Section 5

Pipe Sizes and Materials

STANDARD PIPING SIZES

Piping is divided into three major categories:

 LARGE BORE PIPE generally includes piping which is greater than two inches in diameter
 SMALL BORE PIPE generally includes piping which is two inches and smaller in diameter
 TUBING is supplied in sizes up to four inches in diameter but has a wall thickness less than
that of either large bore or small bore piping and is typically joined by compression fittings

The term diameter for piping sizes is identified by nominal size. The manufacture of nominal
1
sizes of /8 inch through 12 inches inclusive is based on a standardized outside diameter (OD).
This OD was originally selected so that pipe with a standard wall thickness will have the inside
diameter (ID) of the size stated. The 14 inch and larger sizes have the OD equal to the nominal
3 1 1 1
pipe size. Pipe sizes /8 inch, 1 /4 inches, 3 /2 inches, 4 /2 inches, and 5 inches are considered
to be nonstandard and should not be used except to connect to equipment having these sizes. In
these cases the line is normally increased to a standard size as soon as it leaves the equipment.

Tubing is sized to the outside diameter for all applications and pressure rating is dependent on
varying wall thicknesses. Refer to industry handbooks for more information.

Schedule (Wall Thickness)

Pipes are manufactured in a multitude of wall thicknesses, these have been standardized so that
a series of specific thicknesses applies to each size of piping. Each thickness is designated by a
schedule number or descriptive classification, rather than the actual wall thickness. The original
thicknesses were referred to as standard (STD), extra strong (XS), and double extra strong
(XXS). These designations or weight classes have now either been replaced or supplemented by
schedule numbers in most cases.

Schedules begin with 5 and 5S, followed by 10 and 10S, then progress in increments of ten
through Schedule 40 (20, 30, 40) and finally by increments of twenty to Schedule 160 (60, 80,
1
100, 120, 140, 160). Wall thickness for schedule 40 and STD are the same for sizes /8 to 10
1
inches. Schedule 80 and XS also have the same wall thickness for /8 inch through 8 inch
diameter pipe.

Schedules 5 and 10 are generally used for stainless steel piping. Even though it is available in
schedules allowing thinner walls, schedule 80 is generally the minimum size used for 2 inch and
smaller carbon steel piping. This may result in pipe that is stronger than needed, but the greater
mechanical strength of schedule 80 pipe is required where threaded connections are used. The
extra wall thickness also allows for longer spans between supports.

Length

Pipe is usually supplied in random lengths. The shortest, longest, and average length may vary
for piping of different materials, sizes, and wall thickness schedules. Typically an average length
of 20 feet is used for carbon steel pipe, but double random lengths are available from most
suppliers and is generally preferred, especially for rack installations.

© 1996 Bechtel Corp. Piping/Mechanical Handbook 5-1

Section 5 Pipe Sizes and Materials

Pipe ends

Pipe may be obtained with plain, beveled, or threaded ends. Plain ends (PE) are cut square and
reamed to remove burrs. This type of end is needed when being joined by mechanical couplings,
socket weld fittings, or slip-on flanges. Beveled ends (BE) are required for most butt-weld
applications. Threaded ends (TE) are used with screwed joints and are ordered noting threads
on both ends or one end (TBE or TOE).

NOTE: Electrical conduit dies cannot be used to cut pipe threads since this type of threaded
connection will typically fail the piping pressure test. The electrical conduit threads are straight
versus tapered for piping.

STANDARD PIPING MATERIALS

Carbon Steel Pipe

Carbon Steel is one of the most commonly used pipe materials. The specifications that cover
most of the pipe used are published by the American Society for Testing and Materials (ASTM)
and American Society of Mechanical Engineers (ASME). Carbon Steel Material specification
ASTM A106 is available in grades, A, B, and C. These grades refer to the tensile strength of the
steel, with grade C having the highest strength. Common practice is to manufacture the pipe as
A106 Grade B.

ASTM A53 is also commonly specified for galvanized or lined pipe or as an alternate to A106.
The testing requirements for A53 are less stringent than for A106. Three types of carbon steel
pipe are covered by A53. These are type E or electric resistance welded, type F or furnace-butt
welded, and type S or seamless. Type E and S are available in grade A and B, comparable to
grades A and B of A106.

