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Wall Thickness Calculation
Wall Thickness Calculation
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5 Wall thickness calculation for ductile iron pipes The two types of stress are calculated as
follows:
p.D
When laying underground pipelines consisting of ductile iron pipes to standard σt = . [N/mm²] (5.1)
EN 545 [5.1], for the most part the pipes are assembled using push-in joints as 2 e
standardised in DIN 28603 [5.2]. For calculating the wall thickness of ductile iron
pipes, a distinction is made between
p.D
n non-restrained flexible push-in joints and σa = . [N/mm²] (5.2)
n restrained flexible push-in joints. 4 e
Fig. 5.1:
Stresses produced by internal pressure in
a wall of pressure pipes assembled with
restrained joints
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5.2 Calculating the wall thickness Over the last six decades, non-restrained In principle, they are calculated accord-
of pipes with non-restrained flexible push-in joints have had a consid- ing to equation 5.1 (Barlow’s formula):
flexible push-in joints erable influence in shaping the image of
p.D
the cast iron pipe; they are inexpensive σt = . [N/mm²] (5.1)
5.2.1 Calculating the wall thickness and simple to assemble. Non-restrained 2 e
of pipes according to pressure push-in joints do not transmit any axial
classes (C-classes) forces, meaning that the stresses shown σt tangential stress in the
in Fig. 5.1 in the axial direction σa are pressure pipe wall [N/mm²]
For calculating the pipe wall thickness equal zero. As can be seen in Fig. 5.2, the p internal pressure [bar]
of ductile iron pipes with non-restrained stresses in the wall of such a socket pipe D mean diameter
flexible push-in joints, the simple Bar- only run in the circumferential direction (D = (DE + Di) / 2 = DE – e) [mm]
low’s formula is used in which the tan- as tangential stress σt. e wall thickness [mm]
gential stresses produced by internal
pressure, the tensile strength of the pipe This produces the following equation for
material, the thickness of the pipe wall internal pressure p:
and the diameter of the pipe correlate
with each other. [N/mm²] (5.2)
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With a minimum tensile strength 200 222 3.1 3.9 5.0 7.7
Rm = 420 MPa for ductile cast iron and 250 274 3.9 4.8 6.1 9.5
300 326 4.6 5.7 7.3 11.2
the safety factor SF = 3 we arrive at the
350 378 4.7 5.3 6.6 8.5 13.0
following constant 5.4:
400 429 4.8 6.0 7.5 9.6 14.8
450 480 5.1 6.8 8.4 10.7 16.6
20 . Rm 500 532 5.6 7.5 9.3 11.9 18.3
= 2.800 [MPa] (5.4)
SF 600 635 6.7 8.9 11.1 14.2 21.9
700 738 6.8 7.8 10.4 13.0 16.5
800 842 7.5 8.9 11.9 14.8 18.8
The allowable operating pressure PFA 900 945 8.4 10.0 13.3 16.6 Table 5.1:
for the component can be calculated with 1000 1048 9.3 11.1 14.8 18.4 Minimum wall
equation 5.5 from the external pipe wall 1100 1152 8.2 10.2 12.2 16.2 20.2 thicknesses emin
diameter DE and pipe wall thickness emin : 1200 1255 8.9 11.1 13.3 17.7 22.0 for ductile iron
1400 1462 10.4 12.9 15.5 pipes as per
1500 1565 11.1 13.9 16.6
[MPa] (5.5) EN 545 [5.1]
1600 1668 11.8 14.8 17.7
depending on
1800 1875 13.3 16.6 19.9
nominal size DN
2000 2082 14.8 18.4 22.1
and pressure class
Note: the figures in bold represent the standard range
(C-class)
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Using equation 5.5 it is possible to cal- When the first ductile iron pipes were For drinking water supply, type K val-
culate the minimum wall thickness emin produced in the middle of the nineteen ues were 10 to begin with, then later on
for an allowable operating pressure PFA fifties, safety standards were initially still 8 and 9. In order for wall thicknesses of
with a given nominal size: based on the characteristics of thick- the smaller nominal sizes to remain prac-
walled grey cast iron pipes. At the time, tically feasible at all, the lower limit for
DE . PFA [mm] casting machines were still being man- nominal wall thicknesses was reduced to
emin = (5.6)
2.800 + PFA ually controlled, meaning that the min- e = 6 mm. The following determination
imum wall thickness was only observed applies to the minimum wall thickness
Table 5.1 shows the minimum wall thick- with large “allowances”. For a coherent emin for measurement purposes:
nesses emin according to EN 545 [5.1] for representation of wall thicknesses over
the seven pressure classes (C-classes) the entire range of nominal sizes, these emin = e – Δe [mm] (5.9)
which are assigned to operating pressures were divided into K-classes which were
PFA 20; 25; 30; 40; 50; 64 and 100. The in existence for more than four decades. Δe permissible dimensional deviation
lower limit for the minimum wall thick- Nominal wall thicknesses e were deter- (minus tolerance)
nesses has been reduced to emin = 3,0 mm. mined taking account of the permissible
circumferential stresses in the pipe wall
5.2.2 Calculating wall thicknesses using the formula
according K-classes
e = 5 + 0.01 . DN [mm] (5.7)
Since the introduction of ductile cast iron
around 60 years ago, the minimum wall in wall thickness class K 10. Wall thick-
thickness emin has undergone a consid- nesses which deviated from this could be
erable evolution which is due to the represented in their own K-classes
impressive development and optimisa-
tion of centrifugal casting production e = K . (5 + 0.001 . DN) [mm] (5.8)
technology. The primary beneficiaries
of this are the small nominal sizes from whereby the proportionality factor K was
DN 80 to DN 250 which account for an part of a series of whole numbers … 8,
extremely high proportion in urban dis- 9, 10, 11, 12 …
tribution networks.
