Академический Документы
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ASCE 2014
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Senior Technologist, CH2M HILL, Suite 500, 1100 112th Ave NE, Bellevue, WA
98004. Tel: (425) 453-5000, Email: roger.beieler@ch2m.com
2
Water Engineer, CH2M HILL, Suite 500, 1100 112th Ave NE, Bellevue, WA
98004. Tel: (425) 453-5000, Email: amie.roshak@ch2m.com
ABSTRACT
This paper discusses tips and tools to assist with the design of ductile iron and
polyvinyl chloride (PVC) pressure pipelines including a summary of reference
materials useful to designers; a discussion on available sizes, pressure classes, and
joint types; a discussion of software tools and their use; and several design
considerations related to topics on pipe fittings, installing pipe on curves, thrust
block designs, installing pipe inside of casings, backfilling the trench, and
hydrostatic pressure testing.
The topics presented should benefit the water conveyance community by providing
useful information to engineers, designers, and constructors of ductile iron and PVC
pipe systems. Some of the basic information should be of help to staff who are
unfamiliar with ductile iron and PVC pipelines, while other information should help
sharpen the skills of experienced designers.
USEFUL REFERENCE MATERIALS
There are numerous reference materials available to designers, specifiers, and
installers of ductile iron and PVC pipelines. They include references published by
the American Water Works Association (AWWA), trade organizations such as the
Ductile Iron Pipe Research Association (DIPRA) and the Uni-Bell PVC Pipe
Association, and pipe manufacturers.
Reference Materials for Ductile Iron Pipelines
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There are several nationally recognized standards used for manufacturing and
installing both ductile iron and PVC pipelines. The most commonly used standards
include:
Common Standards for Ductile Iron Pipelines
AVAILABLE SIZES
Ductile iron pipe is available in nominal sizes from 3-inches to 64-inches. PVC pipe
included in the AWWA standards for water distribution and conveyance is available
in nominal sizes from 4-inches to 48-inches. PVC pipe included in the ASTM
standards for gravity sewers is available in nominal sizes from 3-inches to 36-inches.
Smaller diameter PVC pipe manufactured to other ASTM standards is available, but
is not used frequently for conveyance projects. One manufacturer began producing
54- and 60-inch diameter PVC pipe for water conveyance in early 2014.
For a given nominal diameter, both ductile iron pipe and PVC pipe covered by the
AWWA standards have constant outside diameters, regardless of the pressure class
and wall thickness. This allows standard fittings to be used on any one diameter of
AWWA pipe regardless of the pressure class and wall thickness. PVC pipe, as shown
in Table 1, manufactured to various standards, may have different outside diameters
depending upon the standard used.
Designers should use care when mixing pipe manufactured to different standards on
a project or when selecting a coupling to connect a new pipe to an existing pipe.
Special couplings may be required for the connections if the outside diameters differ.
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Standard Used
AWWA C900 and C905 with ductile iron pipe ODs
ASTM D1785 (Schedules 40, 80, & 120) ODs
ASTM D2241 (Plastic Irrigation Pipe PIP)
ASTM F679 and D 3034 (Sewer Pipe)
Nominal Diameter in
Inches
6-inch
18-inch
Outside Diameter in Inches
6.900
19.50
6.625
18.00
6.140
18.70
6.275
18.70
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and fittings 54- through 64-inches are rated for 150 psi.
PVC Fittings The AWWA C900 and C905 standards allow fittings to be directly
fabricated from PVC pipe. The pipe segments used to fabricate the fitting can be
joined using solvent cement, butt fusion, or thermal welding. The fabricated fittings
are rated at the same pressure as the pipe and are factory tested to two times the
pressure class. Some fabricators wrap the PVC fittings with fiberglass. Injectionmolded PVC fittings conforming to the AWWA C907 standard are also available in
sizes 4- through 12-inch. Many designers specify ductile iron fittings for use on
projects with PVC pipe manufactured to the AWWA standards.
