DUCTILE IRON PIPE FOR

WASTEWATER APPLICATIONS

 DUCTILE IRON PIPE FOR
WASTEWATER APPLICATIONS
The 1972 AMENDMENTS to Public Law 92-500 (the Clean Water Act) established the federal governments largest domestic
funding program in an attempt to improve the quality of the nations receiving waters through a construction grants program for
wastewater treatment works. The act coincided with the formation of the U.S. Environmental Protection Agency (EPA) in early
1971. Despite dramatic improvements due to the tremendous commitment of resources and funds under the construction grants
program, the original intent of the Clean Water Act has yet to be fully realized.
Generally speaking, the responsibility for new projects and capital improvements, as well as ongoing operation/maintenance costs
for wastewater systems, now fall directly on local authorities with minimal assistance from state regulatory agencies.
Sewer utilities throughout the nation are taking an effective and farsighted approach to all improvement and replacement projects.
They are carefully evaluating present and future sewer systems in terms of design, construction, and maintenance criteria, and
they are building much more efficient collection systems, treating sewage under tighter restrictions, and specifying stronger, more
durable materials.
In selecting a pipe material for sewer service, the design engineer must evaluate the pipes expected performance and consider
the many factors affecting it. These factors include physical strength, available joints and their resistance to infiltration/inflow, ease
of handling and installation, impact-resistance, resistance to corrosion from hydrogen sulfide gas and industrial chemicals, life
expectancy and maintenance costs, and system economics such as initial costs and availability.
Initial capital costs must be compared to annual operating/maintenance costs and system life to get a true picture of the annual
debt service passed on to utility customers. Wastewater piping systems greatly influence the annual costs of utilities, a fact
confirmed by the EPA grants program where billions of dollars were spent on the following problems:
1. Infiltration and inflow: conveying and treating massive flows of unnecessary surface and ground waters.
2. Replace/refurbish existing piping: Some gravity and force mains replaced or relined utilizing EPA funding had a useful service
life of less than 20 years (in some cases, less than 10 years).
3. Gravity sewers versus pumping: installation of lift stations in lieu of deep-bury gravity mains where the net result is often
higher total cost (over a 20- or 40-year period), more maintenance, and less dependability.
Ductile Iron pipe, which has long been the material standard for sewer force mains, pump station piping, and wastewater

General Design Considerations

treatment plant mechanical piping, has gained greater acceptance for use in gravity mains and interceptors.

Ductile Iron pipe is an extremely durable materialits performance should exceed even that of its predecessor, gray Cast Iron pipe,
which has continually served over 600 U.S. communities for more than a century. More than 20 U.S. communities currently have
150-year-old Cast Iron piping still in service.
Most Ductile Iron gravity sewer installations laid in accordance with good engineering practice should serve for a minimum of 50
yearswith a goal of 100 yearswithout failure or infiltration/exfiltration in excess of 10 gallons per day per inch diameter per
mile. Zero infiltration is achievable with Ductile Iron pipe due to its pressure-tight joints. Realistic allowance, however, should be
made for infiltration/inflow at manholes, service laterals, and roof/foundation drain connections, etc.
The strength of Ductile Iron pipe permits a wide variety of design applications including shallow bury/heavy traffic loads, deep
bury/high soil prism loads, and high operating/surge pressures.
Ductile Iron pipe is designed and manufactured in accordance with published standards of the American National Standards
Institute (ANSI), the American Water Works Association (AWWA), and the American Society of Testing and Materials (ASTM).
ANSI/AWWA C150/A21.50 and ANSI/AWWA C151/A21.51 are the design and manufacturing standards for Ductile Iron pipe for water
under pressure and ASTM A746 is the standard for Ductile Iron gravity sewer pipe. The design procedure embodied in these
standards, which is consistent for all diameters, is the most conservative for any piping material commonly used in sewer applications.
The basis of the design standard is the long-established fact that Ductile Iron pipe, subjected to internal pressure and external
loading conditions, behaves as a flexible conduit. This means that the pipe is designed separately to withstand external loads and
internal pressure. The result is more conservative than designing for the combined loading condition.
Additionally, the external loading calculations for Ductile Iron pipe utilize a very conservative full earth prism as opposed to a
method assuming a narrow trench and arching of the soil as utilized in polyvinyl chloride (pvc) pipe design recommendations. The
following criteria are used to calculate the required thickness of Ductile Iron pipe in any given application.

