Technical Manual

Technical Manual

Contents

1 Introduction 1
8.1 Transportation 16
8.2 Unloading 16
2 PVC Pressure Pipe Systems 1
8.3 Storage 16
2.1 Jointing Methods 2
2.1.1 Rubber Ring Joints 2
9 Design Considerations 17
2.1.2 Solvent Cement Joints 2
9.1 Design Life 17
2.2 Application 3
9.2 Design Stress And Safety Factors 18
2.3 Dimensions & Standard Lengths 3
(Design Coefficient)
2.4 Pressure Pipe Systems Fitttings Range 4
9.3 Pressure Variation Considerations 18
2.4.1 Injection Moulded Fittings 4
9.3.1 Static Pressure 18
2.4.2 Fabricated Fittings 5
9.3.2 Dynamic Pressure 18
2.4.3 Cast Iron Fittings 5
9.3.3 Water Hammer 18
2.5 MINE PIPE 5
9.4 Temperature Considerations 19
2.5.1 Pipe range and dimensions 6
9.4.1 Effect On Pressure 19
2.5.2 Typical applications 6
9.4.2 PE Derating factors 19
2.5.3 Pipe attributes 7
9.4.3 Expansion & Contraction 20
2.5.4 Mine pipe coupling system 7
9.5 Head Loss In Fittings 20
2.5.5 Installation tips 7
10 Installation (ZWS 254:LB:2001 & SANS
3 Sewer Pipe Systems 7
2001-DP2:2010) 21
3.1 Application 7
10.1 Excavation 21
3.1.1 Dimensions & Standard Lengths 8
10.2 Embedment 22
10.3 Backfilling 22
4 Polyethelene (PE) Pipes 8
10.4 Anchorage 23
4.1 PE Pipe Systems 8
4.2 Application 9
11 Pipe Laying 24
4.2.1 Water Supply 9
11.1 Rubber Ring Joint (RRJ) 24
4.2.2 Mining (Surface & Underground) 10
11.2 Solvent Cement Joints 25
4.2.3 Agriculture/Irrigation 10
11.2.1 Solvent Cement Accessories 25
4.2.4 Fishing 10
11.2.2 Solvent Cement Use Guide 25
4.2.5 Telecommunication Industry 10
4.3 Dimensions & Standard Lengths 10
12 Pipeline Testing Of Proflo
4.4 Jointing Methods For PE Pipes 11
(uPVC, mPVC & PE) Pipe Systems 26
4.4.1 Butt Fusion Joint 11
12.1 Pipeline preparations For Field
4.4.2 Compression Fittings 12
Pressure Testing 26
4.4.3 Poly Insert Fittings 12
12.1.1 Field Pressure Testing 26
5 Borehole Casings 13
13 Sewer Pipeline Testing 27
5.1 Dimensions & Standard Lengths 14
13.1 Air Test (ZWS 254:LD:2001) 27
6 Electricals 14
14 Friction Loss Chart For PVC & PE 28
6.1 Application 14
6.2 Fittings Range 14
15 Chemical Resistance Guide 32
15.1 Degree Of Chemical Resistance 32
7 Rainwater Systems 15
7.1 Application 15
16 Normative References 43
7.2 Product Range 15
17 Glossary 44
8 Transportation, Unloading & Storage 15

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 Technical Manual

1. Introduction

Proplastics is a leading supplier of world class plastic pipe systems for water and sewer reticulation to Southern
Africa, providing innovation, quality management systems and a continuous improvement to the Southern African
market.

Established in 1965, Proplastics has over 50 years experience in the industry, growing and evolving on the back of
ISO 9001:2008 Quality Management System with enhanced manufacturing processes that are benchmarked against
world class standards. Proplastics is certified to South African Bureau of standards (SABS), Standards Association of
Zimbabwe (SAZ) and Southern Africa Plastic Pipe Manufacturers Association (SAPPMA). ISO 9001 (Quality
Management System) certification ensures effective management and control of product and service quality.

The ISO 9001 standard specifies guidelines that ensure opyimum product and service quality. Periodic audits by
SABS, SAPPMA, SAZ and qualified Proplastics’ internal auditors ensure continued complience to the ISO 9001
guidelines.

This manual, which is intended as a referance , gives a technical description of all Proplastics pipe systems covering
product group, specifications of materials, standards, flow calculations, laying instructions and application of
products. It shows the most correct and appropriate use of the products so that an optimum yeild is obtained from
investment in a pipe system.

2. PVC PRESSURE PIPE

Proplastics supplies and manufactures Proflo (uPVC & mPVC) pressure pipe systems from state-of-the-art blend of
materials that have high quality characteristics resulting in a high performance and robust product designed to have
a working life in excess of fiy (50) years. The Proflo range of products can therefore be engineered to cater for a
wide variety of applications and conditions in particular, the toughness of Proflo mPVC (modified PVC) pressure pipe
enhanced by the incorporation of impact modifying additives. mPVC is a ductile and resilient thermoplastic alloy
developed using modern technology and is an advancement of uPVC (uniplasticised PVC). The enhanced toughness
results in improved resistance to crack propagation and therefore enables the use of a higher design stress which
results in significantly reduced mass. The mass reduction and larger pipe bore brings about savings in energy
consumed during manufacture and subsequent operation.

All Proplastics products undergo rigorous testing and an inspection quality control system on sample basis. The
testing ensures that the product meets the minimum of fiy (50) year life expectancy. Among the tests conducted
are: -

• Dimensions
• Resistance to hydrostatic pressure
• Freedom form toxicity
• Resistance to solar radiation
• Tensile Strength
• Elongation at break
• Diurnal pressure fluctuations
• Notched pipe fluctuations
• High impact resistance
Fig 1 Proplastics Testing Equipment

The Quality control testing and inspection provide a guide to the production process to ensure continued
compliance to product requirements. All quality control data is recorded, collated and stored in such a way that the
records are traceable and readily retrievable to demonstrate compliance to product specifications.

