication resistant brass, CZ 132 to BS 2874

Trust collar Dezincication resistant brass, CZ 132 to BS 2874

Bonnet bolts Stainless steel A2, sealed with hot meltBonnet gasket EPDM rubber

SocketsFitted with EPDM rubber Euro sealing rings to suit metric PVC-pipes (to be ordered separately)

*Also available internally enammeled

16

Physical Properties

Polyvinyl Chloride (PVC) is a thermoplastic material which consists of a PVC resin compounded with varying proportions of stabilizers, lubricants, llers, pigments, plasticizers and processing aids. Different formulations of these ingredients are used to obtain specic properties for different applications. Pipes can therefore be developed to meet the requirements of a wide variety of applications and conditions.

Physical Units Value

Coefcient of linear expansion K-1 6 10-5

Density kg/m2 1.4 103

Flammability (oxygenindex) % 45

Shore hardness 80

Softening point (Vicat - minimum) C 76

Specic heat J/kg/K 1.0 103

Thermal conductivity (at 0 - 50C) W/m/K 0.14

Mechanical

Elastic Modulus (longterm - 50 years) MPa 2800

Elastic Modulus (short term - 100 seconds) MPa 1400

Elongation at break % 75

Poissons Ratio 0.4

Tensile strength (50 year - extrapolated) MPa 26

Tensile strength (minimum) MPa 48

Friction Factors

Manning 0.008 - 0.009

Hazen Williams 150

Nikuradse roughness (k) mm 0.003 - 0.015

General

The general properties given in the table below are those for PVC compound formulations used in pipe manufacture. It should be noted that these properties are relative to temperature and the duration of stress application.

17

The Stress Regression Line

The traditional method of portraying the primary mechanical property of PVC, tensile strength, is by means of a graph of log stress vs. log time to failure. This is known as the stress regression line. It is a plot of the circumferential hoop stress in the wall of the pipe (from internal pressure) against time to failure.

Numerous actual test results, measured at 20C and 60C, over a range of times up to 10,000 hours, are plotted on a log scale and a regression line is calculated to t this data. The resultant regression line is then extrapolated to 50 years (438,000 hours). The method of calculation is an internationally accepted procedure described in ISO/TR 9080. The required values of stress and time are specied in SABS 966 Parts 1 and 2.

The internationally accepted method for calculating circumferential hoop stress is derived from Barlow's formula and is as follows:

= p(d -t)/2t

Where = hoop stress in wall of pipe (MPa) p = internal pressure (MPa) d = mean external diameter (mm) t = minimum wall thickness (mm)

18

Design Stress and Safety Factor (service factor)

Safety factors take into account handling conditions, service conditions and other circumstances not directly considered in the design.

In terms of SABS 966 the following safety factors have been adopted. These factors have resulted in the given design stresses being applicable. The design stress is derived by dividing the 50 year hoop stress (26 MPa - from the stress regression line ) by the chosen safety factor.

uPVC mPVC

Sizes 90 mm

Sizes 110 mm

All Sizes

Safety Factor 2.5 2.0 1.4

Design Stress (Mpa) 10.0 12.5 18.0

Applying Barlow's formula (below) it is now possible to calculate the minimum wall thickness for any given size and pressure class of pipe.

t = p d / (2 + p)

Where: t = minimum wall thickness (mm) p = pressure (MPa) d = mean external diameter (mm) = design stress (MPa)

For example the minimum wall thickness for a 250 mm Class 16 uPVC pipe is:t = 1.6 x 250 /{(2x 12.5)+ 1.6} =15.04 mm (rounded up to 15.1 mm for manufacture)

Effect of Temperature Change

Working PressureThe standard design temperature for PVC pipes is 20C and working pressures are usually quoted for this temperature. PVC pressure pipes function perfectly well below 20C, right down to freezing point, and can in fact withstand higher pressures than those quoted at 20C.

As can be seen from the stress regression lines, the creep rupture strength diminishes with increasing temperature and working pressures must be down-rated if the same factors of safety are to be maintained. The applicable reduction factors are given under "Temperature Considerations" later.

Expansion and ContractionAll plastics have high coefcients of expansion and contraction, several times that of metals. This must be allowed for in any installation by the use of expansion joints, expansion loops etc.

Material Co-efcient of expansion (K-1)

PVC 8 10-5

HDPE 20 10-5

Steel 1.2 10-5

Copper 2.0 10-5

Sub Zero TemperaturesWater has been known to freeze in PVC pipes without causing fractures, but permanent strain can result, leading to severe reduction in the working life of the pipe. Hence PVC pipes - like other pipes - should be protected against sub zero temperatures.

19

The Effect of Ultra Violet Light

Most plastics are affected by UV light. PVC pressure pipes have UV light stabilisers incorporated in their formulation but if pressure pipes have to be exposed for an indenite period, they should be painted, preferably with one coat of white Alkyd Enamel or PVA.

Long-term exposure (more than 4 to 6 months - dependant on climatic conditions) to UV light can cause discolouration of the pigments in the pipe and, in severe cases, lead to some embrittlement. Such embrittlement affects the ability to withstand impacts but does not reduce pressure handling capabilities.

Chemical Resistance

Marley Pipe Systems PVC pipes and ttings are highly resistant to acids, sewage or the most aggressive soils. Alkalis have very little effect on PVC. The table below summarises this resistance but further information can be obtained by contacting our technical department.

Chemical Type PVC Reaction/Suitability

Acids

No attack by concentrated or diluted acids at temperatures up to 60C, except for oxidizing acids such as concentrated nitric which attacks PVC above 20OC. In stressed applications, design stress,at 200C, should be reduced by: from 2.5% for 10% sulphuric - to 27.5% for concentrated nitric.

AlkalisNo attack at temperatures up to 60C even by concentrated alkalis. However in stressed applications, design stress must be reduced signicantly, e.g. by 40 - 50% for 10% sodium hydroxide.

Aromatic hydrocarbons and highly polar organic materials such as ketones, esters, cyclic ethers, nitro-compounds and hydrocarbons.

Not suitable.

Aliphatic hydrocarbons No effect.

Aliphatic alcohols No attack at room temperature but design stress must be reduced by half.

Halogens - chlorine No attack if dry.

Halogens - chlorine Not suitable if moist

Halogens - bromine Not suitable

Halogens - ourine Not suitable

Halogens - iodine Not suitable

Oxidizing agents Little attack even by the strongest, such as concentrated potassium permanganate, but design stress must be reduced by 25%.

