1、Ductile-Iron Pipe and Fittings AWWA MANUAL M41 Third Edition M41 Book.indb 1 3/18/2009 3:30:55 PM Copyright 2009 American Water Works Association. All Rights Reserved.Manual of Water Supply Practices M41, Third Edition Ductile-Iron Pipe and Fittings Copyright 1996, 2003, 2009, American Water Works A
2、ssociation All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information or retrieval system, except in the form of brief excerpts or quotations for review purposes, without
3、the written permission of the publisher. The authors, contributors, editors, and publisher do not assume responsibility for the validity of the content or any consequences of its use. In no event will AWWA be liable for direct, indirect, special, incidental, or consequential damages arising out of t
4、he use of information presented in this book. In particular, AWWA will not be responsible for any costs, including, but not limited to, those incurred as a result of lost revenue. In no event shall AWWAs liability exceed the amount paid for the purchase of this book. AWWA Publications Manager: Gay P
5、orter De Nileon Project Manager/Copy Editor: Martha Ripley Gray Technical Editors: Tim McCandless (AWWA) and Richard Bonds (DIPRA) Production Editor: Darice Zimmermann, Zimm Services Manuals Coordinator: Beth Behner Library of Congress Cataloging-in-Publication Data Ductile-iron pipe and fittings. 3
6、rd ed.p. cm. (Manual of water supply practices ; M41)Includes bibliographical references and index.ISBN 978-1-58321-632-31. Water-pipes 2. Cast-iron pipe. 3. Pipe fittings I. American Water Works Association. TH491.D84 2009 628.15dc22 2008038290 Printed in the United States of America American Water
7、 Works Association 6666 West Quincy Avenue Denver, CO 80235-3098 ISBN 978-1-58321-632-3 Printed on recycled paper M41 Book.indb 2 3/18/2009 3:30:56 PM Copyright 2009 American Water Works Association. All Rights Reserved.Contents List of Figures, vii List of Tables, xi Preface, xiii Acknowledgments,
8、xv General Information and History Chapter 1 1 1.1 History, 1 1.2 Applications and Appurtenances, 3 1.3 Ductile Iron Pipe Research Association (DIPRA), 5 Applicable Standards Chapter 2 7 2.1 Related Standards, 7 2.2 Other Reference Standards and Special Products, 10 References, 10 Manufacturing and
9、Testing Chapter 3 . 13 3.1 Manufacturing, 13 3.2 Testing, 17 3.3 Fittings Testing, 19 References, 20 Design Chapter 4 . 21 4.1 Background, 21 4.2 Major Design Criteria and Formulas, 22 4.3 Truck Loads on Pipe Buried at Shallow Depths, 38 4.4 Thickness Design for Ductile-Iron Pipe Under Railroads, 43
10、 4.5 Thickness Design for Ductile-Iron Pipe on Supports, 45 4.6 Special Use Considerations, 57 References, 58 Pipe Joints Chapter 5 . 59 5.1 Introduction, 59 5.2 Joints, 59 5.3 Gaskets, 64 5.4 Joint Accessories, 64 5.5 Permeation, 65 References, 66 iii M41 Book.indb 3 3/18/2009 3:30:56 PM Copyright
11、2009 American Water Works Association. All Rights Reserved.Ductile- and Gray-Iron Fittings Chapter 6 67 6.1 Introduction, 67 6.2 Fittings, 67 6.3 Special Service Requirements, 70 References, 71 Valves and Hydrants Chapter 7 73 7.1 Introduction, 73 7.2 Types of Valves and Hydrants, 73 7.3 Installatio
12、n, 76 7.4 Operation, 76 7.5 Good Practice, 77 References, 77 Thrust Restraint Design for Ductile-Iron Pipe Chapter 8 . 79 8.1 Introduction, 79 8.2 The Thrust Force, 81 8.3 Thrust Blocks, 82 8.4 Restrained Joints, 85 8.5 Restraint Design for Vertical Bends, Tees, Reducers, and Dead Ends, 93 8.6 Encro
13、aching Restrained Lengths, 97 8.7 Restrained Length, 99 8.8 Select Backfill Considerations, 99 8.9 Combining Thrust Blocks and Restrained Joints, 101 8.10 Pipe in a Casing, 101 8.11 Future Excavations, 101 8.12 Deflected Unrestrained Ductile-Iron Pipe Joints, 101 8.13 Computer Program, 102 8.14 Rest
