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FIELD WELDING AND
CUTTING DUCTILE
IRON PIPE
®
Notice
D
UCTILE IRON PIPE MANU-
FACTURERS have been suc-
cessfully welding Ductile Iron
pipe for many years and should
be consulted on their recommendations
for field welding and torch cutting their
product. The Ductile Iron Pipe Research
Association (DIPRA) does not support
indiscriminate field welding of Ductile
Iron pipe. However, unforeseen circum-
stances might require field welding of
retainer rings, thrust collars, etc., onto
the barrels of Ductile Iron pipe.
This manual is intended as a guide for
field welding and cutting cement-mortar-
lined and unlined Ductile Iron pipe. For
welding or cutting special lined pipe,
consult the pipe manufacturer.
The procedures described are intend-
ed to be used only by qualified welders
having adequate skill and experience in
the practice of the appropriate welding
and cutting methods for cast ferrous
materials. Only such qualified welders
should be allowed to field weld and field
cut restrained joints for Ductile Iron pipe.
Pipe manufacturers’ recommended pro-
cedures shall be followed while exercis-
ing reasonable care. Care should also be
exercised in the application of the princi-
ples contained herein. DIPRA assumes
no responsibility and disclaims liability
for the design or performance of pipe
joints or pipe systems fabricated with this
approach. Also, DIPRA assumes no
responsibility and disclaims liability for
injury or damage to persons or property
arising from the use of these procedures.
Introduction
Welding is a very important fabrication
method in modern industry. If an alloy
can be welded successfully, its usefulness
is clearly enhanced. Ductile Iron can be
welded successfully to produce welds
that have mechanical properties compa-
rable to those of the base iron.
As with any base material, the suc-
cess of welding Ductile Iron depends
on suitable equipment, correct proce-
dures, qualified welders, and effective
quality control procedures.
Ductile Iron Pipe
The first Ductile Iron pipe was cast exper-
imentally in 1948. Years of metallurgical,
casting, and quality control refinement
followed, and in 1955 Ductile Iron pipe
was introduced into the marketplace.
Its phenomenal strength and impact
resistance compared to Gray Iron, along
with many other advantages, created a
rapid increase in demand for this prod-
uct as engineers and utility officials real-
ized that it could be transported,
handled, and installed with virtually no
damage to the pipe. In service, Ductile
Iron pipe showed that expense of repair
was practically eliminated.
Ductile Iron is usually defined as a
Cast Iron with primary graphite in the
nodular or spheroidal form. This change
in the graphite form is accomplished by
adding an alloy, usually magnesium, to
molten iron of appropriate composition.
Properly treated iron will solidify with
the graphite in the form of nodules or
spheroids. The distribution and shape
of the graphite nodules are set when the
metal solidifies in the mold and will
remain essentially unchanged during
subsequent processing. Because of the
mold cooling and rapid iron solidifica-
tion, the pipe must be annealed (heat
treated) to produce the necessary pro-
portion of ferrite that imparts strength,
ductility, and impact properties required
by specifications for water service.
The annealing treatment relieves cast-
ing stresses and produces the microstruc-
tural transformation that increases the
toughness and improves ductility of the
FIELD WELDING AND
CUTTING DUCTILE IRON PIPE
By Richard W. Bonds, P.E.
Research and Technical Director
2
As these photomicrographs show, Ductile
Iron differs from Gray Iron in that its
graphite is spheroidal, or nodular, instead of
the flake form found in Gray Iron. Ductile’s
greater strength, ductility, and toughness
are due to this change in microstructure.
Ductile Iron
Gray Iron
Copyright © 1998, 1992 by Ductile Iron Pipe Research Association
iron while maintaining the required
strength. The effectiveness of the magne-
sium treatment of the iron as well as the
annealing treatment of the pipe is proven
by means of physical tests. The types of
tests, test frequencies, and acceptance
limits that are required are specified in
ANSI/AWWA C151/A21.51 Standard,
“Ductile-Iron Pipe, Centrifugally Cast, for
Water.” The acceptance test require-
ments of the ANSI/AWWA C151/A21.51
Ductile Iron Pipe Standard are:
1.Tensile properties of specimens
machined from the pipe wall: ulti-
mate strength, 60,000 psi minimum;
yield strength, 42,000 psi minimum;
elongation, 10 percent minimum.
2.Charpy V-Notch impact strengths
on specimens cut from the pipe
wall: 7 ft-lb minimum at 70°F;
3 ft-lb minimum at -40°F.
Ferritic Ductile Iron, as compared to
Gray Iron, will have about twice the
strength as determined by a tensile test,
beam test, ring bending test, and burst-
ing test. The tensile elongation and
impact strength of Ductile Iron are
many times that of Gray Iron.
General Welding of Iron
Pipes
Weldability of Ductile Iron
Due to their high carbon content, all cast
irons have a common factor affecting
their weldability. During the welding of
cast irons, the iron immediately adjacent
to the weld metal is heated to its fusion or
melting point. After welding, the entire
heat-affected zone cools very rapidly.
During this heating and cooling, some of
the graphitic carbon dissolves and diffus-
es into the iron, and, as a result, carbides
tend to form at the edge of the fusion
zone, and high-carbon martensite and
bainite tend to form in the remainder of
the heat-affected zone. The formation of
these hard, brittle microconstituents
increases the susceptibility to cracking.
The lower surface-to-volume ratio of the
nodular graphite in Ductile Iron as com-
pared to that for the flake graphite in
Gray Iron results in less carbon dissolu-
tion and the formation of fewer carbides
and less high-carbon martensite.
Also, because of its localized nature,
welding produces thermal stresses in
the weld area. Ductile Iron pipe, having
a predominantly ferritic matrix, is capa-
ble of local plastic deformation to accom-
modate these welding stresses and is
therefore better suited to absorb weld-
ing stresses than is Gray Iron. Success-
ful welds can be made by minimizing
the stress from contraction of the weld
metal as it cools, the pick-up of carbon
by the weld metal, and by controlling
the rate of cooling.
Preparation for Welding
The success of any welding operation is
affected by how effectively the prepara-
tion and cleaning operations are carried
out prior to welding. The welding area
on the pipe and connecting piece must
be untarnished, dry, and grease-free. It
has been found that the asphaltic coating
on the pipe can most easily be removed
with a torch. An alternate method is to
wash and wipe the area with a well-
soaked rag containing mineral spirits or
other solvents. (Safety precautions must
be observed when using flammable
materials.) After the asphaltic coating
and any grease, etc., have been removed
from the weld area, the area should be
ground to bright metal to remove all
annealing oxide. Also, the correspond-
ing surface of the Ductile Iron or alloy
steel connecting piece to be welded
should be cleaned and ground to bright
metal. A shot-blasted surface alone is
not adequate for welding.