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 PVC pressure pipe systems offer many advantages to water engineers when compared to traditional materials.
These are some of the advantages:-

• Light in weight and therefore ease of handling -particularly suited to labour intensive projects
• Corrosion resistance
• Service performance in excess of (50) years
• Significant savings on installation time
• No build-up of scale or other deposits. The bore of the pipe is smooth and hence flow rates are higher
• Maintenance free design life
• Durability and toughness-resistance to handling and installation damage
• Transport costs are minimal due to its extremely light weight
• Low wave celerity
• Highly recyclable - waste generated during extrusion is pulverized and reprocessed that is, it is environmentally
friendly
• Full range of fittings is available

2.1 Jointing Methods

Proplastics pipes and fittings incorporate the following jointing mechanisms:-

2.1.1 Rubber Ring Joints

The socket is integrally moulded on one end of the pipe of fitting and incorporates a factory fitted rubber ring seal
designed to provide a watertight joint at specified pressures.
Depth Of Entry Mark

Fig 2 Rubber Ring Joint

2.1.2 Solvent Cement Joints

Solvent cement joints (recommended for pipes of nominal size not exceeding 200mm) are also used to join high and
low pressure systems. when done properly, solvent cement joints have equal strength as the pipe of fitting being
joined.

Fig 3 Solvent Cement Joint

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2.2 Application

Proplastics Proflo (uPVC &mPVC) pipes and fittings are used below ground for the conveyance of cold potable water
at temperatures not exceeding 25ºC and can be specified with confidence for the following:-

• Water mains and reticulation

• Sewer effluent control and
water purification
• Irrigation systems
• Industrial applications

Fig 4 Proplastics Pressure Pipe Systems

2.3 Dimensions and Standard Lengths (6m)

Proflo uPVC Pipes (SANS 966-1 & ZWS 327-1)

Table 1
Note:-

1. The wall thickness for pipe diameters 90mm and below, including all class 4 pressure range, are based on a
design stress of 10mPa and an overall service (design) coefficient (safety factor) of 2.5.

2 Wall thickness for pipe diameters ≥ 110mm are based on a design stress of 12.5mPa and an overall service
(design) coefficient (safety factor) of 2.

3. All class 10 pipes are produced to Proplastics internal specification and factor a design stress of 10mPa for all
sizes below 90mm and 12.5mPa for sizes greater and including 110mm.

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 Proflo mPVC Pipes (SANS 966-2 & ZWS 327-2)

Table 2

Note:-

1. The wall thickness of Proflo (mPVC) pipes are based on a design stress of 18mPa an overall service (design)
coefficient (safety factor) of 1.4.

2. All class 10 pipes are produced to Proplastics internal specification to a design stress of 18mPa.

2.4 Pressure Pipe Systems Fittings Range

2.4.1 Injection Moulded Fittings

Proplastics manufactures and supplies an extensive range of pressure fittings to complete the PVC pipe systems.
The fittings can be safely and reliably used on both Proflo uPVC and mPVC pipelines and are found in two pressure
classes, 10 and 16. Included in the fittings range are elbows, tees, adaptors, reducers and end caps.

Fig 5 Injection Moulded Fittings

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2.4 Pressure Pipe Systems Fittings Range

2.4.2 Fabricated Fittings

PVC fabricated fittings are used on pressure pipe systems and sizes range from 20mm to 400mm. Fabricated fitted
fittings range include bends, reducers, tees, adaptors, etc.

Fig 6 Fabricated Fittings

2.4.3 Cast Iron Fittings

Cast iron fittings are used for pressure applications. The sizes range from 63mm to 400mm (OD) which include equal
tees, hydrant tees, reducing tees, elbows, end caps, flange adaptors, repair couplings, etc.

Fig 7 Cast Iron Fittings

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 2.5 Mine Pipe

Mine working conditions are extremely harsh with ambient

temperatures approaching 50oC and high humidity. Cooling is effected
by pumping water at 50oC many kilometres down vertical shas, along
haulage ways and to mineral bearing rock faces. Ventilation air is
conveyed underground, and then cooled to reduce ambient
temperatures and improve working conditions.

Fig 8 Proplastics Mine Pipe
Proplastics Minetuff PVC high impact mine pipe has been designed
specifically for such harsh minig environments. Toughness is an
essential requirement for this pipe to prevent brittle failures in
particular at the rigid steel ends resulting from stress concentration
effects. A high-speed (20m/second) impact test is used to characterize
pipe toughness properties of these pipes. The test involves impacting
the pipe from a height of 20m with weights as specified and impact
energies in the range of 600-5000J, depending on the size. Ductile
puncture is the requirement on this test.

