Ductile-Iron Pipe and Fittings AWWA MANUAL M41 Second Edition X\. American Water Works Association Science and Technology AWA wites the drinking water community by developing and astibutng authortatve selentite and technological hnowledgo. Trough its members, ANWA develops industry Standards for products and processes that aiance pubic health ane safety. AWNA also provides qualty improvement programs for water and wastewater utes. Copyright © 2002 American Water Works Association, All Rights Reserved.Mena of Water Supply Pracices — Met, Second Eaton Ductile-Iron Pipe and Fittings Copyright © 1996, 2003 American Water Works Association All rights reserved. No part ofthis publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, inekuding photocopy, recording, or any information or retrieval system, except in the form of brief excerpts or quotations for review purpsces, without the written permission of the publisher. Project ManageriCopy Baltor: Melissa Christonsen ‘Technical Editors: John Wilber (AWWA), Troy Strood (DIPRA) reduction Editor: Carat Stearns Duetilo-iron pipe and fittings ~2nd ed p. em. (AWWA manual ; M41) Manual prepared by the AWWA Standards Committee A21 on Ductile-Iron Pipe and Fittings. Includes bibliographical references and index ISBN 1s8921-018-3 1. Water pipes. 2. Castron pipe. 8. Pipe fitings. . American Water Works Asvociation. Standards Committee A21 on Ductile-iron Pipe and Fittings I, Series, "TD401 .A49 no, M41 2002 628.1 deed leas.r 5021873), 2002026266 Printed in the United States of America American Water Works Assocation (666 West Quiney Avenue Denver, CO 80235-3098 ® ISBN 1s822L-218-9 Printed on reycled paper Copyright © 2002 American Water Works Association, All Rights Reserved.Contents List of Figures, vii List of Tables, xi Preface, xiii Acknowledgments, xv Chapter 1 General Information and History 1.1 History, 1 1.2 Applications and Appurtenances, 3 1.3 Duetile Iron Pipe Research Association (DIPRA), 5 Chapter 2 Applicable Standards 2.1 Related Standards, 7 2.2 Other Reference Standards and Special Products, 10 References, 10 Chapter 3 Manufacturing and Testing 3.1 Manufacturing, 13 3.2 Testing, 17 3.3 Fittings Testing, 19 References, 20 Chapter 4 Design 4.1 Background, 21 4.2 Major Design Criteria and Formulas, 22 4.8 Truck Loads on Pipe Buried at Shallow Depths, 38 4.4 Thickness Design for Ductile-Iron Pipe Under Railroads, 43 4.5 Thickness Design for Ductile-Iron Pipe on Supports, 45 4.6 Special Use Considerations, 57 References, 57 Chapter 5 Pipe Joints 5.1 Introduction, 59 5.2 Joints, 59 5.3 Gaskets, 64 5.4 Permeation, 65 Referenees, 65 Chapter 6 Ductile- and Gray-Iron Fittings 6.1 Introduction, 67 62 Fittings, 67 6.3 Special Service Requirements, 70 References, 71 Copyright © 2002 American Water Works Association, Al Rights Reserved. 13 21 67Chapter 7 Valves and Hydrants 73 7. Introduction, 73 7.2 Types of Valves and Hydrants, 73 7.2 Installation, 76 7.4 Operation, 76 7.5 Good Practice, 77 References, 77 Chapter 8 Thrust Restraint Design for Ductile-Iron Pipe . . . 79 8.1 Introduction, 79 8.2 The Thrust For 8.3 Thrust Blocks, 82 844 Restrained Joints, 85 85 Restraint Design for Vertical Bends, Tees, Reducers, and Dead Ends, 93 8.6 Encroaching Restrained Lengths, 97 8.7 Restrained Length, 99 8.8 Select Backfill Considerations, 99 8,9 Combining Thrust Blocks and Restrained Joints, 101 8.10 Pipe in a Casing, 101 8.11 Future Excavations, 101 8.12 Deflected Unrestrained Ductile-Iron Pipe Joints, 101 8,13 Restrained Length Calculation Procedure, 102 8.14 Tabular Values for F,, (F,)5, and Ry, 103 8.15 Restrained Joint Design Tables for Horizontal Bends, 103 Referenees, 147 , 81 Chapter 9 Interior Linings and Hydraulic 9.1 Cement-Mortar-Lined Ductile-Iron Pipe, 149 9.2 Flow Characteristics of Ductile-Iron Pipe, 153 9.3 Pumping Cost, 155 References, 164 149 Chapter 10 External Corrosion Protection 165 10.1 Introduction, 165 10.2 Basic Corrosion Theory, 165 10.3 Corrosion Resistance of Ductile-Iron Pipe, 172 10.4 Evaluation of Corrosive Soils, 173 10.5 Protection With Polyethylene Encasement, 175 10.6 Other Corrosion Control Measures, 178 Referenees, 180 Chapter 11 Installation of Duetile-Iron Pipe ‘i 181 11.1 Introduction, 181 11.2 Pipe Inspection, Storage, Handling, and Delivery, 181 11.3 Trenching, Embedment, Pipe Installation, and Baekfilling, 183 11.4 Pipeline Accessories, 195 11.5 Thrust Restraint, 198, 116 Flushing, Field Testing, and Disinfection, 198 ALT Serviee Taps, 201 118 Highway and Railroad Crossings, 205 Copyright © 2002 American Water Works Association, All Rights Reserved.11.9 Subaqueous Installations, 206 11.10 Other Installations, 207 References, 210 Chapter 12 Guidelines for Purchase of Pipe and Fit 21 12.1 General, 211 12.2 Duetile-lron Pipe, 213 12.8 Ductile-Iron and Gray-Lron Fittings and Specials, 214 12.4 Polyethylene Eneasement, 214 References, 214 Appendix A Illustrations of Proprietary Joints for Ductile-Iron Pipe and Fittings... 