• Smart Structures and Systems
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• v.7 no.4
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• pp.241-262
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• 2011

Cast iron pipe has been used as a water distribution technology in North America since the early nineteenth century. The first cast iron pipes were made of grey cast iron which was succeeded by ductile iron as a pipe material in the 1940s. These different iron alloys have significantly different microstructures which give rise to distinct mechanical properties. Insight into the non-destructive structural condition assessment of aging pipes can be advantageous in developing mitigation strategies for pipe failures. This paper examines the relationship between the small-strain and large-strain properties of exhumed cast iron water pipes. Nondestructive and destructive testing programs were performed on eight pipes varying in age from 40 to 130 years. The experimental program included microstructure evaluation and ultrasonic, tensile, and flexural testing. New applications of frequency domain analysis techniques including Fourier and wavelet transforms of ultrasonic pulse velocity measurements are presented. A low correlation between wave propagation and large-strain measurements was observed. However, the wave velocities were consistently different between ductile and grey cast iron pipes (14% to 18% difference); the ductile iron pipes showed the smaller variation in wave velocities. Thus, the variation of elastic properties for ductile iron was not enough to define a linear correlation because all the measurements were practically concentrated in single cluster of points. The cross-sectional areas of the specimens tested varied as a result of minor manufacturing defects and levels of corrosion. These variations affect the large strain testing results; but, surface defects have limited effect on wave velocities and may also contribute to the low correlations observed. Lamb waves are typically not considered in the evaluation of ultrasonic pulse velocity. However, Lamb waves were found to contribute significantly to the frequency content of the ultrasonic signals possibly resulting in the poor correlations observed. Therefore, correlations between wave velocities and large strain properties obtained using specimens manufactured in the laboratory must be used with caution in the condition assessment of aged water pipes especially for grey cast iron pipes.

• Clean Technology
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• v.15 no.1
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• pp.16-22
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• 2009

In this study, a fiber reinforced plastic (FRP) pipe with superior wear resistance was developed to replace the fly ash pipe of cast iron. Wear test was performed with various combinations of SiC filler and resin materials of unsaturated polyester, vinylester, epoxy, and phenol. Test results of ASTM D4060 showed the optimal combinations of resin, filler size, and resin/filler ratios. Test results of comparison between FRP and cast iron showed the possibility to replace cast iron pipe with the FRP pipe. Field test executed to compare the wear resistance between cast iron pipe and developed FRP pipe showed the superiority of the FRP pipe.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.21 no.9
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• pp.1491-1497
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• 1997

The purpose of this research is to improve the surface roughness of cast-iron pipe porduced by the centrifugal casting. A twin-fluid atomizer of mold-wash slurry is designed for this project. New atomizer is equipped with the existing manufacturing facility to produce pipes. Cast-iron pipes (.cent.125*L3000mm) are produced and the surface roughnesses of those are analysed by UBM. The average surface roughness of new products is 6.7.mu.m while the old products of sand-resin coating method have 17.0.mu.m of average surface roughness. The surface roughness of cast-iron pipe is improved very much than before.

• Journal of Korean Society on Water Environment
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• v.23 no.1
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• pp.87-96
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• 2007

In this paper a methodology of identifying individual pipes according to the internal and external characteristics of pipe is developed, and the methodology is applied to a case study water distribution pipe break database. Using the newly defined individual pipes the hazard rates of the cast iron 6 inch pipes are modeled by implementing the proportional hazards modeling approach for consecutive pipe failures. The covariates to be considered in the modeling procedures are selected by considering the general availability of the data and the practical applicability of the modeling results. The individual cast iron 6 inch pipes are categorized into seven ordered survival time groups according to the total number of breaks recorded in a pipe to construct distinct proportional hazard model (PHM) for each survival time group (STG). The modeling results show that all of the PHMs have the hazard rate forms of the Weibull distribution. In addition, the estimated baseline survivor functions show that the survival probabilities of the STGs generally decrease as the number of break increases. It is found that STG I has an increasing hazard rate whereas the other STGs have decreasing hazard rates. Regarding the first failure the hazard ratio of spun-rigid and spun-flex cast iron pipes to pit cast iron pipes is estimated as 1.8 and 6.3, respectively. For the second or more failures the relative effects of pipe material/joint type on failure were not conclusive. The degree of land development affected pipe failure for STGs I, II, and V, and the average hazard ratio was estimated as 1.8. The effects of length on failure decreased as more breaks occur and the population in a GRID affected the hazard rate of the first pipe failure.

• Journal of Korean Society of Water and Wastewater
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• v.23 no.3
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• pp.305-313
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• 2009

This paper provides a method for evaluating a residual life of water mains using a proportional hazard model(PHM). The survival time of individual pipe is defined as the elapsed time since installation until a break rate of individual pipe exceeds the Threshold Break Rate. A break rate of an individual pipe is estimated by using the General Pipe Break Model(GPBM). In order to use the GPBM effectively, improvement of the GPBM is presented in this paper by utilizing additional break data that is the cumulative number of pipe break of 0 for the time of installation and adjusting a value of weighting factor(WF). The residual lives and hazard ratios of the case study pipes of which the cumulative number of pipe breaks is more than one is estimated by using the estimated survival function. It is found that the average residual lives of the steel and cast iron pipes are about 25.1 and 21 years, respectively. The hazard rate of the cast iron pipes is found to be higher than the steel pipes until 20 years since installation. However, the hazard rate of the cast iron pipes become lower than the hazard rates of the steel pipes after 20 years since installation.

