SPECIALISEDPRODUCTS

Showcase

www.marleypipesystems.co.za

MEGATUFF HDPE Pipe

HDPE Fabricated Fittings

Electrofusion Fittings

Compression Fittings

Butt Weld Fittings

Weholite

INDEX

INTRODUCTION

PRODUCTS MEGATUFF HDPE

Fabricated Fittings

Electrofusion Fittings

Weholite Pipe

Compression Fittings

MEGATUFF Gas Pipe

MEGATUFF Vent Pipe

MEGATUFF FR Pipe

Butt Weld Fittings

INSTALLATION HDPE Pipes

Electrofusion

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Compression Fittings

Butt Welding

FAQ HDPE Pipe

Weholite

Electrofusion

Compression Fittings

Butt Welding

MARKETING SUPPORT

TRAINING

CONTACT US

01

INTRODUCTION

Marley Pipe Systems, an Aliaxis company, is recognised as the trusted name in fluid handling solutions throughout southern Africa, offering an extensive range of pipes and fittings, and related products that set the standard for quality, compliance and customer satisfaction.

Marley’s dedicated Mining and Industrial Division leads the way with value driven pipe solutions that are proven to improve efficiency, solve key industry challenges, and ensure safe and sustainable

operation in a broad spectrum of demanding pipeline applications. Together with a no compromise commitment to quality and technical support, Marley sets the benchmark for industry standards through the responsible design, manufacture and installation of pipe systems.

02www.marleypipesystems.co.za

YOUR EXPERIENCED PARTNER IN FLUID HANDLING SOLUTIONS

03

MEGATUFF HDPE PIPE

A LEGACy OF QUALITy, TECHNOLOGy AND PERFORMANCE

For some 50 years, Marley Pipe Systems has been a leader in the design, development, manufacture and engineering support of polyethylene piping systems. Our capabilities in HDPE pipe solutions have made us the trusted partner for many mining, civils, agricultural and industrial projects across sub-Saharan Africa.

Our range of HDPE pipes have earned the name MEGATUFF for their endurance in the field – giving engineers and contractors alike the confidence in specifying a quality brand that meets the highest demands from clients and for different applications.

MEGATUFF HDPE Pipe systems are manufactured to, and carry the SABS mark of trusted quality for SANS ISO 4427 and are available in diameters from 16mm up to 1000mm, in pressure ranges from PN2.5 to PN25 in PE100.

FeatureS & BeneFitS

• High Impact Strength: ensures a greater resistance to the rigours of pipe laying conditions

• Damage Resistance: as a result of low notch sensitivity

• Ease of Installation: owing to light weight and availability in long lengths

• High Flow Capacity: lower friction factors than most non-plastic materials

• Long Life: provides a long, maintenance-free lifetime with low whole life costs

• Good Chemical and Corrosion Resistance• Flexibility: can be bent to a minimum

bending radius of 30 times the pipe’s outside diameter

• Good Abrasion Resistance• Good UV Resistance: inclusion of carbon

black in raw material stabilises against direct sunlight

• Cost-effectiveness: providing value over time

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CLICK TO VIEW PIPE DIMENSIONS

CLICK TO VIEW PHySICAL PROPERTIES

CLICK TO VIEW CHEMICAL RESISTANCE CHART

03

04

HDPE FABRICATED FITTINGSQUALITy MADE TO yOUR SPECIFICATIONS

The ever increasing demand for more complex and cost efficient pipeline designs has resulted in a greater need for HDPE fabricated pipe and fittings as a means to solve installation situations where common fittings fail. As part of our turnkey HDPE solution, Marley specialises in the extrusion and fabrication of both Solid-Wall and Structured Wall HDPE pipe and fittings.

Our fully equipped fabrication workshop is operated by a team of highly trained staff, including qualified plasticians who have been certified by the Plastics Federation of South Africa. Utilising state-of-the-art equipment and machinery, including modern trench welders and fabricators, our fabrication solution has been proven to provide the same level of quality that our HDPE offering has become renowned for.