Weld Joint Design
Most weld joint designs commonly used
for welding carbon steels are generally
suitable for welding Ductile Iron (butt
welding is not recommended).
Preheating
Preheating involves raising the tempera-
ture of the base metal in the region to be
welded to a predetermined temperature
prior to carrying out the welding
3
The annealing treatment for Ductile Iron pipe relieves casting stresses and produces the microstructural transformation that increases
the pipe’s toughness and improves the ductility of the iron while maintaining the required strength.
process. Preheating may be applied to
help prevent cold-cracking, reduce hard-
ness in the heat-affected zone, reduce
residual stresses, and reduce distortion.
Normally, preheating of Ductile Iron
pipe is not necessary and is impractical to
do in the field. However, in extreme cold
weather one may find it advantageous to
warm the pipe weld area with a torch.
Shielded Metal-Arc Welding
Shielded metal-arc welding is the most
common welding process used on Duc-
tile Iron pipe in the field. The equip-
ment necessary for shielded metal-arc
welding is as follows:
1.D.C. arc welder using reversed
polarity.
2.Suitable welding electrodes.
3.Welding cable, work-piece cable,
electrode holder, gloves, shield
and protective clothing.
Electrodes for metal-arc welding are
normally covered with a flux coating.
The coating can fulfill the following
functions:
1.Stabilize the arc by ionization.
2.Provide protection for the molten
metal from the atmosphere by
evolution of gases such as carbon
dioxide and by hydrogen and also
by the formation of a protective
slag or flux.
3.Influence the properties of the
weld metal by de-oxidation and
alloying.
4.Control the arc characteristics.
Recommended Electrodes
Some electrodes recommended for
welding Ductile Iron are the 44- and 55-
percent nickel-iron electrodes. Consult
pipe manufacturer for recommenda-
tions. These electrodes provide weld
metal strength and toughness properties
that are comparable to those of the base
iron. The 44- and 55-percent nickel-iron
electrodes should be in conformance
with class designation AWS A5.15
(ERNi-CI) and (ENiFe-CI) respectively.
These electrodes are capable of produc-
ing suitable welds without preheating or
postheating the pipe or connecting
piece. Nickel-iron electrodes are avail-
able from most of the leading electrode
manufacturers and, although composi-
tion with reference to nickel and iron
content remains broadly the same, dif-
ferences in slag-stripping qualities and
operation may be found in electrodes
obtained from different sources. Two
nickel-iron electrodes are Inco Alloys
International’s Ni-Rod 44 and Ni-Rod 55.
Mild-steel, arc-welding electrodes are
not recommended for use with Ductile
Iron because of the high risk of cracking
at the interface of weld and base metal.
Deposited metal from the ENiFe-CI
electrode has a carbon content well
above the solubility limit. The excess
carbon is rejected as graphite during
solidification of the weld metal. This
reaction causes an increase in volume
that tends to minimize weld shrinkage
during solidification. This, in turn,
reduces residual stresses in the weld
metal and the iron’s heat-affected zone.
Care of Electrodes
Electrodes must be completely free from
moisture when used. Porosity in the
weld can and often does originate
because of moisture pick-up by the elec-
trode coating. It is invariably due to the
fact that the electrodes have been stored
in unsatisfactory conditions. Ideally, elec-
trodes should be stored in an oven main-
tained at a temperature of at least 250°F.
If they have not been stored under these
conditions they should be baked for at
least 1 hour at 480°F in a well-ventilated
electric oven prior to use. The practice of
drying electrodes by shorting them out is
not recommended. Excessive heating by
this method, apart from having adverse
effects on the power source, can damage
the coatings and thus reduce their shield-
ing efficiency when used.
Welding Procedures
Welding current for a particular electrode
size should be within the range recom-
mended by the manufacturer but as low
as possible, consistent with smooth oper-
ation, desired head contour, and good
fusion. When used in other than the flat
horizontal position, an electrode recom-
mended for out of position welding, such
as Inco Alloys International’s Ni-Rod 55X,
should be used. The welding current
should be reduced 10 to 20 amps for verti-
cal welding and 5 to 15 amps for overhead
welding with Inco Alloys International’s
Ni-Rod 55X. The arc length should be
kept as short as possible consistent with
obtaining smooth operation and sufficient
penetration and wash at the side of the
joint. A slight weave of the electrode is
recommended, although this should not
exceed three times the diameter (i.e.,
corewire diameter) of the electrode.
When mild-steel components are being
joined to Ductile Iron pipe, the center line
of the arc should be concentrated as far
as possible onto the mild-steel compo-
nent, which is thereby made to absorb as
much heat as possible from the arc. The
relatively low arc intensity associated with
the nickel-iron electrodes, coupled with
the sluggish metal-transfer characteristic,
is conducive to minimum heat input, giv-
ing minimum fusion and minimum car-
bide formation in the base iron.
By depositing narrow beads in short
lengths one can reduce the cumulative
effect of the stresses from shrinkage of
weld metal. Each length of bead should
be allowed to cool until it can be touched
by hand before another deposit is made
within the area heated by the first bead.
While one bead is cooling, others are
deposited at other locations throughout
the joint. All beads should be deposited
in the same direction.
Another method to reduce shrinkage
stresses is to peen a deposited bead of
weld metal while it is still hot. Peening
4
should be done with repeated moderate
blows using a round-nose tool and suffi-
cient force to deform the weld metal but
without rupturing it. Effective peening
stretches the weld metal to help compen-
sate for the shrinkage that occurs during
cooling. The peened metal is then
allowed to cool before another bead is
deposited near it.
By using a low welding current, a
small-diameter electrode, and depositing
multiple narrow beads, only the lower
layer of weld metal has a very high car-
bon content. Subsequent layers of weld
metal tend to temper and reduce hard-
ness of the first layer.
Complete flux removal is essential
after each weld pass before depositing
further weld metal since entrapped slag
can impair the strength properties of the
weld. Flux removal, in the case of nick-
el-iron electrodes, can usually be easily
accomplished with a pointed welder’s
hammer or by wire-brushing.