Reducing agents No effect up to 60C

Detergents No attack

20

Design Considerations

In SABS 966 there are 7 different pressure classes (see page 42). These classes include suitable safety factors and are intended as a guide to trouble free operation under average service conditions. There are however many factors which must be considered when determining the severity of service and the appropriate class of pipe. This section is provided as a guide to the designer in the light of his or her knowledge of the particular circumstances.

Amongst the factors to be considered are:

Operating pressure characteristics:Static conditionsDynamic conditions

Water hammerCyclic loads

TemperatureEffect on pressureEffect on dimensions

Trench load conditionsSoil loadsTrafc loads

BendingThrust supportFlow considerationsSelection of pipe size and class

Pressure Considerations.

Static PressureThe hydrostatic pressure capacity of PVC pipe is related to a number of variables:

The ratio between the outside diameter and the wall thickness (standard dimension ratio)The hydrostatic design stress of the PVC pipe being used (uPVC or mPVC)The operating temperatureThe duration and variability of the stress applied by the internal hydrostatic pressure

Although PVC pipe can withstand short-term hydrostatic pressures at levels substantially higher than the pressure rating, or class, (see "The stress Regression Line" and "Design Stress and Safety Factor" earlier) the duty of PVC pipe should always be based on the pipe's long-term strength at 20C to ensure a design life of at least 50 years.

21

As stated earlier, the relationship between the internal pressure, the diameter and wall thickness and the circumferential hoop stress in the pipe wall, is given by the Barlow Formula, which can also be expressed as follows.

p = 2 x t x /dor alternatively

t = p x d/(2 + p)Where: p = internal pressure (MPa) t = minimum wall thickness (mm) d = mean outside diameter (mm) q =circumferential hoop stress (MPa)

These formulae have been standardized for use in design, testing and research and are applicable at all levels of pressure and stress.

For design purposes, p is taken as the maximum allowable working pressure and q, the maximum allowable hoop stress at 20C.

The design hoop stresses used in SABS 966 are as follows: Part 1 sizes up to 90mm 10 MPa other sizes 12.5 MPa Part 2 all sizes 18 MPa

Dynamic PressureThe pressure classes of SABS 966 PVC pipes are based on constant internal pressures. PVC pipes are however capable of handling dynamic pressure events which exceed the values given by the classes but such occurrences can have a negative effect on the normal 50 year life expectancy, and in extreme cases can result in product failure.

PVC pipes are capable of handling accidental events, such as pressure surges due to a power cut. However, if repetitive surges are likely to exceed about 100,000 occurrences during a 50 year operating lifetime, which is equivalent to an average of one surge wave every four hours for the total life of the pipe, then fatigue is a possibility and a fatigue design should be carried out. For most water supply lines this frequency of surges never occurs.

If stress peaks in excess of the design stresses are present, fatigue proceeds more rapidly and failure can occur earlier. For this reason peak pressures should not be allowed to exceed maximum recommended working pressures.

Studies of fatigue response have shown that a fatigue crack initiates from some dislocation in the material matrix, usually towards the inside surface of the pipe where stress levels are highest, and propagates or grows with each stress cycle at a rate dependent on the magnitude of the stress. Ultimately the crack will penetrate the pipe wall, extending from a few millimetres to a few centimetres long in the axial direction and will produce a leak.

It is important to appreciate that the growth of a fatigue crack is primarily dependent on the stress cycle amplitude, i.e. the maximum pressure minus the minimum pressure. Therefore a pipe subjected to a pressure cycle of zero to half working pressure is as much in danger of fatigue as one subjected to a pressure cycle of half to full working pressure. Thus pipe fatigue failures occur just as frequently at high points in the system as at low points where the total pressure is greater.

22

Water HammerPipelines may be subjected to short-term increase in pressure above the normal working pressure due to water hammer. Water hammer will occur in a pipeline when its equilibrium is disturbed by rapid changes in ow conditions. Examples of such conditions are; starting and stopping of pumps, rapid opening and closing of valves, pipe failures etc.

A rapid change in the velocity v of water in the pipeline gives rise to a pressure increase p according to the formula:

p=cv/gWhere: c = wave celerity (metres per second) g = acceleration due to gravity

The wave celerity for Hydro-Wall (uPVC) and Aqua-Wall (mPVC) have been calculated and are given below.

Class Hydro-wall m/s. Aqua-wall m/s.

6 263 249

9 325 270

12 378 312

16 439 363

20 495 407

25 559 458

Note:Since part of the formula for calculating wave celerity incorporates the ratio between diameter and wall thickness (SDR), which is roughly constant for all sizes within a pressure class, the wave celerities are also constant for all sizes within a pressure class.By way of comparison the wave celerity for steel pipes is about 3 times higher than for PVC (1000 to 1400 m/s).

1.

2.

It is important to note that the pressure increase due to water hammer in a particular class of pipe is a function of the change in velocity and it is therefore important (for this and other reasons) to keep pumping velocities in a pipeline within the conventional norm of 1 to 2 m/s.

In general steps should be taken during design and operation to minimize the frequency and intensity of water hammer. However the total pressure may be permitted to reach a value 50% higher than the nominal pressure if the frequency can be described as "occasional".

Cyclic LoadsA design for fatigue must involve:

An estimate of the magnitude of pressure uctuations likely to occur in the pipeline, i.e. the difference p between maximum and minimum pressures.An estimate of the frequency, usually expressed as cycles per day, at which such uctuations will occur.A statement of the required service life needed from the pipe.

The design can be done on the basis of the established relationship between pressure amplitude and the number of cycles to failure. This relationship is represented graphically below. The pressure amplitude is dened as the maximum pressure, minus the minimum pressure experienced by the system, including all transients, both positive and negative.

1.

2.

3.

23

ExampleA sewer rising main with a static rise of 15 metres and a total pumping head of 50 metres is designed to service a population of 400 growing to 1,000 in 50 years. Throughput is 300 litres/head/day average and well capacity is 20,000 litres.

Over the life of the scheme the average throughput is 210,000 litres/day. Assuming that half the well capacity is utilised, then the average switching rate will be 21 cycles/day. Assuming there is no signicant water hammer, the dynamic range is 35 metres. According to the chart a Class. 6 pipe is satisfactory.

Temperature Considerations

Effect on PressureThe pressure classes of PVC pipes carrying the SABS 966 mark have been allocated on the basis of design at 20C. Any pipes used in applications where operating temperatures exceed 25C need to be de-rated to ensure that the 50 year design life, or the safety factor, is not adversely affected. The following pressure reduction factors should be applied.