Stainless Steel Pipe

Austenitic Stainless Steel pipe commonly referred to as "stainless steel" is virtually non-magnetic.
Stainless steel is manufactured in accordance with ASTM A312 when 8-inch or smaller sizes are
needed. There are eighteen different grades, of which type 304L is the most widely used. Grade
316L has high resistance to chemical and salt water corrosion, and is therefore used in
applications where this characteristic is needed. The "L" denotes low carbon content and is best
suited for welding. Larger sizes (8 inches and up) of stainless steel pipe are covered by ASTM
A358. Extra light wall thickness (Schedule 5S) and light wall (Schedule 10S) stainless steel pipe
is covered by ASTM A409.

Chrome-Moly Pipe

Chromium-Molybdenum Alloy Pipe is commonly referred to as "chrome-moly". Ten grades of this

type pipe material are covered by ASTM A335. Appropriate grades of chrome-moly pipe are
sometimes used in power plants applications requiring good tensile property retention at high
temperatures, especially when the added corrosion resistance of stainless steel is not required.
Chrome-moly pipe is used extensively in heat exchangers. Special care must be exercised when
fabricating or welding this material, since it must be annealed (stress relieved) after being joined.

5-2 Piping/Mechanical Handbook 1996:Rev.2

 Pipe Sizes and Materials Section 5

Plastic Pipe

Thermoplastic Pipe is commonly referred to plastic pipe and is categorized into two principal
groups.

Thermoplastic pipe is available in a great variety of plastic compositions including:

 Polyvinyl chloride (PVC)
 Polyethylene (PE)
 Acrylonitrile-butadiene-styrene (ABS)
 Polyamide (nylon)
 Polypropylene

Thermoplastic pipe is most commonly supplied in PVC material. It also comes in many grades
like steel pipe. It can be obtained threaded or with plain ends for solvent (cement) or thermal
welding. Solvent welding joining is normally used. Some types also include the use of couplings.

Advantages of this material it is very easy to install, and its light weight and socket joints make it
economical for temporary services.

Disadvantages are the temperature limitations and the support spacing required to prevent
sagging.

Thermosetting (Fiberglass) Pipe is made of a plastic that takes a permanent set or hardens
when heated to the curing temperature in the mold. After this initial set the material cannot be
softened by heat or be thermally welded. The principal thermosetting plastic is made of fiberglass
reinforced epoxy, the strongest is helically interweaved glass filaments under tension.

Fiberglass pipe can be obtained in a great variety of sizes and wall schedule like steel pipe.
There are three types of connection methods used to join fiberglass pipe:

 Threaded ends for screwed joints

 Plain for use with socket type fittings
 Adhesive welded bell and spigot taper joints

The adhesive consists of a plastic resin and a catalyst, which thermally set after being mixed and
applied as a joint filler material.

Concrete Pipe

Concrete Pipe is made from a mixture of portland cement, sand, gravel, and water. It is
manufactured as:

 Plain (unreinforced)
 Reinforced concrete pipe
 Prestressed concrete pressure pipe

1996:Rev.2 Piping/Mechanical Handbook 5-3

Section 5 Pipe Sizes and Materials

The usual method for joining this pipe is by bell and spigot ends. The spigot end of one pipe is
inserted into the bell of the mating piece, then the joint is sealed with mortar or a joint compound.
It may also have a provision for a rubber gasket to seal the joint.

Copper Piping

Copper Piping is typically joined with solder fittings and is used for potable water lines in plumbing
systems and for air lines in service air systems.

Nickel and Nickel Alloy Piping

Nickel and Nickel Alloy Pipe has a great resistance to alkalis such as caustic soda and potash.
Nickel and nickel alloys are sometimes used for high temperature applications. Inconel, Incoloy,
and Monel are commonly used nickel alloys.

Cast Iron Piping

Cast Iron Pipe has good corrosion resistance. Ductile iron is commonly used for underground
piping in fire protection systems.

Duriron pipe is a form of cast iron that has a high silicon content that makes it extremely hard. Its
chief advantage is strong resistance to most commercial acids. This pipe is sometimes used for
water treatment chemicals and acid drainage systems. Cast iron pipe is used for floor drains,
sewage, fire protection, or where heavy loads may occur over the underground service pipe.

Special Piping Applications

Other piping materials such as plastic lined, glass lined, concrete lined, and steam jacketed are
utilized in special project applications.

5-4 Piping/Mechanical Handbook 1996:Rev.2