How Multiple Events Collided to Affect Ductile Iron Pipe ...

Raise your hand if you can recall a recent grocery store trip where you craved bagels and cream cheese, only to find the shelves stripped bare of your favorite cream cheese flavor.

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Much like other sectors, the array of unpredictable events leading to worldwide supply chain disruptions has taken us all by surprise. However, in the water and wastewater pipe industry, it's clear we've been facing one obstacle after another.

The challenges surrounding the availability and pricing of ductile iron pipe (DI pipe) have intensified over the past year, and they will likely continue as demand surges alongside rising input costs. The question we must grapple with is how to navigate a storm that shows no signs of abating. In this blog, we will delve into the underlying reasons for the supply chain issues, increasing costs, and the proactive measures McWane Ductile is undertaking to tackle these challenges head-on.

Once again, the supply chain shortages have made an impact.

The Springdale Water Utilities requires local contractors to utilize ductile iron pipe to provide essential water and sewer services. As of now, obtaining ductile iron pipe is proving to be quite difficult, with lead times stretching up to nearly a year, according to local utility directors in Northwest Arkansas.

In response, the Springdale Water and Sewer Commission has authorized utility staff to approve the use of PVC pipe in cases where ductile iron pipe is unavailable. Additionally, staff have the discretion to bypass iron pipe stipulations on a case-by-case basis without needing to secure commission approvals every time.

Heath Ward, the executive director of Springdale Water Utilities, indicated that for smaller projects or smaller pipe diameters, substituting with PVC may be justifiable.

Experts have stated that they do not anticipate significant differences in overall quality between the two types of pipe, and they expect minimal to no increase in leakage, breaks, or other issues.

Regardless of the type of pipe installed underground, customers are unlikely to notice any difference in the service they receive, according to Wen Zhang, an associate professor of civil engineering at the University of Arkansas, Fayetteville.

Ductile iron, a type of cast iron known for its impact and wear resistance, is less likely to fracture under stress than standard cast iron. The unique properties of ductile iron arise from adding carbon during the smelting process, which allows the creation of spherical graphite structures contributing to its ductility.

On the other hand, PVC pipe is favored for its affordability, ease of installation, and durability, according to the Plastic Pipe and Fittings Association. In the U.S., PVC is manufactured using natural gas and salt.

While Ward expressed a preference for ductile iron, he noted, "We will accept something else as long as we are able to sleep at night." He added, "I'm not going to worry if we have one pipe or 50 pipes that are made of PVC."

Rick Pulvirenti, the chief operating officer and engineer for the utility, reported that about 60% of their system currently consists of PVC pipes.

Ward also mentioned that once the supply chain normalizes, the utility will resume using ductile iron pipes.

When comparing ductile iron pipes to PVC, it's important to note that under normal market conditions, PVC is priced lower. However, PVC requires a specific bedding to surround the pipe, which helps distribute pressure evenly from water pumped through it—key for pipelines that will be in place for long periods.

In terms of strength, ductile iron outperforms PVC, but it is more vulnerable to erosion. This particular issue has been observed in pipes buried near a water tank farm in the eastern part of town, prompting the utility to employ sacrificial anodes to protect the ductile iron pipes from corrosion.

As of late, prices for PVC pipes around 8-inch diameter have soared to about $95 for a 100-foot length, a rate comparable to that of ductile iron. Contractors and engineers are increasingly factoring the long-term costs associated with each piping material into their decision-making processes. This includes ongoing maintenance and potential replacement expenses.

Experts like Zhang advocate for PVC pipes, highlighting their resistance to corrosion, and project that today's PVC pipes can endure for approximately 70 years. Generally, the lifespan for any type of pipe ranges between 50 to 100 years.

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Ward has stated that he will continue to use PVC for deep sewer lines, particularly when pipes need to be buried at depths of 15 feet, as digging deeply poses risks of wall collapses during repairs.

Historically, ductile iron, often lined with epoxy, has been the go-to option for the city's water and sewer mains. However, this lining can wear down over time, exposing the metal to erosion. To combat this, utility crews have replaced aging linings with a quick-drying fiberglass tube that provides robust protection.

This lining is utilized on the interior of sewer pipes, while also ensuring that epoxy does not contaminate drinking water within the water lines, Ward confirmed.

Numerous materials are available as casting options for pipes, including ductile iron, cast iron, copper, steel, and various plastic products.

Ben Peters, the city's Engineering Department director, pointed out that stormwater drainage utilizes concrete pipes.

Clay pipes, despite their historical significance, are known to leak at joints, according to Ward, who highlighted aqueducts of ancient Rome, such as the restored Acqua Vergine, built in 19 B.C., that continue to supply water to the Trevi Fountain.

Most pipe installations that connect to individual buildings in the city are already PVC, as the city code accommodates various materials for building projects. Meanwhile, ductile iron is predominantly used for mains that bear significant pressure.

Issues involving rocky soil in Northwest Arkansas have resulted in numerous homeowners discovering that sharp-edged rocks can puncture PVC pipes, leading to repair costs approaching $4,000 for Ward himself.

To mitigate future issues, utilizing thicker PVC, proper burial depth, and suitable bedding for pipes is key, he explained.

Waiting 10 months for ductile iron pipe can hinder project timelines significantly, while local officials have been informed that PVC suppliers can deliver their products within weeks.

Ward empathized with the challenges faced by engineers and contractors under pressure to complete projects, especially when demand for single- and multifamily housing remains high. "They are under market pressure, but we don't want anything substandard," he noted.

The current utility project on Emma Avenue will employ PVC piping to expedite completion, allowing for the reopening of Emma Avenue to traffic sooner.

Meanwhile, Kevan Inboden, chief operating officer of Beaver Water District, mentioned that their new western water pressure main will utilize steel piping, reporting no significant supply issues. They are proceeding with plans as if supply challenges will not impede the project's timeline.

Inboden indicated that the completion of the water delivery infrastructure will occur by the end of this year, with a capacity to pump 70 million gallons of water daily once fully operational. Local cities will connect to the pumping station to ensure adequate water supply reaches the western areas of Washington and Benton counties.

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