Presenter’s CVMike Smart Pr. Eng., B.Sc. (Hons) Civ. Eng., MSAICE

o Mike Smart graduated with a B.Sc. (Honours) Degree in Civil Engineering, is a registered Professional Engineer, a MSAICE and a Henley Management Graduate. He has worked in many sectors of the civil engineering industry; consulting, municipal engineering and contracting. He has owned a thermoplastic pipe manufacturing company and thermoplastic pipe installation company.

o His areas of experience include, inter alia, polyolefin marine outfalls and intakes, thermoplastic (polyolefin and PVC) pipelines, municipal engineering, township development, reticulation systems, mine services, precast pre-stressed concrete structures, hydrology and hydraulic structures, trunk water mains, irrigation dams, quality management systems, QA/QC, project management and the extrusion and fabrication of thermoplastic pipes and fittings.

o He has held positions as Engineer, Resident Engineer, Associate Partner, Partner, and Technical Director and currently has a specialised Consulting Practice consulting to the thermoplastic pipe manufacturing and installation industry, to consultants specifying these products and end users in infrastructure and mining engineering.

o He is currently a member of the SAPPMA (Southern African Plastic Pipe Manufacturers Association) Technical Committee and Chairman of IFPA (Installation and Fabrication Pipe Association).

VinylSA 2017Hosted by SAVA

“PVC-O Innovations”Mike Smart Pr. Eng., B. Sc. (Hons) Civ. Eng., MSAICE

PVC Pressure Pipe Systems 1935 – 20171936 Berlin Olympic Stadium – first major project with PVC pipes

Note: C reducing and σ increasing

PVCType

ApplicableStandard

OD(mm)

Pressure (bar)

Design Coefficient(C)

Design Stress(MPa)

PVC-U SANS 966-1 16 to 90 4 to 20 2,5 10

PVC-U SANS 966-1 110 to 630 6 to 20 2,0 12,5

PVC-M SANS 966-2 50 to 630 6 to 25 1,4 18

PVC-O SANS 16422 110 to 800 12.5 to 25 1,4 or 1,6 or 2,0 36 or 32 or 25

Polymer chains

Molecular Bonds

Orientation process

Oriented Structure

Molecular Orientation

SANS 16422: PVC-O states, “Molecular Orientation of thermoplastics results in improvementof physical and mechanical properties. Orientation is carried out at temperatures well above

the glass transition temperature”.

Molecular Orientation does not change the chemical properties of PVC-U

Material Classification based on MRS (Minimum Required Strength)

PVC-O Classification 500structure welldefinedLaminar

PVC-O Classification 400Laminar structure

PVC-UAmorphous (not clearlydefined) structureAmorphous Structure

Laminar Structure

Molecular Orientation

Modified and Structurally Different Materials

• Cast Iron cf. DI – both iron

• Cast Iron cf. DI – magnesium modifies mechanical properties

• PVC-U cf. PVC-M – both PVC

• PVC-U cf. PVC-M – impact modifier modifies impact strength

• PVC-M is “PVC-A” – “Alloy” PVC-U + impact modifier “behaves” tough

• Coal cf. Diamonds – both carbon

• Coal cf. Diamonds – mechanical heat & pressure alters molecular structure

• PVC-M cf. PVC-O – both PVC

• PVC-M cf. PVC-O – mechanical heat & pressure alters molecular structure

o Laminar structured materials are tough – PVC-O altered molecular structure

o Crack stress opens layer interface – crack blunted; crack tip increases; reduces “stress concentration”

Toughness Mechanism – PVC-O

High “stress concentration”

at crack tip

Interface opens; reduces “stress concentration”; prevents failure

Laminar or layered structure

Mechanical Properties Matrix

0

0,5

1

1,5

2

2,5

3

3,5

4

4,5

5

Impact resistance

Emodulus

Strength (Short term)Strength MRS (Long term)

