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Hydraulic Analysis Pumping Costs for PVC and Ductile Iron Pipe

This paper addresses the inaccurate hydraulic claims made by the Ductile Iron Pipe Research Association (DIPRA) and<br>shows that when industry-accepted data are used, PVC pipe is more energy efficient, cost effective, and sustainable than<br>ductile iron (DI) pipe. DIPRA maintains that DI pipe has lower pumping costs than PVC pipe. The claim is that DIu2019s larger<br>inside diameters (ID) offset PVCu2019s better flow characteristics. However, DIPRAu2019s brochures and on-line calculator contain<br>misleading information and erroneous hydraulic assumptions, generating biased results.

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Hydraulic Analysis Pumping Costs for PVC and Ductile Iron Pipe

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  1. INSTALLATIONGUIDEFOR SOLID-WALL PVCSEWERPIPE

  2. SEWERPIPE TABLEOFCONTENTS Introduction............................................................................................................................................................3 Receiving................................................................................................................................................................4 UnloadingandHandling......................................................................................................................................5-6 Storage...................................................................................................................................................................7 Trenching................................................................................................................................................................8 De-Watering...........................................................................................................................................................9 FieldCutting.........................................................................................................................................................10 LoweringPipeintotheTrench..............................................................................................................................11 CleaningandInspection.......................................................................................................................................12 Lubrication............................................................................................................................................................12 JointAssembly......................................................................................................................................................13 TrenchConstruction.............................................................................................................................................14 Foundation...........................................................................................................................................................14 Bedding................................................................................................................................................................15 Haunching............................................................................................................................................................15 InitialBackfill........................................................................................................................................................16 FinalBackfill..........................................................................................................................................................17 AcceptanceTesting...............................................................................................................................................17 SpecialConsiderations....................................................................................................................................17-18 Checklist...............................................................................................................................................................19 Uni-BellLiterature................................................................................................................................................19 2 UNI-BELLPVCPIPEASSOCIATIONWWW.UNI-BELL.ORG

  3. SEWERPIPE • INTRODUCTION • ThisdocumenthasbeendevelopedbytheUni-BellPVCPipeAssociationforuseasafieldinstallationguide. Generalinformationregardingthecorrectinstallationofgasketed-jointsolid-wallPVCsewerpipeisincluded. Relevantproduct standardsare: • ASTMD3034“StandardSpecificationforTypePSMPoly(VinylChloride)(PVC)SewerPipeandFittings” • ASTMF679“StandardSpecificationforPoly(VinylChloride)(PVC)Large-DiameterPlasticGravitySewerPipe andFittings” • Formoredetailedtechnicalinformationandforinformationonprofile-wallPVCpipes,consultthepipe manufacturerorrefertoASTMD2321,“StandardPracticeforUndergroundInstallationofThermoplasticPipe forSewersandOtherGravity-FlowApplications..”TheHandbookofPVCPipe:DesignandConstructionprovides additionalguidanceonPVCpipedesignandinstallation.Forinformationonthispublication,pleasecontactUni- Bell. • TheUni-BellPVCPipeAssociation,formedin1971,fundsPVCpiperesearchanddevelopment,providestechnical serviceandsupport,developsrecommendedstandards,andpromotesproperuseofPVCpipewithgasketed joints. • Uni-BellmembersaremanufacturerswhoarededicatedtoproducinghighqualityPVCpipeproductsforthe • industry. • ThestatementscontainedinthisinstallationguidearethoseoftheUni-BellPVCPipeAssociationandarenot warranties,noraretheyintendedtobewarranties.Inquiriesforinformationonspecificproducts,theirattributes andrecommendeduses,andthemanufacturer’swarrantyshouldbedirectedtomembercompanies. 3 INSTALLATIONGUIDEFORSOLID-WALLPVCSEWERPIPE