Metal Inert Gas (MIG) Welding
Metal inert gas and pulsed-metal inert gas
arc welding using argon or argon-helium
shielding-gas with short-circuiting trans-
fer is suitable for joining Ductile Iron to
itself and to mild steel. Because of the rel-
atively low heat input with this process,
the hard portion of the heat-affected zone
is usually confined to a thin layer next to
the weld metal. As a result, the strength
and ductility of the welded joint are about
the same as those of the base metal.
Recommended Filler Material
It has been established that the most
satisfactory filler metal for MIG short-
arc welding of Ductile Iron is nickel
(ENi-1).
Flux-Cored Wire Arc Welding
This process is similar to MIG welding
insofar as a consumable wire electrode is
used. However, whereas MIG welding
uses an inert-gas shield to protect the
weld pool, the flex-cored wire process
5
Figure 1 Shielded Metal-Arc Welding Process
Figure 2 Metal Inert Gas (MIG) Welding Process
derives its protection from the slag
formed from the flux materials contained
in the core of the tubular wire. A Ni-Rod
FC55 cored wire electrode is available
that produces weld metal with a compo-
sition and micro-structure similar to that
deposited by ENiFe-CI covered elec-
trodes. The principle of graphite precipi-
tation and the associated volume
increase is the same for both electrodes.
The flux-cored electrode is a self-
shielding design but it may be used with
carbon dioxide (CO2 ) shielding or as a
submerged arc welding electrode. The
electrode producer should be consulted
for recommendations on usage and pro-
cedures for specific applications.
Oxyacetylene Welding
Oxyacetylene welding procedures
require large amounts of heat input dur-
ing both the pre-heating and the welding
operations. The extensive heating is a
limiting factor in the application of this
process. The process is not considered
suitable for fabrication work as the high
heat input can cause excessive distor-
tion; and in the as-deposited condition,
the weld area is likely to contain a high
proportion of iron carbide.
Field Welding Procedure
For Field-Cut Restrained
Joint Ductile Iron Pipe
Many restrained joint designs rely on a
welded-on retainer ring around the spigot
of the pipe to provide part of the means of
restraint. This retainer ring is furnished
factory-welded in position on the pipe.
The welding is performed by welders
qualified to produce high-quality, depend-
able welds. By planning ahead, neces-
sary field cuts of Ductile Iron pipe can
normally be positioned in unrestrained
sections of the pipeline. However, if field
cuts are required in restrained joint pipe
sections utilizing the welded-on retainer
ring, a loose factory-supplied ring can be
field-welded onto the barrel of the field-
cut Ductile Iron pipe.
Welds should be applied using a D.C.
arc welder employing reversed polarity
and operating at amperage ranges recom-
mended by the electrode manufacturer.
General ranges of amperages for
various diameter electrodes are shown in
Table 1 below.
The weld electrodes used should be in
conformance with Class designation AWS
5.15 (ENiFe-CI). Three such electrodes
are Inco Alloys International’s Ni-Rod 44,
Ni-Rod 55 and 55X (consult pipe manu-
facturer for recommendations). The
electrode and electrode diameter recom-
mended by pipe manufacturers for their
retainer ring should be used.
Table 1 General Amperage Ranges for Various Electrodes
6
Figure 3 Flux-Cored Wire Arc Welding Process
Electrode Diameter
3/32-in.
1/8-in.
5/32-in.
3/16-in.
Recommended Current (amp)
40-65
75-95
100-135
120-155
Procedure
1. Measure the candidate pipe diame-
ter (or circumference) at the loca-
tion of the cut to be made to
ensure that the pipe diameter and
circumference are within the toler-
ance shown in Table 2. (Note:
There are minimum laying lengths
for restrained joint pipe. Consult
manufacturer.)
2. Mark the pipe at sufficient intervals
around the circumference by mea-
suring from a reference (usually
the spigot end) such that a square
cut can be made.
3. Cut the pipe at the desired location.
It is important that field cuts for
restrained joint welding be smooth,
regular, and as square as possible
with the axis of the pipe because
the cut end will be used as a refer-
ence to position the retainer ring.
The outside of the cut end should
be beveled smooth per the manu-
facturer’s recommendations using
a grinder or file to prevent damage
to the gasket during assembly.
4. Mark the location of the weld-on
retainer ring from the cut end of
the pipe per the manufacturer’s
specifications.
5. Remove the asphaltic coating on
the pipe in the area the retainer
ring is to be welded with a solvent
wash or by burning with a torch.
After the asphaltic coating has
been removed, grind the retainer
ring location to bright metal. Also,
the corresponding edge of the ring
to be welded should be cleaned
and ground to bright metal. Place
loose locking rings or glands (if
required for the particular joint
7
Step 1. Measure the pipe diameter (or circumference) at the location of the cut to
ensure that it is within the tolerance shown in Table 2 on page 11 of this brochure.
Step 2. Mark the pipe at sufficient intervals around the circumference by measuring
from a reference — usually the spigot end of the pipe.
Step 3. Cut the pipe at the desired location. Following the cut, the outside of the cut
end should be beveled smooth per the manufacturer’s recommendations.
configuration) on the pipe barrel
beyond the retainer ring location.
6. Re-mark the location of the weld-
on retainer ring on the pipe as
was done in Step 4.
7. Some restrained joint designs
require the weld-on retainer ring
to be cut to length in the field.
If such is employed, fit the ring
around the pipe and mark and
cut the ring to the length
recommended by the manufac-
turer. Normally the ring will be
cut “short” to accommodate
lengthening during the welding
operation.
8. Clamp the weld-on retainer ring
securely on the pipe in the correct
location.* This may be accom-
plished using the manufacturer’s
special welding jigs, fixtures,
and/or C-clamps. If the clamping
device bears on the inside
of the pipe, care should be taken
to minimize damage to the pipe
lining. If welding fixtures and/or
C-clamps are used, the weld
deposit should be applied in
circumferential intervals corre-
sponding to the movement of the
clamps as recommended by the
pipe manufacturer.
9. With the retainer ring fitted closely
to the pipe surface, weld on the
side of the ring next to the cut end
of the pipe.* Weld according to
the pipe manufacturer’s recom-
mendations (electrode diameter,
weld size, weld passes required,
Step 4. Mark the location of the weld-on retainer ring from the cut end of the pipe per
the manufacturer’s specifications.