Elasticity

MECHANICAL PROPERTIES

PVC-O

PVC-M

PVC-U

o Brittle materials fail unpredictably – due to “stress concentration”

o Some materials need large C – steel 2; DI 2; GRP 1.8 to 2

o Large C does NOT mean – safer more reliable pipes

o PE100 strength 20% of PVC-O – it’s tough and ductile C = 1,25

o C depends on material properties – strength; toughness; ductility

o PVC-O strength and toughness – Design Coefficient C = 1,4

Design Coefficient C – Properties at 50 Years

SANS 16422 PVC-O Standard ClassificationsAnnex A: MRS (Minimum Required Strength) and C (Design Coefficient)

Annex B: Socket length for applicable Allowable Design Stress σ (= MRS/C)

ApplicablePVC-O

Standard

MRS(ISO 9080)

MPa

ClassificationDesignation(ISO 12162)

Design Coefficient(ISO 12162)

C

Allowable Design Stress σ

MPa

SANS 16422 31,5 315 1,6 or 2,0 20 or 16

SANS 16422 35,5 355 1,6 or 2,0 22 or 18

SANS 16422 40 400 1,6 or 2,0 25 or 20

SANS 16422 45 450 1,4 or 1,6 or 2,0 32 or 28 or 23

SANS 16422 50 500 1,4 or 1,6 or 2,0 36 or 32 or 25

Creep Rupture Regression CurvesPVC-U, PVC-M, and Earlier PVC-O (MRS 45 at 50 Years)

Creep Rupture Regression CurvesLatest PVC-O (TOM 500: MRS 55 at 50 Years), PVC-U and PVC-M

1

10

100

1 10 100 1000 10000 100000 1000000 10000000

Ho

op

Str

ess

-M

Pa

Time - hours

PVC-O 500

PVC-O 355

PVC-O 315

PVC-U & M

PE 100

Log. (PVC-O 500)

Log. (PVC-O 355)

Log. (PVC-O 315)

Log. (PVC-U & M)

Log. (PE 100)

PVC-O (TOM 500) Dimensions and PressuresDN 1000 in 2016 DN 1200 in 2017

ODMin Max

PN 12.5Min e Ave ID

PN 16Min e Ave ID

PN 20Min e Ave ID

PN 25Min e Ave ID

110.0 110.4 2.2 104.4 2.4 104.0 3.1 103.2 3.8 101.4

140.0 140.5 2.8 133.0 3.1 132.4 3.9 131.2 4.8 129.2

160.0 160.5 3.2 152.0 3.5 151.4 4.4 150.0 5.5 147.6

200.0 200.6 4.0 190.0 4.4 189.2 5.5 187.4 6.9 184.4

225.0 225.7 4.5 213.6 5.0 212.8 6.2 210.8 7.7 207.4

250.0 250.8 5.0 237.4 5.5 236.4 6.9 234.2 8.6 230.6

315.0 316.0 6.3 299.2 6.9 298.0 8.7 295.2 10.8 290.6

355.0 356.1 6.2 337.4 7.8 336.0 9.8 332.4 12.2 327.2

400.0 401.2 8.0 379.8 8.8 378.4 11.0 374.8 13.7 369.0

450.0 451.4 7.9 427.6 9.9 426.0 12.4 421.4 15.4 415.0

500.0 501.5 9.9 474.6 11.0 472.8 13.7 468.6 17.1 461.2

630.0 631.9 12.6 597.8 13.8 595.8 17.3 590.4 21.6 581.0

710.0 712.0 14.2 681.6 15.4 679.2 19.2 671.6 - -

800.0 802.0 16.3 760.4 17.4 757.8 21.6 750.4 - -

PVC-O (TOM 500) Diameter and Pressure RangeIncrease possible with improved in-line molecular orientation technology

PN (bar)

25

20 20

16

0

Previous PVC-O limit 315 630 800 1000 1200 (TOM 500) (2015) (2016) (2017)

Outside Diameter (OD) – mm

o Barlow’s Formula computes minimum wall thickness (e):

e = P x OD P = Pressure (MPa)

2s + P OD = Outside Diam. (mm)

o Design stresses (s):

