CHAPTER I - POLYVINYL CHLORIDE (PVC) PIPE

CHAPTER I POLYVINYL CHLORIDE (PVC) PIPE A Product of Modern Technology

HANDBOOK OF PVC PIPE

CHAPTER I POLYVINYL CHLORIDE (PVC) PIPE

During the 20th century a truly revolutionary advancement in pipeline materials engineering occurred. The revolution was born in polymer science and has, through many decades of technological refinement, been accelerating. The polymer that has achieved front-runner status throughout this pipe revolution is polyvinyl chloride (PVC). Recognized by Engineering News Record as being one of the top 125 engineering innovations, the desirable combination of chemical resistance, long-term strength, and high stiffness accounts for PVC having become a popular pipe material for many pressure and non-pressure applications. The use and availability of PVC pipe has grown steadily since the 1950s. PVC has become the dominant pipe material for such major markets as the pressure and non-pressure sanitary sewer market and the pressure water distribution market. In North America each year, the total installed length of PVC water and sanitary sewer pipe exceeds that of any alternative piping material. Much of this handbook is devoted to the proper application of PVC pipe within these major markets. In addition, more recent technological advancements have allowed the PVC pipe industry to expand production to include larger pipe diameters and allow for more efficient use of materials. As a result, PVC pipe has been

CHAPTER I - POLYVINYL CHLORIDE (PVC) PIPE

successfully introduced to several other buried pipe markets, which include gravity storm sewers, highway drainage, agricultural drainage, and the large diameter pressure transmission pipe market.

PVC: AN ENGINEERED THERMOPLASTIC PVC is part of a large, complex, and constantly developing group of materials known as plastics. Plastic materials, like metals and other pipeline materials, possess a wide range of properties that lend themselves to particular applications. Structurally, plastic materials used for pipe fabrication can exhibit properties ranging from soft and flexible to hard and rigid. Plastic pipe materials may be divided into two basic groups, thermoplastic and thermosetting. Thermoplastics, as the name implies, soften whenever heated and harden when cooled. They can be formed and reformed repeatedly, but the reprocessing steps must be controlled and limited to insure retention of original performance properties. PVC is a thermoplastic, which is manufactured using an extrusion process as described in Chapter IV. The ability to be reheated and reformed also enables PVC pipes to be manufactured with a post-extrusion, heat-formed bell end for jointing. PVC fittings are generally made in an injection molding process or fabricated through the assembly of molded or extruded parts. Chapter IV describes both manufacturing processes. Thermosetting plastics go through a soft plastic stage only once, then harden irreversibly, and cannot again be softened without incurring permanent damage. Some of the more common thermosetting plastics used for pipe are glass-fiber-reinforced thermosetting resin and cross-linked polyethylene. HISTORICAL BACKGROUND Polyvinyl chloride was discovered in the waning years of the nineteenth century. Its birth was not particularly glamorous. Scientists observing a newly created organic chemical gas, vinyl chloride (C2H3Cl), discovered that when exposed to sunlight this gaseous material reacted strangely. The chemical reaction, which ensued, resulted in the creation of an off-white accumulation of solid material in the bottom of their test tubes. The scientists had observed simple polymerization or the basic creation of a new plastic material, polyvinyl chloride.

HANDBOOK OF PVC PIPE

Subsequent investigation of the new polymer at first created great excitement and, somewhat later, great disappointment. The scientists were astonished by the incredible new plastic material, which seemed nearly inert to most chemicals and, in fact, virtually indestructible. However, they soon found the material so resistant to change that they were forced to concede that it could not be easily formed or processed into useful applications. Soon thereafter, PVC was termed another of science's great discoveries without an apparent application, and the world forgot about the unique new plastic. Not until the 1920s did curiosity again bring polyvinyl chloride into the limelight. Scientists in Europe and America launched an extended campaign, which eventually brought PVC plastics to the modern world. Technology evolved worldwide, but particularly in Germany, for the use of PVC in its unplasticized, rigid form. In 1931, PVC compounds were developed by German scientists who proceeded to produce millions of pounds, some of it for pipes. Through continued service today, several of these earliest PVC pipelines provide testimony to PVC's outstanding durability. In large part, the PVC pipe industry was born out of a necessity created by World War II. German scientists and engineers turned to PVC as a pipe material to quickly restore essential water and wastewater pipelines in cities damaged by Allied bombings. In the pre-war period, and to some extent during the war, PVC processing was largely carried out on machinery developed for rubber or celluloid. Even immediately after the war, the technology remained fairly primitive and the processing machinery was not engineered specifically for PVC. In the 1950s and 1960s, the two decades following the war, there were considerable advances in PVC technology, both in formulation and processing. The development of more effective stabilizers, lubricants and processing aids, together with processing machinery engineered specifically for PVC, allowed for increasing success in the extrusion of quality, rigid (unplasticized) PVC pipe. The result was that PVC pipe began competing with traditional products in a number of major markets including: gas distribution; sewer and drainage; water distribution; electrical conduit; chemical processing; and drain, waste, and vent plumbing. PVC pipe's success in North America parallels that which occurred in Europe. Since its introduction in North America in 1951, PVC has become the largest volume plastic piping material. In 1955, the year the American