2.5.1 Pipe Range and Dimensions

CLASS 6 CLASS 9 CLASS 12 CLASS 16
kPa 600 900 1200 1600
Bars 6 9 12 16
Pressure
rating

PSI 87 131 174 232

Head, (m) 60 90 120 160
mPa 0.6 0.9 1.2 1.6
MIN MIN MIN MIN
NOM SIZE ID NOM MASS ID NOM MASS ID NOM MASS ID NOM MASS
WALL WALL WALL WALL
(mm) (mm) (kg/length) (mm) (kg/length) (mm) (kg/length) (mm) (kg/length)
(mm) (mm) (mm) (mm)
10mPa 50 1.5 46.9 2.0 2.2 45.4 2.9 2.9 44.0 3.7 3.7 42.3 4.7
105 2.5 99.8 7.0 3.7 97.3 10.3 4.8 95.0 13.2 6.4 91.7 17.3
110 2.6 104.6 7.7 3.9 101.9 11.3 5.1 99.4 14.7 6.7 96.1 18.9
125 3.0 118.8 10.0 4.4 115.8 14.5 5.8 112.9 18.9 7.6 109.2 24.4
140 3.3 133.1 12.4 4.9 129.8 18.1 6.5 126.5 23.8 8.5 122.3 30.6
155 3.6 147.5 14.9 5.4 143.8 22.1 7.1 140.2 28.8 9.4 135.4 37.5
12.5mPa
160 3.8 152.1 16.3 5.6 148.4 23.7 7.4 144.6 30.9 9.7 139.8 39.9
180 4.3 171.1 20.7 6.3 166.9 30.0 8.3 162.7 39.0 10.9 157.3 50.5
200 4.7 190.2 25.2 7.0 185.4 37.0 9.2 180.9 48.1 12.1 174.8 62.2
210 5.0 199.6 28.1 7.3 194.8 40.6 9.7 189.8 53.2 12.7 183.6 68.6
250 5.9 237.7 39.5 8.7 231.9 57.5 11.5 226.1 75.1 15.1 218.6 97.1

Table 3

2.5.1 Typical Applications

• Water transportation
• Process slurry transportation
• Dust suppression
• Mine dewatering
• Depressurization

Fig 9 Typical Applications

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2.5.3 Pipe Attributes

• Flexible hence can be installed to follow curves without additional fittings
• Extra tough and can withstand tough mine weather conditions
• Light in weight and therefore ease of handling and can be taken down mine shaſts easily compared to alternative materials
• Corrosion resistance thus can with stand various chemicals used in mines
• Service performance in excess of 50 years
• No build-up of scale or other deposits. The bore of the pipe remains smooth and hence flow rates are higher
• Transport costs are minimal due to its extremely light weight

2.5.4 Mine Pipe Coupling System

Fig 10 Mine Pipe Coupling System

2.5.5 Installation Tips

• Pipes must be supported every 2 metres
• Supports must be placed in the centre of the pipe line and either side of a coupling or fitting, about 1 metre apart
• Valves and fittings requires additional support to avoid over stressing the pipeline
• Pipe line can be supported by metal ‘S’ hooks, chains and steel spreader bars
• Avoid installing the pipe in direct contact with rocks and minimise abrasion on pipe surface

3 Sewer Pipes

3.1 Application
Proplastics Prodrain pipes and fittings are used for the conveyance of untreated and treated waste. Soil, waste &
vent (SWV) pipes and fittings are used above ground and as such are ultra violet (UV) protected.

Fig 11 Prodrain Sewer Fittings

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 Fig 12 Prodrain Sewer Pipes & Fittings

3.1.1 Dimensions And Standard Lengths

Sewer And Drain Pipe (SANS 791; ZWS 219)

Soil Waste And Vent (SWV)

4 Polyethylene (PE)

4.1 PE Pipe Systems

Polyethylene materials are manufactured from natural gas by two basic polymerization processes, namely low
pressure and high pressure polymerization. SANS 4427-2 and ZWS 4427-2 covers three different material grades (PE
63, PE 80 and PE 100). These three material grades have different properties which enable them to be classified with
minimum required strengths (MRS) of 6.3mPa, 8.0 mPa and 10.0 mPa respectively.

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4 Polyethylene (PE)

Fig 13 HDPE Pipes

Advantages:-

• UV Resistant
• Flexible hence best suited for laying in hilly and uneven terrain
• Flexibility allows simple handling and installation
• Light in weight therefore easy to handle
• Minimal installation costs
• Non-corrosive (good resistance to acids and alkaline)
• Excellent welding propeerties
• Smooth inside surface
• No scale formation.

Fig 14 HDPE Pipe Fittings

4.2 Application

4.2.1 Water Supply

Polyethylene pipes offer distinct advantages over other traditional materials (e.g. steel, fibre cement,
concrete, etc.) when used for water supply and in areas with a high water table in which their installation is
simplified by jointing outside the trench. Examples include:-

• Portable water reticulation

• Sewage works
• Water works and water treatment plants

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 4.2.2 Mining (Surface and Underground)
Owing to high abrasion and corrosion resistance, ease of handling and installation and high mechanical
strength, PE pipes are ideal for:-

Tailings (slurries and effluents)

Irrigation leaching piles
Conveyance of acid and alkaline solutions
Drinking water lines
Chilled water lines
Compressed air lines

4.2.3 Agriculture/ Irrigation

PE pipes have various uses in agriculture which include:-

Spray irrigation (Acids, Ammonia, Brine, Carbon Dioxide, Sugar Solutions, Syrups, Fertilizers, etc.)
Water Pipes

4.2.4 Fishing
The use of PE pipes is increasing in the fishing industry because of their weight and ease of handling,
resistance to salt water and attack by marine organisms. Examples include:-

Salmon breeding cages

Maritime discharge and suction (Abalone farms)
Salt water

4.2.5 Telecommunication Industry

Conduit for cable duct and fibre optics

4.3 Dimensions and Standard lengths

HDPE Pipes (SANS 4427-2 and ZWS ISO 4427-2)

Table 5

Note: Standard lengths for HDPE pipes vary with respect to nominal size.

