The design basis behind DI pipe is the most conservative of products on the market today. Decades of reliable service is evidence of DI pipe’s success. Design calculations are found in the ANSI/AWWA C151/A21.51 Standard Design for Ductile Iron Pipe.
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The most notable difference is the safety factor. The safety factor for DI pipe is 2.0 versus the safety factor for steel, ranging from 1.33 to 2.0, depending on the percent of yield strength used.
Notice the two different equations used to calculate thickness design. Allowing the stress to escalate to 75 percent of yield strength lowers the steel pipe's safety factor to 1.33 when including surge, compared to the 2.0 safety factor used in the DI pipe design. The difference in percentages to yield affect the thickness design of the pipe.
Let’s stick with the more conservative and trustworthy calculations. Take the example of a 24-inch water line with a working pressure of 150 psi. Calculating the thickness:
Required Thickness
Steel Pipe (50% Yield) = .086 Thickness
Steel Pipe (75% Yield) = .095 Thickness
Ductile Iron Pipe = .157 Thickness
The thickness of the DI pipe is much greater than steel. The minimum thickness for a 24-inch Class 200 pipe is .24 inch. This is well beyond the calculated thickness design for internal pressure.
There is a comfortable feeling knowing the product chosen is designed well above the intended use. We do not know what the future will bring 100 years down the road, but we know that the design of DI pipe helps to ensure your water delivery system's longevity.
Everyone would like to see a return on investment. These annual savings could be put to practical use. For more information on the these calculations, check out McWane's Pocket Engineer.
Additionally, DI pipe is also SMaRT certified with as much as 95 percent recycled content used in the manufacturing process. It also has no "end of use," which means that when replaced, it can be recycled over and over again. Choosing a sustainable product like Ductile iron not only benefits the end-user, but also our environment long term.
Ductile iron pipe is unique when it comes to corrosion control. An oxide layer is formed on the inside as well as the outside of all DI pipe during the manufacturing process. This oxide layer provides adequate corrosion protection (in many circumstances.) Utilization of the 10 Point Soil System will determine if there is a need for additional corrosion protection. The next step in corrosion protection for DI pipe is polyethylene encasement, better known as V-Bio®.
V-Bio is formed by bonding three layers of co-extruded, linear, low-density polyethylene into one. The inside surface contains an antimicrobial biocide to control microbiologically influenced corrosion and a volatile corrosion inhibitor to prevent galvanic corrosion.
V-Bio is easily installed in the field prior to pipe installation, making it cost-effective and easy to use. DI pipe and V-Bio can be installed in nearly any weather condition. No other product on the market compares.
Polyethylene encasement has proven to control corrosion in aggressive soils for more than 50 years and is cost-effective. The investment in V-Bio is minimal compared to the project's overall cost, especially when compared to the vastly more expensive alternative of bonded coatings used by the steel pipe industry. Not to mention the even higher costs associated with cathodic protection that is widely used in conjunction with steel.
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Bonded coatings used to protect steel pipe are very expensive. Other issues that plague bonded coatings are handling and patching. The thin wall of steel pipe may not have enough beam strength to support its own weight, making for difficult handling.
It is difficult to handle a steel pipe section through installation without some damage to the bonded coatings. Any void in the bonded coating dramatically increases corrosion's potential, and these voids must be repaired. Contractors do not have the luxury of waiting until the sun shines to get the job done.
Time is money, and these folks need a product that is easy to work with, such as DI pipe. Some steel pipes are also coated with cement mortar, which is porous and subject to cracking. Again, any void in the coating increases the potential for corrosion of steel pipe.
Ductile iron pipe can be installed in the rain, sleet, snow, high heat, or freezing temperatures. Because steel pipe needs to be welded together, a rainstorm can shut down any progress being made.
Ductile iron pipe joints come in 18-to 20-foot lengths, which are much easier to handle in the field than 40- to 50-foot steel joints. Do the math. Four joints of 24-inch ductile per hour = 72 feet, versus one joint of steel at 40 feet.
18-foot DI joints also provide a better opportunity for deflection. This deflection capability reduces the number of fittings. Again, reducing the overall cost of a project.
Jerry Regula, "JR" is a product engineer with McWane Ductile. Jerry’s responsibility is to provide technical support for water professionals at all levels including engineers, private water companies, contractors, municipalities, and water districts. JR has been with McWane Ductile for more than 30 years, starting on the ground floor. Jerry has been involved in nearly all facets of the foundry, providing him with extensive experience in manufacturing, installation, and design of ductile iron water products. JR is a NACE Certified Corrosion Technician, Envision Specialist, and member of the American Society of Civil Engineers. He enjoys spending time with his church where he is a speaker and treasurer, as well as spending time with his wife Susan and their two daughters, Katelyn and Shannon on their farm in Ohio. “Many people do not realize how their water gets to them or how blessed we are to have clean drinking water,” says Regula. “I am honored as a water professional to do my part in ‘Building Iron Strong Utilities for Generations.’" Jerry’s favorite quote: "I can do all things through Christ who strengthens me.” ://www.linkedin.com/in/jerry-regula-6a87b/
Modern infrastructural development has revolutionized the real estate and construction industry. At present, a wide variety of fabricated iron materials are available in the market that serve many purposes in the real estate or construction industry. With a wide variety of manhole covers, drain covers, and access covers, the manufacturers of these products are all set to play a significant role. These specialized covers offer many benefits that every buyer must know before buying.
Here are a few distinct benefits users can get when using Quality DI Manhole Cover!
These Ductile Iron products are manufactured and designed using a professional and technical approach to international standards, resulting in optimized and high-quality end products. This optimization does not aim to minimize the weight of machinery and equipment but lightness, which does not affect the necessary strength for load carrying. For this reason, the manufacturers have managed to produce products that are not only robust but also highly effective, especially under the most testing conditions.
Users must expect this from ductile cast iron products. The average weight of these products is 68% lighter compared to competing products, whereas the strength is not compromised in any way. This lightweight feature translates into multiple benefits, beginning with significant cost savings in acquisition. Because you get the same load-bearing ability from a lot less material, you can save money without losing efficiency.
It is also important to note that by slashing the weight of our products, your handlers are better facilitated during installation. Some materials are easier and lighter to handle and work with, meaning that they can be installed faster by the workers. Such cuts in human time and effort also translate into additional savings for the buyer, resulting in a smooth and far less costly shopping process.
The third area in which these lightweight products create tremendous value is connected with lower transportation expenses. Since the best DI covers and frames are much lighter than users think, more units can be transported per truck, and therefore, fewer trucks are needed to deliver your products. This helps you expand your logistics, greatly reducing your transportation cost and hence making your overall project cheaper.
The best-quality hinge-type products provide extra safety for places where products might be stolen. Adding a hinge mechanism makes it very challenging to tamper with our covers and grates since they stay put firmly in position. This theft-resistant feature offers convenience, especially in cases where implementing measures against theft may not be set or are poor.
Reliability is, therefore, core to the entire product portfolio. Despite their lesser weight, these Cast iron Manhole Cover promise better longevity. As a result, users can use a particular cover for a longer duration. This is a big advantage that these fabricated iron pieces can give to users. You can be a happier user in the end.
Selecting the best-quality DI Manhole Covers and frames means that you will purchase the best in design and quality and save in the long run. Less material and labor expenses, increased security features and durability, and superior performance make these products the winners and the right choice for your project. To get the finest products, you can join hands with the experts at Bengal Iron Corporation (BIC) India, the most celebrated Manhole Cover Manufacturer in India.
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