1 DUCTILE IRON PIPE FOR WASTEWATER APPLICATIONS

 1. Earth load is based on the prism load concept, a conservative assumption for loads experienced by a flexible pipe.
2. Truck loads are based upon a single AASHTO H-20 truck with 16,000 pounds wheel load and an impact factor of 1.5 at all depths.
3. External load design includes calculation of both ring bending stress and deflection. Ring bending stress is limited to 48,000 psi,
providing a safety factor of 2.0 based on ultimate ring strength.
4. Deflection of the pipe ring is limited to a maximum of 3 percent for cement-lined pipe and 5 percent for flexible linings. Again, this
limit provides a safety factor of 2.0 against applicable performance limits of the linings.
5. Five trench types have been defined to provide the designer a selection of laying conditions.
6. Internal pressure design is based on working pressure plus a surge allowance of 100 psi. A safety factor of 2.0 is applied to this calculation.
Table 1 provides illustrations of the five standard laying conditions, which, along with the design tables, allow engineers to choose the
most economical combination of pipe thickness and trench conditions for any given application. Tables 2 and 3 provide guidelines for
depth of bury based on laying conditions and assumed earth prism/traffic loadings. Table 2 covers cement-mortar lining, which is the
standard lining provided by pipe manufacturers. Table 3 covers flexible linings, which can be factory-applied for hydrogen sulfide
resistance and other special waste stream requirements.

Construction and Maintenance

Ductile Iron pipe is available in 3- to 64-inch diameters and is manufactured in 18- to 20-foot laying lengths.

Durability, ease of installation, available standard fittings, and contractor familiarity make Ductile Iron pipe cost-competitive and the
material of choice for current wastewater applications. Superior material strength allows Ductile Iron pipe to be installed with less
stringent bedding and backfill specifications. Other flexible piping material, such as pvc, requires very rigorous bedding/backfill
conditions to prevent over-deflection (egging) and long-term creep, which can cause excessive infiltration or exfiltration.
Ductile Iron gravity and force mains are pressure-tight with design working pressures up to 350 psi with a 100 psi surge allowance.
In addition, because of the unique compression gasket, or push-on joint, used in Ductile Iron pipe for water-tightness,
infiltration/exfiltration and the increased pumping, treatment, and maintenance costs that result are virtually eliminated.
Ductiles push-on joint system has been proven effective in actual tests with up to 1,000 psi internal pressure, 430 psi external pressure,
and 14 psi negative air pressure with no leakage or infiltration (see Figure 1).
Ductiles push-on joints are among the fastest and easiest to assemble joints available today. Also, because Ductile Iron is
manufactured in 18- to 20-foot lengths, it reduces the number of joints to be made and speeds installation time in deep trenches.
These bottle-tight joints are particulary effective in preventing problems of infiltration, exfiltration, and root intrusion that have
plagued sewer systems of other piping materials.
Ductile and Cast Iron tees, wyes, saddles, and other outlets, which provide joint integrity equal to that of the pipe, make excellent service

Table 1
connections. In some cases, tees or outlets also can be used to access the pipe, eliminating the need for expensive manholes.