14、rained Length Calculation Procedure, 102 8.15 Tabular Values for F s , (F s ) b , and R s , 103 8.16 Restrained Joint Design Tables for Horizontal Bends, 104 References, 147 Interior Linings and Hydraulics Chapter 9 149 9.1 CementMortar-Lined Ductile-Iron Pipe, 149 9.2 Flow Characteristics of Ductil
15、e-Iron Pipe, 153 9.3 Pumping Cost, 155 References, 164 External Corrosion Protection Chapter 10 . 165 10.1 Introduction, 165 10.2 Basic Corrosion Theory, 166 10.3 Corrosion Resistance of Ductile-Iron Pipe, 172 10.4 Evaluation of Corrosive Soils, 173 iv M41 Book.indb 4 3/18/2009 3:30:56 PM Copyright
16、2009 American Water Works Association. All Rights Reserved.10.5 Buried ServiceCorrosion Control, 175 10.6 Exposed Service Conditions, 188 10.7 Submerged Service Conditions and Control, 192 References, 193 Installation of Ductile-Iron Pipe Chapter 11 195 11.1 Introduction, 195 11.2 Pipe Inspection, S
17、torage, Handling, and Delivery, 195 11.3 Trenching, Embedment, Pipe Installation, and Backfilling, 197 11.4 Pipeline Accessories, 209 11.5 Thrust Restraint, 212 11.6 Flushing, Field Testing, and Disinfection, 212 11.7 Service Taps, 215 11.8 Highway and Railroad Crossings, 220 11.9 Trenchless Applica
18、tions, 220 11.10 Subaqueous Installations, 220 11.11 Other Installations, 222 References, 225 Trenchless Installation Chapter 12 Horizontal Directional Drilling . 227 12.1 Introduction, 227 12.2 Predesign Investigation, 229 12.3 HDD Assembly Methods for Flexible Restrained-Joint Ductile-Iron Pipe, 2
19、30 12.4 Survey, 232 12.5 Subsurface Analysis, 232 12.6 Borepath Design, 234 12.7 Pipe Design: Introduction, 235 12.8 Testing and Service Pressure/Loads, 238 12.9 Thermal Expansion/Contraction and Pulling Load “Recoil,” 239 References, 239 Guidelines for Purchase of Pipe and Fittings Chapter 13 241 1
20、3.1 General, 241 13.2 Ductile-Iron Pipe, 243 13.3 Ductile-Iron and Gray-Iron Fittings and Specials, 244 13.4 Polyethylene Encasement, 244 References, 245 Appendix A Illustrations of Proprietary Joints for Ductile-Iron Pipe and Fittings 247 Index . . . . . . . . . . . . . . . . . . . . . . . . . . .
21、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 AWWA Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22、 . . . . . . . . . . . . . . . . . . . . 259 v M41 Book.indb 5 3/18/2009 3:30:56 PM Copyright 2009 American Water Works Association. All Rights Reserved.This page intentionally blank. M41 Book.indb 6 3/18/2009 3:30:56 PM Copyright 2009 American Water Works Association. All Rights Reserved.This page
23、intentionally blank. Figures 1-1 A 48-in. ductile-iron pipe water transmission main, 4 3-1 Elements of a casting machine, 15 3-2 Pipe entering an annealing oven, 16 3-3 Vertical annealing furnace, 17 3-4 Hydrostatic testing of pipe to a minimum of 500 psi (3,450 kPa), 18 4-1 Performance test on 36-i
24、n. (914-mm) ductile-iron pipe with push-on joints, 22 4-2 Laying conditions for ductile-iron pipe, 25 4-3 Truck loading conditionssingle-wheel load, 39 4-4 Pipe loading from uniformly distributed railroad loading, 43 4-5 Railroad loading for Cooper E-80 locomotives, 43 4-6 Ductile-iron pipe is well
25、suited for pipe-on-supports applications because of its beam strength, 47 4-7 Saddle angle and width, 47 5-1 Push-on, mechanical, and flanged joints, 61 5-2 Flanged joint details, 61 5-3 Flanged ductile-iron pipe and fittings in a water treatment plant, 62 5-4 Installation of mechanical-joint-type r