PE 100 s = 8 MPa – (SANS 4427)

PVC-U s = 12,5 MPa – (SANS 966-1)

PVC-M s = 18 MPa – (SANS 966-2)

PVC-O (TOM 500) s = 36, 32 or 25 MPa – (SANS 16422)

o PVC-O (TOM 500) cf. HDPE – ID +17%; CSA +37%; V +10%; Q +51%

o PVC-O (TOM 500) cf. PVC-HI – ID +8%; CSA +16%; V +5%; Q +19%

o PVC-O (TOM 500) cf. PVC-M – ID +5%; CSA +9%; V +3%; Q +12%

HDPE, PVC-U, PVC-M and PVC-O Pipe DesignFIRST IMPROVEMENT – CAPACITY

Low Celerity= Low Surge Pressure (ΔP = α ΔV/g)(PVC-O α = PN12.5 – 281; PN16 – 318; PN20 – 356; PN25 – 398. Total ΣP = 2PN – CEN 15223)

SECOND IMPROVEMENT – SURGE

Pipe Material

DN 500 mm

Young’s Modulus

(E)

MPa

Wall Thickness (e)

mm

Celerity (α)

m/s

Ductile Iron 170 000 9 1140

Steel 210 000 5 970

GRP 20 000 7 460

PVC-M 3 000 21,3 363

PE 1 000 45,4 360

PVC-O 4 000 13 318

Thermoplastic Pipes Celerity – Comparisonα = Material Factor . √PN

Thermoplastic

Pipe Class

PN (bar)

PE 100

Celerity (α)

m/s

PVC-U

Celerity (α)

m/s

PVC-M

Celerity (α)

m/s

PVC-O

Celerity (α)

m/s

6 220 263 218 -

9 270 325 270 -

12 312 378 312 281

16 360 439 363 318

20 402 495 407 356

25 450 559 458 398

TOM 500 Socket Details – Determined with (σ)THIRD IMPROVEMENT – SOCKET

o Simultaneously formed during orientation – not reheated & expanded

o Extreme hoop and axial orientation in seal housing – withstands axial stress

o Extra hoop and axial orientation in socket – prevents deformation

o Extra seal housing length – absorbs expansion

o Extra socket length 30% greater than ISO 2045 – absorbs deformation

o Extra lip length and belled entry – fast and easy insertion

TOM 500 Forsheda 576 Anger-Lock Seal DetailsFORTH IMPROVEMENT – SEAL

o Negative pressure capacity (ISO 13844) – SANS 16422 -0.8 bar cyclic test

o 25 bar pressure rated seals – all pipe diameters and classes

o Forsheda 576 Anger-Lock locked-in seal – combined lip and compression seal

o Double ring gasket from Trelleborg – retains and seals joint

o PP rigid retaining ring – prevents seal dislocation

o EPDM lipped rubber seal – perfect leak proof seal

o Seal length fills extra housing length – accommodates deformation

PVC-O (TOM 500) Pressure PipesAnger-Lock Seal

o Definition: “Embedded energy – all energy consumed by all processes associated with raw material manufacture and pipe production.”

Embedded Energy – Thermoplastic PipesFIFTH IMPROVEMENT – EMBEDDED ENERGY

EMBEDDED ENERGY

Pipe Material Energy – kWh

PVC-O 30

PVC-M 50

PVC-U 70

PE 100 83

STEEL 319

DI 419

PVC-O (TOM 500) Superior HydraulicsSIXTH IMPROVEMENT – FRICTION FACTOR

Pipe Material

Prandtl-Colebrook(k) – mm

Hazen-Williams(C)

Manning(n)

