Why Does 3” and 4” Pipe Cost More Than Other Ductile ...

The Challenges Continue During the Cement-Mortar Lining and Seal Coat Process

In the cement lining process, these smaller diameters also affect cycle times, as the lance must be inserted slowly to avoid contact with the pipe, which could damage the pipe, the lining, or the lining equipment. The increased cycle times equate to slower production and increased labor costs.

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The seal coat's application also requires that the lance run slowly to prevent damage to the cement lining or the painting equipment. As with the cement lining process, the increased cycle times slows production and raises labor costs.

The same holds true when lining the Ductile iron with Protecto 401™ Ceramic Epoxy lining, commonly used for sewer lines. Consequently, the epoxy lining is available in 4” only, as the 3” is simply too small.

The challenges in manufacturing 3" and 4" translates to a higher scrap rate, which drives up all cost components – materials, energy, and labor.

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Transportation Costs of the Material

Another major factor impacting the cost of our 3" and 4" Ductile iron pipe is in transportation. McWane Ductile has manufacturing facilities in Provo, UT, Coshocton, OH, and Phillipsburg, NJ; however, McWane Ductile New Jersey is the only plant producing 3" and 4" pipe, and then it is shipped throughout the United States and Canada. Freight is factored into the overall cost of 3" and 4" pipe as well.

I know this is not an easy question to answer, but am looking for a rough order of magnitude of the cost to make large castings (a few hundred pounds max.) in superduplex and/or superaustenitic stainless steels, as opposed to ductile iron.

Background - we manufacture a line of HVAC control valves for chilled water (fresh water) that have certain advantages for large installations. We have been approached by one of our reps who thinks our technologies might have advantages for large desalination works. But, that means replacing all of our mild steel, cast ductile iron, and even generic austenitic stainless steel parts with something more corrosion resistant in salt water and brine. The boss saw a lot of $$ in sales, but I’m seeing $$$ in material costs alone, much less machining. Any help?

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