Standard Laying Conditions for Ductile Iron Pipe

Type 1* Type 2 Type 3 Type 4 Type 5

Flat-bottom trench. Flat-bottom trench. Pipe bedded in 4-inch Pipe bedded in sand, gravel, or Pipe bedded to its centerline in
Loose backfill. Backfill lightly consolidated to minimum loose soil. Backfill lightly crushed stone to depth of 1/8 pipe compacted granular material, 4-in.
centerline of pipe. consolidated to top of pipe. diameter, 4-inch minimum. Backfill minimum under pipe. Compacted
compacted to top of pipe. granular or select material to top
* For 14-inch and larger pipe, consideration should be given to the use of laying conditions other than Type 1. (Approximately 80% Standard of pipe. (Approximately 90%
Flat-bottom is defined as undisturbed earth. Proctor, AASHTO T-99.) Standard Proctor, AASHTO T-99.)
Loose soil or select material is defined as native soil excavated from the trench, free of rocks, foreign
material, and frozen earth.

Figure 1
Ductile Push-on Joint Test 430 psi

Tested: 1,000 psi internal pressure

430 psi external pressure
14 psi negative air pressure
Results: No leakage, no infiltration

DUCTILE IRON PIPE FOR WASTEWATER APPLICATIONS 2

 Table 2 Maximum Depth of Cover for Table 3 Maximum Depth of Cover for
Ductile Iron Pipe with Cement Lining Ductile Iron Pipe with Flexible Lining*
Pipe Pressure Nominal Laying Condition Pipe Pressure Nominal Laying Condition
Size Class Thickness Type 1 Type 2 Type 3 Type 4 Type 5 Size Class Thickness Type 1 Type 2 Type 3 Type 4 Type 5
In. In. Maximum Depth of Cover, ft.A In. In. Maximum Depth of Cover, ft.A
3 350 0.25 78 88 99 B B 3 350 0.25 78 88 99 B B
4 350 0.25 53 61 69 85 B 4 350 0.25 53 61 69 85 B
6 350 0.25 26 31 37 47 65 6 350 0.25 26 31 37 47 65
8 350 0.25 16 20 25 34 50 8 350 0.25 16 20 25 34 50
10 350 0.26 11** 15 19 28 45 10 350 0.26 11** 15 19 28 45
12 350 0.28 10** 15 19 28 44 12 350 0.28 10** 15 19 28 44
14 250 0.28 C 11** 15 23 36 14 250 0.28 C 11** 15 23 41
300 0.30 13 17 26 42 300 0.30 13 17 26 43
350 0.31 14 19 27 44 350 0.31 14 19 27 44
16 250 0.30 C 11** 15 24 34 16 250 0.30 C 11** 15 24 41
300 0.32 13 17 26 39 300 0.32 13 17 26 43
350 0.34 15 20 28 44 350 0.34 15 20 28 45
18 250 0.31 C 10** 14 22 31 18 250 0.31 C 10** 14 23 40
300 0.34 13 17 26 36 300 0.34 13 17 26 43
350 0.36 15 19 28 41 350 0.36 15 19 28 45
20 250 0.33 C 10 14 22 30 20 250 0.33 C 10 14 23 40
300 0.36 13 17 26 35 300 0.36 13 17 26 43
350 0.38 15 19 28 38 350 0.38 15 19 28 44
24 200 0.33 C 8** 12 17 25 24 200 0.33 C 8** 12 20 37
250 0.37 11 15 20 29 250 0.37 11 15 23 41
300 0.40 13 17 24 32 300 0.40 13 17 26 43
350 0.43 15 19 28 37 350 0.43 15 19 28 45
30 150 0.34 C 9 14 22 30 150 0.34 C 9 17 33
200 0.38 8** 12 16 24 200 0.38 8** 12 20 37
250 0.42 11 15 19 27 250 0.42 11 15 23 40
300 0.45 12 16 21 29 300 0.45 12 16 25 42
350 0.49 15 19 25 33 350 0.49 15 19 28 44
36 150 0.38 C 9 14 21 36 150 0.38 C 9 17 33
200 0.42 8** 12 15 23 200 0.42 8** 12 20 37
250 0.47 10 14 18 25 250 0.47 10 14 23 40
300 0.51 12 16 20 28 300 0.51 12 17 25 42
350 0.56 15 19 24 32 350 0.56 15 19 28 45
42 150 0.41 C 9 13 20 42 150 0.41 C 9 16 32
200 0.47 8 12 15 22 200 0.47 8 12 20 37
250 0.52 10 14 17 25 250 0.52 10 14 23 40
300 0.57 12 16 20 27 300 0.57 12 17 25 42
350 0.63 15 19 23 32 350 0.63 15 19 28 45
48 150 0.46 C 9 13 20 48 150 0.46 C 9 17 33
200 0.52 8 11 15 22 200 0.52 8 12 20 37
250 0.58 10 13 17 24 250 0.58 10 14 23 40
300 0.64 12 15 19 27 300 0.64 12 17 25 42
350 0.70 15 18 22 30 350 0.70 15 19 28 44
54 150 0.51 C 9 13 20 54 150 0.51 C 9 17 33
200 0.58 8 11 14 22 200 0.58 8 12 20 37
250 0.65 10 13 16 24 250 0.65 10 14 23 40
300 0.72 13 15 19 27 300 0.72 13 17 25 43
350 0.79 15 18 22 30 350 0.79 15 19 28 45
60 150 0.54 C 5** 9 13 20 60 150 0.54 C 5** 9 17 33
200 0.61 8 11 14 22 200 0.61 8 12 20 37
250 0.68 10 13 16 24 250 0.68 10 14 23 40
300 0.76 13 15 19 26 300 0.76 13 17 25 43
350 0.83 15 18 22 30 350 0.83 15 19 28 45
64 150 0.56 C 5** 9 13 20 64 150 0.56 C 5** 9 17 33
200 0.64 8 11 14 21 200 0.64 8 12 20 36
250 0.72 10 13 16 24 250 0.72 10 15 23 40
300 0.80 12 15 19 26 300 0.80 13 17 26 43
350 0.87 15 17 21 29 350 0.87 15 19 28 45
** Minimum allowable depth of cover is 3 ft. * Examples of flexible linings include, epoxy, asphaltic, etc.
A These pipes are adequate for depths of cover from 2.5 ft. up to the maximum shown ** Minimum allowable depth of cover is 3 ft.
A These pipes are adequate for depths of cover from 2.5 ft. up to the maximum shown
including an allowance for a single H-20 truck with 1.5 impact factor unless noted.
B Calculated maximum depth of cover exceeds 100 ft. including an allowance for a single H-20 truck with 1.5 impact factor unless noted.
C For pipe 14 in. and larger, consideration should be given to the use of laying conditions B Calculated maximum depth of cover exceeds 100 ft.