Temperature Working pressure factor

30C 0.9

35C 0.8

40C 0.7

45C 0.6

50C 0.5

55C 0.4

60C 0.3

At lower temperatures, between 20C and 0C, the pressure handling capability does increase but it is recommended that this be ignored. If water freezes inside a PVC pipe permanent strain (if not fracture) may occur, leading to a possible severe reduction in the working life of the pipe.

N.B. The maximum recommended working temperature is 60C

Effect on DimensionsDue to the relatively high coefcient of expansion and contraction (given in "Expansion and contraction" earlier) it is necessary to make allowance for this in any design and installation which is exposed to wide variations of temperature.

PVC pipes will expand or contract by 0.08mm per metre per C rise or fall in temperature. A 30C temperature rise will therefore cause a 14.4mm expansion of a 6 metre pipe.

Ultraviolet Light Considerations

The vast majority of PVC pressure pipes are intended for burial in trenches and they are therefore manufactured with relatively low levels of additives to protect them against the effects of ultraviolet light.

Pipes which will be exposed indenitely to UV light should be protected by painting with a coat of light coloured Alkyd Enamel or PVA.

Paint containing solvent thinners should be avoided.

It is recommended that pipes should be buried wherever possible.

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Trench Load Considerations

It has been well established by researchers over many years that, for exible pipes, it is the interaction between the soil and the pipe which has to be considered more extensively than is the case for rigid pipes where the material strength of the pipe is the critical issue. The points discussed here are given as a guide only to aid design by the engineer.

Soil and Trafc LoadsThe vertical load on a PVC pipe due to soil is a function of the trench width and depth, the unit weight and type of the soil and the pipe diameter and wall thickness. This loading must generally be corrected because of the fact that the soil is cohesive and the side ll reacts with the ll above the pipe. Furthermore exible pipes deect and shed load to the side ll. This vertical deection is limited by lateral soil resistance. The resultant load is therefore less than that which column theory suggests.

The Soil Loading graphs below show that, after initial rapid increases with increased depth, this rate of increase falls away to almost zero at depths of about 6 metres or more. Typical maximum values of soil loads (without live loads) are between 1000 and 17000 N/m (for sizes between 50 and 500mm), depending largely on soil type, modulus and pipe stiffness. As soil compaction is increased so the maximum soil load on the pipe reduces, assuming that backlling procedures have been followed.

Soil load at shallow depths increases dramatically when a 60kN live load is added. This effect is aggravated by poor compaction. However, from about 3 metres deep this effect becomes negligible.

As can be seen from the Deection vs. Soil Load graph there is a straight line relationship between deection and soil load for each size and class of pipe. Therefore if the soil load reaches a maximum then the deection also has a maximum. These graphs include the maximum soil loads from the soil load graphs and shows the maximum deection (for the conditions represented) of less than 1.8% - for a 500mm Class 6 pipe - even with a 60 kN live load. Large diameter pipes carry more load because of their greater surface area. Thicker pipes carry more soil load because it is more difcult to deect since less load shedding occurs.

The graphs below were based on calculations using values typical for reasonable backll material which has been poorly compacted (soil modulus of 3 MPa) excluding and including a 60 kN live load. Trench widths of 0.4m, 0.6m, 0.7m and 0.8m were used for the following groups of pipe sizes:50mm -160mm, 200mm - 315mm, 400mm and 500mm. Different soil cover over the pipes were used, varying from 0.9m to 10m. The method of calculation was provided by Professor David Stephenson of Witwatersrand University.

We have shown graphs on the following pages for class 6 and class16 only but have available graphs for class 9 and class 12 which show very similar trends. The graphs represent Aqua-Wall mPVC pipes.

25

Soil Loading on PVC Class 16 (No Live Load, Soil Modulus: 3 MPa)

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14000

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0.9 1.2 1.5 2 4 6 8 10Depth of Cover - Metres

N/m

50mm Class 16 75mm Class 16 110mm Class 16 200mm Class 16 315mm Class 16 500mm Class 16

Soil Loading on PVC Class 6 (No live Load, Soil Modulus: 3 MPa)

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Soil Loading on PVC Class 6 (With 60 kN Load, Soil Modulus: 3 MPa)

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Soil Loading on PVC Class 16 (With 60 kN Load, Soil Modulus: 3 MPa)

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Deflection vs Soil Load PVC Class 6 (No Live Load, Soil Modulus: 3 MPa)

0.20

0.40

0.60

0.80

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1.80

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Soil Load - N/m

Def

lect

ion

- %

50mm Class6 75mm Class 6 110mm Class 6 200mm Class 6 315mm Class 6 500mm Class 6

Deflection vs Soil Load PVC Class 16 (No Live Load, Soil Modulus: 3 MPa)

0

0.2

0.4

0.6

0.8

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1.2

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0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000Soil Load - N/m

Def

lect

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Deflection vs Soil Load PVC Class 6 (60 kN Live Load, Soil Modulus: 3 MPa)

0.60

0.80

1.00

1.20

1.40

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1.80

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Soil Load - N/m

Def

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50mm Class6 75mm Class 6 110mm Class 6 200mm Class 6 315mm Class 6 500mm Class 6

Defection vs Soil Load PVC Class 16 (60 kN Live Load, Soil Modulus: 3 MPa)

0

0.2

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0 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000Soil Load - N/m

Def

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- %


Note:Calculations with a higher soil modulus (not shown), implying better compaction, show much lower deection percentages and reduce the gap between the static soil load and the live load.

29

Bending

An important feature of PVC pipes is that they may be deliberately bent, within limits, thus eliminating the need, in some cases, for separate bends. As a rule of thumb the radius of such a bend must not be less than 300 times the pipe diameter. In addition each rubber ring joint can accommodate a further of bend. This feature signicantly reduces costs and speeds up installation times when compared to some traditional pipe materials.

Thrust Support

An unbalanced thrust is developed by a pipeline at:

Changes of direction greater than 10 e.g. Tees and Bends,Changes in pipeline size,Valves and Endcaps.

In most cases the soil bearing capacity is insufcient to withstand such forces and it becomes necessary to use thrust blocks if the pipes have rubber ring joints.

Material Safe Bearing Load (kPa)

Peat, running sand, muck, ash etc 0

Soft clay 50

Medium clay, sandy loam 100

Sand, gavel and hard clay 150

Sand and gravel, cemented with clay 200

Sand and gravel, cemented with rock 240

Table of soil safe bearing loads.