• Journal of Korea Foundry Society
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• v.13 no.1
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• pp.42-49
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• 1993

Conventional manufacturing process for cast iron-babbitt metal composite is complicate and bimetallic bonding by centrifugal casting is also difficult because their melting point is largely different and nonmetallic inclusion exists on outer shell. This study is aiming to simplify multistage process by adding Cu-powder as insert metals during cast iron solidification. The variables on fabrication of composite pipe are mold rotating speed and inner surface temperature of outer metal. The optimum temperature range for fusion bonding between cast iron and Cu-layer was $1100^{\circ}C-1140^{\circ}C$ in case of mold rotating speed was 700rpm. When the inner surface of Cu-layer was at $900^{\circ}C$, the value of interfacial hardness between Cu-layer and babbitt metal were higher than Cu-matrix by forming diffusion layer, interfacial products between Cu-layer and babbitt metal are proved to be $Cu_6Sn_5({\eta})$by XRD.

• Journal of Korean Society of Water and Wastewater
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• v.37 no.4
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• pp.203-214
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• 2023

In this study, the physical properties and fracture characteristics according to the tensile load are evaluated on the materials of the polymeric filler and carbon fiber-based composite sleeve technique. The polymeric filler and the composite sleeve technique are applied to areas where the pipe body thickness is reduced due to corrosion in large-diameter water pipes. First, the tensile strength of the polymeric filler was 161.48~240.43 kg_f/cm², and the tensile strength of the polyurea polymeric filler was relatively higher than that of the epoxy. However, the tensile strength of the polymeric filler is relatively very low compared to ductile cast iron pipes(4,300 kg_f/cm²<) or steel pipes(4,100 kg_f/cm²). Second, the tensile strength of glass fiber, which is mainly used in composite sleeves, is 3,887.0 kg_f/cm², and that of carbon fiber is up to 5,922.5 kg_f/cm². The tensile strengths of glass and carbon fiber are higher than ductile cast iron pipe or steel pipe. Third, when reinforcing the hemispherical simulated corrosion shape of the ductile cast iron pipe and the steel pipe with a polymeric filler, there was an effect of increasing the ultimate tensile load by 1.04 to 1.06 times, but the ultimate load was 37.7 to 53.7% compared to the ductile cast iron or steel specimen without corrosion damage. It was found that the effect on the reinforcement of the corrosion damaged part was insignificant. Fourth, the composite sleeve using carbon fiber showed an ultimate load of 1.10(0.61T, 1,821.0 kg_f) and 1.02(0.60T, 2,290.7 kg_f) times higher than the ductile cast iron pipe(1,657.83 kg_f) and steel pipe(2,236.8 kg_f), respectively. When using a composite sleeve such as fiber, the corrosion damage part of large-diameter water pipes can be reinforced with same level as the original pipe, and the supply stability can be secured through accident prevention.

• Proceedings of the Korean Sanitation Conference
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• 2001.11a
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• pp.119-140
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• 2001

This experiment from March 1, 1998 to August 31, 2001 through XRD, XRF, SEM, EDS had effects as follows. 1. According to the results of test using XRD and EDS, we found that the main ingredients causing corrosion of steel pipe was ${Fe_2}{O_3}$, that of cast iron pipe was $CaCO_3$. 2. The main ingredient of corrosion products in a water pipe was Fe. On an average Fe occuied 93.36% of corrosion products in case of steel pipe while it did 85.47% in case of cast iron pipe. 3. In case of a piped water passed through SCALE BUSTER over 10 times, the corrosion products decreased largely by the galvanic effect and sacrifical anode caused by the concerntration of Zn.

• Journal of Environmental Science International
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• v.8 no.1
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• pp.45-50
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• 1999

Four cast iron pipe sections containing 3 styrene butadiene rubber (SBR) gaskets (1 joint and 2 end caps) were filled with water and maintained at approximately 40 psi internal pressure. The pipe sections were placed inside 16 gallon drums filled with initially clean sand. Three of the tanks were subsequently contaminated with gasoline, gasoline spiked with pyrene and naphthalene, and toluene. The forth tank served as a control. The water inside each pipe was monitored over time for organic chemical contamination. Permeation of organic chemicals into the water inside the pipe systems was found to occur in all 3 contaminated pipe systems after approximately 100 days as measured organic chemicals concentrations were significantly above those in the uncontaminated cell. Flushing experiments in which the water inside the contaminated pipes was replaced with initially clean water showed that organic chemical concentrations inside the pipe rapidly (12 days) reached their preflushing levels.

• Journal of Korea Foundry Society
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• v.18 no.4
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• pp.334-339
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• 1998