All pipes and fittings are fabricated to SANS ISO 4427, ISO 4437 and related standards in compliance with SAPPMA and IFPA requirements.

CLICK TO VIEW PRODUCT RANGE & DIMENSIONS

www.marleypipesystems.co.za

05

ELECTROFUSION FITTINGSFOR SIMPLE, RELIABLE HDPE CONNECTIONS

Electrofusion welding systems are now considered the most highly developed and safe method for joining polyethylene pipes. Thanks to its versatility, electrofusion can be used to weld together pipes or fittings from different polyethylene materials and different thicknesses as long as there is compatibility of melt flow index and raw material density.

Marley Pipe Systems carries a range of FRIALEN safety fittings and machines designed to provide quality connections reliably and simply for pressurised gas and water pipelines in civil and industrial applications.

Fittings are available in sizes from 20mm to 400mm with all fittings up to 160mm rated PN25 (for water) and PN16 for sizes from 180mm to 400mm. All electrofusion fittings are guaranteed for welding on both PE80 and PE100 pipelines.

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FeatureS & BeneFitS

Exposed heating coil for improved hold

FRIALEN safety fittings are designed with exposed heating coils. These provide consistent heat transfer during fusion ensuring a homogenous joint that is stronger than the pipe itself.

Longer fusion zone for more bite

The length of the coupler is beyond the standards set out, meaning that FRIALEN safety fittings have a longer fusion zone which allows a considerably greater solidity and reliability of the fusion joint.

Larger insertion depth for a perfect result

Longer couplers also mean larger insertion depth of the pipe ends inside the coupler, which contributes considerably to the reliability and safety of your pipe connections and compensates for bending stresses.

CLICK TO VIEW PRODUCT RANGE & INFORMATION

06

WEHOLITE STRUCTURED WALL HDPE PIPETHE LIGHTWEIGHT, ENGINEERED PIPE WITH SUPERIOR LOADING CAPACITy

Marley Pipe Systems is the South African licensee of the Weholite pipework system, a large diameter gravity or low pressure high density polyethylene (HDPE) pipe. Constructed by a unique patented structured wall process, Weholite can be manufactured in a range of ring stiffnesses and large pipe sizes from 280mm up to 3500mm – depending on customer requirements.

Weholite Structured Wall HDPE pipe provides all the technical advantages of equivalent polyethylene Solid-Wall pipes, but with substantial savings in weight, thus combining greater ease of installation with increased cost effectiveness when compared to traditional materials. Marley also supplies a range of Weholite LP Couplings designed and manufactured specifically for use with Weholite pipes.

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FeatureS & BeneFitS

• Virtually Leak-proof: 12m lengths offer a greatly reduced joint frequency

• Corrosion Resistant: less susceptible to salt water and chemicals associated with sanitary sewage effluent

• Flexible: high tolerance for harsh environments and virtually unbreakable in freezing conditions

• Lightweight: can be transported and handled easily on site, making for ease of installation

• Weld Ability: welded joints render the sewer pipe 100% root ingress resistant

APPLICATIONS

• Irrigation Systems• Sanitary Sewer Systems• Culvert Replacement • Drainage & Stormwater Pipelines• Cooling water intakes• Manholes• Pumping chambers• Marine outfall• Ventilation pipes• Surface drainage• Inter-process pipework• Tanks, floats, ventilation ducts

CLICK TO VIEW PRODUCT RANGE & INFORMATION

CLICK TO VIEW COMPARISON GUIDE

07

ASTORE COMPRESSION FITTINGSCONNECTING HDPE PIPES CONSISTENTLy

Marley supplies a comprehensive range of Astore Compression Fittings engineered for use with HDPE pipe dedicated to fluid reticulation in irrigation and drinking water systems as well as a wide range of plant engineering installation requirements.

The fittings are made in compliance with the requirements of a number of international standards and also carry the SABS mark of approval (SANS 14236:2003). Sizes range from 16mm to 110mm. All fittings with a female threaded portion of 32mm or greater are reinforced externally with a stainless steel ring.