CHAPTER I - POLYVINYL CHLORIDE (PVC) PIPE

Society for Testing and Materials (ASTM) organized a group to write plastic pipe standards, North American plastic pipe shipments were just under 40 million pounds. By 1968, North American PVC pipe sales surpassed 200 million pounds annually. Figure 1.1 charts the PVC pipe industry's progress and growth from the mid-seventies for North America and the world. The PVC pipe industry's growth rate has been nothing short of phenomenal. The factors behind the product's success and rapid growth are continuing advancements in processing technology; improved joining materials; continuing standardization programs; improved quality control testing; and continuing and increasing understanding and acceptance by designers, contractors, and purchasing agents. FIGURE 1.1 PVC PIPE AND FITTINGS INDUSTRY GROWTH
25

PVC Pipe and Fittings Shipments (lbs) (Billions)

20

Worldwide
15

10

USA & Canada

0 1975 1980 1985 1990 1995 2000

Year

A RATIONAL CHOICE The range of useful properties afforded by PVC makes it one of the most versatile of all pipe materials, a fact attested to by the variety of applications and markets served by PVC pipes. The rationale for specifying or using
5

HANDBOOK OF PVC PIPE

PVC pipe is justified on the basis of any or several of the following attributes. Corrosion Resistance: PVC pipes are non-conductors of electricity and immune to electrochemical reactions caused by acids, bases, and salts that cause corrosion in metals. This characteristic exists on both the inside and outside of PVC pipe. Consequently, PVC pipe is frequently cost effective in applications where soil is aggressive. PVC pipe can be expected to outlast alternative pipes without the need for protective coatings or liners.

Chemical Resistance: PVC pipes exhibit resistance to a wide range of chemical reagents in temperatures up to 140F and are resistant to chemicals normally found or used in homes. Some industrial applications will warrant an evaluation of chemical resistance. The chemical resistance quality of PVC is further evidenced by its frequent usage as a protective liner for other pipe materials. Strength to Weight Ratio, Light Weight: PVC pipes offer a tremendous weight advantage that is a particularly important safety aspect. The material's ability to be handled more easily minimizes worker injury and facilitates lower cost installation and transportation. A person can easily carry two 20-foot lengths of 4-inch PVC pipe, but could carry less than 5 feet of 4-inch iron pipe with the same effort.

CHAPTER I - POLYVINYL CHLORIDE (PVC) PIPE

Flexibility: PVC pipe's resistance to fracture is an extremely important performance advantage. While PVC pipes are made from rigid (unplasticized) PVC compound, the pipe itself has the ability to yield under loading without fracturing. The modulus of elasticity of PVC is a major advantage for buried applications, particularly where soil movement or vibration is anticipated. In pressure applications, PVC's modulus of elasticity also reduces the magnitude of pressure surges (i.e., water hammer). Long-Term Tensile Strength: PVC pipe compounds are formulated to attain long-term tensile strength. The long-term hydrostatic design basis (HDB) for PVC is two or more times greater than that for other common thermoplastic pipe materials. Watertight Joints: A major advantage for nearly all piping applications is joint tightness. PVC pipes are available with deep insertion, push-together gasketed joints. Gasketed PVC pipe joints have consistently out-performed those of traditional pipe products in actual service. They are simple and easy to assemble and can be filled, tested, and placed in service immediately after assembly. Abrasion/Wear Resistance: PVC pipes exhibit outstanding resistance to wear and abrasion. PVC pipe has proven more durable than metal, concrete, and clay pipe for the transport of abrasive slurries. Impact Strength: Under normal conditions, PVC pipes possess relatively high resistance to impact damage when compared to pipes made from clay, concrete, and most other conventional materials. Even though PVC pipes do exhibit a reduction in impact strength at very low temperatures, the impact strength remains more than adequate, usually exceeding that of alternate pipe materials. Coefficient of Friction: PVC pipes provide smoother wall surfaces that reduce fluid friction and resistance to flow. This hydraulic smoothness inhibits slime buildup in sewers and virtually eliminates tuberculation and encrustation in water distribution mains. The end results are significantly lower maintenance costs and more efficient initial pipeline design. Longer Lengths: PVC pipe generally is available in lengths of either 13 feet or 20 feet. This reduces the number of joints required as compared with other pipe products. Fewer joints allow for faster, more efficient installation, less hydraulic friction, and fewer opportunities for leakage.