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4 Polyethylene (PE)

LDPE Pipes

4.4 Jointing Methods For PE Pipes

4.4.1 Butt Fusion Joint

Butt fusion jointing is a thermo fusion process which involves the simultaneous heating of the ends of
two components which are to be joined until a melt state is attained on each contact surface. The two
surfaces are then brought together under controlled pressure for a specific cooling time and
homogenous fusion is formed upon cooling. The resultant joint is resistant to the end thrust and has
comparable performance under pressure to the pipe.

Fig 15 Butt Fusion Joint

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 4.4.2 Compression Fittings
Compression fittings are used with HDPE pipes and sizes range from 20mm - 110mm (ID). The
compression fitting design uses the mechanical advantage of the nut thread to place the seal into a
compressed position. This means no resistance when inserting the pipe into the fitting, thus eliminating
damage or displacement to the seal during installation.

Fig 16 Compression Fittings

4.4.3 Poly Insert Fittings

Proplastics insert fittings were engineered to provide a positive grip and ease of installation. High
quality and reliability have made proplastics insert fittings the preferred choice for irrigation
applications. A wide variety of insert fittings configurations and adapters are available for use with
polyethylene pipe sizes 14mm through to 40mm.

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4 Polyethylene (PE)

Fig 17 Poly Insert Fittings

5 Borehole Casings
uPVC casings and screen pipes are manufactured with selected PVC compounds to provide absolute
non-corrosive pipes with excellent mechanical properties. The casings and screens have two joining
mechanisms which are either threaded or solvent welded.

Borehole casings keep loose sand and gravel from collapsing into the borehole. The casings support the
borehole walls while allowing water to enter the well. Unslotted casing is placed above the screen to keep the
rest of the borehole open and serves as housing for pumping equipment.

Advantages:-
• Chemically inert thereby corrosion resistant
• Resistant to collapsing
• Consistent slot sizes for better flow rates
• Light weight and easy to install
• High tensile strength (for boreholes up to at least 200m deep)

Fig 18 Borehole Casings

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 5.1 Dimensions and Standards Length

6 Electricals

6 Electricals
Proplastics manufactures and supplies PVC conduits from 19mm - 25mm which are light in weight compared
to other conduit materials like steel and usually lower in cost. Electrical conduits are used in electrical tubing,
protection and routing of electrical wiring and provide very good protection to enclosed conductors from
impact, moisture and chemical vapours.

6.1 Application
Contractors and electricians use electrical conduits to shield electrical wires from moisture, fire, chemicals
and other adverse conitions.

6.2 Fittings Range

Round boxes, couplings, nipples, square boxes etc.

Fig 19 Electrical Fittings

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7 Rainwater Systems

Proplastics supplies a complete range of uPVc rainwater gutters and fittings. The gutters are supplied in long
lengths for easy and economical installation whilst the fittings are injection moulded to ensure uniform
shape and high quality finish. Features and benefits enjoyed by contractors and house owners include:-

• Ease of installation (light in weight, simplified joining using non expensive tooling or equipment)
• Resilience - offers high resistance to impact
• High performance - corrosion resistance and excellent flow rates
• Service life in excess of twenty five (25) years

7.1 Application
Rainwater management for protecting siding and foundation of buildings by directing the flow of water
away from the building.

7.2 Product Range

Half round and square gutter systems complete with fittings.

Fig 20 Gutter Systems

8 Transportation, Unloading and Storage

Fig 21 Pipes Transportation

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 8.1 Transportation
Flat bed vehicles must be free of nails and sharp objects. The tray should be equipped with strong flat faced
uprights along each side of the tray at about two meter intervals. Each layer of pipes must face the
opposite way, to avoid sockets touching by more than half a meter. Any two adjacent pipes must face
alternative directions to avoid sockets touching each other.

8.2 Unloading
The means by which the pipe is unloaded in the field is the decision and the responsibility of the receiver.
These recommendations should be followed:-

• Remove restraints from the top unit loads. These may be straps, ropes or chains with padding.
•
at a time from the truck.
•
straps approximately eight feet apart. Loop straps under the load. Cables may be used only if they are
cushioned to prevent damage to the pipe.
• Place pipe package units on level ground.

Fig 22 PVC Pipe Stacking

8.3 Storage
PVC plastics pipes are affected by UV light and tend to discolour due to long term exposure to UV Light. UV
stabilizers are incorporated in PVC formulations. If pressure pipes have to be exposed for an indefinite
period, they should be painted, preferably with one coat of white alkyd enamel or PVA, or a suitable
covering should be provided. Paint containing solvent thinners should be avoided.

The following procedures are recommended to prevent damage and deterioration of product quality:-

Store the pipe under a shed as pipes should not be subjected to direct sunlight.
Avoid compression, deformation or damage to socket ends of the pipe.
When unit packages are stacked, ensure that the weight of upper units does not cause deformation to pipes
in lower units.
Support pipe unit packages on wood blocking to prevent damage to the bottom surfaces during storage.
Do not store pipe where rubber seals may be exposed to ozone, grease or oil.
Protect pipe interior and sealing surfaces from dirt and foreign matter.
When unit packages are stacked, ensure that the stack remains stable.

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9 Design consideration

Proplastics pressure systems have six (6) pressure categories. These classes include suitable safety factors
and are intended for use 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 light of his or her knowledge
of the particular circumstances.

