Ductile Iron Pipe | DN800 ‑ DN2200

Ductile Iron Pipe | DN800 ‑ DN2200

The PAM Zinalium® Hydroclass® and Integral® large diameter ductile iron pipe range is a flexible pipe system suitable for pressure and non-pressure water supply, sewerage and aggressive medium applications.

PAM is the world’s leading manufacturer of ductile iron pipe with over 160 years of experience in designing and manufacturing state-of-the-art pipeline solutions.

  • Clover is Australia's trusted supplier of ductile iron pipe and fitting systems.

  • The PAM Zinalium range can be installed in most Australian soil conditions without the need for polyethylene sleeving.

  • Extensive range of pressure, coating and lining options available to suit any pipeline application.

Techincal Information

Usage & Features

Applications

PAM Ductile iron pipes are suitable for both pressure and non-pressure applications and can be installed buried or above ground.

Typical applications include;

  • Potable and recycled water supply
  • Irrigation and raw water
  • Gravity and sewer rising mains
  • Mining and slurry
  • Stormwater and drainage
  • Buried and above ground

Features and Benefits

PAM Ductile iron pipes possess many advantages over other pipeline materials.

Features Benefits
High hoop and axial strength High hoop and axial strength provides PAM ductile iron pipe the ability to resist the extreme stresses imparted by soil, construction loads and variable pipeline operating conditions including surge.
Tough material PAM ductile iron is tough allowing it to endure irregular operating conditions and the demands of handling in the field.
High burst strength High burst strength makes PAM ductile iron pipe well suited for high-pressure applications.
Long-term corrosion resistance PAM ductile iron pipes are supplied with a patented Zinalium zinc aluminium external corrosion protection system.

 

Zinalium extends the lifespan of a pipeline by actively protecting the pipe against the corrosive effects of the surrounding soil.

 

Zinalium coated ductile iron pipes can be directly buried in contact with the majority of soils without the need for loose polyethylene sleeving.  Contact the Clover engineering team to discuss suitable ground conditions.

Long Term Performance PAM ductile iron pipe has a worldwide proven long-term performance and maintenance free operation.
Joint Deflection Each PAM ductile iron pipe joint can be deflected allowing the installer to reduce the number of bends required and simplifying Installation.
Accreditations

Product Standards

PAM large diameter ductile iron pipes are manufactured and independently third party certified to the following standards;

  • ISO2531 “Ductile iron pipes, fittings, accessories and their joints for water applications”
  • ISO7186 “Ductile iron products for sewerage applications”
  • EN545 “Ductile iron pipes, fittings, accessories and their joints for water applications”
  • EN598 “Ductile iron pipes, fittings, accessories and their joints for sewerage applications”
  • AS/NZS4020 “Testing of products for use in contact with drinking water”

WSAA Appraisal

PAM large diameter ductile iron pipes are independently appraised and recommended by the Water Services Association of Australia (WSAA);

  • Product Appraisal 14/09

WSAA Purchase Specification

PAM large diameter ductile iron pipes comply with the requirements of the following Water Services Association of Australia (WSAA) purchase specification(s);

  • PS202 – Ductile Iron Pipes and Fittings (ISO Sized) for Pressure Applications – Water Supply.
  • PS202S – Ductile Iron Pipes and Fittings (ISO Sized) for Pressure Applications – Sewerage

Suitability for Use with Potable Water (AS/NZS4020 Compliance)

PAM Hydroclass ductile iron pipes are cement mortar lined with a standard Sulphate Resistant (SR) Blast Furnace Cement mortar which is suitable for potable water applications and complies with AS/NZS4020 “Testing of products for use in contact with drinking water”.

PAM Integral ductile iron pipes are lined with calcium aluminate cement (CAC) mortar which is intended for sewerage and aggressive water applications and are not suitable for potable water applications.

Product Details

Diameter Range

PAM Hydroclass and Integral large diameter ductile iron pipes are manufactured with nominal diameters ranging from DN800 to DN2200.

For ductile iron pipes with smaller diameters refer to this page.

Pressure

PAM Hydroclass and Integral C25 ductile iron pipes are manufactured with a standard nominal pressure range of PN25 (2,500kPa).

Alternative standard pressure classes of PN30 (C30), PN40 (C40), PN50 (C50) PN64 (C64) and PN100 (C100) are also available.