C For pipe 14 in. and larger, consideration should be given to the use of laying conditions
other than Type 1.
NOTE: Ring deflection limited to 3%, minimum safety factor of 2. Earth load (Pe) based on soil other than Type 1.
weight of 120 pcf. NOTE: Ring deflection limited to 5%, minimum safety factor of 2. Earth load (Pe) based on soil
weight of 120 pcf.

3 DUCTILE IRON PIPE FOR WASTEWATER APPLICATIONS

Sylvia Caswell

Due to Ductile Iron pipes exceptional strength and durability, it can be used in a wide variety of wastewater applications.

The dependability of Ductile Iron pipe with push-on joints is

evidenced by the fact that, while most state health departments
require other piping materials to be encased in concrete where
sewer and water pipes are parallel or cross within a certain distance,
Ductile Iron pipe can generally be used alone, without concrete
encasement, in these applications.
Despite Ductiles strength, it is easy to cut in the field with an abrasive
wheel saw, milling wheel saw, or other appropriate device.
Its long service life and durability make Ductile Iron pipe the
favored piping material of operations and maintenance personnel.
Ductile Iron is highly resistant to shearing and breakage caused by
differential settlement, frost heaving, and seismic events. It is easy
to tap and repair, even in adverse trench conditions. Gravity and
force mains can be cleaned using rods, cutter heads, and, in some
cases, even pressure steam to remove solids and grease build-ups.
Other piping materials, notably pvc, can be damaged or fractured

Available Linings
by these necessary cleaning operations.