The pressure rating of the fittings at 20°C is as follows:

• Sizes from 16mm to 63mm (Blue coloured nut): 16 Bar• Sizes from 75mm to 110mm (Black coloured nut): 10 Bar

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CLICK TO VIEW PRODUCT RANGE & INFORMATION

08

MEGATUFF GAS PIPE

HDPE SOLUTIONS FOR LONG-LASTING GAS INSTALLATIONS

Marley offers a comprehensive range of HDPE pipe and fittings specifically designed for buried installations in gas distribution applications. MEGATUFF Gas Pipe combines all the raw material benefits of HDPE polymers with high strength and high stress crack resistant properties, which is particularly important in gas pipelines.

Manufactured in accordance with SABS SANS 4437 standards, MEGATUFF Gas Pipe and Fittings are quality tested throughout the entire production process to ensure their reliability and effectiveness for gas transportation.

MEGATUFF Gas Pipe is available in a range of sizes from 25mm to 630mm and is manufactured from HDPE PE100 material grade. The preferred series of pipes are SDR11 and SDR17 for gas applications. These high performance gas pipe systems can be joined using electrofusion jointing methods, and in some cases, butt welding, providing a completely homogeneous leak free system.

www.marleypipesystems.co.za

09

MEGATUFF VENT PIPE

FIT-FOR-PURPOSE SOLUTIONS FOR MINE VENTILATION SySTEMS

As the leaders in the manufacturer of HDPE pipe systems in South Africa, Marley Pipe Systems continues to add value in the mining sector through solutions that meet the performance as well as health and safety demands of Africa’s rapidly evolving mines. The MEGATUFF Vent Pipe System has been specially developed to provide a complete solution for mine ventilation systems in the control of health hazards associated with harmful atmospheric conditions in underground mines.

Manufactured from the highest quality HDPE materials, MEGATUFF Vent Pipe combines strength and durability with flexibility and ease of installation for a fit-for-purpose solution that can be manufactured to your specific requirements and in compliance with rigorous health and safety requirements.

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FeatureS & BeneFitS

• Ease of Installation: owing to its light weight, which also makes it easy to dismantle

• Improved Blast Resistance: enhancing worker safety in the event of an emergency

• Ease of Suspension: pipes can be easily suspended without the need for additional support

• Flush Fittings: completely concealed to prevent damage and movement of the pipe

• Minimal Leakages: as a result of reduced joint frequency

• Ease of Repair: and offers an extended wear life

CLICK TO VIEW TECHNICAL INFORMATION

10

MEGATUFF FR PIPE

IMPROVING FIRE SAFETy IN UNDERGROUND MINES

MEGATUFF FR Pipe is a robust, fire retardant HDPE pipe system for application in underground mines where fire safety is a concern.

Manufactured from heat resistant materials and a polymer compound coating, MEGATUFF FR Pipe significantly reduces the spread of flame in a fire. As a result of excellent intumescent properties, carbonaceous char forms on the product after being exposed to flames which effectively protects the pipe and its contents from ignition and contributes to the reflection of heat.

In addition, the MEGATUFF FR Pipe system has undergone extensive tests to ensure its safety for use in a multitude of applications where fire hazards are a concern.

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FeatureS & BeneFitS

• Available in sizes from 50mm to 355mm• Flame retardant pipe• 50 year design life• Good chemical resistance• Lightweight• Rapid installation• Reduced pump costs as a result of the

low friction factor of HDPE• Excellent impact resistance• Suitable for backfill operations• Piping can be used continuously or as a

firebreak

CLICK TO VIEW TECHNICAL INFORMATION

03

BUTT WELD FITTINGS

ACHIEVE QUALITy jOINTS FASTER AND ECONOMICALLy

Marley supplies a complete range of high density polyethylene (HDPE) butt weld fittings with for use exclusively with butt welding. These fittings are often a preferred option for butt weld contractors as they are compact, easily stacked for simplified transportation and storage, and excellent for prefabricated pipe works.