Amongst the factors to be considered are:-

• Operating pressure characteristics:-

- Statistic conditions
- Dynamic conditions
- Water hammer
• Cyclic loads
• Temperature
- Effect on pressure
- Expansion and contraction:-
• Trench load condition:-
- Soil loads and soil type
- Traffic loads
• Bedding
• Thrust blocks

9.1 Design Life

Although the HDPE and PVC pipes can withstand short term hydrostatic pressures at levels substantially
higher than the pressure rating or class, the duty of PVC and HDPE pipes should always be based on the
pipe's long term strength at 20oC to ensure a design life of fiy (50) years. The pipe material strength is
predicted by a regression curve which is basically a plot of the circumferential hoop stress in the wall of the
pipe (from internal pressure) against time to failure measured under specified conditions of temperature of
20oC and 60oC for MPVC and 20oC and 80oC for HDPE. Actual test results are measured over a range of
times up to 10000 hours and plotted on log scale and a line is calculated to best fit the data. . The resultant
regression line is then extrapolated to 50 years (438,000 hours). The method of calculation is an interna-
tionally accepted procedure described in ISO / TR 9080.

The minimum required strength (MRS) is 25MPa that gives the fiy (50) years design strength of uPVC and
mPVC whilst for the HDPE PE 100, the MRS is 10MPa. The stress regression lines for PVC and HDPE are as
shown below:

The stress regression line is used to predict the pipe material strength. it is essentially a graph of log stress
versus log time to failure measured under specified conditions of 20°C and 60°C. It is a plot of
circumfrerential hoop stress in the walls of the pipe (from internal pressure) measured against the time to
failure. Actual test results are measured over a range of times up to 10 000 hours and plotted on a log

(438000) as guided by ISO/TR 9080.

Fig 23 Stress Regression Line for PVC and HDPE

mPVC.
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 The following formula is used to determine wall thickness:-
t=pxd/(2σ+p)
where t = minimum wall thickness in mm
d = average outside diameter in mm
p = maximum allowable internal pressure in MPa
σ = circumferential hoop stress in MPa

9.2 Design Stress and Safety Factors (Design Coefficient)

The design stress is the constant stress that a pipe can withstand over fiy (50) years with a specific safety
factor (C). The design stress is derived by dividing the MRS at fiy (50) years from the regression line
corresponding to a specific safety factor. The safety factor is adopted taking into consideration the handling
conditions, service conditions and other circumstances not direct conditions, service conditions and other
conditions not directly considered in a design e.g. the large safety factors with uPVC is because of the fact that
the pipe may not only be under load from internal pressure but other external forces from which its outer
surface lies, thus chances of premature brittle failure are high. Proplastics SABS 966/ZWS 327 pipes adopted
the following safety factors based on material properties and taking into account unknown loading
or environmental conditions.

Table 9 Design Stress & Safety Factors

9.3 Pressure Variation Considerations

9.3.1 Static Pressure
The Hydrostatic pressure capacity of a PVC pipe is related to a number of variables:-
1. The ratio between the outside diameter and the wall thickness (standard dimension ration - SDR)
2. The hydrostatic design stress of the PVC pipe being used (uPVC or mPVC)
3. The operating temperature
4. The duration and variability of the stress applied by the internal hydrostatic pressure

Although a PVC pipe can withstand short-term hydrostatic pressures at levels substantially higher than the
pressure rating or class, the duty of PVC pipe should always be based on the pipe’s long-term strength at 20

9.3.2 Dynamic Pressure

The pressure classes of SANS 966/ZWS 327 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

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

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.

9.3.3 Water Hammer

Pipelines 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 distributed by rapid changes
in flow 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 the water in the pipeline gives rise to
a pressure increase p according to the formula:-

p=c v/g
Where: c = wave celerity (metres per second)
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9 Design consideration

The wave celerity for (uPVC) and (mPVC) have been calculated and are given below:-

Table 10

Note:- I. Since part of the formula for calculating wave celerity incorporates the ration btween 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.
II. By way of comparison the wave celerity for steel pipes is about three (3) times higher than for PVC (1000
to 1400 m/s).

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
permittted to reach a value 50% higher than the nominal pressure if the frequency can be described as
“occasional”.

9.4 Temperature Considerations

9.4.1 Effect on pressure
The pressure classes of PVC pipes carrying the SANS 966/ZWS 327 mark have been allocated on the basis
of design at 20℃. Any pipes used in applications where operating temperatures exceed 25℃ need to be

following pressure reduction factors should be applied:-

Pressure Rating
(Bars)

Working temperature
Fig 24 PVC Pressure Derating Curve

At lower temperatures, between 20℃ and 0℃, 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.

9.4.2 PE Derating Factors

Pressure derating factors should be applied to HDPE pipes when operating temperatures rise above 20℃.
The derating factors below are applicable to HDPE:-
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 Pressure Rating
(Bars)

Fig 25 PE Pressure Derating Curve

9.4.3 Expansion and Contraction

Due to the relatively high coefficient of expansion and contraction, it is necessary to make allowance for
this in any design installation which is exposed to wide variations of temperature. PVC pipes will expand or
contract by 0.06 mm per metre per ℃ rise or fall in temperature. A 30℃ temperature rise will therefore
cause a 10.8mm expansion of six (6) metre pipe.

CORRECT PIPE INSERTION INCORRECT PIPE INSERTION

The spigot mark should be visible The connecting pipe has room to move The spigot mark is comletely The connecting pipe has no room to move during
during expansion and contraction submerged into the socket expansion and contraction and is already under
stress before pressure is applied

Fig 26 Pipe Joining

9.5 Head Loss in Fittings

When there is change to pipe section of the direction of flow in a pipe, energy is lost and this must be
accounted for in the hydraulic design. The general relationship for head losses in fittings may be expressed
as follows:-

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 Technical Manual

9 Design consideration

H=K(v²/2g)
Where H=head loss (m)
V=velocity of flow (m/s)*
K=head loss cefficient
g=gravitational acceleration(9.81 m/s²)

*Velocity varies. For this calculated example velocity was 1m/s

The value of the head loss coefficient K is dependant on th particular geometry of each fitting, and values
for specific cases are listed in the table below:-

Table 11 Head Loss Calculations

The total head loss in the pipeline network is then obtained by adding together the calculations performed for each
fitting in the system, the head loss in the pipes and any other design head losses.

