Pipe made of ductile cast iron
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Section of DICL pipe (ductile iron concrete lined), commonly used for utility water mains, showing iron casing, concrete lining, and textured polymer protective coatings on the inner and outer surfaces.
Ductile iron pipe is made of ductile cast iron commonly used for potable water transmission and distribution.[1] This type of pipe is a direct development of earlier cast iron pipes, which it has superseded.[1]
Description
The ductile iron used to manufacture the pipe is characterized by the spheroidal or nodular nature of the graphite within the iron.[2] Typically, the pipe is manufactured using centrifugal casting in metal or resin-lined molds.[3] Protective internal linings and external coatings are often applied to ductile iron pipes to inhibit corrosion. The standard internal lining is cement mortar and standard external coatings include bonded zinc, asphalt, or water-based paint. In highly corrosive environments, loose polyethylene sleeving (LPS) to encase the pipe may also be used.
The life expectancy of unprotected ductile iron pipes depends on the corrosiveness of the soil present and tends to be shorter where soil is highly corrosive.[4] However, a lifespan in excess of 100 years has been estimated for ductile iron pipelines installed using "evolved laying practices", including the use of properly installed LPS (polyethylene encasement).[5][6] Studies of ductile iron pipe's environmental impact have differing findings regarding emissions and energy consumed. Ductile iron pipe manufactured in the US has been certified as a sustainable product by the Institute for Market Transformation to Sustainability.[7][8]
Dimensions
Ductile iron pipe is sized according to a dimensionless term known as the Pipe Size or Nominal Diameter (known by its French abbreviation, DN). This is roughly equivalent to the pipe's internal diameter in inches or millimeters. However, it is the external diameter of the pipe that is kept constant between changes in wall thickness to maintain compatibility in joints and fittings. Consequently, the internal diameter varies, sometimes significantly, from its nominal size.
Pipe dimensions are standardized to the mutually incompatible AWWA C151 (US Customary Units) in the United States, ISO 2531/EN 545/598 (metric) in Europe, and AS/NZS 2280 (metric) in Australia and New Zealand. Although both metric, the European and Australian standards are not compatible and pipes of identical nominal diameters have quite different dimensions.
North America
In the US, nominal pipe sizes range from 3 inches to 64 inches, in increments of at least 1 inch, and are standardized according to the American AWWA C-151.
| Pipe Size |
Outside Diameter |
| 3 |
3.96 in (100.584 mm) |
| 4 |
4.80 in (121.92 mm) |
| 6 |
6.90 in (175.26 mm) |
| 8 |
9.05 in (229.87 mm) |
| 10 |
11.10 in (281.94 mm) |
| 12 |
13.20 in (335.28 mm) |
| 14 |
15.30 in (388.62 mm) |
| 16 |
17.40 in (441.96 mm) |
| 18 |
19.50 in (495.3 mm) |
| 20 |
21.60 in (548.64 mm) |
| 24 |
25.80 in (655.32 mm) |
| 30 |
32.00 in (812.8 mm) |
Europe
European pipes are standardized to ISO 2531 and its descendent specifications EN 545 (potable water) and EN 598 (sewage). European pipes are sized to match the internal diameter of the pipe, following internal lining, to the nominal diameter. ISO 2531 maintains dimensional compatibility with older German cast iron pipes. Older British pipes, which used the incompatible imperial standard, BS 78, require adapter pieces when connecting to newly installed pipes. The British harmonization with European pipe standards occurred at approximately the same time as its transition to ductile iron, so almost all cast iron pipes are imperial and all ductile pipes are metric.
| DN |
Outside Diameter |
Wall Thickness |
Class 40 |
K9 |
K10 |
| 40 |
56 mm (2.205 in) |
4.8 mm (0.189 in) |
6.0 mm (0.236 in) |
6.0 mm (0.236 in) |
| 50 |
66 mm (2.598 in) |
4.8 mm (0.189 in) |
6.0 mm (0.236 in) |
6.0 mm (0.236 in) |
| 60 |
77 mm (3.031 in) |
4.8 mm (0.189 in) |
6.0 mm (0.236 in) |
6.0 mm (0.236 in) |
| 65 |
82 mm (3.228 in) |
4.8 mm (0.189 in) |
6.0 mm (0.236 in) |
6.0 mm (0.236 in) |
| 80 |
98 mm (3.858 in) |
4.8 mm (0.189 in) |
6.0 mm (0.236 in) |
6.0 mm (0.236 in) |
| 100 |
118 mm (4.646 in) |
4.8 mm (0.189 in) |
6.0 mm (0.236 in) |
6.0 mm (0.236 in) |
| 125 |
144 mm (5.669 in) |
4.8 mm (0.189 in) |
6.0 mm (0.236 in) |
6.0 mm (0.236 in) |
| 150 |
170 mm (6.693 in) |
5.0 mm (0.197 in) |
6.0 mm (0.236 in) |
6.5 mm (0.256 in) |
| 200 |
222 mm (8.740 in) |
5.4 mm (0.213 in) |
6.3 mm (0.248 in) |
7.0 mm (0.276 in) |
| 250 |
274 mm (10.787 in) |
5.8 mm (0.228 in) |
6.8 mm (0.268 in) |
7.5 mm (0.295 in) |
| 300 |
326 mm (12.835 in) |
6.2 mm (0.244 in) |
7.2 mm (0.283 in) |
8.0 mm (0.315 in) |
| 350 |