Step 5. Remove the pipe’s asphaltic coating on the area where the retainer ring will be
welded with a solvent wash or by burning with a torch; then grind the retainer location
to bright metal.
Step 8. Clamp the weld-on retainer ring securely on the pipe in the correct location.* If
the clamping device bears on the inside of the pipe, take care to minimize damage to
the pipe lining.
*The configuration of rings varies slightly
from manufacturer to manufacturer. Contact
your DIPRA member company regarding
the ring configuration it recommends.
8
welding technique, etc). To mini-
mize heat build-up that may possi-
bly cause thermal stresses and/or
damage to linings, skip welding
techniques can be used. Thorough
peening of the weld passes before
they cool will minimize thermal
stresses. The ends of adjoining
passes should be slightly over--
lapped before the arc is broken. If
weld cracks occur, they should be
ground away and repaired with a
weld overlay. After the entire ring
has been welded to the pipe, weld
the ring ends to the pipe and weld
in the space remaining between
the ring ends according to the
pipe manufacturer’s instructions.
10. Thoroughly clean the weld and
ring* to remove all weld flux and
splatter. The pipe spigot should
be clean of weld splatter for proper
gasket sealing and joint assembly.
11. Coat the ring* weld and ground
pipe surface with a smooth uni-
form coat of brushable mastic.
12. Inspect the pipe lining for possible
damage. Cement-mortar linings
are normally not adversely affect-
ed by such welding procedures;
however, if cement lining damage
occurs, it should be patched in
accordance with recommended
procedures as noted in
ANSI/AWWA C104/A21.4 Stan-
dard, “Cement-Mortar Linings for
Ductile-Iron Pipe and Fittings for
Water.” Contact the pipe manu-
facturer for repair of special linings.
Step 9. With the retainer ring fitted closely to the pipe surface, weld on the side of the
ring next to the cut end of the pipe according to the manufacturer’s recommendations.*
(Skip welding techniques can be used.) After the entire ring has been welded to the
pipe, weld the ring ends to the pipe and weld in the space remaining between the ring
ends.
Step 10. Thoroughly clean the weld and ring* to remove all weld flux and splatter so the
pipe spigot is clean for proper gasket sealing and joint assembly.
Step 11. Coat the ring*, weld, and ground pipe surface with a smooth uniform coat of
brushable mastic.
9
*The configuration of rings varies slightly
from manufacturer to manufacturer. Contact
your DIPRA member company regarding
the ring configuration it recommends.
Cutting Ductile Iron Pipe
Ductile Iron pipe may be cut using an
abrasive pipe saw, a rotary wheel cut-
ter, a guillotine pipe saw, or a milling
wheel saw. Cement-mortar-lined or
unlined Ductile Iron pipe can also be
cut with an oxyacetylene torch if rec-
ommended by the pipe manufacturer
for its product.
The ANSI/AWWA standard for Duc-
tile Iron pipe requires factory gauging
of the spigot end. Accordingly, pipes
selected for cutting should be field-
gauged in the location of the cut and be
within tolerance as shown in Table 2.
Torch cutting of Ductile Iron pipe
normally results in a heat-affected zone
extending less than 1/4-inch from the
cut face but might result in small
cracks in this area which should be
removed by grinding. Some difficulty
might result in threading or machining
in this particular portion of the pipe
due to hardening of the metal. Such
hardening does not interfere with push-
on or mechanical joint assembly or
performance.
Pipe manufacturers who recom-
mend torch cutting of their pipe report
best results are obtained by using a No.
8 or No. 10 tip with approximately 75
psi oxygen and 10 to 15 psi acetylene.
For cement-lined Ductile Iron pipe, the
best results are normally obtained
when the torch head is inclined approx-
imately 60 degrees to the direction of
cutting. Cutting time for pipe cut by
oxyacetylene methods is approximately
one minute per inch of diameter for
cement-lined pipe and even less for
unlined pipe.
Cut ends and rough edges should
be ground smooth and for push-on con-
nections, the cut end should be
beveled to the approximate profile of
the factory supplied end.
In addition to being cut with an abrasive pipe saw, a rotary wheel cutter, a guillotine pipe
saw, or a milling saw, Ductile Iron pipe can also be cut with an oxyacetylene torch if rec-
ommended by the pipe manufacturer. Cut ends and rough edges should be ground
smooth. For push-on connections, the cut end should be beveled to the approximate pro-
file of the factory supplied end.
10
References
1. American Cast Iron Pipe Company,
“Instructions for Field Welding of
American Restrained Ductile Iron
Pipe Joints.”
2. ANSI/AWS D11.2 Standard, “Guide
for Welding Iron Castings,” 1989.
3. ANSI/AWS A5.15 Standard, “Spec-
ification for Welding Electrodes
and Rods for Cast Iron.”
4. ANSI/AWWA C151/A21.51 Stan-
dard, “Ductile-Iron Pipe, Centrifu-
gally Cast, for Water.”
5. British Cast Iron Research Associa-
tion, “The Joining and Fabrication
of Nodular Iron Castings by Weld-
ing,” 1982.
6. INCO Alloys International, Ni-Rod 44
and Ni-Rod 55 Welding Electrodes.
7. INCO Alloys International, Ni-Rod
99X and Ni-Rod 55X Welding Elec-
trodes.
8. Jefferson, T.B., “Metals and How to
Weld Them,” Second Edition,
Welding Engineer Publication, Inc.
9. The Lincoln Electric Company,
“The Procedure Handbook of Arc
Welding,” Twelfth Edition.
10.U.S. Pipe and Foundry Company,
“Field Cutting and Welding Proce-
dure for TR FLEX Pipe,” 1997 Edi-
tion.
Table 2
Suitable Pipe Diameters for Field Cuts and Restrained Joint Field
Fabrication
Nominal
Pipe Min. Pipe Max. Pipe Min. Pipe Max. Pipe
Size Diameter Diameter Circumference Circumference
In. In. In. In. In.