217 Index, 223 List of AWWA Manuals, 233 Copyright © 2002 American Water Works Association, All Rights Reserved.AWWA MANUAL QUT Chapter 4 Design 4.1 BACKGROUND. The design of ductile-iron pipe for most services requiring pressure pipe is described in ANSI/AWWA C150/A21.50, American National Standard for the Thickness Design of Ductile-Iron Pipe. The design procedures published in this standard have evolved through the work of the A21 Committee on Ductile-Iron Pipe and Fittings (A21 Committee) of AWWA. Ductile-iron pipe has been carefully studied since it was introduced in the 1950s, and the A21 Committee has been provided with extensive test data on virtually all aspects of the material that could affect its performance. The A21 Committee meets periodically to review and update ANSVAWWA C150/ 421,50 and other standards concerning ductile-iron pipe and fittings. ‘The design of ductile-iron pipe is based on the flexible conduit theory developed in the 1940s by Professor M.G. Spangler” and others at Iowa State University and confirmed by tests conducted by E.C. Sears® in 1961 (Figure 4-1). Additional tests conducted in 1971 at Utah State University, as reported by R.K. Watkins and Harold Kennedy Jr, further confirmed the conservatism of the design method. Briefly, the design procedure for ductile-iron pipe is as follows: 1. Design for external load (earth load plus truck or transient load). 2. Design for internal pressures (static or operating pressure plus water hammer allowance). 3, Use the larger resulting wall thickness. 4. Add a 0.08-in, (2.0-mm) service allowance. 5. Add a standard casting allowance. ‘This design procedure results in the total calculated design thickness from which the appropriate class is chosen. ‘American National Standards Institute, 25 W. 43rd St,, Fourth Floor, New York, NY 10036. 7406. 21 Copyright © 2002 American Water Works Association, All Rights Reserved,Figure 4-1 DUCTILEARON PIPE AND FITTINGS Performance test on 36-in. (914-mm) ductile-iron pipe with push-on joints 4.2 MAJOR DESIGN CRITERIA AND FORMULAS. ‘The A21 Committee carefully chose the following criteria for use in calculating required thicknesses of ductile-iron pipe. Definitions of symbols used in Sec 4.2 are provided in ‘Table 4-1, 4.2.1 Earth Load Earth load is based on the prism load formula (Eq 4-1). This formula gives the weight of the column of earth directly above the pipe. This is the maximum earth load that can be imposed on a flexible conduit in a ditch condition because, in most eases, this load is reduced by the support of the sidefill soil. The unit weight of the backfill soil is conservatively assumed to be 120 Ib/ft3 (18.85 kN/m®). wit a) 4.2.2 Truck Loads ‘Truck loads are computed by Eq 4-2 using the surface load factors from Eq 4-3 and the reduction factor R from Table 4-2 for a single, American Association of State Highway and Transportation Officials (AASHTO) H-20 truck on unpaved road or flexible pavement, 16,000-Ib (71,170 N) wheel load, and an impact factor of 1.5 at all depths. ‘The surface load factor C calculated by using Eq 4-3 is based on a single concentrated wheel load centered over an effective pipe length of 3 ft (0.914 m). The reduction factor R takes into account that the part of the pipe directly below the ‘wheels is aided in carrying the truck load by adjacent parts of the pipe that receive little or no load from the wheels. P,= RF GE (4-2) Copyright © 2002 American Water Works Association, All Rights Reserved.Table 4-1 Nomenclature ‘Outside radius of pipe, ForA nt, DininsA = D4 (For Ain m, Din mmeA =D/2000) 144 (lor kN/m? to kPa: @ = 1) Conversion factor. For Ibi to psi: 15 (0.457 m) Effective pipe length: 36 in. (0.914 m) ‘Surface load factor Outside diameter, in. (mm) (see Table 4-5) Modulus of elasticity: 24 x 108 psi (165.5 x 10° kPa) Modulus of gil reaction, psi (kPa) (see Table 4-3) Impact factor: 15 Desig bending stress: 48,000 pai (31 x 10° kPa) Depth of cover, fm) Bending moment coefficient (see Table 4-3) Deflection coefficient (see Table 