Depending on the design and make, butt-fusion machines may or may not be capable of accepting fittings as moulded for direct welding to pipes. Marley therefore offers two ranges of fittings for butt-fusion systems to provide the greatest flexibility:

• long spigot fittings• ‘pupped’ fittings

Pupped fittings are fabricated by butt-fusing, (in the factory), 0.5m lengths of pipe to each leg of a spigot fitting, thereby allowing the straight length of pipe to be gripped by clamps of the butt-fusion machine.

The Marley butt-fusion system comprises: • Straight polyethylene pipe• Long spigot fittings• Pupped fittings• Accessories

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CLICK TO VIEW PRODUCT RANGE

11

COMPRESSION FITTING INSTALLATION

14www.marleypipesystems.co.za

16-63mm

• Use a pipe cutter to cut the pipe at 90° to its axis (Fig. 1)• Insert over the pipe end in the following order: nut, clinch

ring and O-ring on the mouth of the pipe (Fig. 2)• Insert the pipe end and O-ring into the body of the joint;

up to the insertion depth tab (Fig. 3)• Push the clinch ring into the body of the joint (Fig. 4)• Engage the nut and fully tighten. The nut can be

tightened manually up to fittings of 32mm diameter. It is advisable to use a strap or plumbing wrench for larger diameter fittings (Fig. 5 & 6)

75-90mm

• Use a pipe cutter to cut the pipe at 90° to its axis (Fig. 1)• Insert over the pipe end in the following order: nut, clinch

ring, thrust bushing and O-ring on the mouth of the pipe (Fig. 7)

• Lubricate the pipe and the O-ring. Insert the pipe end and O-ring into the body of the joint; up to the insertion depth tab (Fig. 8)

• Push the thrust bushing into the body of the joint. Slide the clinch ring up to the thrust bushing (Fig. 9)

• Engage the nut and fully tighten with a strap or plumbing wrench (Fig. 5 & 6)

110mm

• Use a pipe cutter to cut the pipe at 90° to its axis (Fig. 1)• Insert over the pipe end in the following order: nut, thrust

bushing and O-ring on the mouth of the pipe (Fig. 10)• Lubricate the pipe and the O-ring. Insert the pipe end and

O-ring into the body of the joint; up to the insertion depth tab (Fig. 11)

• Push the thrust bushing into the body of the joint and fasten the nut

• Unfasten the nut and slip the clinch ring over the pipe. Slide the clinch ring up to the thrust bushing (Fig. 12)

• Engage the nut and fully tighten with a strap or plumbing wrench (Fig. 5 & 6)

BUTT WELD FITTING INSTALLATION

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• Make sure the work site is sheltered from weather conditions.

• Regularly check the operation of butt welding equipment, especially machines used on construction sites.

• Align the pipes or fittings to be welded in the machine and clamp them so that no misalignment of the walls, more than 10% of the wall thickness, exists.

• Plane the pipe or fitting surfaces to be welded to make them coplanar and parallel to the hot plate so they can subsequently be evenly heated.

• Make sure that all welding surfaces are kept clean and free of oil, grease and dust.

• Regularly clean the hot plate with a non-fraying paper and an appropriate, non-contaminating cleaning agent.

• Ensure that the hot plate is between 200°C and 220°C. The higher temperature is used with smaller wall thicknesses.

• Attempt to weld together pipes of different SDR (wall thickness).

• Touch trimmed pipe ends.• Leave trimming swarf inside pipe or on welding

machine.• Allow equipment to get wet or dusty.• Use non-approved machinery.• Remove a weld from the machine before cooling

time has elapsed.• Allow untrained personnel to use welding

equipment.• Cut corners in any part of the welding procedure.• Weld pipes of different material on site (in factory

controlled conditions it may be possible to do this).

• Use a generator of inadequate capacity.