4 4.74 4.86 14 29/32 15 9/32
6 6.84 6.96 21 1/2 21 7/8
8 8.99 9.11 28 1/4 28 5/8
10 11.04 11.16 34 11/16 35 1/16
12 13.14 13.26 41 9/32 41 21/32
14 15.22 15.35 47 13/16 48 7/32
16 17.32 17.45 54 13/32 54 13/16
18 19.42 19.55 61 61 13/32
20 21.52 21.65 67 19/32 68
24 25.72 25.85 80 13/16 81 7/32
30 31.94 32.08 100 11/32 100 25/32
36 38.24 38.38 120 1/8 120 9/16
42 44.44 44.58 139 5/8 140 1/16
48 50.74 50.88 159 13/32 159 27/32
54 57.46 57.60 180 17/32 180 31/32
60 61.51 61.65 193 1/4 193 11/16
64 65.57 65.71 206 206 7/16
Above table based on ANSI/AWWA C151/A21.51
guidelines for push-on joints
11
Manufactured from recycled materials.
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 Company
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
United States Pipe and Foundry Company
P.O. Box 10406
Birmingham, Alabama 35202-0406
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
http://www.dipra.org
FW/12-99/2M Revised 12-98
Published 2-92

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Field welding and cutting ductile iron pipe

  • 1. FIELD WELDING AND CUTTING DUCTILE IRON PIPE ®
  • 2. Notice D UCTILE IRON PIPE MANU- FACTURERS have been suc- cessfully welding Ductile Iron pipe for many years and should be consulted on their recommendations for field welding and torch cutting their product. The Ductile Iron Pipe Research Association (DIPRA) does not support indiscriminate field welding of Ductile Iron pipe. However, unforeseen circum- stances might require field welding of retainer rings, thrust collars, etc., onto the barrels of Ductile Iron pipe. This manual is intended as a guide for field welding and cutting cement-mortar- lined and unlined Ductile Iron pipe. For welding or cutting special lined pipe, consult the pipe manufacturer. The procedures described are intend- ed to be used only by qualified welders having adequate skill and experience in the practice of the appropriate welding and cutting methods for cast ferrous materials. Only such qualified welders should be allowed to field weld and field cut restrained joints for Ductile Iron pipe. Pipe manufacturers’ recommended pro- cedures shall be followed while exercis- ing reasonable care. Care should also be exercised in the application of the princi- ples contained herein. DIPRA assumes no responsibility and disclaims liability for the design or performance of pipe joints or pipe systems fabricated with this approach. Also, DIPRA assumes no responsibility and disclaims liability for injury or damage to persons or property arising from the use of these procedures. Introduction Welding is a very important fabrication method in modern industry. If an alloy can be welded successfully, its usefulness is clearly enhanced. Ductile Iron can be welded successfully to produce welds that have mechanical properties compa- rable to those of the base iron. As with any base material, the suc- cess of welding Ductile Iron depends on suitable equipment, correct proce- dures, qualified welders, and effective quality control procedures. Ductile Iron Pipe The first Ductile Iron pipe was cast exper- imentally in 1948. Years of metallurgical, casting, and quality control refinement followed, and in 1955 Ductile Iron pipe was introduced into the marketplace. Its phenomenal strength and impact resistance compared to Gray Iron, along with many other advantages, created a rapid increase in demand for this prod- uct as engineers and utility officials real- ized that it could be transported, handled, and installed with virtually no damage to the pipe. In service, Ductile Iron pipe showed that expense of repair was practically eliminated. Ductile Iron is usually defined as a Cast Iron with primary graphite in the nodular or spheroidal form. This change in the graphite form is accomplished by adding an alloy, usually magnesium, to molten iron of appropriate composition. Properly treated iron will solidify with the graphite in the form of nodules or spheroids. The distribution and shape of the graphite nodules are set when the metal solidifies in the mold and will remain essentially unchanged during subsequent processing. Because of the mold cooling and rapid iron solidifica- tion, the pipe must be annealed (heat treated) to produce the necessary pro- portion of ferrite that imparts strength, ductility, and impact properties required by specifications for water service. The annealing treatment relieves cast- ing stresses and produces the microstruc- tural transformation that increases the toughness and improves ductility of the FIELD WELDING AND CUTTING DUCTILE IRON PIPE By Richard W. Bonds, P.E. Research and Technical Director 2 As these photomicrographs show, Ductile Iron differs from Gray Iron in that its graphite is spheroidal, or nodular, instead of the flake form found in Gray Iron. Ductile’s greater strength, ductility, and toughness are due to this change in microstructure. Ductile Iron Gray Iron Copyright © 1998, 1992 by Ductile Iron Pipe Research Association
  • 3. iron while maintaining the required strength. The effectiveness of the magne- sium treatment of the iron as well as the annealing treatment of the pipe is proven by means of physical tests. The types of tests, test frequencies, and acceptance limits that are required are specified in ANSI/AWWA C151/A21.51 Standard, “Ductile-Iron Pipe, Centrifugally Cast, for Water.” The acceptance test require- ments of the ANSI/AWWA C151/A21.51 Ductile Iron Pipe Standard are: 1.Tensile properties of specimens machined from the pipe wall: ulti- mate strength, 60,000 psi minimum; yield strength, 42,000 psi minimum; elongation, 10 percent minimum. 2.Charpy V-Notch impact strengths on specimens cut from the pipe wall: 7 ft-lb minimum at 70°F; 3 ft-lb minimum at -40°F. Ferritic Ductile Iron, as compared to Gray Iron, will have about twice the strength as determined by a tensile test, beam test, ring bending test, and burst- ing test. The tensile elongation and impact strength of Ductile Iron are many times that of Gray Iron. General Welding of Iron Pipes Weldability of Ductile Iron Due to their high carbon content, all cast irons have a common factor affecting their weldability. During the welding of cast irons, the iron immediately adjacent to the weld metal is heated to its fusion or melting point. After welding, the entire heat-affected zone cools very rapidly. During this heating and cooling, some of the graphitic carbon dissolves and diffus- es into the iron, and, as a result, carbides tend to form at the edge of the fusion zone, and high-carbon martensite and bainite tend to form in the remainder of the heat-affected zone. The formation of these hard, brittle microconstituents increases the susceptibility to cracking. The lower surface-to-volume ratio of the nodular graphite in Ductile Iron as com- pared to that for the flake graphite in Gray Iron results in less carbon dissolu- tion and the formation of fewer carbides and less high-carbon martensite. Also, because of its localized nature, welding produces thermal stresses in the weld area. Ductile Iron pipe, having a predominantly ferritic matrix, is capa- ble of local plastic deformation to accom- modate these welding stresses and is therefore better suited to absorb weld- ing stresses than is Gray Iron. Success- ful welds can be made by minimizing the stress from contraction of the weld metal as it cools, the pick-up of carbon by the weld metal, and by controlling the rate of cooling. Preparation for Welding The success of any welding operation is affected by how effectively the prepara- tion and cleaning operations are carried out prior to welding. The welding area on the pipe and connecting piece must be untarnished, dry, and grease-free. It has been found that the asphaltic coating on the pipe can most easily be removed with a torch. An alternate method is to wash and wipe the area with a well- soaked rag containing mineral spirits or other solvents. (Safety precautions must be observed when using flammable materials.) After the asphaltic coating and any grease, etc., have been removed from the weld area, the area should be ground to bright metal to remove all annealing oxide. Also, the correspond- ing surface of the Ductile Iron or alloy steel connecting piece to be welded should be cleaned and ground to bright metal. A shot-blasted surface alone is not adequate for welding. Weld Joint Design Most weld joint designs commonly used for welding carbon steels are generally suitable for welding Ductile Iron (butt welding is not recommended). Preheating Preheating involves raising the tempera- ture of the base metal in the region to be welded to a predetermined temperature prior to carrying out the welding 3 The annealing treatment for Ductile Iron pipe relieves casting stresses and produces the microstructural transformation that increases the pipe’s toughness and improves the ductility of the iron while maintaining the required strength.