4-3) ‘Wheel load: 16,000 Ib (71,170 N) arth load, psi (KPa) Design internal pressure, in psi (kPa): P; = 2 (Py + P,) Working pressure, psi (ldPa) Standard surge allowance, 100 psi (689 kPa) ‘Truck load, in psi (kPa) "Trench load, in psi (kPa): Py = Pe + Pr Reduction factor, which takes into account that the part of the pipe directly below the wheels is sided in carrying the truck load by adjacent parts of the pipe that receive little or no load from the wheels (see Table 4-2) Minimum yield strength in tension: 42,000 psi (289.6 x 103 kPa) Not thickness, in. (mm) ‘Minimum manufacturing thicknoss. In in. ty = ¢ + 0.08 (in mm: t Soil weight: 120 lly (18.85 kN/m*) Design deflection, inn. (mm/mm): Ax = 0.08D +20) 43) Nore: Angles are in radians, Copyright © 2002 American Water Works Association, All Rights Reserved.24 DUCTILEARON PIPE AND FITTINGS Table 4-2. Reduction factors, R, for truck load calculations Depth of Cover, fe Nominal ee Pie 4 49 710 10 Size, TTT i Reduction Factor 12 1.00 1.00 1.00 1.00 4 092 1.00 1.00 1.00 16 oss 0.95 1.00 1.00 18 0.85, 0.90 1.00 1.00 20 083 0.80 0.95 100 24-20 os 0.85, 0.95 1.00 36-64 0.80 0.85, 0.90 1.00 [NOTE ‘To convert inches Cin.) to mlimtre (mm, multiply by 25.4; to convert fect (R) to meters (m), multiply by O08, 4.2.3 External Load Design ‘The net wall thickness required for external load is based on two design considerations: limitation of ring bending stress’ and ring deflection. When a trench load of sufficient magnitude is applied, ductile-iron pipe can deflect amply to develop passive resistance from the sidefill sil, thereby transmitting part of the trench load to the sidefill soil. Thus, the load-carrying capacity of ductile-iron pipe is a function of soil and ring stiffness. In addition, a reaction equal to the vertical trench load exerted on the pipe develops where the pipe embeds into the trench. This reaction is distributed almost uniformly over the width of bedding of the pipe. ‘The width of bedding is the effective contact area on the pipe bottom where bedding support is sufficient to develop an equal reaction to the vertical trench load. The greater the width of bedding, the greater the load-carrying capacity of the pipe. Therefore, certain design criteria dependent on the width of bedding and on the passi resistance of the sidefill soil are essential to ealculating ring bending stress and ring deflection of ductile-iron pipe and have been established from test data for the standard laying conditions shown in Figure 4-2. Net thicknesses are computed using the bending stress and deflection equations deseribed in the following section. The larger of the two thicknesses is then selected as the net thickness required for external load design. 4.2.4 Bending Stress Design Ring bending stress is limited to 48,000 psi (931.0 x 10° kPa). This design value provides ample safety factors on material strength as discussed later in this chapter. Equation 4-4 is used to calculate the trench load required to develop bending stress. at the pipe invert. Most other flexible conduit material designs do not include caleulations for bending stress ‘caused by external load (with accompanying ring deflection). Ductile-iron pipe design conserva: tively includes calculations for bending stress caused by external loads, which in some eases con- trols the design thickness. Copyright © 2002 American Water Works Aesociation, All Rights Reserved.‘ Cord rte ea ee CEE EEC ECE EEE EEE EEE OEE EE EE ete (eC ‘ Type 4 Type 5 Nore: For design values, 600 Table 43. Figure 4-2 Standard pipe laying conditions Copyright © 2002 American Water Works Association, All Rights Reserved. DESIGN 256 DUCTILEARON PIPE AND FITTINGS (44) —SE__ 0.732 D 4.2.5 Deflection Design ‘The maximum allowable ring deflection for cement-mortar-lined ductile-iron pipe is 3 percent’ of the outside diameter. This design deflection provides a conservative safety factor against failure ofthe eement-mortar lining, because much larger deflections can be sustained without damage tothe pipe wall or coment-martar lining. Equation 45 is derived from Spanglers defection equation and is used to ealcalate the trench load required to develop the design ring deflection ofthe pipe outside diameter. | (_se Day ol (45) 0.7328" | 0 K ‘The conservatism of this design is demonstrated in several ways. Tests in which cement-mortar-lined ductile-iron pipe were loaded to obtain large deflections proved that the cement-mortar lining will not fail by deflections of up to 6 