10 Installation (ZWS 254:LB:2001&SANS 2001-DP2:2010)

10.1 Excavation
Trench excavation should be kept to a minimum width, allowing just sufficient working area for jointing and
embedment compaction around the pipe. For small diameter pipes, a trench 300mm wider than the
diameter of the pipe allows enough room for jointing. For pipes 300mm in diameter and larger, the trench
widths recommended in the relevant sections of SANS 2001 should be followed.

Fig 27 Trench Details

It is important that the trench is not opened too far in advance of the pipe laying operation. Pipes must be

values, it will be necessary to increase the trench width to accomodate additional embedment material to
provide the pipes eewith adequate lateral support. It is recommended that the depth of the cover from the
top of the pipe to the ground surface is not less than 0.9 metres or the pipe diameter, whichever is greater.
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 10.2 Embedment
The quality of the bedding material and its compaction, together with the nature of the undis
turbed material of the wall, are all relevant to the ultimate performance of all pipes once installed.

• Only certain soils are suitable for backfilling around the pipe.
• Involve your consulting engineer at an early stage on the soil suitability.

Reference should also be made to SANS 2001-4 or the equivalent for bedding specification.

10.3 Backfilling
• Pipes must be backfilled immediately aſter checking the joints and leaving them exposed for testing.
Immediate backfilling restricts expansion and contraction to each individual pipe length where it is catered
for by the integral socket.
• Place selected material gently and evenly in uncompacted layers of 75mm in thickness between the sides
of the trench and other pipes.
• Tamp each layer firmly with a hand tamper until the level of the crown of the pipe is reached ensuring

• Excavated trench material may be used in 300mm layers to completee the backfilling, provided it is free
from stones with sharp edges. Each layer must be firmly tamped, the first layer by hand and subsequent
layers by mechanical means if so required.
• The final level to which the trench is filled should be slightly higher than the natural ground level to
accomodate the consolidation of the backfill material in the trench.

Fig 28 Bedding and Backfill Details

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 Technical Manual

10 Installation (ZWS 254:LB:2001&SANS 2001-DP2:2010)

The Main Backfill for the remainder of the

trench, excluding the areas where joints must
still remain exposed, should be placed and
compacted in 300mm thick layers. Excavated
trench material can be used. Each layer must
be firmly tamped, the first layer by hand and
subsequent layers by mechanical means if so
required. The main backfill should be
compacted to the same density as the
surrounding insitu material. The final level to
which the trench is backfilled should be
slightly higher than the natural ground level
to accomodate the consolidation of the
backfill material in the trench.
Fig 29 Pipe Laying

10.4 Anchorage
When an internal hydrostatic pressure is applied to the pipe, unbalanced forces develop at all changes of
size and direction in a pipeline. Thrust blocks prevent the movement of fittings and must be placed at all
changes of direction, valves, stop ends and reducers. Concrete thrust blocks are the most commonly used at
all anchor points. The dimensions of the thrust blocks must be calculated to suit the pipe diameter, pressure
and the load bearing capacity of the soil Typical thrust block sizes are given in Table 12. The actual size
required for a particular project should be calculated and specified by the design engineer.

Fig 30 Thrust Blocks

(mm)

Table 12 Thrust Block Dimensions

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 11 Pipe Laying

11.1 Rubber Ring Joint (RRJ)

• Check the pipe spigot end and remove any burrs that
may occur on the spigot end of the pipe.
• Check the entire spigot of the pipe making sure that it is
correctly chamfered to 15as demonstrated in Fig 31

Chamfer

Fig 31

• The rubber seal is fitted in the factory. Check that the

seals are seated correctly and that they are free from
dirt or mud deposits.
• Clean the spigot end of the pipe as demonstrated in Fig
32 checking to see that the surface is smooth and free
from indentations or deep scratches. If the end has any
indentations or deep scratches, place the pipe length to
one side for inspection by a factory technical representa-
tive.

Fig 32

• Apply lubricant evenly around the spigot end, approxi-

mately half the distance between the pipe and the mark
which indicate the depth of entry. Lubricant the ring as
well. The use of grease or petroleum products is not
recommended.
• Position the spigot end of the pipe so that the leading
edge rests against the rubber ring in the socket.
• Check the horizontal and vertical alignment of the pipe
and socket. The long land canal of the mouth of the
socket facilitates easy entry of the pipe.
• Push the pipe into the socket and position it so that the
depth of entry mark is visible as demonstrated in Fig 33.
This procedure should be done in one fluid movement. A
twisting action will aid entry. The joint is now complete.

Fig 33

24
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 Technical Manual

11 Pipe Laying

11.2 Solvent Cement Joint

11.2.1 Solvent Cement Accessories

• A fine tooth hacksaw or angle grinder

• Correct type of solvent cement
• A clean brush
• A clean rug

Fig 34 Solvent Cement Accessories

The guideline below assist in ensuring that a proper joint is made every time:-

1. Use the rag to clean the pipe and fitting to be joined.

2. Apply the solvent cement evenly to the pipe and fitting using a suitable brush.
° and
ensure that it is fully inserted.
4. Wipe any excess solvent from the joint using a clean cloth.
5. Leave the joint to cure as per instruction on the solvent cement container.
6. Do not apply pressure for at least 24 hours.

11.2.2 Solvent Cement Use Guide

Table 13

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 12 Pipeline Testing Of Proflo (mPVC, uPVC & PE) Pipe

12.1 Pipeline preperations for field pressure testing

12.1.1 Field pressure testing
The purporse of a field pressure test is to test the design of the pipeline and the quality workmanship
applied during construction. Pressure testing is done according to SANS 2001:2010 or as specified by the
design engineer.