Rules for Proper Butt-fusion

DO NEVER

MEGATUFF HDPE FAQs

www.marleypipesystems.co.za

Is HDPE safe for drinking water?

Are both ductile iron pipe size (DIPS) and iron pipe size (IPS) outside diameters available?

Yes – HDPE pipes certified for potable water applications are produced from pressure rated polyethylene compounds ap-proved by NSF (National Sanita-tion Foundation)

yes. Typical DIPS sizes range from 100mm to 915mm diameters and typical IPS sizes range from 20mm to 1650mm diameters.

yes. Typical SIDR sizes range from 12mm to75mm diameters and typical CTS-SDR sizes range from 20mm to 50mm diameters.

yes. It is safe when manufactured, used, or incinerated. It helps preserve water and electricity as there is no loss of water through the fused joint.

Gutter brackets should be placed at centres not exceeding 1 metre.

A fusion joined pipeline may be thought of as a continuous pipeline without joints. On the other hand, gasket joints are a potential source of leakage and lost water in many water systems.

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Are small diameter HDPE pipe products available in both inside diameter controlled (SIDR) and copper tube size outside diameter controlled (CTS-SDR)?

Is HDPE a green pipe solution?

At what distance should gutter and downpipe brackets be spaced?

Why is a fusion joint better than a gasket joint?

17 www.marleypipesystems.co.za

WEHOLITE FAQs

What applications is Weholite suited to?

Can Weholite be used as an alternative to other materials such as concrete?

Weholite the preferred solution for many municipal and industrial applications in both the public and private sector – including stormwater management, sewage treatment systems, culverts, marine pipelines and irrigation water distribution.

Owing to the economic advantages of structured wall (or profiled-wall) technology, Weholite HDPE pipe can now be used as an economic alternative to traditional materials such as vitrified clay, reinforced concrete (R/C), fibre cement (F/C) pipes and corrugated galvanised steel.

Marley offers a range of Weholite LP Couplings, designed and manufactured specifically for use with Weholite pipes.

It can be field bent to a radius 200 times the nominal pipe diameter eliminating many fittings required for directional changes in piping systems made from other materials.In addition, the flexibility of Weholite pipe makes it well suited for dynamic soils and dolomitic areas.

In general, Weholite’s service life will be at least 50% greater than concrete. In corrosive applications, it will be double.

WhatfittingsareavailabletoconnectWeholite pipes?

Whatarethebenefitsofflexiblepipes over rigid pipes?

What is the service life and cost of Weholite compared to concrete?

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ELECTROFUSION FAQs

Is it possible to use electrofusion jointing methods with other pipe materials (i.e. PVC, PP, etc.)?

What applications can electrofusion fittingsbeusedfor?

No. Fusion with other pipe materials is not possible.

Electrofusion jointing can be used to join new pipelines, which are conveying water, gas and sewage along with various other applications.

A welder must be competent with basic welding equipment and processes as well as have a general understanding of thermoplastics and its variable properties. Further training is required on the use and functionality of electrofusion welding equipment such as machines, couplers and fittings, specific to the manufacturer.

What training does a welder need to perform an electrofusion weld?

If the pipe has been prepared in accordance with guidelines and the jointing process has been carried out correctly, by a competent installer, the fitting is expected to last as long as the lifetime of the pipe system and a minimum of 50 years.

The three main causes of joint failure when using electrofusion fittings are: poor joint preparation, contamination of the joint caused during the jointing process, and misalignment of the pipe within the fitting.

How long will an electrofusion joint last?

What can be done to ensure joints don’t fail?

19 www.marleypipesystems.co.za

COMPRESSION FITTINGS FAQs

What are the pressure ratings of Marley Astore Compression Fittings?

What is the size range of Marley Astore Compression Fittings?

The pressure rating at 20°C is as follows:• Sizes from 16mm to 63mm

(Blue coloured nut): 16 Bar• Sizes from 75mm to 110mm

(Black coloured nut): 10 Bar

The size range is from 16 mm up to 110 mm. Fittings provided with female thread have stainless steel reinforcement on sizes of 32mm or larger.