percent and greater; thus the 3-percent design limit provides ample safety factors, as explained later in this chapter. Furthermore, prism earth loads used in ductile-iron pipe design exceed Spangler’ flexible pipe loads, which are used in most other flexible pipe designs. The maximum ring deflection normally occurs in the relatively short period after installation and before pressurization. After pressurization, deflection is substantially reduced by rerounding. Actual trench tests have shown that no further deflection occurs while the pipe is under pressure; in fact, a slight reduction in deflection occurs with time, probably as a result of a slight yielding of the earth above the pipe as the earth is forced upward by the rerounding force in the pipe. (Internal pressures in most modern pipelines exceed by many magnitudes the external trench load P,,) Tests have also proved that if pressure is relieved in a Tine after it has been operating, the deflections are unlikely to return to values obtained before initial pressurization. This is because of the settling of soil into voids left at the sides and haunehes of the rerounded pipe and a subsequent increase in lateral soil support as the soil consolidates with time. * Ductile-iron pipe with flexible linings is designed with a 5 percent maximum allowable deflee: tion per American Society for Testing and Materials (ASTM) A-746, Standard Specifications for Ductile iron Gravity Sewer Pipe and (ASTM) A-716, Standard Specifications for Ductile Iron Culvert Pipe. Copyright © 2002 American Water Works Association, All Rights Reserved.DESIGN 27 4.2.6 Standard Laying Conditions [As indicated previously, certain factors dependent on the specified type of laying condition are essential to the design of ductile-iron pipe for external loads. Two of these factors, bending moment coefficient, Ky, and deflection coefficient, K,, depend on the width of bedding at the pipe bottom. The angle subtended by the width of bedding is commonly referred to as the bedding angle. The remaining factor is ‘modulus of soil reaction, ’, which is a measure of the passive resistance that can be developed in the sidefill soil, To facilitate design calculations, conservative factors have been established from reliable test data for five standard laying conditions as shown in Table 43. Thus, a designer has a great deal of flexibility in selecting the most economical combination of wall thickness and bedding requirements. It is important to note that use of the equations for bending stress and deflection to determine net thickness is somewhat lengthy and time consuming. To expedite calculations, design tables that provide diameter-thickness ratios for a wide range of trench loads have been developed from these equations for all five standard laying conditions and are included in ANSVAWWA C150/A21.50. With these design tables, a designer need only know trench load and desired laying conditions to compute net thickness required for bending stress and deflection designs. An example calculation is also included in the standard. Table 4-3 Design values for standard laying conditions Bedding Laying E, Angle, Conditions Deseription pei, degrees __Ky K ‘Type 17 Flatcbottom trench Loose backfill 150 300285 0.108 Type 2 Flat-bottom trench. Backfill lightly consolidated to 300 45 0210 0.105 centerline of pipe ‘Type $ Pipe bedded in 4-in. minimum loose soil Backfill 400 60 0.189 0.108, lightly consolidated to top of pipe Type 4 Pipe bedded in sand, gravel, or crushed stone to 500 90 0.187 0.096 depth of 8 pipe diameter, 4-n, minimum, Backfill compacted Lo top of pipe. (Approximately 80 pereent Standard Proctor, AASHTO 7-99.) ‘Type 5 Pipe bedded to its centerline in compacted granular 700 «150.128 0.085 material, 4-in. minimum under pipe. Compacted ‘granular or select material§ to top of pipe. (Approxi- ‘mately 90 percent Standard Proctor, AASHTO T.99,)" No kilopascals (kPa, multiply by 6.895. To convert inches (in. to millimeters (mm), multiply by 2544; to convert pounds per square inch (ps to Consideration of the pipe zone embedment conditions included inthis table may be influenced by factors other than pipe wth and deflection. For additional information on pipe bedding and backfil, gee chapter 1, ‘Seo Figure 42. or pipe 14 in. (350 mm) and larger, consideration should be given to the use af a {Flat-bottom is defined as “undisturbed earth ing conditions other than Type 1. ‘Loote soll or select material is defined as “native soil exeavated