  4. SEWERPIPE RECEIVING Whenaloadofpipearrivesatthejobsite,itisyourresponsibilitytocheckitthoroughly.Ifpossible,inspecteach piecefordamage.Checkquantitiesagainsttheshippinglist.Notethatthepolicyofmostpipemanufacturers isthatoncethepipeleavesthemanufacturer’splant,itbecomesthepropertyoftheshippingcompany.Any damagedormissingitemsshouldbedocumentedonthebilloflading.Setasideanydamageditemsand notify the shipper. 4 UNI-BELLPVCPIPEASSOCIATION WWW.UNI-BELL.ORG

  5. SEWERPIPE • UNLOADINGANDHANDLING • Itisalsoyourresponsibilitytounloadtheshipment.UNLOADWITHREASONABLECARE.Carelessunloadingcan • resultindamagedproductor personalinjury. • Useaforkliftorafront-endloaderwithforkattachment,ifavailable.Makesurethattheforksaresufficiently longtosupportthebundles.Whenunloadingbyhand,removeonepieceatatimeandblocktheshipmentto keeppipefromrollingoffthetruck. • Observethefollowingprecautions: • DONOTdroppipeoffthetruck. • DONOTinsertaforkliftforkintoapipeendtotransport. • Lowerthepipeintotheditch.DONOTdrop. 5 INSTALLATIONGUIDEFORSOLID-WALLPVCSEWERPIPE

  6. SEWERPIPE Thetablesbelowareprovidedforuseasguidesinselectionofhandlingequipment: APPROXIMATEWEIGHTOFPIPELENGTHS(lbs) 6 UNI-BELLPVCPIPEASSOCIATIONWWW.UNI-BELL.ORG

  7. SEWERPIPE STORAGE Ifyoucanunloadtheshipmentinunitpackages,thepipewillbeeasiertostore.Stackthepackagesonreasonably levelground.Ifyouunloadonepieceatatime,placethepipebeveltobell.Neverstackovereightfeetinheight. Donotstackthepipenexttoheatsourcesorengineexhausts. Gaskets shouldalsobeprotectedfromheat,oil, andgrease. 7 INSTALLATIONGUIDEFORSOLID-WALLPVCSEWERPIPE

  8. SEWERPIPE TRENCHING Donotlettheexcavatedmaterialblocksidewalks,drives,orutilityoutlets.Followallsafetyrulesandregulations. Protectworkersbyusingsheetingandtrenchboxesinhazardousareasandbyslopingthetrenchwallsindry soils.Whensheetingoratrenchboxismoved,makesurethatthepipeisnotmovedandthattheside-support materialisnot disturbed. 8 UNI-BELLPVCPIPEASSOCIATION WWW.UNI-BELL.ORG

  9. SEWERPIPE DE-WATERING Dokeepthetrenchasdryaspossibleuntilthepipehasbeeninstalledandenoughbackfillplacedtoprevent thepipefromfloating.PVCpipewillfloatifnotfilledwithwaterorweighteddown.Theheightofloosebackfill materialrequiredtopreventflotationofemptypipeisconservativelyequalto1½timesthepipediameter. 9 INSTALLATIONGUIDEFORSOLID-WALLPVCSEWERPIPE

  10. SEWERPIPE FIELDCUTTING PVCpipecanbeeasilycutwithapowerhandsaworpower-drivenabrasivedisc.Besureyoumakeasquarecut. Beveltheendwithabevelingtool,woodrasp,orpowersandertothesameangleandlengthasprovidedonthe factory-finishedpipe. Redrawtheinsertion lineonthespigotusinga factory-markedspigotasa guide. 10 UNI-BELLPVCPIPEASSOCIATIONWWW.UNI-BELL.ORG

  11. SEWERPIPE LOWERINGPIPEINTOTHETRENCH Placethepipeandfittingsintothetrenchusingropesandskids,slingsonthebackhoebucket,orbyhand.Do notthrow the pipe or fittings into thetrench or allowany part of thepipeto take anunrestrained fall ontothe trenchbottom.Atthispoint,thepipeandotheraccessoriesareinagoodpositionforfinalinspection.Ensure therearenodamagedmaterialsbeforeassemblybegins. 11 INSTALLATIONGUIDEFORSOLID-WALLPVCSEWERPIPE

