Comparing Strength and Performance of DI Pipes vs Other Pipes

Not all pipe performance is the same, basically due to their manufacturing materials. When deciding which kind of pipe is appropriate for a particular project, there are a number of variables for design engineers to take into account. These variables include project requirements, system startup cost, maintenance charges, dependability, and performance over time. To get the best pipe performance, it is necessary to use the right pipe material for any project. Today, Ductile Iron pipes stand out among the available options. Understanding the differences between DI pipes and other pipes can help engineers in choosing the ideal material for their respective projects.

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Pipe Material Comparison: Performance of Ductile Iron and Other Pipes

There are several kinds of pipes available for various applications. Having a pipe material comparison between the different pipes and ductile iron pipes will make every engineer’s work easier.

Ductile Iron Pipes and Galvanised Iron Pipes: DI vs GI pipes

Ductile Iron Pipes:

• DI pipes are a combination of silicon, carbon, and ductile iron. A melted mixture is shaped like a cylinder and chilled.
• Due to their great tensile strength, ductile iron pipes are resilient to collisions, vibrations, and large loads, among other external factors.
• Ductile iron pipes are simple to install and manage since they are connected via a variety of modes, such as push-on flexible joints, mechanical joints, and flanged joints.

Galvanised Iron Pipes:

• Steel is used to make galvanised iron pipes. A zinc covering protects the pipes from rust and corrosion.
• Galvanised iron pipes are durable but ductile, which makes them more vulnerable to breaking and bursting under strain.
• The setting up of galvanised iron pipes calls for certain equipment and techniques, which can be costly and tedious. They additionally need routine maintenance to avoid corrosion and rust.

Ductile iron pipes are often more costly than galvanised pipes due to their increased strength, longevity, and dependability. But because they last longer and need less upkeep and repair, they offer a long-term, affordable solution. Although galvanised iron pipes can be less costly at first, their rust and corrosion risk, as well as their shorter lifespan, can make them more expensive over time.

Ductile Iron Pipes and Steel Pipes

Ductile Iron Pipes:

• A ductile iron pipe has a polyethylene encasement to reduce the risk of corrosion in harsh conditions.
• Ductile iron pipes have a substantially greater carbon content, ranging between 3 and 3.9%. The increased carbon content increases the strength, stress resistance, and resistance to natural disasters of ductile iron pipes.
• The ductile iron pipe is capable of being rerouted using its push-on joints. The installers have greater flexibility because of this feature. Regardless of the weather or temperature, they are simple to install.

Steel Iron Pipes:

• Steel pipe needs a bonded coating (usually a tape-wrap or cement-mortar coating) in order to be resistant to corrosion. The steel pipe industry recommends different kinds of corrosion control depending on the manufacturer and market conditions.
• Usually, the carbon content of steel is less than 0.4%. It is feasible to contain up to 2% carbon, though.
• Steel pipes must be welded together before being installed. Unfavourable weather can cause the installation to stop.

Ductile iron pipe offers a more affordable transmission line than steel iron pipe because of its bigger interior diameter.

Ductile Iron Pipe vs. PVC Pipes

The difference between ductile iron and PVC pipes are:

• Ductile iron pipe offers more than 13 times the impact strength, nine times the tensile strength, and four times the burst strength of PVC pipe.
• Ductile iron pipe is resilient under stress. PVC fails eventually under stress. The more stress it experiences, the faster it will fail.
• Petrochemicals are used to make PVC pipes, a procedure that may be bad for the environment and people’s health. Recycled steel and iron are used to make ductile iron pipes.
• Temperature variations have little effect on ductile iron pipes. PVC pipe weakens in hotter climates and becomes brittle in cooler ones.

Ductile Iron Pipe vs. HDPE Pipes

The comparison between ductile iron and HDPE pipes:

• HDPE is manufactured from ethylene, which is obtained from petroleum and natural gas.
• On the other hand, the ductile iron pipe is made from iron scrap metal that usually has more than 98 per cent recycled material in it.
• In comparison to HDPE, DI pipe has a hydrostatic design base that is 26 times larger.
• HDPE connectors are butt-fusion welded together, whereas DI pipe relies on a push-on rubber gasket joint that is simple to construct and disassemble.
• Ductile iron has greater than 24 times the tensile strength of HDPE pipe.

Advantages and Disadvantages of Ductile Iron Pipes

Ductile iron pipes have certain advantages and disadvantages.

Advantages

The advantages of ductile iron pipes are as follows:

• The ductile pipe is able to resist external forces, endure high water supply pressure, and adjust to shifting geological conditions.
• Strong corrosion resistance makes ductile iron pipes suitable for use in salty and coastal environments.
• Flexible joints are used in ductile iron pipes, which make the construction process easier and can save costs while increasing the efficiency of construction and improving construction settings.
• DI pipe is SMART-approved and contains up to 95 per cent recycled content in the manufacturing process.

Disadvantages

The disadvantages of ductile iron pipes are as follows:

• Even though ductile iron is considerably more malleable than grey iron, significant forces can still cause it to shatter abruptly and unexpectedly, making it inappropriate for constructions or applications that are susceptible to shocks.
• Ductile iron is challenging to perform welding due to its high carbon level, cracking tendency, and poor heat transmission.
• The mechanical and physical qualities of ductile iron can vary based on the manufacturing method, alloy composition, and cooling rate.
• The manufacture of ductile iron requires a large amount of energy and emits greenhouse gases such as carbon dioxide and methane.
• Ductile iron scrap disposal and recycling becomes difficult because the alloy contains hazardous components such as lead, nickel, and chromium.