Zinalium® Coating

Zinalium is a PAM patented active corrosion protection system, consisting of on a zinc and aluminium alloy coating in the mass ratio of 85(Zn) to 15(Al). The alloy in wire-form, feeds an electric arc where it is melted onto the as-cast surface of the pipe by high-pressure air. The alloying ensures the intimate mixing of zinc and aluminium and the resulting microstructure optimises the spatial distribution of the zinc in the coating, maximising corrosion protection. The minimum coating application is 400g/m2.

A synthetic epoxy pore sealer is applied to the as sprayed zinc-aluminium coating to a minimum thickness of 100μm. The pore sealer inhibits corrosion of the zinc-aluminium and helps to trap any galvanic corrosion. These corrosion products are insoluble and help build a barrier that further inhibits corrosion.

Pore sealers are blue in colour for drinking water applications (Hydroclass) and red in colour for sewerage/aggressive applications (Integral). Where small quantities of pipe are required for recycled water applications a lilac coloured loose polyethylene sleeving is recommended for identification purposes. Where large quantities are required for recycled water applications, a lilac coloured pore sealer would be utilised.

Zinalium extends the lifespan of a pipeline by actively protecting the pipe against the corrosive effects of the surrounding soil.

Zinalium coated ductile iron pipes can be directly buried in contact with the majority of soils without the need for loose polyethylene sleeving.  Contact the Clover engineering team to discuss suitable ground conditions.

Polyethylene Sleeving

Some Australian Water agencies specify polyethylene sleeving of ductile iron pipes as a means of additional passive corrosion protection. Polyethylene sleeving provides corrosion protection in aggressive soils by creating a uniform environment around the pipe and limiting oxygen exposure.

Loose PE sleeving is installed on site to ductile iron pipelines in the form of a tubular film. Cut lengths are slipped over the pipe, overlapped and wrapped up tight before securing in place with bands and plastic adhesive tape.

Polyethylene sleeving should be installed in accordance with AS 3681:2008 “Guidelines for the application of polyethylene sleeving to ductile iron pipeline”. Accredited pipe layers trained in the application of sleeving should be employed.

Cement Mortar Lining - Hydroclass (Blue - Potable Water)

PAM Hydroclass ductile iron pipes are cement mortar lined with a standard Sulphate Resistant (SR) Blast Furnace Cement mortar.

The cement mortar lining is applied by a centrifugal process.

Zinalium hydroclass cmeent mortal lining cross-section

The cement mortar lining thickness for the Hydroclass ductile iron pipe is given below;

Nominal Diameter (DN) Cement Mortar Lining Thickness (mm)
Nominal Minimum
800 – 1200 6.0 3.5
1400 – 2000 9.0 6.0
2200 12.0 7.0

PAM Hydroclass ductile iron pipes are suitable for potable water applications and comply with AS/NZS4020 “Testing of products for use in contact with drinking water”.

Seal Coating

An optional bituminous seal coat may be applied to the cement mortar lining on Hydroclass ductile Iron pipes.

The intended purpose of a seal coat is to reduce the contact between the cement mortar lining and the contents of the water main, thereby restricting lime leaching and consequent high pH levels in supply when conveying soft (i.e. low carbonate alkalinity) water, especially where flow rates are low and residence times are lengthy. Consideration should be given to the use of seal coatings where the total alkalinity of the water being conveyed is less than 30 mg/L.

The seal coat adhesion rating and coating thickness comply with the requirements of ISO16132 “Ductile iron pipes and fittings — Seal coats for cement mortar linings”.

Cement Mortar Lining - Integral (Red)

PAM Integral ductile iron pipes are cement mortar lined using a Calcium Aluminate Cement (CAC) mortar.

The cement mortar lining is applied by a centrifugal process.

Zinalium Integral Cement mortar lining cross section

The cement mortar lining thickness for the Integral® ductile iron pipe is given below;

Nominal Diameter (DN) Cement Mortar Lining Thickness (mm)
Nominal Minimum
800 – 1200 6.0 3.5
1400 – 2000 9.0 6.0
2200 12.0 7.0

Where the fluid being conveyed is aggressive to a cement mortar, a thicker cement mortar lining or an alternative lining may be specified by the purchaser.