Pipe O.D. (mm)

90 Bend (kN)

Closed end (kN)

Tee or 45 Bend

(kN)

22 1/2 Bend (kN)

11 1/4 Bend (kN)

50 0.27 0.19 0.15 0.08 0.04

63 0.43 0.31 0.23 0.12 0.06

75 0.61 0.43 0.33 0.17 0.08

90 0.88 0.62 0.48 0.24 0.12

110 1.32 0.93 0.71 0.36 0.18

125 1.70 1.20 0.92 0.47 0.24

140 2.13 1.51 1.16 0.59 0.30

160 2.79 1.97 1.51 0.77 0.39

200 4.36 3.08 2.36 1.20 0.60

250 6.81 4.81 3.68 1.88 0.94

315 10.81 7.64 5.85 2.98 1.50

355 13.72 9.70 7.43 3.79 1.90

400 17.42 12.32 9.43 4.81 2.42

Table of approximate thrust on ttings for each 10m (100kPa) of pressure in the line.

The size of the bearing area of the thrust block is determined by the bearing capacity of the particular type of soil into which the pipe is installed and by the diameter and operating pressure of the pipeline. When cover is less than 600mm it may be necessary to take further precautions to prevent vertical movement due to thrust. If the pipeline is to be pressure tested at a pressure higher than working pressure then thrust block design must allow for this pressure.

The tables below along with the supplied example, provide a guide to determine thrust block sizes.

From the parameter table above the thrust equals: 4.36 x 120/10 = 52.36 kNThe safe bearing load of sand/gravel = 150kPaThe bearing area of the thrust block = 52.36/150 = 0.35mThe thrust block bearing surface dimensions should be 0.6m x 0.6m = 0.36m

Class of pipe 12

Maximum working pressure 96m

Test pressure 120m

Bearing soil Sand / gravel

Example:Calculate the bearing area of a thrust block for a 200mm x 90 bend.

Flow Considerations

The tables that follow provide a guide to friction losses that can be expected when using clean Hydro-wall (uPVC) and Aqua-Wall (mPVC) pressure pipes with clean water at 20C. Possible ttings in line was not taken into account.

How to read these charts.Choose the particular chart for the type (uPVC or mPVC) and class of pipe being used.In one of the rst three columns nd the nearest value of the quantity of water to be pumped according to the preferred unit of measurement.

GPH = Gallons per hourm/hr = Cubic meters per hourl/s = Litres per second

Align the selected reading horizontally to the light green shaded values. The value in the shaded block is the friction loss for the size of pipe given at the top of that particular column. (Expressed in meters per 100 metres).The reverse sequence can be used to determine the amount of water that can be pumped through a given pipe size (and how much friction loss is created)

30

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Outside Diameter (mm) 50 63 75 90 110 125 140 160 200 250 315 355 400 450 500Wall Thickness (mm) 1.5 1.5 1.5 1.8 2.2 2.5 2.8 3.2 3.9 4.9 6.2 7.0 7.9 8.9 9.8Inside Diameter (mm) 47.0 60.0 72.0 86.4 105.6 120.0 134.4 153.6 192.2 240.2 302.6 341.0 384.2 432.2 480.4

G.P.H. m3/hr. l/s.396 1.8 0.5 0.29 0.09 0.04792 3.6 1 0.98 0.30 0.13

1584 7.2 2 3.33 1.04 0.43 0.182376 10.8 3 6.82 2.13 0.89 0.37 0.143168 14.4 4 11.35 3.54 1.48 0.62 0.243960 18 5 16.84 5.25 2.20 0.92 0.35 0.19 0.114752 21.6 6 7.26 3.04 1.27 0.49 0.27 0.15 0.085544 25.2 7 9.53 3.99 1.67 0.64 0.35 0.20 0.116336 28.8 8 12.07 5.06 2.12 0.81 0.44 0.26 0.147128 32.4 9 6.23 2.61 1.00 0.55 0.32 0.17 0.067920 36 10 7.51 3.15 1.21 0.66 0.38 0.20 0.079504 43.2 12 10.37 4.35 1.67 0.91 0.53 0.28 0.10

11088 50.4 14 5.71 2.19 1.19 0.69 0.37 0.13 0.0412672 57.6 16 7.23 2.78 1.51 0.88 0.46 0.16 0.0614256 64.8 18 3.42 1.86 1.08 0.57 0.20 0.0715840 72 20 4.12 2.24 1.30 0.69 0.24 0.0817424 79.2 22 4.88 2.65 1.54 0.82 0.28 0.10 0.0319008 86.4 24 5.69 3.09 1.80 0.95 0.33 0.11 0.0420592 93.6 26 6.56 3.56 2.08 1.10 0.38 0.13 0.0422176 100.8 28 4.06 2.37 1.25 0.43 0.15 0.05 0.0323760 108 30 4.59 2.67 1.41 0.49 0.17 0.06 0.0325344 115.2 32 5.15 3.00 1.59 0.54 0.19 0.06 0.0426928 122.4 34 3.34 1.77 0.61 0.21 0.07 0.0428512 129.6 36 3.69 1.95 0.67 0.23 0.08 0.04 0.0230096 136.8 38 4.06 2.15 0.74 0.25 0.08 0.05 0.0331680 144 40 4.45 2.35 0.81 0.28 0.09 0.05 0.0335640 162 45 2.90 0.99 0.34 0.11 0.06 0.04 0.0239600 180 50 3.49 1.20 0.41 0.14 0.08 0.04 0.0343560 198 55 4.14 1.42 0.49 0.16 0.09 0.05 0.03 0.0247520 216 60 1.66 0.57 0.19 0.11 0.06 0.03 0.0251480 234 65 1.91 0.66 0.22 0.12 0.07 0.04 0.0255440 252 70 2.17 0.75 0.25 0.14 0.08 0.05 0.0359400 270 75 2.46 0.85 0.28 0.16 0.09 0.05 0.0363360 288 80 2.75 0.95 0.32 0.18 0.10 0.06 0.0371280 324 90 1.17 0.39 0.22 0.12 0.07 0.0479200 360 100 1.41 0.47 0.27 0.15 0.09 0.0587120 396 110 1.67 0.56 0.31 0.18 0.10 0.0695040 432 120 1.95 0.65 0.37 0.21 0.12 0.07