The following equipment is required:-

1. End caps or end plugs with inlets and outlets for filling and emptying water
2. Pressure pump capable of generating pressure to the required pressures
3. Calibrated pressure gauge
4. Braces for supporting end caps or end plugs

The test pressure for field testing 1.25 times the designated working pressure at any point on the longi-
tudinal section of the pipeline up to a maximum of 10 bars, above which it will be the designated working
pressure plus 5 bars.
Apply test pressure and sustain this pressure for a period of one (1) hour. For PE pipelines, allow initial
expansion of the pipe under test and sufficient make-up water must be added to the system at hourly
intervals for three (3) hours to maintain the test pressure. Aer about four (4) hours, initial expansion
should be complete and the actual test cn start.
During this period carry out an inspection for leaks or other anomalies. Make good all visible leaks and
replace any pipe or fitting found to be defective. Test such replacement material aer installation.
Restore test pressure and make up water. Maintain the test pressure for a further one (1) hour, during
which time measure the volume of water required to be pumped into the pipeline for maintenance of the
pressure. Check that additional water required does not exceed the value, in liters, calculated from the
formula below:-

ALR (allowable leakage rate) = 0.01 x PD x TS x STP

Where PD = pipe diameter in millimeters

STP = Square root of the test pressure in mPa
TS = Test section, in kilometers

(mm)

Table 14

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 Technical Manual

13 Sewer Pipeline Testing

13.1 Air Test (ZWS 254:LD:2001)

• An approved air testing machine shall be used to raise the gauge pressure in the section of the pipeline
under test first to 0,04 bars.
• Aſter a two (2) minute stabilization period, the pressure shall be reduced to 0,025 bars.
• The machine shall then be switched off and the time taken for the pressure to drop from 0,025 bars to
0,013 bars shall be determined.
• The time shall be at least the applicable of the following values:-

Table 15

The line shall be deemed to be a pass if the time taken for pressure to drop is within the values given in table 15 above.
If the time is above the specified times, the leaking point should be identified and repaired and, repeat test as above.

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 14 Frictional Loss Charts for PVC and PE

One of the key performance advantages of a PVC & PE piping system is its glasslike internal finish. This hydraulically
smooth surface means that PVC and PS systems can cut friction losses and increase flows for a given pipe size. These
hydraulic benefits apply to both pressure and gravity flow applications and have been proven through extensive
research and field testing.

Fluid will flow over a smooth surface more easily than over a rough or uneven surface. Since the inside finish of
various pipe materials have varying degrees of roughness, flow characteristics of each pipe material differ signifi-
cantly.

Colebrook-White gives a more rigorous formula that accounts for the absolute roughness of the pipe material and
the viscosity of the fluid. The values are more accurate, but also more difficult to calculate. It is expressed as:-

Where: V = Velocity (m/s)

D = diameter (m)
Ks = Absolute roughness of pipe (mm)
C = roughness coefficient
S = hydraulic gradient (m/m)
v = kinetic viscosity of fluid (m2 /s) formula
g = acceleration due to gravity (m2 /s) formula

For a quick determination of flow parameters, the frictional loss chart overleaf can be used. However when accurate
values are required, they should be calculated.

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 Technical Manual

14 Frictional Loss Charts for PVC and PE

Flow / Frictional Loss Chart for Proflo mPVC

Fig 35 Frictional Loss Chart for mPVC

Use of Flow Chart

1. Using Column A identify size and class, e.g. 200mm Class 12

2. Using Column C select Velocity e.g. 1.4m per second
3. Place a ruler on A and C intercepts as in the example line drawn above
4. Read delivery and pressure loss from lines B and D respectively. In this example delivery is 40 litres per
second and pressure loss is 0,86 metres per 100 metres

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 Fig 36 Flow / Frictional Loss Chart for uPVC

Fig 36 Frictional Loss Chart for uPVC

Use of Flow Chart

1. Using Column A identify size and class, e.g. 200mm Class 16

2. Using Column C select Velocity e.g. 1.3m per second
3. Place a ruler on A and C intercepts as in the example line drawn above
4. Read delivery and pressure loss from lines B and D respectively. In this example delivery is 30 litres per
second and pressure loss is 0,8 metres per 100 metres

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 Technical Manual

14 Frictional Loss Charts for PVC and PE

Frictional Loss Chart for Proflo PE

Fig 37 Frictional Loss Chart for PE

Use of Flow Chart

1. Using Column A identify nominal inside diameter of the pipe, e.g. 170mm
2. Using Column C select Velocity e.g. 1.5m/s
3. Place a ruler on A and C intercepts as in the example line drawn above
4. Read delivery and pressure loss from lines B and D respectively. In this example delivery is 30 litres per
second and pressure loss is 0,8 metres per 100 metres
31 w w w.pro pl ast i cs.co .z w
 15 Chemical Resistance Guide

15.1 DEGREE OF CHEMICAL RESISTANCE

This guide specifies three “Classes” of chemical resistance:

Class 1: HIGH RESISTANCE all material belonging to this class are completely or almost completely corrosion proof
against the conveyed liquid at the specified operating conditions.

Class 2: LIMITED RESISTANCE the materials belonging to this class are partially attacked by the conveyed chemical
compound. The average life of the material is therefore shorter and it is advisable to use a higher safety
factor that the one adopted for Class 1.

Class 3: NO RESISTANCE all material belonging to this class are subjected to corrosion by the conveyed fluid and
they should therefore not to be used where no class is indicated. This means that no data is available
concerning the chemical resistance of the material in respect of the fluid to be conveyed.