  12. SEWERPIPE CLEANINGANDINSPECTION Removeanymud,sand,orotherforeignmaterialfromthebellinteriorandspigotexteriorthatcouldpreventan effective sealbetweenthebellandspigot.Carefully cleanthegasketarea.Donotremovethegasketfromthe bell.Makesurethegasketisseateduniformlyinthegroovebyrunningyourfingeraroundtheinneredgeof the gasket. LUBRICATION Lubricantshouldbeappliedinaccordancewiththepipemanufacturer’sinstructions.Useonlythelubricants suppliedor recommendedbythepipe manufacturer. 12 UNI-BELLPVCPIPEASSOCIATIONWWW.UNI-BELL.ORG

  13. SEWERPIPE • JOINTASSEMBLY • Pushthelubricatedspigotendpastthegasketintothebelluntiltheinsertionlineonthespigotisevenwiththe edgeofthebell.DONOTOVERINSERT. • Ifyouhavetroublewithassembly,disassemblethejointandexaminethegasket.Ifthegasketisremovable, replaceifdamaged.Ifnon-removablegasketsaredamaged,cutoffthebell,bevelthenewedge,andusea couplingtoassemble.Besurethatthegasketisproperlyseatedandthatbothpipelengthsareinstraight alignment.Repeatassembly stepsabove.Correctassemblyisachievedwhentheinsertionlineonthespigotis linedupwiththeedgeofthebell.Ifmultipleinsertionlinesexist,insertuntilonlyonelineisvisible. • Thebar-and-blockmethodofjointassemblyisrecommended,astheinstallerisabletofeeltheamountofforce beingusedandwhetherthejointgoestogethersmoothly.Largerpipemayrequiremechanicalassistanceto applysufficientforcetoassemblethejoint. • Whenmechanicaldevicesareused,caremustbetakentoensurethatthespigotisinsertedtotheproper depthandthatpreviouslyassembledpipejointsarenotdisturbed.Thisisaccomplishedbyinsertingonlyto theinsertionlineonthespigotend.Ifthespigotisover-inserted,backthepipeoutuntiltheinsertionlineis visible.Inallcases,straightalignmentofthepipeisessentialforproperassembly.Ifthepipeismisaligned,over- inserted,orassembledwithexcessiveforce,thefollowingarepossibleconsequences: • rolledgaskets • failuretopassacceptancetesting(e.g.,low-pressureairtestinganddeflection-mandreltesting) • over-insertionofpreviously assembled joints ManualBar-and-Block Method 13 INSTALLATIONGUIDEFORSOLID-WALLPVCSEWERPIPE

  14. SEWERPIPE TRENCHCONSTRUCTION Termsused in pipeinstallation are illustratedin the trench cross-section below. The use ofproper embedment materialsisveryimportanttotrouble-freeoperationofpipesystems.Theparticlesizeofmaterialincontactwith thepipeshallnot exceed1½inches. FOUNDATION Afoundationisrequiredwhenthetrenchbottomisunstable.Thebottomofthetrenchisover-excavatedand broughtbackuptogradewithsuitablematerial.Whereover-excavationoccurs,ensurethattheelevationunder theentirelengthofthepipeisbroughtup(ratherthanonlyatthebells).Properplacementofnewfoundation materialswillsupportthepipeandpreventsagging betweenjoints. 14 UNI-BELLPVCPIPEASSOCIATIONWWW.UNI-BELL.ORG

  15. SEWERPIPE BEDDING Beddingmaybeusedtobringthetrenchbottomuptogradebeforethepipeisinstalled.Itspurposeistoprovide continuousanduniformsupport.Wherebeddingisrequired,amaximumcompacteddepthof4to6inchesis typical.Holesforpipebellsshouldbeprovidedateachjointtoensureuniformsupportforthepipe.Bellholes shouldbenolargerthannecessaryforpipeassembly. HAUNCHING Placementandcompactionofthehaunchingmaterialarethemostimportantfactorsaffectingpipeperformance anddeflection.Properplacementandcompactionofmaterialinthehaunchreducevoidsandincreasepipe support.Granularmaterialsmaybeproperlyplacedusingtechniquessuchasshovelslicing.Placematerial underthehaunchesandatleasthalfwayupthepipetoprovidesidesupport.Makesurematerialisproperly compacted.DONOTDISTURBSIDESUPPORTWHENMOVINGSHEETINGORTRENCHBOX. 15 INSTALLATIONGUIDEFORSOLID-WALLPVCSEWERPIPE