JOINT TYPES
Ductile Iron Pipe The most common joint types for ductile iron pipelines used for
conveyance include push-on, mechanical, flanged, and restrained. The majority of
pipe sold today has push-on joints. Pipe with mechanical joints is not commonly
used and has limited availability. Pipe with flanged ends is commonly used to
connect to valves and flanged fittings. The most common joint type for fittings (such
as elbows, tees, and reducers) is the mechanical joint (MJ). The MJ fittings slip
together with minimal force (compared to push-on joints), and it is not necessary to
bevel the pipe spigot ends on field-cut pipe.
Some municipalities require all ductile iron pipe to be restrained joint (RJ). This
avoids the concern that another utility may be installed in the area and require
excavation behind a thrust block. One supplier estimated that 20 to 40 percent of the
pipe his company provides is restrained joint. For RJ pipe in 12-inch or smaller
diameter, about 80 percent is restrained using locking gaskets, and 20 percent is
restrained using proprietary mechanical locking systems. For RJ pipe with diameters
between 14- and 24-inch, about half of the pipe is restrained with locking gaskets
and half with mechanical locking systems. For pipe furnished with restrained joints
in diameters above 30-inch, the joints are restrained with mechanical locking
systems, rather than locking gaskets.
PVC Pipe - For PVC pipe, the most common joint has been rubber gasket push-on.
Solvent weld joints are also available, but are not commonly used in the sizes over 4inch diameter. Flanged coupling adaptors or flange by MJ fittings are commonly
used when connecting PVC pipe to flanged valves. PVC fittings are available with
gasketed bell ends, solvent weld bell ends, flanged ends, and other configurations.
Butt fusion joints are also available for use with a specific formulation of PVC pipe.
Restrained joints are discussed in a subsequent paragraph.
LININGS AND COATINGS
Ductile Iron Pipe The standard interior lining and exterior coating for ductile iron
pipe is a cement mortar lining and an asphaltic coating. A small percentage of
owners require a double thickness of cement mortar lining to provide extra
protection against corrosion due to soft water (water containing little or no dissolved
salts of calcium or magnesium). Prior to 1995, the AWWA standards required that an
asphaltic seal-coat be applied to the mortar lining. The current AWWA standard
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allows the manufacturer the option to apply a seal-coat lining, and most suppliers do
apply the seal-coat as it slows down the loss of moisture in the mortar.
The 1 mil thick exterior asphaltic coating protects against rusting and provides some
reduction of friction for joint assembly. In conditions with aggressive soils, many
designers require the pipe be polyethylene-encased in accordance with the AWWA
C105 standard. For sewer applications, where the presence of hydrogen sulfide may
result in damage to the cement mortar lining, a high-solids, chemically cured epoxy
lining is frequently required on both the pipe and fittings. Epoxy coating is also
occasionally specified on the pipe exterior if the soils are aggressive.
PVC Pipe PVC pipe is not furnished with a lining or coating. For PVC pipe
exposed to sunlight, some designers require two coats of water-based acrylic paint be
applied to the exterior. In order to improve adhesion, the surface of the pipe should
be lightly sanded prior to paint application.
SOFTWARE TOOLS
Several tools are available to assist with the design of ductile iron and PVC pipe
systems. These include programs to compute the required restrained joint lengths in
areas where unbalanced thrust forces exist, programs to compute the required wall
thickness, programs to compute support spacing, and programs to calculate hydraulic
friction loss. Both DIPRA and the Uni-Bell PVC Pipe Association allow free
downloads of their software programs.
DESIGN CONSIDERATIONS
Thrust Blocks Equations and guidelines for sizing thrust blocks are included in the
AWWA design manuals and several manufacturers installation guides. There is no
difference in the thrust block sizing procedure for PVC pipe compared to ductile iron
pipe. The AWWA M41 Manual provides recommended relative dimensions of thrust
blocks that are not included in many other manuals.