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 Technical Manual

15 Chemical Resistance Guide

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 Technical Manual

15 Chemical Resistance Guide

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 Technical Manual

15 Chemical Resistance Guide

13 Sewer Pipeline Testing

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w w w.p rop l a sti c s. c o. zw 38
 Technical Manual

15 Chemical Resistance Guide

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15 Chemical Resistance Guide

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 Technical Manual

16 Normative References

The following standards contain provisions which through reference in this text, constitute provisions of this part of
the Technical Manual. Standards are subject to revisions and parties to agreements based on this Technical Manual
are encouraged to ensure use of the most recent standards:-

1. SANS 966-1 Components of pressure pipe systems: uPVC pressure pipe systems

2. SANS 966-2 Components of pressure pipe systems: mPVC pressure pipe systems

3. SANS 2001-DP2:2010 Construction Works: Medium pressure pipelines

4. SANS 11 uPVC components for external rainwater systems

5. ZWS 327-1 Components for pressure pipe systems: uPVC pressure pipe systems

6. ZWS 327-2 Components for pressure pipe systems: mPVC pressure pipe systems

7. SANS 791 uPVC Sewer and drain pipes and fittings

8. ZWS 254: LB:2001 Standardized specific for civil engineering construction LB : Bedding
(Pipes)

9. ZWS 254: LD:2001 Standardized specific for civil engineering construction LD : Sewers

10. ZWS 277 Non metallic conduits

11. ZWS 219 uPVC Sewer and drain pipes and fittings

43 w w w.pro pl ast i cs.co .z w

 17 Glossary

Bore nominal inside diameter of the pipe.

Head is the vertical distance, height or energy of water above a point. A head of water may be measured
in either height (m) or pressure (psi, bars, etc).

Head loss is the measure of the reduction in the total head of the liquid as it moves through a system. The
total head is the sum of the elevation head, velocity head and pressure head. Head loss is
unavoidable and is present because of the friction between the fluid and the walls of the pipe and is
also present between adjacent fluid particles as they flow along the pipe.

Hoop Stress circumferential stress induced in the wall of a pipe when the pipe is subjected to internal hydrostatic
pressure.

Design Stress the stress induced into the wall of a pipe when the pipe is subjected to internal hydrostatic pressure.

MRS all plastic materials used for the manufacture of pipes have been extensively tested and can be

the MRS.

Safety Factor MRS divided by the Design Stress. The ratio of burst strength to working strength. A pipe with a
safety factor of 2;1 has a burst pressure that is two (2) times the working pressure.

Test Pressure pressure applied to an installed pipeline in order to establish the quality of workmanship of the
contractor.

Flow Rate this is the volume of water (or other fluid) that is flowing through a pipeline per given time. It is

Flow Velocity the speed in meters per second (m/s) at which water is travelling along a pipeline.

Friction Factor also known as coefficient of friction. The degree of roughness on the inside surface of the pipe. All
pipe types offer varying “resistance to flow” (or friction) to the flow of water. Extensive research has
established friction factors for each pipe type. Pipes with “low” friction factors will typically be more
energy efficient to operate.

Friction Losses head loss due to friction between pipe internal surfaces and the flowing water. The friction factor for
the pipe being used, the volume of water flowing through the pipeline and the length of the pipeline,
will result in a specific amount of head loss.

SDR outside diameter (O.D.) ÷ wall thickness. For example a 160mm pipe with a wall thickness of 9,4mm
has an SDR of 17. All sizes of pipe in a particular pressure class (PN) will have the same SDR.

Water Hammer a shock wave of high pressure travelling at a high speed caused by sudden stop of flow of water in a
pipeline. Severe cases of water hammer can be heard as very rapid banging in the pipeline and can
cause serious damage.

Wave Celerity the speed in meters per second at which the shock wave of water hammer travels in the pipeline.
Higher values of wave celerity result in higher peaks of water hammer pressure.

Working Pressure the pressure rating that indicates the maximum pressure a pipeline should experience in service.

PN this is the abbreviation for “Pressure Nominal” and is commonly used as a Pressure Classification
number for a particular pressure class of pipe. For example a “PN 9” pipe is designed to operate at a
maximum of 9 bars.

DISCLAIMER: Care has been taken in the preparation of this Technical Manual. However, Proplastics bears no liability for
any errors printed in this publication nor any costs or loss of property resulting from misuse of this manual. It should also
be noted that this manual shall be used for guidance only and due consultation with the installation engineer and/or
Proplastics is required when designing for particular applications.
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 www.proplastics.co.zw

Contact Us

Harare Branch & Head Office Bulawayo Branch

5 Spurn Road, Ardbennie
P.O. Box CY1199 Causeway, Harare, Zimbabwe
Tel: +263 4 621 651 – 5 / 661 341 – 3
Mobile: +263 773 888 923 / 894 561 – 2
Fax: +263 4 660 545
Email: info@proplastics.co.zw
Military Road (Off Khami Road)
P.O. Box RY115 Raylton, Bulawayo, Zimbabwe
Tel: +263 9 68396 / 62059 Fax: +263 9 76130
Email: sales@proplastics.co.zw
Harare Agricultural Show Grounds
Stand No. 14 1st Avenue Harare Show Grounds
Tel: 08644219155

Disclaimer:-Care has been taken in the preparation of this catalogue. However, Proplastics bears no
liability for any errors printed therein nor any costs or loss of property resulting from its misuse. It should
also be noted that this catalogue shall be used for guidance and due consultation with the Installation
Engineer and/or Proplastics is required when designing for particular applications.