102960 468 130 2.25 0.75 0.42 0.24 0.14 0.08110880 504 140 0.85 0.48 0.27 0.16 0.09118800 540 150 0.96 0.54 0.31 0.18 0.11126720 576 160 1.08 0.61 0.35 0.20 0.12134640 612 170 1.20 0.68 0.38 0.22 0.13142560 648 180 1.33 0.75 0.43 0.24 0.15150480 684 190 1.46 0.83 0.47 0.27 0.16158400 720 200 1.60 0.91 0.51 0.29 0.18166320 756 210 1.74 0.99 0.56 0.32 0.19174240 792 220 1.07 0.61 0.35 0.21182160 828 230 1.16 0.66 0.37 0.23190080 864 240 1.25 0.71 0.40 0.24198000 900 250 1.34 0.76 0.43 0.26205920 936 260 1.44 0.82 0.46 0.28213840 972 270 1.54 0.87 0.50 0.30221760 1008 280 0.93 0.53 0.32229680 1044 290 0.99 0.56 0.34237600 1080 300 1.05 0.60 0.36245520 1116 310 1.11 0.63 0.38253440 1152 320 1.18 0.67 0.41261360 1188 330 1.24 0.71 0.43269280 1224 340 1.31 0.75 0.45277200 1260 350 0.79 0.48285120 1296 360 0.83 0.50293040 1332 370 0.87 0.52300960 1368 380 0.91 0.55308880 1404 390 0.95 0.58316800 1440 400 1.00 0.60332640 1512 420 1.09 0.66348480 1584 440 0.71364320 1656 460 0.77380160 1728 480 0.83396000 1800 500 0.89

Colour Code Velocity - m/s CommentsUnshaded data above Yellow >0.3 and 2.5 and

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Outside Diameter (mm) 25 32 40 50 63 75 90 110 125 140 160 200 250 315 355 400 450 500Wall Thickness (mm) 1.5 1.8 2.3 2.8 3.6 4.3 5.1 5.1 5.8 6.5 7.4 9.2 11.5 14.5 16.3 18.4 20.7 22.9Inside Diameter (mm) 22.0 28.4 35.4 44.4 55.8 66.4 79.8 99.8 113.4 127.0 145.2 181.6 227.0 286.0 322.4 363.2 408.6 454.2

G.P.H. m3/hr. l/s.158 0.7 0.2 2.11 0.62 0.22 0.07238 1.1 0.3 4.33 1.28 0.45 0.15 0.05317 1.4 0.4 7.20 2.13 0.74 0.25 0.08 0.04396 1.8 0.5 10.69 3.16 1.11 0.38 0.13 0.06 0.02792 3.6 1 36.46 10.78 3.77 1.28 0.43 0.19 0.08 0.03

1584 7.2 2 12.86 4.36 1.47 0.64 0.27 0.09 0.05 0.032376 10.8 3 8.95 3.01 1.31 0.55 0.19 0.10 0.06 0.033168 14.4 4 14.89 5.00 2.18 0.91 0.31 0.17 0.10 0.053960 18 5 7.43 3.24 1.35 0.46 0.25 0.15 0.08 0.034752 21.6 6 10.26 4.47 1.86 0.64 0.35 0.20 0.11 0.045544 25.2 7 13.47 5.88 2.45 0.84 0.46 0.27 0.14 0.056336 28.8 8 7.45 3.10 1.07 0.58 0.34 0.18 0.067128 32.4 9 9.17 3.82 1.31 0.71 0.42 0.22 0.08 0.037920 36 10 11.05 4.60 1.58 0.86 0.50 0.26 0.09 0.039504 43.2 12 6.35 2.18 1.19 0.69 0.37 0.13 0.04

11088 50.4 14 8.34 2.87 1.56 0.91 0.48 0.17 0.0612672 57.6 16 3.64 1.98 1.15 0.61 0.21 0.0714256 64.8 18 4.48 2.43 1.42 0.75 0.26 0.09 0.0315840 72 20 5.40 2.93 1.71 0.90 0.31 0.11 0.0417424 79.2 22 6.39 3.47 2.02 1.07 0.37 0.13 0.0419008 86.4 24 4.05 2.36 1.25 0.43 0.15 0.05 0.0320592 93.6 26 4.67 2.72 1.44 0.49 0.17 0.06 0.0322176 100.8 28 5.32 3.10 1.64 0.56 0.19 0.06 0.0423760 108 30 6.01 3.50 1.85 0.64 0.22 0.07 0.0425344 115.2 32 3.93 2.07 0.71 0.25 0.08 0.05 0.0326928 122.4 34 4.37 2.31 0.79 0.27 0.09 0.05 0.0328512 129.6 36 4.84 2.55 0.88 0.30 0.10 0.06 0.0330096 136.8 38 2.81 0.97 0.33 0.11 0.06 0.0431680 144 40 3.08 1.06 0.37 0.12 0.07 0.0435640 162 45 3.79 1.30 0.45 0.15 0.08 0.05 0.0339600 180 50 1.57 0.54 0.18 0.10 0.06 0.0343560 198 55 1.86 0.64 0.21 0.12 0.07 0.0447520 216 60 2.17 0.75 0.25 0.14 0.08 0.05 0.0351480 234 65 2.50 0.86 0.29 0.16 0.09 0.05 0.0355440 252 70 2.85 0.98 0.33 0.18 0.10 0.06 0.0459400 270 75 3.22 1.11 0.37 0.21 0.12 0.07 0.0463360 288 80 1.25 0.41 0.23 0.13 0.08 0.0571280 324 90 1.53 0.51 0.29 0.16 0.09 0.0679200 360 100 1.85 0.61 0.35 0.20 0.11 0.0787120 396 110 2.19 0.73 0.41 0.23 0.13 0.0895040 432 120 2.55 0.85 0.48 0.27 0.15 0.09

102960 468 130 0.98 0.55 0.31 0.18 0.11110880 504 140 1.11 0.63 0.36 0.20 0.12118800 540 150 1.26 0.71 0.40 0.23 0.14126720 576 160 1.41 0.80 0.45 0.26 0.16134640 612 170 1.57 0.89 0.50 0.29 0.17142560 648 180 1.74 0.98 0.56 0.32 0.19150480 684 190 1.91 1.08 0.61 0.35 0.21158400 720 200 1.18 0.67 0.38 0.23166320 756 210 1.29 0.73 0.42 0.25174240 792 220 1.40 0.79 0.45 0.27182160 828 230 1.51 0.86 0.49 0.30190080 864 240 1.63 0.93 0.53 0.32198000 900 250 0.99 0.57 0.34205920 936 260 1.07 0.61 0.37213840 972 270 1.14 0.65 0.39221760 1008 280 1.22 0.69 0.42229680 1044 290 1.29 0.74 0.45237600 1080 300 1.37 0.78 0.47245520 1116 310 1.46 0.83 0.50253440 1152 320 0.88 0.53261360 1188 330 0.93 0.56269280 1224 340 0.98 0.59277200 1260 350 1.03 0.62285120 1296 360 1.08 0.65293040 1332 370 1.13 0.69300960 1368 380 1.19 0.72308880 1404 390 1.25 0.75316800 1440 400 1.30 0.79332640 1512 420 0.86348480 1584 440 0.93364320 1656 460 1.01380160 1728 480 1.09396000 1800 500