  • 4. process. Preheating may be applied to help prevent cold-cracking, reduce hard- ness in the heat-affected zone, reduce residual stresses, and reduce distortion. Normally, preheating of Ductile Iron pipe is not necessary and is impractical to do in the field. However, in extreme cold weather one may find it advantageous to warm the pipe weld area with a torch. Shielded Metal-Arc Welding Shielded metal-arc welding is the most common welding process used on Duc- tile Iron pipe in the field. The equip- ment necessary for shielded metal-arc welding is as follows: 1.D.C. arc welder using reversed polarity. 2.Suitable welding electrodes. 3.Welding cable, work-piece cable, electrode holder, gloves, shield and protective clothing. Electrodes for metal-arc welding are normally covered with a flux coating. The coating can fulfill the following functions: 1.Stabilize the arc by ionization. 2.Provide protection for the molten metal from the atmosphere by evolution of gases such as carbon dioxide and by hydrogen and also by the formation of a protective slag or flux. 3.Influence the properties of the weld metal by de-oxidation and alloying. 4.Control the arc characteristics. Recommended Electrodes Some electrodes recommended for welding Ductile Iron are the 44- and 55- percent nickel-iron electrodes. Consult pipe manufacturer for recommenda- tions. These electrodes provide weld metal strength and toughness properties that are comparable to those of the base iron. The 44- and 55-percent nickel-iron electrodes should be in conformance with class designation AWS A5.15 (ERNi-CI) and (ENiFe-CI) respectively. These electrodes are capable of produc- ing suitable welds without preheating or postheating the pipe or connecting piece. Nickel-iron electrodes are avail- able from most of the leading electrode manufacturers and, although composi- tion with reference to nickel and iron content remains broadly the same, dif- ferences in slag-stripping qualities and operation may be found in electrodes obtained from different sources. Two nickel-iron electrodes are Inco Alloys International’s Ni-Rod 44 and Ni-Rod 55. Mild-steel, arc-welding electrodes are not recommended for use with Ductile Iron because of the high risk of cracking at the interface of weld and base metal. Deposited metal from the ENiFe-CI electrode has a carbon content well above the solubility limit. The excess carbon is rejected as graphite during solidification of the weld metal. This reaction causes an increase in volume that tends to minimize weld shrinkage during solidification. This, in turn, reduces residual stresses in the weld metal and the iron’s heat-affected zone. Care of Electrodes Electrodes must be completely free from moisture when used. Porosity in the weld can and often does originate because of moisture pick-up by the elec- trode coating. It is invariably due to the fact that the electrodes have been stored in unsatisfactory conditions. Ideally, elec- trodes should be stored in an oven main- tained at a temperature of at least 250°F. If they have not been stored under these conditions they should be baked for at least 1 hour at 480°F in a well-ventilated electric oven prior to use. The practice of drying electrodes by shorting them out is not recommended. Excessive heating by this method, apart from having adverse effects on the power source, can damage the coatings and thus reduce their shield- ing efficiency when used. Welding Procedures Welding current for a particular electrode size should be within the range recom- mended by the manufacturer but as low as possible, consistent with smooth oper- ation, desired head contour, and good fusion. When used in other than the flat horizontal position, an electrode recom- mended for out of position welding, such as Inco Alloys International’s Ni-Rod 55X, should be used. The welding current should be reduced 10 to 20 amps for verti- cal welding and 5 to 15 amps for overhead welding with Inco Alloys International’s Ni-Rod 55X. The arc length should be kept as short as possible consistent with obtaining smooth operation and sufficient penetration and wash at the side of the joint. A slight weave of the electrode is recommended, although this should not exceed three times the diameter (i.e., corewire diameter) of the electrode. When mild-steel components are being joined to Ductile Iron pipe, the center line of the arc should be concentrated as far as possible onto the mild-steel compo- nent, which is thereby made to absorb as much heat as possible from the arc. The relatively low arc intensity associated with the nickel-iron electrodes, coupled with the sluggish metal-transfer characteristic, is conducive to minimum heat input, giv- ing minimum fusion and minimum car- bide formation in the base iron. By depositing narrow beads in short lengths one can reduce the cumulative effect of the stresses from shrinkage of weld metal. Each length of bead should be allowed to cool until it can be touched by hand before another deposit is made within the area heated by the first bead. While one bead is cooling, others are deposited at other locations throughout the joint. All beads should be deposited in the same direction. Another method to reduce shrinkage stresses is to peen a deposited bead of weld metal while it is still hot. Peening 4