No tools are required for connecting Astore compression fittings. However, the pipe must be cut square, deburred and free of debris before installing and lubricant can be used to ease the joint.

Yes, fittings can be reused for testing purposes, but any fitting used repeatedly for testing must not then be used in a permanent installation.

Compression fittings can be used in swimming pool systems, for potable water distribution, irrigation and telecommunications, as well as in the mining industry and horticulture.

Do I need tools to connect Marley Astore Compression Fittings?

Is a Marley Astore Compression Fitting re-usable?

Can I use Marley Astore Compression Fittings for anything other than potable water (e.g, air, gas, oil, etc.) applications?

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BUTT WELDING FAQs

What factors affect whether I should choose butt fusion or electrofusion welding for joining PE pipes?

What equipment is needed for butt-fusion?

A number of factors will influence the decision of jointing technique, including accessibility, pipe size, pipe material, pipe structure and installation method. If the pipe is to be used as a close-fit lining in an existing pipeline, then butt fusion is the only viable technique.

The following equipment is required to make a proper butt-fusion joint: generator to supply the heater plate, trimmer and hydraulic pump; butt-fusion machine fitted with the correct size clamp shells, trimmer, heater plate, hydraulic pump and timer; pipe support rollers; welding tent; external/internal de-beading tool.

Removing the internal bead after performing a butt weld is commonly referred to as ‘debeading’ and is used as a quality control measure.

yes it can, but due to the materials being different, you will notice a difference in the bead.

What is de-beading, and why must it be done?

Can PE80 pipe be welded to PE100 pipe?

MARKETING SUPPORT

yOUR SUCCESS IS OURS, SO WE MAKE SURE yOU’VE GOT SUPPORT IN ALL SORTS OF WAyS

An important part of our business philosophy is to build good partnerships and trading relationships with our customers. To do this, a large portion of our service offering is dedicated to providing support for contractors, installers and end users alike.

So, not only can partners have full confidence in a brand that customers trust, but they will also have access to sales and marketing support, installation training and on-site technical support that will result in smooth and successful project outcomes.

• Dedicated account service and knowledgeable product support• Access to a library of support catalogues and product literature• Comprehensive installation instruction videos• Pipeline installation and welding courses• On-site support and technical services

www.marleypipesystems.co.za21

TRAINING

EMPOWERING THE INDUSTRY TOWARDS BETTER PRODUCT INSTALLATIONS

Marley is a company that prides itself on nothing but quality – not only in the products that we manufacture, but also the very integrity of the product installations that make up the backbone of every building in South Africa, from a freestanding house to a multi-storey high rise.

As part of our commitment to sustainable development at all levels of the value chain, we strive to create opportunities for skills development. Not only do we offer on-site and classroom training led by industry experts to support plumbers and installers, but we also aim to provide knowledgeable technical training at school and FET level to empower the plumbers and installers of tomorrow.

The price of success is hard work, dedication to the job at hand, and the determination that whether we win or lose, we have applied the best of ourselves to the task at hand.

- Vince Lombardi

22www.marleypipesystems.co.za

CONTACT USBranchOffices

Bloemfontein: +27 51 434 2331/5Cape Town: +27 21 045 0050Durban: +27 31 791 5800East London: +27 43 726 6505George: +27 44 874 1160jet Park (MEGAFLEX): +27 11 823 1160Namibia: +264 81 237 200Nelspruit: +27 13 753 2571Polokwane: +27 15 292 4141Port Elizabeth: +27 41 045 0998Zimbabwe +263 772 229 940 Agents: Contract Supplies (Botswana): +267 392 2922

www.marleypipesystems.co.za

BuildingHeadOffice1 Bickley Road,Pretoriusstad, NigelTel: +27 11 739-8600Fax: +27 11 739-8680

Mining and IndustrialHeadOffice1 Piet Pretorius Street,Rosslyn, PretoriaTel: 0861 MARLEyTel: +27 12 045-0997

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