378 mm (14.882 in) |
7.0 mm (0.276 in) |
7.7 mm (0.303 in) |
8.5 mm (0.335 in) |
| 400 |
429 mm (16.890 in) |
7.8 mm (0.307 in) |
8.1 mm (0.319 in) |
9.0 mm (0.354 in) |
| 450 |
480 mm (18.898 in) |
8.6 mm (0.339 in) |
9.5 mm (0.374 in) |
|
| 500 |
532 mm (20.945 in) |
9.0 mm (0.354 in) |
10.0 mm (0.394 in) |
|
| 600 |
635 mm (25.000 in) |
9.9 mm (0.390 in) |
11.1 mm (0.437 in) |
|
| 700 |
738 mm (29.055 in) |
10.9 mm (0.429 in) |
12.0 mm (0.472 in) |
|
| 800 |
842 mm (33.150 in) |
11.7 mm (0.461 in) |
13.0 mm (0.512 in) |
|
| 900 |
945 mm (37.205 in) |
12.9 mm (0.508 in) |
14.1 mm (0.555 in) |
|
| 1000 |
1,048 mm (41.260 in) |
13.5 mm (0.531 in) |
15.0 mm (0.591 in) |
|
| 1100 |
1,152 mm (45.354 in) |
14.4 mm (0.567 in) |
16.0 mm (0.630 in) |
|
| 1200 |
1,255 mm (49.409 in) |
15.3 mm (0.602 in) |
17.0 mm (0.669 in) |
|
| 1400 |
1,462 mm (57.559 in) |
17.1 mm (0.673 in) |
19.0 mm (0.748 in) |
|
| 1500 |
1,565 mm (61.614 in) |
18.0 mm (0.709 in) |
20.0 mm (0.787 in) |
|
| 1600 |
1,668 mm (65.669 in) |
18.9 mm (0.744 in) |
21.0 mm (0.827 in) |
|
| 1800 |
1,875 mm (73.819 in) |
20.7 mm (0.815 in) |
23.0 mm (0.906 in) |
|
| 2000 |
2,082 mm (81.969 in) |
22.5 mm (0.886 in) |
25.0 mm (0.984 in) |
|
Other European Standards give specifications on more dedicated products:
- EN 15655:2009 – Ductile iron pipes, fittings, and accessories – Internal polyurethane lining for pipes and fittings – Requirements and test methods
- EN 877:1999/A1:2006 – Cast iron pipes and fittings, their joints, and accessories for the evacuation of water from buildings – Requirements, test methods, and quality assurance
- CEN/TR 15545:2006 – Guide to the use of EN 545
- CEN/TR 16017:2010 – Guide to the use of EN 598
- EN 877:1999 – Cast iron pipes and fittings, their joints, and accessories for the evacuation of water from buildings – Requirements, test methods, and quality assurance
- EN 877:1999/A1:2006/AC:2008 – Cast iron pipes and fittings, their joints, and accessories for the evacuation of water from buildings – Requirements, test methods, and quality assurance
- EN 598:2007+A1:2009 – Ductile iron pipes, fittings, accessories, and their joints for sewerage applications – Requirements and test methods
- EN 12842:2012 – Ductile iron fittings for PVC-U or PE piping systems – Requirements and test methods
- CEN/TR 16470:2013 – Environmental aspects of ductile iron pipe systems for water and sewerage applications
- EN 14628:2005 – Ductile iron pipes, fittings, and accessories – External polyethylene coating for pipes – Requirements and test methods
- EN 15189:2006 – Ductile iron pipes, fittings, and accessories – External polyurethane coating for pipes – Requirements and test methods
- EN 14901:2014 – Ductile iron pipes, fittings, and accessories – Epoxy coating (heavy duty) of ductile iron fittings and accessories – Requirements and test methods
- EN 969:2009 – Ductile iron pipes, fittings, accessories, and their joints for gas pipelines – Requirements and test methods
- EN 15542:2008 – Ductile iron pipes, fittings, and accessories – External cement mortar coating for pipes – Requirements and test methods
- EN 545:2010 – Ductile iron pipes, fittings, accessories, and their joints for water pipelines – Requirements and test methods
- EN 14525:2004 – Ductile iron wide tolerance couplings and flange adaptors for use with pipes of different materials: ductile iron, Grey iron, Steel, PVC-U, PE, Fiber-cement
Australia and New Zealand
Australian and New Zealand pipes are sized to an independent specification, AS/NZS[9] 2280, that is not compatible with European pipes even though the same nomenclature is used.
Australia adopted at an early point the imperial British cast iron pipe standard BS 78, and when this was retired on British adoption of ISO 2531, rather than similarly harmonizing with Europe, Australia opted for a "soft" conversion from imperial units to metric, published as AS/NZS 2280, with the physical outer diameters remaining unchanged, allowing continuity of manufacture and backward compatibility. Therefore, the inner diameters of lined pipes differ widely from the nominal diameter, and hydraulic calculations require specific knowledge of the pipe standard.
| Nominal Size (DN) |
Outside Diameter |
Nominal Wall Thickness |
Flange Class |
| 100 |
122 mm (4.803 in) |
5.0 mm (0.197 in) |
7.0 mm |
| 150 |
177 mm (6.969 in) |
5.0 mm (0.197 in) |
8.0 mm |
| 200 |
232 mm (9.134 in) |
5.0 mm (0.197 in) |
8.0 mm |
| 225 |
259 mm (10.197 in) |
5.0 mm (0.197 in) |
9.0 mm |
| 250 |
286 mm (11.260 in) |
5.0 mm (0.197 in) |
9.0 mm |
| 300 |
345 mm (13.583 in) |
5.0 mm (0.197 in) |
10.0 mm |
| 375 |
426 mm (16.772 in) |
5.1 mm (0.201 in) |
10.0 mm |
| 450 |
507 mm (19.961 in) |
5.6 mm (0.220 in) |
11.0 mm |
| 500 |
560 mm (22.047 in) |
6.0 mm (0.236 in) |
12.0
|
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