Following the installation of the German-engineered Krauss Maffei extrusion line in mid-2013, polyvinyl chloride (PVC) pipe manufacturer DPI Plastics became the only plastic pipe manufacturer in Africa capable of producing 630-mm-bore PVC pipes.

Industrial water treatment company Aquserv placed the first order for the new pipes of R3.4-million earlier this year for the Chimunda irrigation system, in Mozambique.

“DPI Plastics developed a solution by manufacturing the pipes in 5.5 m lengths, which ensured that all 440 pipes were efficiently delivered on site using 13 separate trucks, each carrying about 34 pipes,” explains DPI Plastics exports manager Rajesh Naval.

Aquserv director Luís Sampaio notes that this large-scale project requires high outputs.

“In the past, the only solution was to lay two parallel pipelines or to import the pipes from Europe at a high cost. The DPI Plastics’ 630-mm-bore unplasticised polyvinyl chloride (uPVC) pipeline ensures that a single pipeline is now required, which results in substantial savings with regard to materials bought and transportation costs. This, in turn, significantly reduces installation times and associated costs,” he adds.

Naval explains that the SANS 966-approved pipes supplied to the project boast a pressure rating of 6 bar, with numerous benefits.

“PVC is more cost effective and boasts a longer life expectancy, compared with industry-standard steel and concrete, which are often prone to corrosion damage over extended periods. PVC is also highly durable, with low frictional resistance and low wave celerity, thereby ensuring resistance to surges,” he adds.

Owing to the sheer size of the pipes, which come in standard 6 m lengths, Naval admits that transport proved to be a challenge, as the pipes did not initially fit onto the delivery trucks, which resulted in the pipes being cut to 5.5 m to fit onto the trucks.

Sampaio states that strict planning with regard to transporting the pipes resulted in overcoming logistical challenges, which include Mozambique’s poor road infrastructure and cross-border red tape.

“The delivery process was further streamlined through clear and consistent communication between Aquserv and its client, as well as all relevant suppliers and service providers,” he adds.

Following the successful on-site delivery of all the pipes in March 2014, Sampaio indicates that the contractor has started laying the pipes.

“In addition to the 630 mm pipes, we are also supplying our client with a wide range of alternate-diameter uPVC and steel pipes, pipe fittings, pumps, valves and associated accessories worth R6.5-million to meet the unique demands of this project,” says Sampaio.

The Krauss Maffei extrusion line at DPI Plastics’ factory, in Johannesburg, can produce up to 22 t/d of PVC piping products.

The extrusion line can also produce up to 630-mm-diameter SANS 966-approved PVC pipe, with pressure ratings of up to 12 bar, and up to 630-mm-diameter SANS 791-approved underground sewerage and drainage pipe, with both pipe ranges available in standard-duty and heavy-duty options, highlights Naval.

“With infrastructural development taking place across Africa, the number of enquiries pertaining to the 630 mm PVC piping range has increased. As a result, I believe that DPI Plastics is in a strong position to expand its footprint across the continent,” he says.

Further, DPI Plastics technical and product manager Renier Snyman notes that the company is competing directly against steel, ductile iron and fibreglass products in the pressure-pipe market, as well as against concrete and high-density polyethylene products in the sewerage pipes market.