Ductile Iron pipe and Cast and Ductile Iron fittings are normally
furnished with a cement-mortar lining conforming to ANSI/AWWA
C104/A21.4. Originally developed to prevent tuberculation in
water mains, cement-mortar lining is also highly suitable for non-
septic gravity sewers and sanitary sewer force mains. Long-term
testing of lined pipe, both in the field and in the laboratory, has
proven the effectiveness of cement-mortar lining.
H. H. Sisson

Special linings are often recommended for Ductile Iron pipe handling
industrial chemical wastes such as acids, alkali waste, and pickling
brine, or in instances where hydrogen sulfides are a problem, such
as in septic sewers. Contact DIPRA member companies regarding the
most suitable lining for these special services. Ductile Iron pipe is utilized for innovative solutions of sewerage piping
problems. Illustrated is an at grade gravity sewer.

DUCTILE IRON PIPE FOR WASTEWATER APPLICATIONS 4

4
Gravity Sewers
Hydrogen sulfide gas (H2S) can sometimes pose a problem in gravity
sewers if the pipe has an air space allowing O2 to combine with H2S
creating sulfuric acid (H2SO4). Since H2S is extremely hazardous to
personnel, the designer should provide adequate slope and maintain a
velocity of two fps in the piping system, which should help prevent the
waste stream from becoming anaerobic and generating H2S.
Gravity sewers are designed utilizing the Manning formula for uniform flow.
The Manning roughness coefficient, n, is generally accepted as 0.011 for
cement-mortar lining and epoxy linings. Ductile Iron pipe typically has a
larger inside diameter than other piping materials, which allows for greater
design flows and carrying capacities. In larger diameter sewers, for
example, Ductiles larger inside diameter could accommodate several million
gallons per day additional flow (see Figure 2).
As previously discussed, Ductile Iron pipes long service life and bottle-
tight joints make it especially suitable for gravity flow applications.

Force Mains
Ductile Iron pipe is especially suited for pressure sewer applications because
its standard pressure classes provide for high operating pressures with a

Bill Carter
minimum 100 psi surge allowance. Surges, or hydraulic transients, are a very
serious problem for pressure sewers as pump stations are vulnerable to power
outages and surge control devices for raw wastewater are not always
dependable. The surge forces, which can rupture some piping materials, are
caused by momentum in the liquid due to change in velocity. Well-suited for difficult installations due to its inherent strength, Ductile
Iron is an excellent piping material for use in gravity sewer applications. Its
Pressure sewers are designed much the same as water transmission lines. superior ring strength, combined with its bottle-tight joints, makes it
The Hazen-Williams formula is the most popular flow formula. The ideally suited for deep trenches and installations in areas of high water table.
Hazen-Williams friction coefficient, C, is generally accepted as 140 for
cement-mortar linings and 150 for epoxy linings. Special linings are not usually specified if the pipe is always flowing full and the
waste stream is domestic sewage. However, the designer has the option of the factory-applied linings to resist H2S as discussed
under Gravity Sewers. In either case, the hydraulic efficiency of Ductile Iron pipe, coupled with its larger than nominal inside
diameter, results in reduced pumping costs over the life of the pipeline.
Piping for pressure sewers can be provided not only
in push-on and mechanical joints, but also with
restrained joints having deflection capabilities after
installation. All Ductile Iron force main piping can be
interfaced with pumps, lift stations, and plant piping
with standard fittings and factory-supplied spools.

Figure 2 - Additional Flow with

Ductile Iron Pipe
Based on full flow, 1% grade and approximately 8% more flow
with Ductile Iron pipe.
MGD
Bill Carter

Ductile Iron pipe has long been the material of choice for water and wastewater treatment
plant piping due to its wide selection of joints and fittings and the fact that it can be fabricated
Nominal inside diameter-inches
for any application.