26、estrained joints, 63 6-1 Welded-on push-on joint outlet, 68 6-2 Ductile-iron fittings stacked in a storage yard, 69 7-1 Installation of a large-diameter gate valve, 74 7-2 Swing-check valves in a pump discharge line, 75 8-1 Push-on joint detail, 79 8-2 Thrust forces at joint of straight pipe, 81 8-3
27、 Thrust forces at bend, 82 8-4 Thrust forces on other pipe configurations or appurtenances, 83 8-5 Bearing block details, 84 8-6 Gravity thrust block, 86 8-7 Restrained joints in a buried piping system, 86 8-8 Schematic of pipesoil behavior at horizontal bend (or vertical up-bend), 88 8-9 Unit norma
28、l forces on pipe, 91 8-10 Vertical down-bend diagram, 94 8-11 Reaction forces at tees, 96 8-12 Reaction forces for reducers, 96 vii vii M41 Book.indb 7 3/18/2009 3:30:56 PM Copyright 2009 American Water Works Association. All Rights Reserved.viii 8-13 Reaction forces at dead ends, 96 8-14 Equal angl
29、e vertical offset (), 97 8-15 Combined horizontal equal angle bends (), 100 8-16 Combined equal angle vertical offsets (), 100 9-1 Cementmortar-lined ductile-iron pipe, 150 9-2 Nomograph for pipe size, head loss, and discharge for ductile-iron pipe, 154 10-1 Chemical reactions in a typical galvanic
30、corrosion cell, 167 10-2 Corrosion cell, 169 10-3 Electrolytic corrosion cell, 170 10-4 Typical stray current environment, 170 10-5 Alternate polyethylene encasement installation methods, 177 10-6 Installation of polyethylene encasement using Method A, 178 10-7 Peened surface of a deLavaud pipe mold
31、, 182 10-8 Close-up photograph of the cast surface of a typical ductile-iron pipe made by the deLavaud process, 182 10-9 Scanning electron microscope photomicrograph of a ductile-iron pipe surface profile. The layers consist of a 135- to 143-m (5- to 6-mil) thickness of annealing oxide with underlyi
32、ng ductile iron, 183 10-10 Schematic diagram of a typical cross section of a ductile-iron pipe, 183 10-11a Annealed ductile-iron pipe before over-blasting, 184 10-11b Same ductile-iron pipe resulting in blisters and disbondment from over-blasting, 184 10-12 Typical risk model, 188 11-1 Unloading pip
33、e with a forklift, 196 11-2 Unloading pipe with a crane, 197 11-3 Installing small-diameter ductile-iron pipe in a narrow trench, 200 11-4 Because of its ruggedness, ductile-iron pipe is particularly suitable for installation in demanding environments, 200 11-5 Polyethylene-encased ductile-iron pipe
34、, 201 11-6 Laying conditions for ductile-iron pipe, 203 11-7 Push-on joint assembly, 204 11-8 Mechanical joint assembly, 205 11-9 Sweeping curves without fittings and specials are possible because of liberal joint deflection allowance by ductile-iron pipe push-on joints, 206 11-10 Pipeline curve geo
35、metry, 208 11-11 Cutting pipe with an abrasive wheel saw, 208 11-12 Installing valves and fittings, 210 11-13 Installation of a 48-in. (1,219-mm) butterfly valve, 211 11-14 Fire hydrant installation, 213 M41 Book.indb 8 3/18/2009 3:30:56 PM Copyright 2009 American Water Works Association. All Rights
36、 Reserved.ix 11-15 Direct service connection tapped through polyethylene adhesive tape and polyethylene film, 217 11-16 Ball-and-socket ductile-iron pipe used in a subaqueous installation using the “chute” method, 221 11-17 Subaqueous pipe being floated into position, 221 11-18 Ductile-iron pipe ins
37、talled on a bridge, 222 11-19 Ductile-iron pipe spanning waterway, 223 11-20 Pump station piping, 224 11-21 Ductile-iron pipe being installed in a deep trench, 224 12-1 Pilot bore, 227 12-2 Prereaming, 228 12-3 Pipe pullback, 229 12-4 Assembled line method, 231 12-5 Cartridge method, 231 12-6 Polyet
38、hylene encasement, 234 13-1 A full truck load of ductile-iron pipe, 243 A-1 Push-on joints, 248 A-2 Ball-and-socket joints, 248 A-3 Grooved-and-shouldered joints, 249 A-4 Restrained jointspush-on type, 249 A-5 Restrained jointsmechanical joint and other joint type, 251 M41 Book.indb 9 3/18/2009 3:30