  16. SEWERPIPE INITIALBACKFILL Keeptheinitialbackfillfreefromrockswhichcoulddamagethepipeduringfinalbackfill.Depthoftheinitial backfillshouldbeatleast6inchesoverthetopofthepipe.Initialbackfillprotectsthepipefromdamageduring finalbackfill.Machinecompactionofinitialbackfilldirectlyoverthepipeisnotdesirableunlessadequatecover has been provided toprotect the pipe. Adequatecover will dependon the type ofcompaction equipment. For adequatecovertopreventpipedamageordeflection,consulttheprojectengineer. 16 UNI-BELLPVCPIPEASSOCIATIONWWW.UNI-BELL.ORG

  17. SEWERPIPE • FINALBACKFILL • Finalbackfillisoften specifiedbytheprojectengineerbasedonsitedesign.Materialselection, placement,and compactionshouldmeettheprojectrequirements. • ACCEPTANCETESTING • AftertheinstalledPVCpipelineisthoroughlycleaned,oneormoreofthefollowingtestsmaybeperformed: • Visualinspection • Deflection test • Leakagetest • Visual Inspection: Sewer pipelines canbe inspected visuallyto verifyaccuracy of alignment andfreedom from debrisandobstructions.Thetestistypicallyperformedby closed-circuitTV. • DeflectionTesting:Deflectiontestingisusuallyperformed withaproperlysized“go/no-go”mandrel.Mandrel sizesfor7½%deflectionofthebaseinsidediameterarefoundintheASTMproductstandards(D3034andF679) andarealsogivenintheHandbookofPVCPipe:DesignandConstruction. • LeakageTesting:Low-pressureairtestingisanacceptablemethodofinsuringintegrityoftheinstalledsewer system.ASTMF1417“StandardTestMethodforInstallationAcceptanceofPlasticGravitySewerLinesUsingLow- PressureAir”providesproceduresforleakagetestingofplasticsewerlines.UNI-B-6 “Recommended Practicefor Low-PressureAirTestingofInstalledSewerPipe”describestestingproceduresandisavailableontheUni-Bell website.Water-infiltrationtestingisanalternativemethodwhichisaccurateonlywhenthepipeiscompletely underwater.Water-exfiltration testingisararelyusedmethodthatcanbecomplicated by entrapped air. • SPECIALCONSIDERATIONS • ChangesinDirection: • Pipebending–Somechangesin direction maybe accomplishedwithouttheuseofbends,sweeps, or other fittings.ControlledbendingwithinacceptablelimitscanbeaccommodatedbyPVCpipe.Ageneralruleof thumbfortheminimumbendingradius(Rb)calculationisRb=200OD.Tighterbendingradiimaybeachieved forcertainproducts.Consultthemanufacturerforspecificproductinformation.Inmostcases,bending should beaccomplishedmanually. Itisnotrecommended to attempt bending pipesgreater than12 inches indiameterduetotheforcesrequired. • Jointdeflection–Changesindirectionmayalsobeaccomplishedthroughjointdeflection.Allowablejoint deflectionisdependentonpipesizeandjointdesign.Jointdeflectionlimitsshouldbeobtainedfromthepipe manufacturer. 17 INSTALLATIONGUIDEFORSOLID-WALLPVCSEWERPIPE