  • 5. should be done with repeated moderate blows using a round-nose tool and suffi- cient force to deform the weld metal but without rupturing it. Effective peening stretches the weld metal to help compen- sate for the shrinkage that occurs during cooling. The peened metal is then allowed to cool before another bead is deposited near it. By using a low welding current, a small-diameter electrode, and depositing multiple narrow beads, only the lower layer of weld metal has a very high car- bon content. Subsequent layers of weld metal tend to temper and reduce hard- ness of the first layer. Complete flux removal is essential after each weld pass before depositing further weld metal since entrapped slag can impair the strength properties of the weld. Flux removal, in the case of nick- el-iron electrodes, can usually be easily accomplished with a pointed welder’s hammer or by wire-brushing. Metal Inert Gas (MIG) Welding Metal inert gas and pulsed-metal inert gas arc welding using argon or argon-helium shielding-gas with short-circuiting trans- fer is suitable for joining Ductile Iron to itself and to mild steel. Because of the rel- atively low heat input with this process, the hard portion of the heat-affected zone is usually confined to a thin layer next to the weld metal. As a result, the strength and ductility of the welded joint are about the same as those of the base metal. Recommended Filler Material It has been established that the most satisfactory filler metal for MIG short- arc welding of Ductile Iron is nickel (ENi-1). Flux-Cored Wire Arc Welding This process is similar to MIG welding insofar as a consumable wire electrode is used. However, whereas MIG welding uses an inert-gas shield to protect the weld pool, the flex-cored wire process 5 Figure 1 Shielded Metal-Arc Welding Process Figure 2 Metal Inert Gas (MIG) Welding Process
  • 6. derives its protection from the slag formed from the flux materials contained in the core of the tubular wire. A Ni-Rod FC55 cored wire electrode is available that produces weld metal with a compo- sition and micro-structure similar to that deposited by ENiFe-CI covered elec- trodes. The principle of graphite precipi- tation and the associated volume increase is the same for both electrodes. The flux-cored electrode is a self- shielding design but it may be used with carbon dioxide (CO2 ) shielding or as a submerged arc welding electrode. The electrode producer should be consulted for recommendations on usage and pro- cedures for specific applications. Oxyacetylene Welding Oxyacetylene welding procedures require large amounts of heat input dur- ing both the pre-heating and the welding operations. The extensive heating is a limiting factor in the application of this process. The process is not considered suitable for fabrication work as the high heat input can cause excessive distor- tion; and in the as-deposited condition, the weld area is likely to contain a high proportion of iron carbide. Field Welding Procedure For Field-Cut Restrained Joint Ductile Iron Pipe Many restrained joint designs rely on a welded-on retainer ring around the spigot of the pipe to provide part of the means of restraint. This retainer ring is furnished factory-welded in position on the pipe. The welding is performed by welders qualified to produce high-quality, depend- able welds. By planning ahead, neces- sary field cuts of Ductile Iron pipe can normally be positioned in unrestrained sections of the pipeline. However, if field cuts are required in restrained joint pipe sections utilizing the welded-on retainer ring, a loose factory-supplied ring can be field-welded onto the barrel of the field- cut Ductile Iron pipe. Welds should be applied using a D.C. arc welder employing reversed polarity and operating at amperage ranges recom- mended by the electrode manufacturer. General ranges of amperages for various diameter electrodes are shown in Table 1 below. The weld electrodes used should be in conformance with Class designation AWS 5.15 (ENiFe-CI). Three such electrodes are Inco Alloys International’s Ni-Rod 44, Ni-Rod 55 and 55X (consult pipe manu- facturer for recommendations). The electrode and electrode diameter recom- mended by pipe manufacturers for their retainer ring should be used. Table 1 General Amperage Ranges for Various Electrodes 6 Figure 3 Flux-Cored Wire Arc Welding Process Electrode Diameter 3/32-in. 1/8-in. 5/32-in. 3/16-in. Recommended Current (amp) 40-65 75-95 100-135 120-155
  • 7. Procedure 1. Measure the candidate pipe diame- ter (or circumference) at the loca- tion of the cut to be made to ensure that the pipe diameter and circumference are within the toler- ance shown in Table 2. (Note: There are minimum laying lengths for restrained joint pipe. Consult manufacturer.) 2. Mark the pipe at sufficient intervals around the circumference by mea- suring from a reference (usually the spigot end) such that a square cut can be made. 3. Cut the pipe at the desired location. It is important that field cuts for restrained joint welding be smooth, regular, and as square as possible with the axis of the pipe because the cut end will be used as a refer- ence to position the retainer ring. The outside of the cut end should be beveled smooth per the manu- facturer’s recommendations using a grinder or file to prevent damage to the gasket during assembly. 4. Mark the location of the weld-on retainer ring from the cut end of the pipe per the manufacturer’s specifications. 5. Remove the asphaltic coating on the pipe in the area the retainer ring is to be welded with a solvent wash or by burning with a torch. After the asphaltic coating has been removed, grind the retainer ring location to bright metal. Also, the corresponding edge of the ring to be welded should be cleaned and ground to bright metal. Place loose locking rings or glands (if required for the particular joint 7 Step 1. Measure the pipe diameter (or circumference) at the location of the cut to ensure that it is within the tolerance shown in Table 2 on page 11 of this brochure. Step 2. Mark the pipe at sufficient intervals around the circumference by measuring from a reference — usually the spigot end of the pipe. Step 3. Cut the pipe at the desired location. Following the cut, the outside of the cut end should be beveled smooth per the manufacturer’s recommendations.