from the trench, fe of rocks, foreign material, and frozen earth.” "AASHTO 7.98, “Standard Methods of Test fr the Moisture Density Relations of Soils Using a 65 Ib (2.5 ke) Rammer 12 i. S05-ma) Drop” available from the American Association of State Highway and Transportation Offisials, 444 N, Capital StNW, Washington, DC 20001 Copyright © 2002 American Water Works Association, All Rights Reserved.28 DUCTILB-IRON PIPE AND FITTINGS 4.2.7 Internal Pressure Design ‘The hoop stress formula (Bq 4-6) is used to calculate net thickness required for internal pressure. In the formula, the internal pressure design is equal to a safety factor of 2.0 times the sum of working pressure and surge allowance. The surge allowance used in standard ductile-iron pipe design is 100 psi (689 kPa), which is adequate for most water service applications. (See chapter 9 for a discussion on water hammer or surge.) If anticipated surge pressures are other than 100 psi, the designer should use the actual anticipated pressure. (46) Where: = net pipe wall thickness, in. (mm) P; = design internal pressure, psi (kPa) = 2 (Py + P,) Pu working pressure, psi (kPa) P, = standard surge allowance, 100 psi (689 kPa)" D_— = outside diameter of pipe, in. (mm) S = minimum yield strength in tension = 42,000 psi (289,590 kPa) 4.2.8 Standard Allowances Once the net thickness requirement has been determined (the larger net thickness from either external load design or internal pressure design), certain allowances are added to obtain the total calculated thickness requirement. To obtain the minimum. manufacturing thickness, a service allowance of 0.08 in. (2.0 mm) for all pipe sizes is added to provide an additional safety factor against any possible thickness reduction from surface imperfections or minor damage received during handling and installa- tion. A standard casting allowance is then added to provide for possible manufactur ing variations. Casting allowance depends on the pipe size as shown in Table 4-4, 4.2.9 Standard Pressure Classes Ductile-iron pipe is manufactured in standard pressure classes varying from Class 150 to Class 350 in 50 psi (944.75 kPa) inerements, depending on pipe size. Nominal thicknesses for these standard classes are shown in Table 4-5. Once the total calculated thickness has been determined, a standard pressure class should be selected for ordering and specifying. When the calculated thickness is between two standard thicknesses, the larger of the two should be selected. On specific projects, manufacturers may be willing to provide pipe with thicknesses that fall between those of standard classes, 4.2.10 Standard Selection Table Using the design procedure described, Table 4-6, a standard selection table, was developed that gives maximum depth of cover and rated working pressure for each standard pressure class and laying condition. This table has been provided so that a designer may select, rather than calculate, the appropriate pressure elass and laying conditions for a given design application, “ Ifanticipated surge pressures are greater than 100 psi (689 kPa), the maximum anticipated pressure must be used, Copyright © 2002 American Water Works Association, All Rights Reserved.29 Table 4-4 Allowances for casting tolerance Nominal Pipe Size, Casting Allowance, 38 0.05 10-12 0.06 a2 07 48 0.08 5404 0.08 "Nowe To convert inches (in) eo millimeters mm), multiply by 25.4 Table 4-5 Standard pressure classes of ductile-iron pipe Pressure Class Nominal Pipe Outside 150 200 250 300 350 Size Diameter, in in, Nominal Thickness, in 3 3.96 = = = = 025" 4 480 = = = = 0.25" 6 690 = = = = 025" 8 9.05 = = 0.25" 10 1120 = = 0.26, 2B 1320 = 028 u 15.30 = = 028 0.30 oat 16 1740 0.30 032 oa 18 19.50 : ost 034 036 20 21.60 = = 0.33 036 0.38 24 25.80 = 03 037 040 03 30 82.00 034 0.38 oz 04s 049 36 38.30 oss oaz oat os1 0.56 42 44.50 oat 047 052 087 0.63 48 50.80 046 os2 0.58 0.64 0.70 ad 57.56 051 058 0.65 on 079 60 6161 054 061 0.68 076 0.83 64 65.67 0.6 064 0.72 0.80 ost 1Novnis. Pressure classes are defined as the rated water working pressure ofthe pipe in pounda por aquare inch (pal. ‘The thicknesses shoven are adequate for the rated water Working pressure plus a surge allowance of 100 psi (689 kPa) CCalealations are based on a minimum yield strength in tension of 42,000 pi (289.6 x 10® kPa) and a 2.0 safety fsetor ‘umes the um of working pressure and 100 psi (B89 kPa) surge allowance To convert inches tn.) vo millimeters (my), multiply by 25.4 Thickness can be