  18. SEWERPIPE • Combinedpipebendingandjointdeflection–Eitherjointdeflectionorlongitudinalbendingmaybeusedfor changesindirection,BUTNOTBOTHonthesamelengthofpipe. • ManholeConnections:Propermanholeconnectionsareessentialtogoodsystemperformance.Thefollowing precautionsarerecommended: • Insurestable foundation and beddingfor the manholeand connectingpipe to prevent shiftingwhich could damagethe connection. • Useawater-stopgasketproducedfromelastomericmaterialwhichpreventsleakagewhileallowing • longitudinalpipemovement. • Useanon-shrinkingorexpansivetypegroutformakingconnectionsofpipeandwater-stoptomanhole • walls. • ColdWeatherInstallation:Extremelycoldtemperaturesresultinincreasesinpipestiffnessandtensilestrength anddecreasesinimpactstrength.Thedecreaseinimpactstrengthrequirescareinhandlingduringinstallation incoldtemperatures. • Risers:Sewerrisersorverticalstacksmayberequiredindeepsanitarysewerstominimizeexcavationforservices lines.Risersaregenerallypermittedwherethemainsewerlineisdeeperthan7feet. • Theverticalriserpipecreatesaloadscenarionotcommoninothersewerinstallations.Anysettlementof materialalongsidetheriser produces a“drag-down”loaddue tothefrictionalforcesatthepipe/soilinterface. Additionally,settlement ofthelateralfittingassemblyproducesasimilardrag-download.Theseloadsmustbe mitigatedortransferredharmlesslyoffthestacktopreventproblemssuchasover-insertion,fittingfracture, mainsewerlinedeflection/misalignment, etc. • Thefollowingpracticesareconsideredappropriateforallriserinstallations: • Transitionsfromhorizontaltoverticalshouldbesmoothandwellsupported.Thismaybeaccomplishedwith fittingcombinations,gradualbendsand/ortrenchgeometry. • Servicelateralsfromthemainsewershouldexitatananglenogreaterthan45degreesfromthehorizontal. Asinglelengthoflateralpipeshouldbeusedfortherisersectionwheneverpossible. • To minimizeoreliminatesettlementandtheresultingloading,compactioniscritical beneaththemainline sewerandlateralconnections. • SoilMigration:Whererunningorstandingwateroccursinthetrenchorsubstantialseasonalwatertablechanges areexpected,considerationmustbegiventopreventingsoilmigration.Migrationcouldcauselossofsoilsupport forinstalledpipe.Materialsusedforunderdrains,bedding,andhaunchingshouldbeofpropergradationand thicknesstopreventmigrationofmaterialfromfine-grainednativesoils. 18 UNI-BELLPVCPIPEASSOCIATIONWWW.UNI-BELL.ORG

  19. SEWERPIPE • CHECKLIST • Takeallprecautionsnecessarytoprotectworkersandmaterials. • Planaheadforfittings. • Usetrenchboxesorshoringinunstableconditions. • Donotdisturbinstalledpipewhenmovingtrenchboxesorshoringmaterials. • Properlyassemblepipejointsbyinsertingthespigotenduntiltheinsertionlineisevenwiththebell lip. • Insurewatertightsealsatmanholeconnections. • Keepthetrenchbottomasdryaspossible. • Fordetailedinstallationrecommendations,seeASTMD2321“StandardPracticeforUndergroundInstallation of ThermoplasticPipeforSewers andOtherGravity-FlowApplications.” • Consultthepipemanufacturerforspecificsregardinggasketsandlubricants. • Checkwiththeprojectengineerregardingspecifications and procedures. UNI-BELLLITERATURE RecommendedStandards UNI-B-6“RecommendedPracticeforLow-PressureAirTesting ofInstalledSewerPipe” Technical Reports UNI-TR-1“Deflection:ThePipe/SoilMechanism” UNI-TR-3 “MaintenanceofPVCSewer Pipe” UNI-TR-5“TheEffectsof UltravioletRadiationonPVC Pipe” UNI-PUB-06-21 19 INSTALLATIONGUIDEFORSOLID-WALLPVCSEWERPIPE

  20. UNI-BELLPVCPIPEASSOCIATION 201E.JohnCarpenterFreeway Suite750 Irving,TX75062 (972)243-3902 WWW.UNI-BELL.ORG

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