  • 8. configuration) on the pipe barrel beyond the retainer ring location. 6. Re-mark the location of the weld- on retainer ring on the pipe as was done in Step 4. 7. Some restrained joint designs require the weld-on retainer ring to be cut to length in the field. If such is employed, fit the ring around the pipe and mark and cut the ring to the length recommended by the manufac- turer. Normally the ring will be cut “short” to accommodate lengthening during the welding operation. 8. Clamp the weld-on retainer ring securely on the pipe in the correct location.* This may be accom- plished using the manufacturer’s special welding jigs, fixtures, and/or C-clamps. If the clamping device bears on the inside of the pipe, care should be taken to minimize damage to the pipe lining. If welding fixtures and/or C-clamps are used, the weld deposit should be applied in circumferential intervals corre- sponding to the movement of the clamps as recommended by the pipe manufacturer. 9. With the retainer ring fitted closely to the pipe surface, weld on the side of the ring next to the cut end of the pipe.* Weld according to the pipe manufacturer’s recom- mendations (electrode diameter, weld size, weld passes required, Step 4. Mark the location of the weld-on retainer ring from the cut end of the pipe per the manufacturer’s specifications. Step 5. Remove the pipe’s asphaltic coating on the area where the retainer ring will be welded with a solvent wash or by burning with a torch; then grind the retainer location to bright metal. Step 8. Clamp the weld-on retainer ring securely on the pipe in the correct location.* If the clamping device bears on the inside of the pipe, take care to minimize damage to the pipe lining. *The configuration of rings varies slightly from manufacturer to manufacturer. Contact your DIPRA member company regarding the ring configuration it recommends. 8
  • 9. welding technique, etc). To mini- mize heat build-up that may possi- bly cause thermal stresses and/or damage to linings, skip welding techniques can be used. Thorough peening of the weld passes before they cool will minimize thermal stresses. The ends of adjoining passes should be slightly over-- lapped before the arc is broken. If weld cracks occur, they should be ground away and repaired with a weld overlay. After the entire ring has been welded to the pipe, weld the ring ends to the pipe and weld in the space remaining between the ring ends according to the pipe manufacturer’s instructions. 10. Thoroughly clean the weld and ring* to remove all weld flux and splatter. The pipe spigot should be clean of weld splatter for proper gasket sealing and joint assembly. 11. Coat the ring* weld and ground pipe surface with a smooth uni- form coat of brushable mastic. 12. Inspect the pipe lining for possible damage. Cement-mortar linings are normally not adversely affect- ed by such welding procedures; however, if cement lining damage occurs, it should be patched in accordance with recommended procedures as noted in ANSI/AWWA C104/A21.4 Stan- dard, “Cement-Mortar Linings for Ductile-Iron Pipe and Fittings for Water.” Contact the pipe manu- facturer for repair of special linings. Step 9. With the retainer ring fitted closely to the pipe surface, weld on the side of the ring next to the cut end of the pipe according to the manufacturer’s recommendations.* (Skip welding techniques can be used.) After the entire ring has been welded to the pipe, weld the ring ends to the pipe and weld in the space remaining between the ring ends. Step 10. Thoroughly clean the weld and ring* to remove all weld flux and splatter so the pipe spigot is clean for proper gasket sealing and joint assembly. Step 11. Coat the ring*, weld, and ground pipe surface with a smooth uniform coat of brushable mastic. 9 *The configuration of rings varies slightly from manufacturer to manufacturer. Contact your DIPRA member company regarding the ring configuration it recommends.
  • 10. Cutting Ductile Iron Pipe Ductile Iron pipe may be cut using an abrasive pipe saw, a rotary wheel cut- ter, a guillotine pipe saw, or a milling wheel saw. Cement-mortar-lined or unlined Ductile Iron pipe can also be cut with an oxyacetylene torch if rec- ommended by the pipe manufacturer for its product. The ANSI/AWWA standard for Duc- tile Iron pipe requires factory gauging of the spigot end. Accordingly, pipes selected for cutting should be field- gauged in the location of the cut and be within tolerance as shown in Table 2. Torch cutting of Ductile Iron pipe normally results in a heat-affected zone extending less than 1/4-inch from the cut face but might result in small cracks in this area which should be removed by grinding. Some difficulty might result in threading or machining in this particular portion of the pipe due to hardening of the metal. Such hardening does not interfere with push- on or mechanical joint assembly or performance. Pipe manufacturers who recom- mend torch cutting of their pipe report best results are obtained by using a No. 8 or No. 10 tip with approximately 75 psi oxygen and 10 to 15 psi acetylene. For cement-lined Ductile Iron pipe, the best results are normally obtained when the torch head is inclined approx- imately 60 degrees to the direction of cutting. Cutting time for pipe cut by oxyacetylene methods is approximately one minute per inch of diameter for cement-lined pipe and even less for unlined pipe. Cut ends and rough edges should be ground smooth and for push-on con- nections, the cut end should be beveled to the approximate profile of the factory supplied end. In addition to being cut with an abrasive pipe saw, a rotary wheel cutter, a guillotine pipe saw, or a milling saw, Ductile Iron pipe can also be cut with an oxyacetylene torch if rec- ommended by the pipe manufacturer. Cut ends and rough edges should be ground smooth. For push-on connections, the cut end should be beveled to the approximate pro- file of the factory supplied end. 10
  • 11. References 1. American Cast Iron Pipe Company, “Instructions for Field Welding of American Restrained Ductile Iron Pipe Joints.” 2. ANSI/AWS D11.2 Standard, “Guide for Welding Iron Castings,” 1989. 3. ANSI/AWS A5.15 Standard, “Spec- ification for Welding Electrodes and Rods for Cast Iron.” 4. ANSI/AWWA C151/A21.51 Stan- dard, “Ductile-Iron Pipe, Centrifu- gally Cast, for Water.” 5. British Cast Iron Research Associa- tion, “The Joining and Fabrication of Nodular Iron Castings by Weld- ing,” 1982. 6. INCO Alloys International, Ni-Rod 44 and Ni-Rod 55 Welding Electrodes. 7. INCO Alloys International, Ni-Rod 99X and Ni-Rod 55X Welding Elec- trodes. 8. Jefferson, T.B., “Metals and How to Weld Them,” Second Edition, Welding Engineer Publication, Inc. 9. The Lincoln Electric Company, “The Procedure Handbook of Arc Welding,” Twelfth Edition. 10.U.S. Pipe and Foundry Company, “Field Cutting and Welding Proce- dure for TR FLEX Pipe,” 1997 Edi- tion. Table 2 Suitable Pipe Diameters for Field Cuts and Restrained Joint Field Fabrication Nominal Pipe Min. Pipe Max. Pipe Min. Pipe Max. Pipe Size Diameter Diameter Circumference Circumference In. In. In. In. In. 4 4.74 4.86 14 29/32 15 9/32 6 6.84 6.96 21 1/2 21 7/8 8 8.99 9.11 28 1/4 28 5/8 10 11.04 11.16 34 11/16 35 1/16 12 13.14 13.26 41 9/32 41 21/32 14 15.22 15.35 47 13/16 48 7/32 16 17.32 17.45 54 13/32 54 13/16 18 19.42 19.55 61 61 13/32 20 21.52 21.65 67 19/32 68 24 25.72 25.85 80 13/16 81 7/32 30 31.94 32.08 100 11/32 100 25/32 36 38.24 38.38 120 1/8 120 9/16 42 44.44 44.58 139 5/8 140 1/16 48 50.74 50.88 159 13/32 159 27/32 54 57.46 57.60 180 17/32 180 31/32 60 61.51 61.65 193 1/4 193 11/16 64 65.57 65.71 206 206 7/16 Above table based on ANSI/AWWA C151/A21.51 guidelines for push-on joints 11
  • 12. Manufactured from recycled materials. 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 Company 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 United States Pipe and Foundry Company P.O. Box 10406 Birmingham, Alabama 35202-0406 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 http://www.dipra.org FW/12-99/2M Revised 12-98 Published 2-92