calculated for rated water working presmure and surges other than those indicated by use ofthe formula shown in ANSUAWWA C150/A21.50, Ductle-iron pipe is available for water working preseures grester than $50 psi (2,413 KPa) Pipe i available with thicknesses greater than Preasure Clast 350, See Table 4-7 Lowest nominal thicknesses shown in ANSUAWWA C115/A24.18 for threaded flanged pipe are still require lowest rhominal thicknesses shown in ANSUAWWA C606 for pipe with greeved and shouldered jeinte are till required Caleulated thicknesses for thee siz and prossure ratings are loss than those ehovin above, (See Table 13 of ANSVAWWA ((1501A21.30 for actual caleulated thicknesses) Presently these are the lowest nominal thicknesses available in these size. Copyright © 2002 American Water Works Association, All Rights Reserved.30 DUCTILE-IRON PIPE AND FITTINGS 4.2.11 Special Thickness Classes Prior to the 1991 revision of AWWA C150/A21.50 and AWWA C151/A21.51,° standard thickness classes of ductileiron pipe were identified as Classes 50 through 56. These are now designated as special thickness classes and continue to be available for and 4-6. Wall thicknesses for these special thickness classes are shown in Table 4-7, and their rated working pressures and ‘maximum depths of cover are presented in Table 4-8. design conditions not covered in Tables 4. Table 4-6 Rated working pressure and maximum clepth of cover, standard pressure classes Laying Conditions Nominal . ‘Type1 Type? Type. Typed Type Pipe Pressure’ Nominal Tyench ‘Trench Trench Trench Trench Size Class, Thickness, —————¥___t_Tme’_ume- a ‘psi in, Maximum Depth of Cover,' /t 3 350 0.25 78 88 99 100" 100% 4 350 0.25 53. 61 69 85 100¢ 6 50 025 26 st 37 ar 65 8 16 20 25 34 50 10 us 15 19 28 45 10° 15, 19 28 44 - us 15 23 36 : 18 "1 26 2 7 ry ct 20 “4 16 0.0 = ut 6 2 34 0.32 . 13. a 26 39 034 6 20 28 “4 18 250 031 7 108 4 22 al 300 ona 13 "7 26 36 350 0.36 ~ 15 19 28 41 20 250 03 0 “4 22 30 300 0.36 = 13 Ww 26 35 350 0.38 ~ 15 19 28 38 4 200 0.38 © Bf 12 7 25 250 037 2 u 15 20 29 300 0.40 “ 13, aw 24 32 350 0.3 6 19 23 37 'No7k To convert inches ln.) to mlimeters (mim, multiply by 28-4 to convert fect (R) to meter (ns mally by {0.3048; to convert pounds per square inc (psi to Klopaseals (kPa), multiply by 6.895. “Dectlesiran pipe is adequate for the rated working pressure indicated foreach nominal size plus a surge allowance of 100 si (680 kPa), Calculations are based on a 20 safety factor times the aum of working pressure and 100 psi (689 kPa) surge allowance, (See ANSHAWWA C15Q/A21.50 for design formulae.) Ductile-iron pipe for working pressures higher Uhan $50 pst (2.418 kPa) i available, ‘An allowance fora single 1-20 truck with 5 impact factor i ineluded forall depths of cover. Calculated maximum depth of cover exceeds 100 (30.5 m) {Minimum allowable depth of eover is 311(0:9 mi For pipe 14 in, (350 mum snd larger, consideration should bo given tothe use of laying conditions other than Type 1 Table continued next page. Copyright © 2002 American Water Works Association, All Rights Reserved.DESIGN 31 Table 4-6 Rated working pressure and maximum depth of cover, standard pressure classes (continued) Laying Conditions SOE" pega’ ona RRA Bm? Bre? Dee Bs in, pst in, ‘Maximum Depth of Coven ft 200 0.38 Bf 12 16 24 300 045 : 12 16 21 29 350 049 “ 15, 19 25. 33, 36 150 0.38 - 9 4 a 200 0.42 - 8 2 15 23, 250 047 a 10 “4 18: 25 300 051 Oo” 12 16 20 28 350 0.56 7 15 19 cy 32 42 150 O41 - 9 13 20 200, O47 . 8 12 15 22 250, 0.52 - 10 14 Ww 25 300, 057 ” 12 16 20 27 350 0.63 7 6 19 23 32 48 150, 0.46 - - 9 13 20 200 052 “ 8 u 15 22 350 0.70 . 15 18 2 30 a 150 051 - 9 13 20 200 0.58 o 8 ul 4 22 250 0.65 - 10 13, 16 oy 300 0.72 ~ 13 15 19 27 350 0.79 ~ 15 18 22 30 250 0.68 . 10 13, 16 or 300 0.76 . 3 15 19 2 350, 0.83, ee 5 18, 22 30 64 150 0.6 a st 9 13 20 200 0.64 ~ 8 AL 4 21 Nor To convert inches (i. to millimeters (mm), multiply by 25.4; to conver fst (R) bo meters a), multiply By (0.3088; eo convert pounds per square inch (si) to kilopascala (kPa), multiply by 6.885, Ductleiron pipe is adoquate for the rated working prescure indiated for each nominal size plus a surge allowance of 100 psi 1689 kPa) Caleulntions are based on a 2.0 safety facto times the aum of working pressure and 200 psi (689 kPa) surge allowance, ‘See ANSVAWWA C150/421.50 for design formulae.) Ducileion pipe for working pressures higher than 250 pei '2413 kPa is available, “An allowance fora single H-20 truck with 15 impact factor