Restrained Joints There are several types of restrained joints offered for both
ductile iron and PVC pipe. Some products include stainless steel gripper teeth in the
gasket or in a separate unit adjacent to the gasket to provide restraint. These products
are available for either mechanical joints or push-on joints. Other products use
gripper teeth or wedge-type grippers that can be tightened to restrain the pipe. Some
products work in conjunction with tie-rods across the joint. Some of the wedge-type
grippers allow the wedge to move slightly within a pocket and hence, a limited
amount of post-assembly angular deflection is permissible.
For ductile iron pipe, proprietary restrained joint systems with locking mechanisms
are also available. These systems include a weld bead or a bar that is shop-welded to
the spigot end. These joints are assembled by pushing the spigot end into the bell,
then inserting locking segments. In certain cases, it is recommended that the joint be
pulled to remove any slack. In areas subject to seismic movement, leaving the line
with some slack in the joints may be preferable. These proprietary systems generally
allow some joint deflection after the assembly is made. The systems that do allow
deflection include a circular face on the bell end that uniformly distributes the thrust
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force around the perimeter of the joint, rather than causing a point load.
Required Restrained Joint Lengths Based on Soil Type The AWWA M41
Manual includes seven different soil designations, each with different parameters
related to the required restrained joint length to resist thrust forces. The soil
designation is a significant factor in computing the restrained joint length as shown
in Table 2. The recommended restrained joint length is presented for a 24-inch
diameter ductile iron pipe with no polyethylene encasement, a dead end fitting such
as a valve, 5 feet of cover, a Type 5 trench, and a test pressure of 150 psi. The
recommended restrained joint lengths vary from 73 feet to 132 feet.
Technical specifications frequently state the allowable gradation of the pipe zone
material within a fairly broad range. Depending on the material provided by the
contractor, the material may be considered clean sand or gravel, silty gravel, silty
sand, or cohesive-granular. On some projects, contractors will request a change order
allowing them to use native material for the pipe zone, and perhaps offer a
significant cost reduction to the owner. Even if imported pipe zone material is
provided, as the pipe is pressurized, the thrust force will be resisted by both the pipe
zone material and the native soil around the pipe zone of the backfilled trench.
Because there are several unknowns regarding the material that will resist the thrust
forces, some designers check the required restrained joint length for all the possible
materials and select the most conservative length.
Table 2. Comparison of Restrained Joint Lengths with Different Soils Based on
Recommendations in AWWA Manual M41
Required Restrained
Joint Length
73 feet
132 feet
73 feet
132 feet
111 feet
127 feet
87 feet
Assumptions: 24-inch ductile iron pipe, hydrostatic pressure of 150 psi, bare pipe (no
polywrap), 5 feet of cover, Type 5 Trench, 1.5 safety factor, and a dead end fitting
Curved Alignments Within certain limits, both PVC and ductile iron pipe can be
installed on curved alignments without the use of elbows. If the curve is made using
deflection at the joints, designers can use pipe lengths shorter than the standard pipe
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particularly ductile iron pipe with polyethylene encasement. For PVC pipe, the
AWWA C605 standard recommends that the maximum particle size not exceed
inch for angular rock or 1 inch for rounded rock. For ductile iron pipe with
polyethylene encasement, a maximum particle size of 3/8 inch is commonly
recommended. For ductile iron pipe under 18-inches in diameter with no
polyethylene encasement, a maximum particle size of inch is commonly
recommended, and for pipe larger than 18-inches in diameter with no polyethylene
encasement, a maximum particle size of 1 inch is commonly recommended.
Selection of Materials in Contaminated Areas In areas where the pipe may be
exposed to petroleum products or solvents, careful consideration of materials is
required. Both polyvinyl chloride (PVC) material and the material used to
manufacture certain gasket products (for PVC and DI pipe) may be subject to
permeation and leakage. Appendix A of AWWA M23 includes tables indicating the
resistance of PVC material and common gasket materials to various chemicals.
Use of Restrained Joints in Non-Tension Areas In general, restrained joints are
intended to resist pull-out due to tension caused by internal pressure, and are not
intended to resist movement caused by compressive forces on the joint. This is
particularly important to consider where isolation valves are installed along the
length of a pipeline, and the hydrostatic forces may be applied to either side of the
valve. Where mechanical joint (MJ) sleeves are installed, some owners install a short
section of pipe (sometimes referred to as a pup) inside the sleeve to prevent the
two ends of the pipe in the sleeve from moving closer together due to compressive
forces (see Figure 1).