uPVC Class12

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mPVC Class12Outside Diameter (mm) 50 63 75 90 110 125 140 160 200 250 315 355 400 450 500Wall Thickness (mm) 1.7 2.1 2.5 3.0 3.6 4.1 4.6 5.2 6.5 8.1 10.2 11.5 12.9 14.6 16.2Inside Diameter (mm) 46.6 58.8 70.0 84.0 102.8 116.8 130.8 149.6 187.0 233.8 294.6 332.0 374.2 420.8 467.6

G.P.H. m3/hr. l/s.396 1.8 0.5 0.30 0.10 0.04 0.02792 3.6 1 1.02 0.34 0.15 0.06 0.02

1584 7.2 2 3.47 1.14 0.50 0.21 0.08 0.04 0.032376 10.8 3 7.10 2.34 1.02 0.43 0.16 0.09 0.05 0.033168 14.4 4 11.82 3.90 1.70 0.71 0.27 0.15 0.09 0.053960 18 5 17.54 5.79 2.52 1.06 0.40 0.22 0.13 0.07 0.024752 21.6 6 7.99 3.48 1.46 0.56 0.30 0.18 0.09 0.035544 25.2 7 10.50 4.57 1.91 0.73 0.40 0.23 0.12 0.046336 28.8 8 13.29 5.79 2.43 0.93 0.50 0.29 0.15 0.05 0.027128 32.4 9 7.13 2.99 1.14 0.62 0.36 0.19 0.07 0.027920 36 10 8.59 3.60 1.37 0.75 0.44 0.23 0.08 0.039504 43.2 12 4.97 1.90 1.03 0.60 0.32 0.11 0.04

11088 50.4 14 6.53 2.49 1.36 0.79 0.42 0.14 0.0512672 57.6 16 8.27 3.16 1.72 1.00 0.53 0.18 0.06 0.0214256 64.8 18 3.89 2.11 1.23 0.65 0.22 0.08 0.0315840 72 20 4.69 2.55 1.49 0.78 0.27 0.09 0.03 0.0217424 79.2 22 5.55 3.02 1.76 0.93 0.32 0.11 0.04 0.0219008 86.4 24 6.47 3.52 2.05 1.08 0.37 0.13 0.04 0.0220592 93.6 26 4.05 2.36 1.25 0.43 0.15 0.05 0.0322176 100.8 28 4.62 2.69 1.42 0.49 0.17 0.06 0.03 0.0223760 108 30 5.22 3.04 1.60 0.55 0.19 0.06 0.04 0.0225344 115.2 32 5.86 3.41 1.80 0.62 0.21 0.07 0.04 0.0226928 122.4 34 3.80 2.00 0.69 0.24 0.08 0.04 0.0328512 129.6 36 4.20 2.21 0.76 0.26 0.09 0.05 0.03 0.0230096 136.8 38 4.63 2.44 0.84 0.29 0.10 0.05 0.03 0.0231680 144 40 5.06 2.67 0.92 0.32 0.11 0.06 0.03 0.0235640 162 45 3.29 1.13 0.39 0.13 0.07 0.04 0.0239600 180 50 3.96 1.37 0.47 0.16 0.09 0.05 0.0343560 198 55 1.62 0.56 0.19 0.10 0.06 0.0347520 216 60 1.89 0.65 0.22 0.12 0.07 0.04 0.0251480 234 65 2.17 0.75 0.25 0.14 0.08 0.05 0.0355440 252 70 2.48 0.85 0.28 0.16 0.09 0.05 0.0359400 270 75 2.80 0.97 0.32 0.18 0.10 0.06 0.0463360 288 80 3.14 1.08 0.36 0.20 0.11 0.07 0.0471280 324 90 3.87 1.33 0.44 0.25 0.14 0.08 0.0579200 360 100 1.61 0.53 0.30 0.17 0.10 0.0687120 396 110 1.90 0.63 0.36 0.20 0.12 0.0795040 432 120 2.22 0.74 0.42 0.24 0.13 0.08

102960 468 130 0.85 0.48 0.27 0.15 0.09110880 504 140 0.97 0.55 0.31 0.18 0.11118800 540 150 1.09 0.62 0.35 0.20 0.12126720 576 160 1.23 0.69 0.39 0.22 0.14134640 612 170 1.36 0.77 0.44 0.25 0.15142560 648 180 1.51 0.85 0.48 0.28 0.17150480 684 190 1.66 0.94 0.53 0.30 0.18158400 720 200 1.82 1.03 0.58 0.33 0.20166320 756 210 1.12 0.63 0.36 0.22174240 792 220 1.22 0.69 0.39 0.24182160 828 230 1.32 0.74 0.43 0.26190080 864 240 1.42 0.80 0.46 0.28198000 900 250 1.53 0.86 0.49 0.30205920 936 260 1.64 0.92 0.53 0.32213840 972 270 0.99 0.56 0.34221760 1008 280 1.05 0.60 0.36229680 1044 290 1.12 0.64 0.39237600 1080 300 1.19 0.68 0.41245520 1116 310 1.26 0.72 0.44253440 1152 320 1.34 0.76 0.46261360 1188 330 1.41 0.81 0.49269280 1224 340 0.85 0.51277200 1260 350 0.89 0.54285120 1296 360 0.94 0.57293040 1332 370 0.99 0.60300960 1368 380 1.03 0.63308880 1404 390 1.08 0.65316800 1440 400 1.13 0.68332640 1512 420 0.75348480 1584 440 0.81364320 1656 460 0.88380160 1728 480 0.95396000 1800 500 1.02


40

mPVC Class 16Outside Diameter (mm) 50 63 75 90 110 125 140 160 200 250 315 355 400 450 500Wall Thickness (mm) 2.2 2.7 3.2 3.9 4.7 5.4 6.0 6.9 8.6 10.7 13.4 15.2 17.1 19.2 21.3Inside Diameter (mm) 45.6 57.6 68.6 82.2 100.6 114.2 128.0 146.2 182.8 228.6 288.2 324.6 365.8 411.6 457.4