New Old New Old New Old

DI 0,030 0,200 130 115 0,012 0,017

Concrete 0,300 3,000 120 100 0,013 0,017

Steel 0,030 0,100 125 107 0,008 0,011

PE 0,005 0,030 150 140 0,007 0,009

PVC-O 0,003 0,060 150 140 0,007 0,009

GRP 0,030 0,060 130 100 0,009 0,010

Pipe Life Cycle Cost – kW vs YearsSEVENTH IMPROVEMENT – LIFE CYCLE COST

o Pipeline operating energy proportional to: - pipe material friction coefficient

o Energy Required Start 50 Years 100 Years

o Thermoplastics Unity +10% +20%

o Ductile Iron +10% +25% +50%

o Steel +15% +30% +75%

y = 33,424e0,0019x

y = 44,014e0,0042x

y = 46,911e0,0056x

0,000

10,000

20,000

30,000

40,000

50,000

60,000

70,000

80,000

90,000

0 20 40 60 80 100 120

PO

WER

kW

YEARS

Thermoplastics

Ductile Iron

Steel

Expon. (Thermoplastics)

Expon. (Ductile Iron)

Expon. (Steel)

Thermoplastic Pipes Low Environmental ImpactEIGHTH IMPROVEMENT – ENVIRONMENTAL IMPACT

o Manufacturers may utilise their own scrap – cannot outsource

o Manufacturers generate about 5% scrap – high scrap rates N/A

o Manufacturers recycle in-house – maintain quality control

o PVC-O (TOM 500) material – can be recycled

o Recycled material conformance requirements – Clause 5.2 SANS 16422

o Recycled material monitored and controlled by – ISO 9001 QMS

– SATAS audits

– SAPPMA audits

1. PVC-O (TOM 500) large ID + high pressure – capacity +12% PVC-M and +18% PVC-HI2. PVC-O (TOM 500) low Celerity = low surge – increased velocity gives increased capacity3. PVC-O (TOM 500) high strength socket – extreme orientation and extra length4. PVC-O (TOM 500) Forsheda Anger-lock seal – PP retainer with EPDM seal all 25 bar5. PVC-O (TOM 500) low embodied energy – low environmental impact6. PVC-O (TOM 500) superior hydraulics – low rugosity, low friction uses less energy7. PVC-O (TOM 500) low life cycle cost – low energy gives low operating cost8. PVC-O (TOM 500) may be recycled – low environmental impact

9. PVC-O (TOM 500) seal lifetime – 380 years (ISO11346) EPDM (ISO3384)10. PVC-O (TOM 500) fast jointing time – spigot and socket cf. welding11. PVC-O (TOM 500) stray currents no affect – power line and railway servitudes12. PVC-O (TOM 500) no cathodic protection – saves capital and maintenance costs13. PVC-O (TOM 500) flexible and lightweight – labour intensive construction14. PVC-O (TOM 500) thermoplastic advantages – no corrosion & negligible friction increase15. PVC-O (TOM 500) endurance limit (fatigue) – 10⁷ cycles, every 10 min. 50 yrs = 2,6 . 10⁶16. PVC-O (TOM 500) reduced construction cost – 50% DI and less for steel

17. PVC-O technology “tried and tested” – used for over 40 years18. PVC-O pipes produced in 23 countries – 87,000 tons globally in 2013

PVC-O (TOM 500) – 8 more improvements

SOUTH AFRICA:o PVC-O (TOM 500) local production – skills transfer to South Africao PVC-O (TOM 500) local production – job creation in South Africa (RBIDZ)o PVC-O (TOM 500) local production – latest technology transfer to South Africao PVC-O (TOM 500) local production – *GTPP for emerging contractorso PVC-O (TOM 500) local production – Eco-friendly sustainable “Green Technology” o PVC-O (TOM 500) local production – “Green Building” designated factory

THE PRODUCT:o PVC-O (TOM 500) local production – ISO 9001 QMS accreditationo PVC-O (TOM 500) local production – SANS 16422 SATAS Certificate No. 204/1o PVC-O (TOM 500) local production – IMESA Affiliate Gold Member S4097

THE SYSTEM:o PVC-O (TOM 500) piping system – complete fitting range steel with 300 μm

sintered epoxy made in South Africa

*GTPP – Government Target Procurement Policy

PVC-O (TOM 500)Sizabantu’s Added Value

Many thanks for your attention!Are there any questions?