HANDBOOK OF PVC PIPE

Water Quality: PVC pipes non-corrosive nature and resistance to chemical attack also renders it non-reactive with drinking water. PVC pressure pipes do not adversely alter water quality. There are no corrosion byproducts with PVC pipe. PVC water pipes have been tested extensively using aggressive waters to verify their safety advantage. Thermal Insulation: PVC has lower thermal conductivity than traditional pipe materials. This characteristic makes PVC pipe desirable for a variety of thermal insulation applications.
8

CHAPTER I - POLYVINYL CHLORIDE (PVC) PIPE

Flame Resistance: PVC pipe is difficult to ignite and will not continue burning in the absence of an external ignition source. The spontaneous ignition temperature is 850F, which is well above that of most construction materials. PVC pipe is sometimes referred to as self-extinguishing because the products of combustion immediately combine with any available oxygen, thus starving the flame. Environmental Benefit: PVC, as a raw material, is energy efficient to process. More than half of the raw material used in production of resin is provided by salt, of which there is virtually unlimited supply. Similarly, PVC pipe is efficient to manufacture and transport, using less nonrenewable resources than competing materials. However, a complete evaluation of benefit recognizes the entire life cycle of the product, from manufacture to disposal. Given the durable nature of the material, the long life afforded by PVC pipe essentially eliminates the question of disposal. Nevertheless, PVC is recyclable, with existing markets for recycled material, and new ones continually developing. Favorable Cost: PVC pipe is competitive with other pipes, particularly when installation and life cycle operating costs are taken into consideration. PVC PIPE TECHNOLOGY Notwithstanding current advantages afforded by PVC pipe, the industry is continuing to improve upon the technology. Through research and development, the PVC pipe industry is striving to make the best possible pipe and fittings products. With the ability to draw from PVC pipe's worldwide experience, and with the opportunity to learn from the shortcomings of predecessor pipe products, the PVC pipe industry will maintain its product's advantages and work toward the betterment of those advantages. PVC pipe is a product of modern technology, offering reliable and durable service to a variety of consumers (i.e., contractors, engineers, operators, industries, utilities, and irrigation districts). PVC pipe is a tried and proven performer, a credit to PVC's inherently superior characteristics and thorough engineering design.

HANDBOOK OF PVC PIPE

CHAPTER I BIBLIOGRAPHY
1. American Society of Civil Engineers (ASCE), Structural Plastics Design Manual, ASCE Manual No. 63 (1984). 2. Bulkey, Charles W., Robert G. Morin and Alan J. Stockwell, "Vinyl Polymers and Copolymers," Modern Plastics Encyclopedia 1968, v. 45: No. 14A (Oct. 1968), p. 336. 3. Committee on Resin Statistics, the Society of the Plastics Industry (SPI), Facts & Figures of the U.S. Plastics Industry, Washington, DC, (1997).

4. Henson, J. H. L. and A. Whelan, Developments in PVC Technology, National College of Rubber Technology, London (Feb. 1973). 5. McJunkin, Frederick E. and Charles S. Pineo, Role of Plastic Pipe in Community Water Supplies in Developing Countries, Agency for International Development, (1971). 6. Modern Plastics, McGraw-Hill Publications, New York, (Jan. annually). 7. Penn, W. S., PVC Technology, Wiley Interscience, A Division of John Wiley and Sons, Inc., New York (1967). 8. World PVC Demand, SRI International (1989). 9. Engineering News Record, McGraw Hill Companies, Inc. (October 18, 1999).

10