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For example, a 12-inch valve with a 150 psi test pressure, 2,000 psf allowable soil
bearing, and 1.5 factor of safety would require a block about 13 feet wide. The block
would need to be reinforced in order to act as a beam and avoid cracking as the thrust
force is spread into the soil. Note that the straps used to hold the valve to the block
are partially exposed to the soil. An alternative that some designers use is referred to
as a thrust collar or straddle block as shown in Figure 3.
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These blocks can be quite large and may be an obstacle to other utilities in the area.
For example, a block for an 18-inch diameter, 45 degree bend, with a 150 psi test
pressure and a 1.5 factor of safety would need to resist an upward thrust force of
about 40,000 pounds. The block would need a volume of approximately 10 cubic
yards. The dimensions could be a cube with the length of each side equal to 6.5 feet.
Some designers consider the weight of the soil above the block as contributing to the
force resisting the upward force. If the block is located in an area where the soil
could become saturated, the buoyant unit weight of the block and soil must be used.
This nearly doubles the volume of block required.
Combining Different Means of Thrust Restraint Occasionally designers use a
combination of thrust blocks and restrained joints to resist thrust forces. If both
systems are designed to act independently, this approach works well. For example, if
it is necessary to excavate behind a thrust block to install another utility, the
restrained joints can provide the necessary thrust restraint, even though the thrust
block provides no restraint during the time the excavation is open. However, if the
project is designed such that neither restraint system is adequate to independently
resist the thrust, failure is likely. Typically, restrained joints require a slight amount
of movement in order to engage. Thrust blocks or foundation walls may, or may not,
require slight movement to engage.
Location of Taps on PVC Pipe If PVC pipe is installed on a curved alignment by
bending of the pipe, installation of hot taps can cause pipe failure if the tap is
installed on the tension (outside radius) side. Hot taps should always be made on the
compression (inside radius) side.
Cautions Regarding Wedge-Type Grippers for Restraint at Mechanical Joints
Wedge-type grippers should not be used on the plain end of fittings where the fitting
connects to a mechanical joint. The plain end of fittings is frequently tapered and the
wedges will not grip properly. In addition, some fitting manufacturers use a
hardening process on their fittings that prevent the teeth on the wedge from properly
forming grooves in the pipe material.
Attaching Wood Skids to PVC Pipe Occasionally, wood skids are used when
sliding a pipe into a casing. The skids hold the pipe above the bottom of the casing
and avoid damage to the bells. Any scraping at rough spots inside the casing causes
wear on the skid, rather than on the pipe. If PVC pipe is being inserted into the
casing, the skids should not be creosote-treated as the creosote can weaken the PVC
pipe material.
Allowance for Make-up Water during Hydrostatic Testing The recommended
hydrostatic testing procedure, stated in the AWWA manuals, for ductile iron and
PVC pipelines is essentially the same (see formulas below). For ductile iron pipe, the
equation to compute the recommended maximum allowance for make-up water is
based on the length of pipe being tested. For PVC pipe, the equation to compute the
recommended maximum allowance for make-up water is based on the number of
pipe joints in the section of pipe being tested. Assuming the length of pipe between
joints is 18 feet, the two equations result in the same recommended allowance for
make-up water.
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AWWA M41
AWWA M23
=
133,200
7,400
Where:
L = Testing allowance (make-up water) in gallons per hour
S = Length of pipe being tested in feet
D = Nominal diameter of pipe in inches
P = Average test pressure in pounds per square inch
N = Number of joints in the length of pipeline being tested
CONCLUSION
Several tips and tools for design and construction of PVC and ductile iron pipelines
are presented in this paper. These tips and tools should benefit the professional
community by providing useful information to engineers, designers, inspectors, and
constructors of both ductile iron and PVC pipe systems.
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