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The following applies for e > 6 mm: As from 2010, EN 545 [5.1] now only con-
tains the pressure (C) classes.
Δe = – (1.3 + 0.001 ∙ DN) [mm] (5.10)
The development of minimum pipe wall
The following applies for e ≤ 6 mm: thicknesses over the last decades in Fig.
5.3 shows that, since the introduction of
Δe = –1.3 [mm] (5.11) ductile iron pipes, in terms of production
technology it has been possible to reduce
Hence the lowest minimum pipe wall minimum wall thicknesses by almost half.
thickness was 4.7 mm.
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This effect is based solely on the fact that, 5.5 The effect of longitudinal
Soil load
with the introduction of pressure classes bending strength and ring
(C-classes), the limit value for mini- Water filling stiffness on the calculation
mum wall thickness has been reduced Dead weight of pipe wall thickness dimen-
by roughly one third, from 4.7 mm to 3.0 sions
Traffic loads
mm. The equation applicable for calcu-
lating wall thicknesses (5.6) remains the
same as before. Fastening plate Classification according to pressure
classes (C-classes) is only applicable
Table 5.2 illustrates the relationship Pipe cradle for non-restrained systems in which
between the previous K-classes and the foundation pile only tangential stresses σt produced by
new pressure classes (C-classes) for each + Bending moment internal pressure are decisive when it
nominal size. The wall thickness meas- – progression
(idealised)
comes to calculating pipe wall thickness
ured in millimetres represents the com- (Fig. 5.2).
mon comparison parameter for C-classes Fig. 5.5:
and for K-classes. The table shows the Bending moments for a buried pipeline on However, such influencing factors should
areas with similar wall thicknesses and piles also be taken into account when calcu-
the areas corresponding to pressure lating non-restrained systems as they
classes for the allowable operating pres- cause a significant proportion of axial
sure PFA in the same colours. stresses σa in the system to be calcu-
Traffic loads
lated. These may be axial stresses due
This table offers the possibility of compar- to bending moments in the longitudi-
ing the earlier K-classes (wall thickness h
Road
Road substructure
nal direction (Fig. 5.5) or to uneven
classes) with the new pressure classes Propagation of the load loads in the circumferential direction
(C-classes), because the actual minimum Ovalised pipe (Fig. 5.6).
wall thickness emin is the common refer- Initial condition of the pipe
Ground
ence parameter.
Fig. 5.6:
Ovalisation due to soil loads and traffic
loads
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As seen in Fig. 5.1, restrained pipe joints this situation by publishing its own identi- ing bead on the spigot end. A mini-
produce a multiaxial stress state in the fication standard, EADIPS®/FGR®-NORM mum wall thickness of approximately
pipe wall whereby, with the allowable 75 [5.5],(Chapter 3, Figs. 3.35 and 3.36). 5 mm for a high-quality weld penetra-
operating pressure PFA being lower when tion is considered as a precondition for
compared with the non-restrained joint, 5.6.2 Positive locking push-in joints compliance with the required permissi-
the pressure class is therefore lower. ble tensile strength. Also, with trenchless
A further requirement has come more pushing-in techniques, a minimum wall
The multiaxial stress state in a pipe wall and more into the foreground in the thickness is required for transferring the
which, in addition to the tangential stress last decade: the increasing frequency compressive forces, so that the permissi-
σt produced by internal pressure, must with which restrained push-in joints ble compression stresses in the connec-
also take up axial stresses σσa, results in a are being used with the trenchless tion joint are not exceeded.
distinct reduction in the allowable oper- laying techniques and the associated
ating pressure PFA as compared with requirement for the maximum per- Depending on the application case,
the non-restrained design. Therefore the missible tensile strength values in the a number of load types due to inter-
specification of pressure class C as a syn- Technical Rules of DVGW Worksheet nal pressure, vertical load and bend-
onym for the allowable operating pressure GW 320-1 [5.6] etc. (see also Chapter 22 ing stress, as well as those due to the
PFA is no longer sufficient for restrained- on trenchless pipe laying and replace- maximum permissible tensile and com-
joint pipelines. This has consequences ment techniques). In these sets of rules, pressive forces associated with trench-
for the identification of the pipes. Fig. 5.8 the permissible tensile strength of, less laying techniques must therefore
shows the identification requirements of above all, positive locking push-in joints be calculated and the optimum pipe
EN 545 [5.1], Section 4.7.1. with a welding bead on the spigot end determined. The effects on practical
(Fig. 9.5) plays a decisive role for the planning are described in articles in
According to EN 545 [5.1], Section 4.2, pulling-in length of a pipe string. Hence EADIPS®/FGR® Annual Journals 45 [5.7]
manufacturers must state the lower it is a determining factor for excavation and 46 [5.8].
values for the PFA of their restrained distances and therefore for the effi-
push-in joints. However, there is no ciency of a pipe material for a specific
clear and unambiguous determination trenchless technique. Trenchless pipe
of the identification of pipes with laying techniques are mainly performed
restrained joints to be found in EN 545 with positive locking restrained push-in
[5.1]. EADIPS®/FGR® has responded to joints. These joints must have a weld-
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