Choosing the Ideal Pipe with L&T SuFin

Ductile iron pipes are one of the most durable and cost-effective pipeline solutions. DI pipelines help in the transportation of both wastewater and water. They are less prone to wear and stress than other pipe materials, which makes them a great alternative for numerous infrastructure projects. Now, as we understand the DI pipes vs. other materials comparison, we can understand the specific characteristics that make these pipes better suited for certain projects. Finding the ideal pipe has been made easier for everyone with L&T SuFin. At L&T SuFin, one can enjoy the amazing features such as:

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• Connecting with KYC-verified buyers and sellers
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EVEN IN THIS MODERN ERA, we are still concerned with many of the issues that early civilizations faced when providing water to our communities, such as supply and demand, pipeline construction and upkeep, cleanliness, conservation and cost. In the fall of , McWane Ductile’s Senior Regional Engineer, Roy Mundy, had the opportunity to interview Consolidated Utility District General Manager Bill Dunnill. The two gentlemen, both with utility management experience, had a candid conversation about Bill’s day-to-day challenges, successes and his preferred choice of pipeline material. The following are excerpts from their discussion.

Roy Mundy: Tell us a little bit about yourself. You are obviously an experienced, well-credentialed and well-respected leader in our industry.

Bill Dunnill: I graduated from Bradley University with a B.S. in civil engineering in . I spent over 16 years in the oil and gas industry, where I was responsible for the transportation of crude oil and natural gas. During this tenure, I also served as mayor of a small southern Illinois community, which introduced me to public utilities. This led to my migration to Tennessee and, ultimately, General Manager of Consolidated Utility District, which is the sixth largest public water purveyor in the state.

Mundy: Tell us about the Consolidated Utility District (CUD).

Dunnill: CUD has more than 55,000 active customers and 517 square miles of service territory. Our water plant averages over 10 million gallons per day (MGD) and peaks at 14 MGD. The customer base consists of 97 percent residential, 2.5 percent commercial and industrial and 0.5 percent wholesale to other utilities. Our water source is the east fork of the Stones River with an intake at the headwaters of J. Percy Priest Lake. The current customer growth is just over 2,100 per year, with an ever-increasing percentage of commercial and industrial growth.

Mundy: One key component in your plan to control system demand is water loss reduction. Coming back to the types of pipeline material in your system, do you monitor the percentage of leaks based on the material of the pipe? Tell us what you’ve found.

Dunnill: Absolutely! Our experience shows that AC is about 10 times as likely to fail as PVC. Cast iron runs about five times as likely as PVC. Conversely, we have only one fifth the leaks on DIP as PVC, and most of those are caused by physical damage from someone working around the pipe. Hence, CUD now specifies only DIP on all transmission and distribution mains.

Mundy: Have you done any studies on the cost of ductile iron pipe vs. PVC regarding new development projects in your service area?

Dunnill: When we changed our specs in , the cost to the developer was a consideration. We made some concessions in service line materials and even DIP wall thickness. The net increase was about $370 per lot at that time. Although not insignificant, it was miniscule in comparison to the cost of the lot, and the long-term benefit to CUD ratepayers is tremendous.

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McWane Ductile would like to thank Bill Dunhill for his time and expertise in providing an open and honest conversation about how CUD successfully addresses these issues daily. We hope you found this information helpful and informative. 

McWane Ductile offers multiple services for our customers extending far beyond manufacturing ductile iron pipe. From design to installation, we take great pride in providing education and training to water professionals throughout the water and waste water industry. Together, we are Building Iron Strong Utilities for Generations!

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Roy Mundy, P.E., ENV SP, Assoc. DBIA currently serves as Senior Regional Engineer for McWane Ductile, assisting utilities and engineering firms with value engineering of pipeline projects, educating them in pipeline material selection, and assisting them with specification development and updating. Roy has a BS in Civil Engineering from West Virginia Institute of Technology and an MS in Engineering Management from West Virginia University College of Graduate Studies. He is a registered professional engineer in six states and an ENVISION Sustainability Professional. Before McWane Ductile, Roy served as Lead Executive with the American Water System, retiring as President/CEO of Kentucky-American Water Co. Roy has served as Section Chair and on several national committees of AWWA, Board of Directors, and national committees of NAWC, Chair of ORSANCO, member of Kentucky Infrastructure Authority. He currently serves on AWWA – Business Practices Standards Committee, the KY/TN Section Management Committee, and the Water/Wastewater and Legislative Committees of DBIA. Roy is a member of AWWA, NSPE, KSPE, ASCE, DBIA, and KYRWA.

"I joined McWane Ductile in after spending most of my career in the water industry in the private water utility sector," said Mundy. "I enjoy the opportunity to work with engineering firms and utilities to assist with value engineering projects and provide education on the various aspects of our products. I enjoy restoring classic cars, but foremost enjoy time with my family traveling and working around our small farm in Kentucky."

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