Calcium Aluminate Cement mortar lining is not compliant to AS/NZS4020 “Testing of products for use in contact with drinking water” and is typically used in the conveyance of gravity and pressure sewerage mediums with pH4 to pH12. CAC mortar lining is not suitable for drinking water applications.

Specifications SYM UNITS DN 800 DN 900 DN 1000 DN 1100 DN 1200
Pressure nominal PN Nom 25 25 25 25 25
Mean pipe outside diameter Øy mm 842 945 1048 1152 1255
Effective length EL m 6.0 6.0 6.0 6.0 6.0
Effective joint deflection ̊ deg 2.0 2.0 2.0 2.0 4.0
Mean internal pipe diameter – cement mortar lined Øz mm 810.8 911.8 1012.8 1114.8 1215.8
Nominal pipe wall thickness t mm 9.6 10.6 11.6 12.6 13.6
Minimum pipe wall thickness a mm 7.5 8.4 9.3 10.2 11.1
Nominal cement mortar lining thickness c nom mm 6.0 6.0 6.0 6.0 6.0
Minimum cement mortar lining thickness c min mm 3.5 3.5 3.5 3.5 3.5
Pipe socket depth of entry D mm 160 175 185 200 215
Pipe socket outside diameter Øx mm 943 1052 1158 1267 1377
Weight of pipe length W kg 1363 1674 2010 2402 2808

Joints

PAM Hydroclass and Integral ductile iron pipes incorporate a spigot and socket elastomeric joint. The pipes are supplied with gaskets for simple and effective jointing.

PAM Hydroclass pipes feature an EPDM gasket.

PAM Integral pipes feature an SBR gasket.

Optional restraint joint gaskets are available for the PAM large diameter ductile iron pipe range providing;

  • Thrust restraint to eliminate requirements for concrete thrust blocks;
  • Security in poor soil conditions.

Restraint joints are suitable for below ground applications only.

Contact the Clover engineering team to discuss the suitability of a restraint joint system for any project needs.

Gaskets comply with the requirements of AS1646 “Elastomeric seals for waterworks purposes”.

Joint Deflection

PAM Hydroclass and Integral pipes incorporate a proven spigot and socket elastomeric gasket. Each pipe join can be deflected allowing the installer to reduce the number of bends required during installation.

The effective joint deflection for PAM ductile iron pipes are provided below;

Nominal Diameter (DN) Effective Joint Deflection (deg)
800 – 1100 2.0°
1200 4.0°
1400 – 1800 3.0°
2000 2.5°
2200 2.0°

Pressure

Nominal Diameter (DN) Nominal Pressure (PN) Nominal Pressure (MPa) Allowable Operating Pressure (AOP) Maximum Allowable Operating Pressure (MAOP) Allowable Site Test Pressure (ASTP)
800 – 2200 25 2.5 MPa 2.5 MPa 3.0 MPa 3.5 MPa

Alternative standard pressure classes of PN30 (C30), PN40 (C40), PN50 (C50) PN64 (C64) and PN100 (C100) are also available.

Lengths

PAM large diameter ductile iron pipes are supplied in standard 6m effective lengths.

Product Marking

All PAM ductile iron pipes are clearly branded with the following markings in accordance with ISO2531 “Ductile iron pipes, fittings and accessories”;

  1. Manufacturers mark – Clover PAM
  2. Nominal diameter – DN XXXX
  3. Nominal pressure – C25, C30, C40, C50, C64 or C100
  4. Reference to product standard – ISO2531, EN545 or EN598

Pipes feature two red markings on the socket face.

Fittings and valves

A full range of compatible fittings, valves and connections are available in sizes DN800 to DN2200 with combinations of socket and flange ends.

Contact Clover for additional technical or pricing information.

Options

Clover provides an extensive range of additional options to complement our PAM large diameter ductile iron pipe range;

  • Restraint joints
  • Fabricated and flange class pipework
  • Zinc external coating system (Zn 200g/m2)
  • Smaller diameter pipes (DN100 to DN750)
  • Higher pressure pipes (Up to PN100)
  • Polyethylene coating and lining options
  • Polyurethane coating and lining options

Contact Clover for additional technical information or support with your project.