39、:56 PM Copyright 2009 American Water Works Association. All Rights Reserved.This page intentionally blank. M41 Book.indb 10 3/18/2009 3:30:56 PM Copyright 2009 American Water Works Association. All Rights Reserved.This page intentionally blank. Tables 3-1 Acceptance values for tensile tests, 19 4-1
40、Reduction factors, R, for truck load calculations, 24 4-2 Design values for standard laying conditions, 27 4-3 Allowances for casting tolerance, 29 4-4 Standard pressure classes of ductile-iron pipe, 29 4-5 Rated working pressure and maximum depth of cover, standard pressure classes, 30 4-6 Special
41、thickness classes of ductile-iron pipe, 32 4-7 Rated working pressure and maximum depth of cover, special thickness classes, 33 4-8 Earth loads P e , truck loads P t , and trench loads P v(psi), 40 4-9 Surface load factors C for single truck on unpaved road, 40 4-10 Thickness for earth load plus tru
42、ck load, 41 4-11 Surface load factors for Cooper railroad loading, 45 4-12 Pipe plus water weight (W p+ W w ) and design wall thickness t n , 50 4-13 Earth loads P eand truck loads P t(psi), 54 5-1 Gasket materials used for ductile-iron pipe in water and sewage service, 65 8-1 Horizontal soil-bearin
43、g strength, 84 8-2 Suggested values for soil parameters and reduction constant K n , 87 8-3 Soil classification chartASTM Standard D2487, 90 8-4 Values for D, A, W p , W w , and (W p+ W w ), 92 8-5 Thrust restraint design for ductile-iron pipe for clay 1 soil type, 105 8-6 Thrust restraint design fo
44、r ductile-iron pipe for silt 1 soil type, 108 8-7 Thrust restraint design for ductile-iron pipe for clay 2 soil type, 111 8-8 Thrust restraint design for ductile-iron pipe for silt 2 soil type, 114 8-9 Thrust restraint design for ductile-iron pipe for coh-gran soil type, 117 8-10 Thrust restraint de
45、sign for ductile-iron pipe for sand silt soil type, 120 8-11 Thrust restraint design for ductile-iron pipe for good sand soil type, 123 8-12 Restrained joint lengths for horizontal bends for clay 1 soil type, 126 8-13 Restrained joint lengths for horizontal bends for silt 1 soil type, 129 8-14 Restr
46、ained joint lengths for horizontal bends for clay 2 soil type, 132 8-15 Restrained joint lengths for horizontal bends for silt 2 soil type, 135 8-16 Restrained joint lengths for horizontal bends for coh-gran soil type, 138 xi M41 Book.indb 11 3/18/2009 3:30:57 PM Copyright 2009 American Water Works
47、Association. All Rights Reserved.xii 8-17 Restrained joint lengths for horizontal bends for sand silt soil type, 141 8-18 Restrained joint lengths for horizontal bends for good sand soil type, 144 9-1 Inside diameters and flow areas of the minimum available pressure classes of cement mortar-lined du
48、ctile-iron pipe, 156 9-2 Head loss in feet per 1,000 ft of pipe (6 in. to 12 in.), cementmortar-lined ductile-iron pipe, nominal ID pipe, C = 140, 157 9-3 Head loss in feet per 1,000 ft of pipe (14 in. to 20 in.), cementmortar-lined ductile-iron pipe, nominal ID pipe, C = 140, 157 9-4 Head loss in f
49、eet per 1,000 ft of pipe (24 in. to 36 in.), cementmortar-lined ductile-iron pipe, nominal ID pipe, C = 140, 158 9-5 Head loss in feet per 1,000 ft of pipe (42 in. to 54 in.), cementmortar-lined ductile-iron pipe, nominal ID pipe, C = 140, 158 9-6 Head loss in feet per 1,000 ft of pipe (60 in. to 64 in.), cementmortar-lined ductile-iron pipe, nominal ID pipe, C = 140, 159 10-1 Galvanic series of selected metals and alloys (in seawater), 168 10-2 Soil-test evaluation for gray or ductile cast-iron pipe (10-point system), 174 1