G.P.H. m3/hr. l/s.396 1.8 0.5 0.33 0.11 0.05792 3.6 1 1.13 0.37 0.16 0.07 0.03

1584 7.2 2 3.84 1.26 0.55 0.23 0.09 0.05 0.032376 10.8 3 7.88 2.58 1.12 0.47 0.18 0.10 0.06 0.033168 14.4 4 13.11 4.30 1.87 0.79 0.30 0.16 0.10 0.053960 18 5 6.38 2.77 1.17 0.45 0.24 0.14 0.08 0.034752 21.6 6 8.82 3.83 1.62 0.62 0.34 0.20 0.10 0.045544 25.2 7 11.58 5.03 2.12 0.81 0.44 0.26 0.14 0.056336 28.8 8 6.37 2.69 1.03 0.56 0.33 0.17 0.067128 32.4 9 7.85 3.31 1.26 0.69 0.40 0.21 0.07 0.037920 36 10 9.46 3.99 1.52 0.83 0.48 0.26 0.09 0.039504 43.2 12 5.51 2.10 1.15 0.67 0.35 0.12 0.04

11088 50.4 14 7.24 2.76 1.51 0.88 0.46 0.16 0.0612672 57.6 16 9.17 3.50 1.91 1.11 0.59 0.20 0.0714256 64.8 18 4.31 2.35 1.37 0.72 0.25 0.09 0.0315840 72 20 5.19 2.84 1.65 0.87 0.30 0.10 0.0317424 79.2 22 6.15 3.36 1.95 1.03 0.36 0.12 0.0419008 86.4 24 3.92 2.27 1.21 0.42 0.14 0.05 0.0320592 93.6 26 4.51 2.62 1.39 0.48 0.16 0.05 0.0322176 100.8 28 5.15 2.99 1.58 0.55 0.19 0.06 0.0423760 108 30 5.82 3.37 1.79 0.62 0.21 0.07 0.0425344 115.2 32 3.78 2.01 0.69 0.24 0.08 0.04 0.0326928 122.4 34 4.21 2.23 0.77 0.26 0.09 0.05 0.0328512 129.6 36 4.66 2.47 0.85 0.29 0.10 0.06 0.0330096 136.8 38 5.13 2.72 0.94 0.32 0.11 0.06 0.0331680 144 40 2.98 1.03 0.35 0.12 0.07 0.0435640 162 45 3.67 1.26 0.44 0.14 0.08 0.05 0.0339600 180 50 4.42 1.52 0.52 0.17 0.10 0.06 0.0343560 198 55 1.80 0.62 0.21 0.12 0.07 0.0447520 216 60 2.10 0.72 0.24 0.14 0.08 0.04 0.0351480 234 65 2.42 0.83 0.28 0.16 0.09 0.05 0.0355440 252 70 2.76 0.95 0.31 0.18 0.10 0.06 0.0359400 270 75 3.12 1.07 0.36 0.20 0.11 0.07 0.0463360 288 80 1.20 0.40 0.23 0.13 0.07 0.0471280 324 90 1.48 0.49 0.28 0.16 0.09 0.0579200 360 100 1.79 0.59 0.34 0.19 0.11 0.0787120 396 110 2.12 0.70 0.40 0.22 0.13 0.0895040 432 120 2.47 0.82 0.46 0.26 0.15 0.09

102960 468 130 0.94 0.53 0.30 0.17 0.10110880 504 140 1.07 0.61 0.34 0.20 0.12118800 540 150 1.21 0.69 0.39 0.22 0.13126720 576 160 1.36 0.77 0.44 0.25 0.15134640 612 170 1.51 0.86 0.49 0.28 0.17142560 648 180 1.68 0.95 0.54 0.31 0.19150480 684 190 1.84 1.05 0.59 0.34 0.20158400 720 200 1.15 0.65 0.37 0.22166320 756 210 1.25 0.71 0.40 0.24174240 792 220 1.36 0.77 0.44 0.26182160 828 230 1.47 0.83 0.47 0.29190080 864 240 1.58 0.89 0.51 0.31198000 900 250 0.96 0.55 0.33205920 936 260 1.03 0.59 0.35213840 972 270 1.10 0.63 0.38221760 1008 280 1.17 0.67 0.40229680 1044 290 1.25 0.71 0.43237600 1080 300 1.33 0.76 0.46245520 1116 310 1.41 0.80 0.48253440 1152 320 0.85 0.51261360 1188 330 0.90 0.54269280 1224 340 0.94 0.57277200 1260 350 0.99 0.60285120 1296 360 1.04 0.63293040 1332 370 1.10 0.66300960 1368 380 1.15 0.69308880 1404 390 1.20 0.73316800 1440 400 0.76332640 1512 420 0.83348480 1584 440 0.90364320 1656 460 0.97380160 1728 480 1.05396000 1800 500


41

mPVC Class 20Outside Diameter (mm) 50 63 75 90 110 125 140 160 200 250 315 355 400Wall Thickness (mm) 2.7 3.4 4.0 4.8 5.8 6.6 7.4 8.5 10.6 13.2 16.6 18.7 21.1Inside Diameter (mm) 44.6 56.2 67.0 80.4 98.4 111.8 125.2 143.0 178.8 223.6 281.8 317.6 357.8

G.P.H. m3/hr. l/s.396 1.8 0.5 0.37 0.12 0.05792 3.6 1 1.25 0.42 0.18 0.08 0.03

1584 7.2 2 4.27 1.42 0.61 0.26 0.10 0.05 0.032376 10.8 3 8.76 2.91 1.26 0.53 0.20 0.11 0.06 0.033168 14.4 4 14.57 4.84 2.09 0.88 0.33 0.18 0.11 0.063960 18 5 7.18 3.10 1.30 0.50 0.27 0.16 0.08 0.034752 21.6 6 9.91 4.29 1.80 0.69 0.37 0.22 0.12 0.045544 25.2 7 13.02 5.63 2.36 0.90 0.49 0.29 0.15 0.056336 28.8 8 7.13 2.99 1.14 0.62 0.36 0.19 0.077128 32.4 9 8.79 3.68 1.40 0.76 0.45 0.24 0.08 0.037920 36 10 10.59 4.44 1.69 0.92 0.54 0.28 0.10 0.039504 43.2 12 6.13 2.34 1.27 0.74 0.39 0.14 0.05