Properties

Mechanical Properties

Property Value & Unit
Ultimate tensile strength (Minimum) 420MPa
Elongation (Minimum) 10%
Hardness Brinell (Maximum) 230
Tensile Modulus 170MPa
Poisson’s Ratio 0.3
Design Stress 140MPa
Ring bending modulus (3 mins) 165MPa
Ring bending modulus (50 yrs) 165MPa
Density (Specific Gravity) 7.1

 

Thermal Properties

Property Value & Unit
Thermal Coefficient of expansion 12.5 x 10-3 /OC
Flammability Non-Flammable

Chemical Resistance

PAM ductile iron is highly resistant to chemical attack and suitable for aggressive environments. Ductile Iron is a well-established pipe material that is suitable for the most corrosive of fluids, making it an ideal option for wastewater mains and industrial processing applications.

PAM Integral ductile iron pipes are intended for use with water and wastewater mediums, ranging from pH4 to 12 and at temperatures of up to 35°C.  Alternative lining systems can be specified to improve chemical and temperature resistance

Contact Clover Pipelines engineers for any parameters in excess of these values for guidance on suitability.

Design & Install

Installation

Installation methods for PAM ductile iron pipes are generally in accordance with AS/NZS2566.2 “Buried flexible pipelines – Installation”. The standard specifies the requirements for the installation of buried flexible pipelines with structural design in accordance with AS/NZS2566.1 “Buried flexible pipelines – Design”.

Testing & Commissioning

Testing and commissioning methods for PAM ductile iron pipes are generally in accordance with AS/NZS2566.2 “Buried flexible pipelines – Installation”. The standard specifies the requirements for the field-testing and commissioning of buried flexible pipelines with structural design in accordance with AS/NZS2566.1 “Buried flexible pipelines – Design”.

Installation Training

Clover’s in-house engineering team provides a range of training, accreditation and technical support services.

The Clover Academy installation training course provides installers with important information relating to the correct handling, installation, testing, maintenance and repair of Clover pipe systems and products.

Contact the Clover engineering team to discuss scheduling a training program.

Technical Support

Clover’s in-house engineering team combines specialist technical knowledge, creative thinking and on-the-job experience, to offer our clients a range of project planning and consultation services.

From recommendations on product innovations, to crafting complex end-to-end solutions, our collaborative approach bridges the gap between contractors, authorities and suppliers. The only Australian provider able to offer clients the full product suite, Clover offers unbiased, strategic insights that always consider the bigger picture.

From initial planning, to onsite training and technical assistance, we offer input across every stage of your project’s timeline. Our contribution continues beyond the project design, and we remain accessible for ongoing changes and developments over the course of each project.

We work with contractors, asset managers, local councils and government, developers and other pipeline professionals to specify bespoke product solutions. By engaging our team of engineers, you gain access to unparalleled product knowledge and expertise.

Maintenance

Clover supplies an extensive range of high quality mechanical couplings and repair clamps compatible with PAM Hydroclass and Integral ductile iron pipes.

Life Expectancy

Life expectancies for PAM ductile iron pipes are provided below.

Estimated life expectancy of PAM ductile iron pipe

Coating & Lining Options Environment
Benign Moderately Aggressive Aggressive
Internal Lining
Blast Furnace Cement > 100
Years
> 50
Years
> 25
Years
Blast Furnace Cement + Seal Coat > 100
Years
> 100
Years
> 75
Years
Calcium Aluminate Cement > 100
Years
> 75
Years
> 50
Years
External Coating
200 g/m2 zinc + finishing layer > 100
Years
> 50
Years
> 20
Years
200 g/m2 zinc + finishing layer + PE sleeving > 100
Years
> 100
Years
> 75
Years
400 g/m2 Zinc Aluminum (ZnAl) + finishing layer > 100
Years
> 100
Years
> 75
Years

Above table referenced from WSAA Product Appraisal 14/19.

Life expectancy estimates are indicative only and may increase or decrease as a result of the system operating conditions, preventative maintenance programs, operating environment and other geographical and site-specific factors.

It should be noted that the service life for a pipeline is not necessarily defined as the time to first failure but as the typical service life achievable before major rehabilitation is required.

Resources

Technical Documents

Ductile Iron Pipe data sheet (DN800-DN2200)

PDF, 253.9K

Clover DICL Large Diameter Pipe ISO WSAA Appraisal

PDF, 2.0M