is inchuded forall depths of cover. {sCaleulated maximum depth of cover exceeds 100 (20.5 m) ‘Minimum allowable depth of cover ie 3 (0.9m “For pipe 14 in, (380 mm) and larger, consideration should be given tothe © of laying conditions other than Type 1 Copyright © 2002 American Water Works Association, All Rights Reserved.32 DUCTILERON PIPE. AND FITTINGS Table 4-7 Special thickness classes of ductile-iron pipe Special Thickness Class Nominal Pipe Outside 51 52 58 54 55 56 Size, Diameter, in. in, Thickness, in, 3.96 = 028 (Ol 04 0a7 Oo 4 480 029° (082 (a5 oa3 (at 6 690 0.25 028 ost oad 037 040 043 8 9.05 027 030 (083086 0.39 042045 10 11.10 02900820358 044047 BR 01 ost oa? 00a. 048 09 4 0.33 036 = 089042, 048 O61 16 034087 oda 046 049052 18 0.35 03s (Oat oa oa7 050058 20 036 ©0890-0425 Oi 058 24 038 oan 0440.4 0.50 053086 30 039° (04387 OSL 0.55, 059° 068 0.3 048 053058068 068 073 O47 053053065 ort os ot 058 08507209 08s 0.93 54 57.86 057085073 0.89 097 1.05 Nore: To convert inc (in. to millimeters (mm; multiply by 25-4 4.2.12 Safety Factor ‘The safety factor for internal pressure is 2.0 based on minimum yield strength of ductile iron in tension. For external loads, two safety factors are specified: 1.5 based on minimum ring yield strength and at least 2.0 based on ring ultimate strength. Also, the design ring deflection provides a safety factor of at least 2.0 based on test data regarding deflections required to cause failure in coment-mortar linings, ‘These safety factors are used to establish minimum design criteria and should not be confused with the total available safety factor of duetile-iron pipe, which is, generally much greater than the minimum because of the following: ‘The design criteria for ductile-iron pipe are not based on performance limits associated with actual failure of the pipe wall. Specified safety factors are used to calculate net wall thickness require- ments, after which both service allowance and casting allowance are added ‘The yield strength of ductile-iron pipe will consistently exceed the minimum. values specified for design. Ductile-iron pipe can sustain stresses considerably higher than yield strength determined by standard test methods without damage to the pipe wall Design considerations dependent on laying conditions were established on a conservative basis. Copyright © 2002 American Water Works Association, All Rights Reserved.DESIGN 33 Table 4-8 Rated working pressure and maximum depth of cover, special thickness classes (continued) Rated Water Nominal Special Nominal Working Laying Condition Pipe Size, Thickness Thickness, Pressure, “Type Type ‘Type 3 “Type Type 5 in Class in psi “Maximum Depth of Covert ft a 51 0.25) 350° 78 88 99 100% 1008 52 0.28 350° 100E 100 100F 1001008 53 oi 350° 100¢ 1008-0} Loo 100 54 034 350° 100; «10081001000 55 037 350° 100; 1001001001008 56 040 350° 100: 100-100} 1001008 4 51 0.26 350° ee na 80 98 100 52 029 350° 94 -100F 10000: 300% 53 oz 350° 100: 100810010010 54 0.35, 350° 1003 «1001001001008 55, 038 350° 100; «1008100200 1008 56 oa 350° 100; 1008100100100 6 50 0.25, 350° 26 a 37 a1 6 aL 028 350° 40 a1 53 or 88 52 oat 250° 58 66 5 92 1003 53 034 850° 78 89 10081003100 Ba 037 850° 100: «10010081003 100 55 0.40 350° 100; 100-100}. toot 100 56 043 350° 1007 100s 100-100 8 50 o2t 850° a 26 a1 40 eT Bl 0.30 350° 30 36 2 53 a 52 0.33, 350° a 48 55 69 90 53 0.36 350° 55 63 a 88 1008 54 0.39 300° 7 9 90 1003100 55 0.43, 350° 87 99 100310031008 56 0.45, 350° 1o0f 1008 100t = 100F 100 10 50 029 850° 16 a 25 35 ot Bt 02 350° 23 28 33 3 60 52 035 350° 31 36 a2 54 2 33 0.38 350° 40 46 53 66 87 54 oat 350° 50 58 65 a1 100% 35 4d 350° 62 a 80 98 100% 56 a7 350° % 85 96 100} 1007 [Nott o convert inches in.) 40a convert pounds per square inch (psi to kilepaseals (kPa), moltiply by 6.896, adequate for the rated water working pressure indicated foreach nominal sie plus a surge allowance » Duct ron pipe ters (mm), multiply by 25.4; to convert fet (F) to meters (m), multiply by 0.2048; to of 100 pe (689 KPa) Calculations are based on a2 0 safety factor times the sun of working pressure and 100 psi (689 KP) surge allowance. Caleulations are rounded to the nearest 5 pi ¥ An allowance for a single H-20 teuek with 1.5 impact factor is included forall depths of caver. + Tho calculated actual rated water working pressure exceeds 350 psi (2,413 kPa). Duetil.iron pipe for rated water working prossures higher than 350 pai (2,418 KPa) ss available £ Caleulated maximum depth of cover exceeds 100 (305 m) '§ Minimum allowable depth of ever is 8 ft (0.9 m) For pipe 14 in, (350 mm) and larger, consideration should be given tothe use of laying conditions other Type 1. Table continued next page. Copyright © 2002 American Water Works Association, All Rights Reserved.34 DUCTILE-ARON PIPE AND FITTINGS Table 4-8 Rated working pressure and maximum depth of cover, special thickness classes (continued) Rated Water Nominal Special Nominal Working _____Laying Condition Pipe Size, Thickness Thickness, Pressure, _ ‘Type! _Type2 ‘Type ‘Typed ‘Type in Chass in psit_____ Maximum Dopth of Cover. 