11088 50.4 14 8.05 3.07 1.67 0.97 0.52 0.18 0.0612672 57.6 16 3.89 2.12 1.23 0.65 0.23 0.08 0.0314256 64.8 18 4.79 2.61 1.52 0.81 0.28 0.10 0.0315840 72 20 5.77 3.14 1.83 0.97 0.33 0.12 0.0417424 79.2 22 6.83 3.72 2.17 1.15 0.40 0.14 0.05 0.0319008 86.4 24 4.34 2.53 1.34 0.46 0.16 0.05 0.0320592 93.6 26 5.00 2.91 1.54 0.53 0.18 0.06 0.0322176 100.8 28 5.70 3.32 1.76 0.61 0.21 0.07 0.0423760 108 30 3.75 1.99 0.69 0.24 0.08 0.04 0.0325344 115.2 32 4.20 2.23 0.77 0.26 0.09 0.05 0.0326928 122.4 34 4.68 2.48 0.86 0.29 0.10 0.06 0.0328512 129.6 36 5.18 2.75 0.95 0.33 0.11 0.06 0.0330096 136.8 38 3.02 1.04 0.36 0.12 0.07 0.0431680 144 40 3.31 1.14 0.39 0.13 0.07 0.0435640 162 45 4.08 1.40 0.48 0.16 0.09 0.0539600 180 50 4.91 1.69 0.58 0.19 0.11 0.0643560 198 55 2.00 0.69 0.23 0.13 0.0747520 216 60 2.34 0.80 0.27 0.15 0.0951480 234 65 2.69 0.93 0.31 0.17 0.1055440 252 70 3.07 1.06 0.35 0.20 0.1159400 270 75 3.47 1.19 0.40 0.22 0.1363360 288 80 3.89 1.34 0.44 0.25 0.1471280 324 90 1.65 0.55 0.31 0.1879200 360 100 1.99 0.66 0.37 0.2187120 396 110 2.35 0.78 0.44 0.2595040 432 120 2.74 0.91 0.51 0.29

102960 468 130 1.05 0.59 0.34110880 504 140 1.20 0.68 0.38118800 540 150 1.35 0.76 0.43126720 576 160 1.51 0.86 0.48134640 612 170 1.69 0.95 0.54142560 648 180 1.87 1.05 0.60150480 684 190 2.05 1.16 0.66158400 720 200 1.27 0.72166320 756 210 1.39 0.78174240 792 220 1.50 0.85182160 828 230 1.63 0.92190080 864 240 0.99198000 900 250 1.07205920 936 260 1.14213840 972 270 1.22221760 1008 280 1.31229680 1044 290 1.39237600 1080 300 1.47245520 1116 310


42


43

Nominal bore of SABS 966 Pipes (mm)Class 4 6 9 12 16 20 25

Working Pressure kPa 400 600 900 1200 1600 2000 2500

Test Pressure 1.25 * Pressure Class (SABS

1200) kPa500 750 1125 1500 2000 2500 3125

Outside Diameter (mm) uPVC mPVC uPVC mPVC uPVC mPVC uPVC mPVC uPVC mPVC uPVC mPVC uPVC mPVC

16 13 - 13 - 13 - 13 - 13 - 13 - - -

20 17 - 17 - 17 - 17 - 17 - 16 - - -

25 22 - 22 - 22 - 22 - 21 - 20 - - -

32 30 - 29 - 29 - 28 - 27 - 25 - - -

40 38 - 37 - 36 - 35 - 34 - 32 - - -

50 48 - 46 47 45 47 44 46 42 45 40 44 - 43

63 60 - 59 60 57 60 55 58 53 57 51 56 - 54

75 71 - 70 72 68 71 66 70 63 68 60 66 - 65

90 85 - 84 86 82 85 79 84 76 82 72 79 - 78

110 - - 104 105 102 104 99 102 96 100 92 98 89 95

125 - - 119 120 116 118 113 116 109 114 104 111 101 108

140 - - 133 134 129 133 126 130 122 127 118 124 113 121

160 - - 152 153 148 151 144 149 139 145 134 142 129 138

200 - - 190 192 185 190 180 186 174 182 168 178 161 173

250 - - 237 240 231 237 225 233 218 227 210 222 201 216

315 - - 299 302 291 299 264 293 274 287 - 280 - -

355 - - 337 340 328 337 320 331 309 323 - 316 - -

400 - - 380 384 370 379 360 373 348 364 - 356 - -

450 - - 427 431 416 427 405 419 - 410 - 400 - -

500 - - 475 479 463 474 451 466 - 455 - 444 - -

Selection of Pipe Size and Class

44

Quality Assurance

Marley Pipe Systems (and previously Marley SA) has been a SABS mark holder for over 40 years.

Products are manufactured to the relevant SABS specications at the Port Shepstone and Nigel plants. Both manufacturing facilities conform to the ISO

9001 of 2000 Quality Management system.

Fully audited Quality Control laboratories are operational at both Port Shepstone and Nigel, where scheduled and random testing of products is

performed.

Legal Disclaimer and CopywriteWhilst every care has been taken in the preparation of this brochure, neither Marley Pipe Systems nor any of their agencies can be held liable for any errors printed in this publication. It should also be noted that this brochure is intended for reference only. Due consultation is required when designing for particular applications, and no liability will be entertained in this regard. Copywrite Marley Pipe Systems (Pty.) Ltd. 2006

Gauteng 0861 MARLEYBloemfontein +27 (0)51 434-2331/5

Cape Town +27 (0)21 980-8460Durban +27 (0)31 791-5800

East London +27 (0)43 726-6505Port Elizabeth +27 (0)41 484-7744

George +27 (0)44 871 4889Nelspruit +27 (0)13 753-2571

Polokwane +27 (0)15 292-4141Klerksdorp +27 (0)18 462-2655

Zimbabwe +263 4 663256Marley (Namibia) (Pty) Ltd. (00264) 61-237201

Contract Supplies (Botswana) (00267) 392-2922

Copyright on the Flow Charts in this publication is reserved. No copy or representation

of these tables may be made without express written permission of either Marley Pipe

Systems (Pty) Ltd or Mr Bevan Richardson. (Copyright 2004)

Bevan Richardson has spent most of his working life in the pipe business; initially steel

pipes and more recently as Product Manager for PVC pressure pipes. He has a National

Technicians Diploma in Mechanical Engineering and his work experience covers a wide

spectrum of associated products and disciplines in the Agricultural, Civils and Mining

industries in South Africa and neighbouring countries. He has been involved in a problem

solving capacity at many pipeline installations in these areas.

Branches

www.marleypipesystems.co.za

Tel: 0861-MARLEY(0861-627539)

Documents

Marley Pvc Civils Technical Manual