5 DUCTILE IRON PIPE FOR WASTEWATER APPLICATIONS

Special Wastewater Applications
1. Wastewater treatment facilities and pump stations
Ductile Iron pipe with Ductile and Cast Iron fittings is the standard for most plant piping and mechanical room
applications. All valves, pumps, couplings, and other appurtenances necessary for complete systems are compatible with pipe and
fittings currently manufactured by DIPRA member companies.
2. Sewage outfall lines
Because of its durability and excellent flow
characteristics, many treatment facilities utilize Ductile
Iron pipe for effluent discharge. This use includes not
only land-based outfalls but also outfalls into oceans.
3. Other piping applications
Other special wastewater applications for which Ductile
Iron pipe is especially suited include:
a. Inverted siphons and river crossings
b. Bridge crossings
c. Elevated or pier-supported piping
d. Sludge transfer lines
e. Steep slope conditions (gravity or force main)
f. Piping in lake beds
Ductile Iron pipe systems can utilize special joints such
as restrained joints and ball and socket river crossing
David Justus
pipe, as well as standard push-on, mechanical, and
flanged joints, all of which can be installed in the field Ductile Iron is well-suited for use in pipe-on-supports applications due to its

Service History and Dependability

with no special fabrication. tremendous beam strength.

Ductile Iron pipe is a very economical solution for modern sewers. Ductiles long laying lengths and bottle-tight joints minimize
potential infiltration and aid in construction. For most sizes, its larger inside diameters deliver up to several million gallons per day
more flow than nominal pipe diameters. Its standard cement-mortar lining ensures an excellent friction coefficient and resistance
to scour and cement deterioration from most domestic sewage. And its high material strength resists heavy impact, handles
extreme external loadings, and in many cases, there is no need for special bedding or backfill.
Ductile Iron pipe can be used in a wide variety of
applications, including challenging conditions like deep
trenches, shallow cover, seismic activity, subsequent
adjacent excavations, beam loading, and ring crushing.
Following its introduction in the early 1950s, Ductile
Iron pipe rapidly became the industry standard for
water and wastewater pressure pipe. Engineers have
long depended upon it to handle the most difficult
applications. But today, in light of governmental
restrictions on infiltration/exfiltration, demanding
environmental guidelines, and potential liability
from broken sewer mains, many of these same
engineers are specifying Ductile Iron only.

Since Ductile Iron pipe can stand up to the most

demanding applications, it makes sense to insist upon
the same quality pipe for the entire system, thus
ensuring longevity and integrity throughout.
Scott Fergerson

Ductile Iron pipe is often used for inverted siphons in difficult installations such as the
stream crossing shown here because of its great strength, joint integrity, and its
versatile and readily available joints and fittings.

DUCTILE IRON PIPE FOR WASTEWATER APPLICATIONS 6

 DIPRA MEMBER COMPANIES

American Cast Iron Pipe Company

P.O. Box 2727
Birmingham, Alabama 35202-2727
Atlantic States Cast Iron Pipe Company
183 Sitgreaves Street
Phillipsburg, New Jersey 08865-3000
Canada Pipe Company, Ltd.
1757 Burlington Street East
Hamilton, Ontario L8N 3R5 Canada
Clow Water Systems Company
P.O. Box 6001
Coshocton, Ohio 43812-6001
Griffin Pipe Products Co.
1400 Opus Place, Suite 700
Downers Grove, Illinois 60515-5707
McWane Cast Iron Pipe Company
1201 Vanderbilt Road
Birmingham, Alabama 35234
Pacific States Cast Iron Pipe Company
P.O. Box 1219
Provo, Utah 84603-1219

DUCTILE IRON PIPE

R E S E A R C H A S S O C I AT I O N
An association of quality producers dedicated to highest pipe
standards through a program of continuing research.
245 Riverchase Parkway East, Suite O
Birmingham, Alabama 35244-1856
Telephone 205 402-8700 FAX 205 402-8730
www.dipra.org

DUCTILE IRON PIPE THE RIGHT

DECISION

Manufactured from recycled materials.

WW/7-06/3.5M Copyright 2006, 2001, 1999, 1995, 1991, 1988 by Ductile Iron Pipe Research Association.
Published 7-88 This publication, or parts thereof, may not be reproduced in any form without permission of
Revised 7-06 the publishers.