Thermoplastic Industrial
Piping Systems Presentation
Prepared and Presented by
TIPS Product Line Committee of the PPFA
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
All text, charts, and photos prepared and edited by Chasis Consulting, Inc.
Disclaimer
The material in this presentation/handbook has been prepared for the general information of the reader/user. The information presented is
believed to be technically correct, however, the author, PPFA, PPEF, and their directors, officers, staff, and agents do not warrant the
presentation/handbook or any of its contents suitable for any specific application. The presented material is published as an information
guideline only. It shall be the responsibility of the reader/user to incorporate prudent and generally accepted engineering practices and
meet the requirements of all involved regulatory agencies and their codes and standards.
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
PPFA Educational Materials
• PPFA offers a wide range of educational materials,
developed to help you become more proficient in the
design, installation, and use of the ultimate piping
system – thermoplastics!
• Now available:
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Facilitated, on-site seminars (full-day, half-day, 90-minute)
CD-based seminars (full-day, half-day, 90-minute)
Workbooks
Online tutorials
• For more information on these products, visit us at
http://www.ppfahome.org/tips
3 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
What is the PPFA?
• The Plastic Pipe and Fittings Association (PPFA) is
composed of more than 50 companies involved in
the manufacturing of products for plastic piping
systems. PPFA has been a major force in educating
the American market for over two decades in
thermoplastic residential, commercial and industrial
piping products and installations. For further
information, log on to www.ppfahome.org.
4 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
What is TIPS?
• TIPS is the acronym for Thermoplastic Industrial
Piping Systems; it also is the name of a product line
committee (plc) of the PPFA. TIPS/plc is made up of
several prestigious manufacturers in the industry
whose goals are to educate and promote to the
market place the many benefits of thermoplastic
industrial piping systems. For further information log
on to www.ppfahome.org/tips.
5 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
What does TIPS exclude?
• For purposes of this presentation, TIPS is all piping
excluding the following applications and product
groups:
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6 - Introduction
Irrigation
Above-ground Fire Sprinkler Systems
Residential Swimming Pools
Gas Distribution and Transmission
Municipal, Commercial, and Residential Potable Water, Sewer,
Drain and Vent
Plastic-lined Metal Piping
Flexible Tubing
Composite Piping
Thermosets (Glass Reinforced Resins)
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Presentation Objectives
• This presentation is to provide knowledge,
proficiency and a comfort level in designing,
specifying, and installing TIPS. For maximum
educational benefit, the joint use of the one-day
PowerPoint CD and workbook is recommended.
7 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Definitions and History
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Plastic
• A material that contains organic, polymeric
substances of large molecular weight, is solid in its
finished state, and at some stage in its manufacture
or processing into a finished article, can be shaped
by flow
9 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Thermoplastic
• A plastic that can be repeatedly softened by heating
and hardened by cooling through a temperature
range characteristic of the plastic, and that in the
softened state, can be shaped by flow into an article
by molding or extrusion
Water analogy: Thermoplastics, similar to water, can be heated and cooled
repeatedly without any change in the material’s basic properties. (i.e., recyclable)
10 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Thermoset
• A plastic that, when cured by application of heat or
by chemical means, changes into a substantially
infusible and product
Egg analogy: Thermosets, similar to eggs, can be processed only once with
changes occurring in the material’s basic properties.
11 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Monomer
• A relatively simple compound that can react to form
a polymer
Polymer
• A substance consisting of molecules characterized
by the repetition of one or more types of monomeric
units
Copolymer
• A polymer formed by the polymerization of two
chemically different monomers
12 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Resin
• Broadly stated, the term designates any polymer or
copolymer that is the basic material for a plastic
Plastic resin
13 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Additives
• Chemical ingredients incorporated in the resin or
added during the manufacturing process to give
desired product performance characteristics. These
can include the following:
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14 - Introduction
Heat Stabilizers - Protect against thermal degradation
Antioxidants - Protect against oxidation
Ultraviolet Stabilizers - Protect against ultraviolet degradation
Lubricants - Improve manufacturing processing
Pigments - Add a distinctive color & aid in UV protection
Fillers - Reduce cost and may also increase stiffness
Property Modifiers - Enhance a particular material property
Processing Aids - Assist material mixing/fusion during processing
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Compound
• A mixture of a thermoplastic resin with other
additives or ingredients
Plastic pellet and
powder compound
15 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Extrusion
Extrusion Diagram
• All thermoplastic pipe is extruded. Extrusion
is a
process whereby heated plastic forced throughExtruder
a
shaping orifice becomes one continuously formed
piece.