2 50 oat 350" 15 w Py 38 49 51 0.34 350° 20 25 30 39 56 52 037 350" % a 37 a 65 53 040 350" 33 29 4 87 76 54 043 380" a 48 5a 63 89 55 0.46 350° 50 37 65 81100 56 049 350" 60 6a ” 951008 4 50 0.33 350" ~ Ww 21 30 47 SL 0.36 360" - a 26 35. 62 52 0.39 360" - 26 31 41 58 53 042 350° ” a8 48 66 Bt 0.45 350" = 39 45, a7 6 55, 0.48 350° = 46 53, 66 87 56 051 350" = 54 62 7 99 16 50 os4 aso" “ 15 20 2a a“ 51 ost 350" “ 19 2a 22 9 52 040 50+ “ 23 28 37 54 53 03 350" ” 2 33 49 60 es 046 aot * 33 38 49 er 55 0.89 350° ” 38 a4 56 8 56 052 350° “ oad 64 85 18 50 0.38 330 " u 18 a7 38 51 0.8 350° * Ww 2 30 46 52 oat 350° ” 20 25 4 51 53 oa 360" Py 29 39 55 m4 047 850° ” 28 34 a 61 55, 050 360° “ 33 39 50 6 56 058 350" " 38 44 56 6 [Nom To convert inches (in. to millimeters (nm), multiply by 25.4; to eonvert fet (F) to meters (im), multiply by 0.9048; to convert pounds per square inch (psi to kilopaseals (kPa, multiply by 6.898, Ductlesiron pipe is adequate forthe rated water working pressure indicated for each nominal sie plus a surge allowance ‘of 100 psi (689 kPa Calculations are based on a 2-0 safety fator times the sum of working pressure and 100 psi (689 KPa) ‘surge allowance. Caleuations are rounded tothe nearest 5 psi ¥ An allowance for a single H-20 truck with 1.5 impact factor is included forall depths of cover. + The calculated actual rated water working pressure excoods 360 psi (2,413 kPa), Ductileion pipe for rated water working pressures higher than 360 psi (2,413 KPa) is available Caleulatod maximum depth of cover exceeds 100 (30.5 m). Minimum allowable depth of cover is 3 (0.9m) ° For pw 14 in. (350 mm) and anger, consideration should be given to the use of laying conditions other Type 1. ‘Table continued next page. Copyright © 2002 American Water Works Association, All Rights Reserved.DESIGN 35 Table 4-8 Rated working pressure and maximum depth of cover, special thickness classes (continued) Rated Water Nominal Special Nominal Working Laying Condition Pipe Size, Thickness Thickness, Pressure, ‘Type ‘Type? Type 3 “Type 4 Type5 in Class in. psi® ‘Maximum Depth of Covert ft 20 50 0.36) a10 ” 13 w 26 35 St 0.39) 350° ” 16 20 29 41 52 042 350° ie 18 23 32 48 53 045, 350° * 22 26 36 52 54 0.48, 350° ” 25 30 40 5T 55 051 350° . 29 34 45 62 56 04 350° ” 33 39 50 68 4 50 0.38 215 ” u 16 2 30 51 oat 825 ” u 1B 5 34 52 044 350° ” 16 20 29 38 53 a7 350° ” 18 23 32 a 54 050 50° " aa 26 35 51 55 0.53 350° " 24 29 38 55 56 0.56 850° “ a 32 a2 59 30 50 0.39 215 ” § 18 wv 4 a 03 270 “ " 6 20 27 52 aT 820 ” 13 18 23 a1 53 0.61 350° " 16 20 a7 36 Ba 0.55, 350° * 18 23 32 a1 35 0.59 350" * a 26 35, 48 56 0.63 850° = 4 29 39 56 36 50 043, 205 " 8 2 16 23 a1 0.48, 260 “ " 16 18 26 82 0.53, 315 ” 13 18 22 30 53 0.58 350° ve 16 20 26 34 a4 0.683 350° ” 19 23 30 40 55 0.68 350° “ Bt 26 35 46 56 073 350° 25 30 39 54 [Not"To convert inches tin.) to millimets ‘convert pounds per square inch (pi) to kilepascale (kPa), multiply by 6.895, Duectilesiron pipe is adequate for the rated water warking pressure indiested foreach nominal size plus a sur (nm), multiply by 254; to convert fet (to meters (m), multiply by 0:2048; to ‘of 10 psi (689 kPa). Calculations are based on «2.0 safety factor times the sum of working pressure and 100 psi (89 KPa) ‘surgp allowance. Caleulations are rounded tothe nearest 5 pei ¥ An allowance for a single H-20 truck with 1.5 impact factor is included forall depths of cover. + The caleulated actual rated water working pressure exceeds 250 psi (2,418 kPa), Duetile-iton pipe for rated water workin: pressut higher than 360 pal (2,413 KPa) lg availble + Caleulated maximum depth of cover exceeds 100 ft (0.5 m), Minimum allowable depth of ever ie 8 (0.9m *For pipe 14 in. (850 mm) and larger, consideration should be piven tothe use of laying conditions other Type 3 Copyright © 2002 American Water Works Association, All Rights Reserved. Table continued next page.