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DUCTILE VS. STEEL: MAKING the BEST CHOICE Pg SUMMER 2014 DUCTILE VS. STEEL: MAKING THE BEST CHOICE Pg. 3 Pg. 7 USS Iowa 2014 Community Outreach Donation Through Engineering Contractors’ Association (ECA) Pg. 8 McWane Ductile Project Profiles Pg. 14 Ask the Ditch Doctor INSIDE FIND YOUR SALES REPRESENTATIVE (PG. 15) McWane Ductile TR FLEX®: McWANE’S COMPLETE PIPE SYSTEM (PG. 16) Canada Pipe Company ULC IN THIS ISSUE WELCOME TO MODERN McWANE Dear Readers, historic significance of Boston’s water system. Through the diligent effort and foresight of its past and current Thank you again for receiving staff, Boston has used primarily iron pipe since it stopped us this quarter. We hope all of using wood pipe nearly 200 years ago. This foresight has you are having a happy, safe, allowed the Boston Water and Sewer Commission to and enjoyable summer. This manage and maintain a major utility system that averages time of year brings us outdoors fewer than 40 main breaks a year, in spite of still having to enjoy activities such as pipes in service dating back to 1848 — that’s well over 150 backyard family barbecues, fireworks, and days at the years! This is certainly a service record that most utilities beach that we can’t enjoy other times of the year. half its size would envy. In fact, some utilities have 40 breaks a month, or even a week, because they use cheap, Summer also brings the onslaught of hurricane season. inferior pipe materials like PVC and HDPE. Our first storm of the year, Arthur, created much attention, although thankfully visited very briefly. It did, however, show some of the benefits of using McWane Ductile Iron Pipe, most notably ductile iron pipe’s ability to stay where a utility buries it. Hurricanes bring storm surges, resulting in unusually high water levels. Some piping materials, like HDPE, are less dense than water and, therefore, are prone to floating. In buried installations, this may not seem to be a concern; however, high water levels in saturated sandy environments create the potential for HDPE pipe to float out of the location where it was buried. The next time you see a report from a flooded area, look for a ribbon of HDPE pipe sprawled across the roadway. If you see one, you’ll So, while many of our readers are in the midst of their know how it got there. busiest time of year, installing many miles of McWane Ductile Iron Pipe, we want to offer our thanks for your June, besides bringing the start of hurricane season, also support and reassure you that we’re at your service now brings water works professionals together from across and for generations to come. A contractor popularized the world at AWWA’s Annual Conference and Exhibition. on television by the name of Mike Holmes has a saying: For the first time in 40 years it was held in Boston, “Do it right the first time.” We have a similar saying: “Do it Massachusetts, and more than 11,000 people attended. right — do it Ductile.” Even famed basketball coach Rick Pitino of the Louisville Cardinals stopped by the McWane booth to meet, greet and talk a little basketball with our visitors. Many Mark Niewodowski National Manager attendees also took some additional time to visit some Marketing & Specifications Department of the historical sites around town, but few realized the McWane Ductile 2 By: Jerry Regula, National Product Engineer, McWane Ductile DUCTILE VS. STEEL: MAKING THE BEST CHOICE Initial consideration for a project involves determining the best product for the job. Upon weighing all the factors, we can all certainly agree that ductile iron is the best overall choice for water utility projects. DESIGN The design basis behind ductile HOOP STRESS EQUATION: T = FS (PW + PS) (D) iron pipe is the most conservative 2S DUCTILE of products on the market today. Where T = pipe wall thickness D = outside diameter in inches Decades of reliable service IRON Fs = factor of safety (2) S = specified minimum yield provide evidence of ductile iron’s Pw = working pressure, psi strength ductile iron 42,000 psi Ps = surge pressure, psi success. Design calculations are found in the ANSI/AWWA C151/A21.51 standard design for ductile iron pipe. The most HOOP STRESS EQUATION: notable difference is the safety factor. The safety factor for T = (PW) (D) T = (PW + PS) (D) ductile iron pipe is 2.0, while the STEEL 2S OR 2S safety factor for steel ranges Where S = allowable stress, psi Where S = allowable stress, psi from 1.33 to 2.0, depending on the = 50% yield strength of steel = 75% yield strength of steel percent of yield strength used. 3 LET’S TALK CASH Ductile Steel Pressure Rating (PSI) 350 DUCTILE IRON PIPE IS A 150 PRODUCT THAT PROVIDES A Actual ID (Inches) 24.95 22.94 COST-EFFECTIVE TRANSMISSION Flow Rate (Gallons/Min) 7620 7620 LINE OVER ALTERNATIVE Velocity (Feet/Second) 5.0 5.9 PRODUCTS. THE CHART IS AN Unit Head Loss (Ft/1,000 ft) 6.0 9.09 EXAMPLE USING A 24-INCH LINE Total Head Loss (Feet) 5.37 8.09 AT 2,000 FEET OPERATING 24 Annual Pumping Cost ($/Yr) 9650.32 14,540.23 HOURS PER DAY. Annual Savings $7361 Notice the two different equations used to calculate LET’S TALK CASH thickness design. Allowing the stress to escalate Everyone would like to see a return on investment, and to 75 percent of yield strength, in effect, lowers the this annual savings could be put to good use. Ductile safety factor of steel pipe to 1.33 when including surge. iron pipe is also SMaRT certified. With as much as Compare that to the 2.0 safety factor used in the ductile 95 percent recycled materials, using ductile iron is a iron pipe design. The difference in percentages of yield benefit to our environment. Ductile iron also has no affect the thickness design of the pipe. Let’s stay with expiration, which basically means that when replaced the more conservative, trustworthy calculations. it can be recycled over and over again. Look at this from another angle. We have a 24-inch CORROSION AND PROTECTION water line with a working pressure of 150 psi. Ductile iron pipe is unique when it comes to corrosion control. An oxide layer is formed on the inside CALCULATING THE THICKNESS: and the outside of all ductile iron pipes during the Required Thickness manufacturing process. This oxide layer provides Steel pipe (50% yield) = .086 thickness adequate corrosion protection in many circumstances. Steel pipe (75% yield) = .095 thickness Utilization of the 10 Point Soil System will determine if Ductile iron pipe = .157 thickness there is a need for additional corrosion protection. The next step in corrosion protection for ductile iron pipe is The thickness of the ductile iron pipe is much greater than polyethylene encasement, also known as V-Bio. that of the steel. Also, the minimum thickness for a 24-inch Class 200 pipe is .24 inches, which is well beyond the Bonding three layers of co-extruded linear low-density calculated thickness design for internal pressure. There polyethylene into one forms V-Bio. The inside surface is a comfortable feeling knowing the product chosen is contains an anti-microbial biocide to control microbiologically designed well above the intended use. We do not know influenced corrosion, and a volatile corrosion inhibitor to what the future will bring 100 years down the road, but control galvanic corrosion. V-Bio is quite easy to install in the we do know that the design of ductile iron pipe provides field prior to pipe installation. Much like ductile iron pipe, ensurance that we are well prepared. V-Bio can be installed in virtually any weather condition. No other product on the market compares. Polyethylene encasement has proven to control corrosion in aggressive soils for more than 50 years. In addition, it is very cost effective. The cost for V-Bio is minimal as compared 4 to the overall cost of the project, especially when ADDITIONAL CATHODIC PROTECTION ISSUES compared to the vastly more expensive alternative Cathodic protection is rarely required and/or used bonded coatings used by the steel pipe industry. Not with ductile iron pipe. Steel pipe, on the other hand, to mention the even more expensive costs associated is more reliant on cathodic protection. Ductile iron with cathodic protection, which is widely used pipe joints are discontinuous, which helps to isolate in conjunction with steel. In general, the bonded corrosion cells to one piece of pipe. Contrarily, steel coatings that are used to protect steel pipe are very joints are continuous, which increases the potential expensive. Other issues that plague bonded coatings for electrolysis and, therefore, the need for cathodic are handling and patching. The thin wall of steel protection. Cathodic protection systems also require pipe may have insufficient beam strength to support maintenance. In comparison, while the use of ductile its own weight, which makes handling somewhat iron pipe provides an opportunity to save money in the challenging. It is difficult to handle a section of steel future, the use of steel pipe increases pumping and pipe throughout installation without experiencing maintenance costs. some type of damage to the bonded coatings. Any void in a bonded coating greatly increases the INSTALLATION FACTORS potential for corrosion. Therefore, these voids must Whether it’s rain, sleet, snow, heat, or freezing be repaired. Contractors do not have the luxury of temperatures, ductile iron pipe can handle them all. Let’s waiting until the sun shines to get the job done. Time look at a scenario: It is 3:00 p.m.
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