16 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Injection Molding
• Most voluminous thermoplastic non-pipe products
are injection molded. Injection molding is the
Injection Molding
Machine
process of forming a material by forcing it, under
pressure, from a heated cylinder through a sprue
(runner) into the cavity of a closed mold.
Injection Molding Diagram
17 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Injection Molding
Mold
Sprue Bushing
Injection Nozzle
Press Clamp Unit
Reciprocating
Screw
Reciprocating
Hydraulic Injection Unit
18 - Introduction
Screw Rotation
Transmission
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Injection Molding
“Hopper”
Loading System
Screw
Movement
Material
Plasticized In Barrel
19 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Injection Molding
Stationary Platen
Moving Platen
Screw
Movement
20 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Injection Molding
Mold Halves
Platen Movement
21 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Injection Molding
Molded Part
22 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Injection Molding
Ejector Pins
23 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Injection Molding
Platen Movement
24 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Injection Molding
Screw
Movement
25 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
History of Thermoplastic Piping Materials
Estimated Year Plastic Discovered
Plastic Material*
Estimated Year of Piping Usage
1868
Cellulose Nitrate (Celluloid)
First semi-synthetic plastic
1909
Phenol Formaldehyde (Bakelite)
First all synthetic plastic
1927
Polyvinyl Chloride (PVC)
1940
1933
Polyethylene (PE)
1948
1938
Cellulose Acetate Butyrate (CAB)
1940
1938
Polytetrafluoroethylene (PTFE)
1960
1943
Chlorinated Polyvinyl Chloride (CPVC)
1960
1948
Acrylonitrile Butadiene Styrene (ABS)
1952
1955
Ethylene Chlorotrifluoroethylene (ECTFE)
1966
1956
Fluorinated Ethylenepropylene (FEP)
1965
1957
Polypropylene (PP)
1958
1960
Cross-Linked Polyethylene (PEX)**
1965
1962
Polybutylene (PB)
1971
1963
Polyvinylidene Fluoride (PVDF)
1964
1968
Perfluoroalkoxy (PFA)
1972
* Items in bold print are plastic materials included in this presentation.
26 - Introduction
**A thermoset material
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Plastic Piping Materials
• Thermoplastics accounted for over 95% of an
estimated 11 billion pounds of plastic that went into
all pipe, conduit and fittings in 2002. The estimated
TIPS Market ($) share by
pipe/valves/fitting materials
for Year 2002 is shown in
the pie chart.
27 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Material Characteristics
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Plastic Material Designations
• ASTM is the standards development organization
that classifies plastic piping materials by common
physical characteristics categories. Over the past
decade, there has been a movement to refine the
classifications in a more meaningful way; however,
the old designations are still in use.
29 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Plastic Material Designations
• Old ASTM Designations: Material Designation
– First Digit = Type
– Second Digit = Grade
– Third / Fourth Digit = Hydrostatic design stress divided by 100
• Example: PVC 1120
30 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Plastic Material Designations
• New ASTM Designation Called Cell Classification
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First Digit = Material
Second Digit = Impact Strength
Third Digit = Tensile Strength
Fourth Digit = Modulus of Elasticity
Fifth Digit = Heat Deflection Temperature
• Example: PVC 12454 (Similar to PVC 1120)
31 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Plastic Material Designations
• This seminar will include the following materials:*
CPVC
ASTM D1784-03
Cell Classification 23447/24448
HDPE
ASTM D3350-02a
Cell Classification 345464C
PP
ASTM D4101
Type I
PVC
ASTM D1784-03
Cell Classification 12454
PVDF
ASTM D3222
Type I Grade 2
* Thermoplastic compounds can be reformulated to accentuate certain properties. Check
with product manufacturers for latest compound usage.
ABS material is not included in the Engineering and Physical Characteristics sections,
because most ABS applications in the USA are for residential drain waste and vent, rather
than industrial uses.
32 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Physical Characteristics*
* The physical values listed may differ slightly due to
variations of manufacturer’s resins and compounds.
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Specific Gravity
• The ratio of the density of a material to the density of
water at standard temperature (ASTM D-792 Test
Method). The lower the number, the lighter the
weight.
Note: Water= 1.0
34 - Introduction
PP
0.91
PE
0.92
PVC
1.38
CPVC
1.55
PVDF
1.76
PE Piping Lighter than Water
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Tensile Strength
• The pulling force necessary to break
a specimen, divided by the crosssection area at the point of failure.
(ASTM D-638 Test Method)
(psi @ 73°F)
35 - Introduction
PVDF
8000
CPVC
7500
PVC
7300
PP
4600
PE
3500
Tensile
TensileTesting
Plastic
Specimen
Test
Machine
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Modulus of Elasticity
• The ratio of the stress to the elongation per inch due
to this stress, in a material that deforms elastically.
(ASTM D-638 Test Method) (psi @ 73°F x 105)
36 - Introduction
PVC
4.2
CPVC
3.6
PVDF
2.1
PP
2.0
PE
1.2
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Flexural Strength
• The strength of a plastic material in bending as
expressed by the tensile stress of
the outermost fibers of a bent test
sample at the instant of failure.
(ASTM D-790 Test Method) (psi)
37 - Introduction
PVC
14500
CPVC
13400
PVDF
9700
PP
7000
PE
3000
Flexural Plastic
Specimen Test
Flexural
Testing
Machine
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Izod Impact Strength
• The resistance of a notched test specimen has to a
sharp blow from a pendulum
hammer. (ASTM Test D-256)
(ft-lb/in) The lower the number,
the lower the impact strength.
38 - Introduction
PE
7.0
PVDF
3.8
CPVC
2.0
PVC
1.1
PP
0.8
Izod Testing
Izod Testing
MachineMachine
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Coefficient of Thermal Expansion
• The fractional change in a length of a specimen due
to a unit change in temperature. (ASTM D-6960 Test
Method) (in./in./°F x 10-5) The lower the number, the
lower the expansion rate.
39 - Introduction
PVC
3.0
CPVC
3.8
PP
5.0
PVDF
7.3
PE
7.8
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Thermal Conductivity
• The time rate of transferring heat by conduction
through a material of a given thickness and area for
a given temperature difference. (ASTM C-177 Test
Method)(Btu in./hr/ft2/°F) The lower the number, the
less conductive.
40 - Introduction
CPVC
0.95
PVDF
1.18
PVC
1.20
PP
1.20
PE
2.60
Thermal Conductivity
via Modulated DSC
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Heat Resistance
• The general maximum allowable temperature of a
piping system in which 20-psi working pressure or
less may be used (°F)
Heat Deflection Testing Machine
41 - Introduction
PVC
140
PE
160
PP
180
CPVC
210
PVDF
285
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Abrasion Resistance
• Using the Taber Abrasion Test, the weight loss of a
material is measured after being exposed to an
abrasive wheel for 1000 cycles. (mg) The lower the
number, the more abrasion resistant.
Note:Stainless Steel is 50.
42 - Introduction
PE
5
PVDF
5-10
PP
15-20
PVC
12-20
CPVC
20
Taber Machine
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Flash Ignition Temperature
• The lowest temperature of a substance at which
sufficient combustible gas is evolved to be ignited by
a small external flame. (°F)
Note: Wood products ignite
at 500°F and lower.
43 - Introduction
CPVC
900
PVDF
790
PVC
730
PE
660
PP
N/A
Instrument to Test
Flash Points of Materials
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Flammability Rating
• An Underwriter Laboratories test to measure a
material’s resistance to burning, dripping, glow
emission and burn-through. The 94V-0 designation
is the most resistant to burning; 94HB is the least
resistant to burning.
PVDF
94V-0
CPVC
94V-0
PVC
94V-0
PP*
94HB
PE
94V-2
* Fire retardant grades can
increase value to 94V-2.
44 - Introduction
Flammability Testing by
Underwriter Laboratories
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Limiting Oxygen Index
• The percentage of oxygen needed in an atmosphere
to support combustion (ASTM D2863 Test Method).
The higher the number, the greater the resistance to
burning. (%)
45 - Introduction
CPVC
60
PVDF
44-75
PVC
43
PP
18
PE
17
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
Flame Spread /
Smoke Development Indices
• These material
are
determined
by
Flame Spreadcharacteristics
Index*
Smoke
Development
Index*
testing the
surface0 flame spread
of and5-50
smoke
PVDF
PVDF
developed
by plastic
piping asPVC
compared
to fixed
>300
PVC
15-20
index elements
of15mineral fiber
cement>350
board and
CPVC
CPVC
red oak flooring. (ASTM E-84, NFPA 255, UL 723
PP
N/A
PP
>400
and UBC 8-1) (42-1 Test Method).
PE
N/A
PE
>400
Note:
MajorPP
building
andare
mechanical
require
that combustible
*CPVC,
and PVC
available codes
in specially
formulated
product
piping
installedthat
within
animproved
air plenumflame
mustspread
have aand/or
maximum
flame
compounds
have
smoke
spread
index of characteristics.
25 and a maximum smoke development index of 50.
development
46 - Introduction
©2003, 2004, 2005 - Plastics Pipe and Fittings Association
TIPS are...
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47 - Introduction
Environmentally sound
Easy and safe to install
Reliable
Long-lasting
Cost-effective
©2003, 2004, 2005 - Plastics Pipe and Fittings Association