Ductile Iron

Pipeline Systems
Design Manual

your pipeline partner

 Tyco Water (formerly Tubemakers Water) is widely
recognised as Australia’s premier supplier of pipeline
systems to the Water Industry.
Tubemakers of Australia Limited was formed in
1946 as a holding company to consolidate the various
interests of BHP, Stewarts and Lloyds and Tube
Investments, however its origins date back to the late
1800’s. The group was restructured in 1969 to provide
for public listing and in 1996 BHP acquired full
ownership of Tubemakers.
Tyco International Ltd acquired Tubemakers Water
from BHP in 1999. The Company now trades as Tyco
Water Pty Ltd, a member of the Tyco Flow Control
Asia Pacific group.
Tyco International Ltd is a diversified company that
provides vital products and services to customers in
more than 60 countries around the world.Tyco is a
leading provider of electronic security and fire control
products and services along with valves and controls
and other industrial products.
Tyco Water is proud of its long history of
involvement in the Water Industry and boasts an
experienced and professional workforce which
contributes to its recognised status as industry leader.
The history is one of commitment to our
customers and delivering benefits in meeting
customer needs. Tyco Water strives to maintain the
tradition in endeavouring to be your pipeline partner.
Ductile Iron Pipeline Systems – Tyco Water

DI:1
 Foreword
Our communities today depend heavily on the
integrity and continuity of water and sewerage
systems in domestic, industrial and mining fields.
For any application, an engineer requires a
pipeline which will meet operating conditions
without undue risk of damage or failure. These
conditions embrace the flow requirements,
operating pressure, external loads due to earth
pressure, transient loads due to vehicles as well
as risks of damage during handling, transport and
installation.
The inherent properties of ductile iron
combined with easy to apply corrosion protection
systems ensure that ductile iron pipelines provide
the answers to all the conditions encountered in a
water supply system as well as many other
industry applications.
Over the past 40 years, there have been
many significant developments in TYTON® Ductile
Iron Pipeline Systems covering the full spectrum
of materials, manufacturing, quality assurance,
products, services, feedback systems, design,
distribution, along with handling & installation.
TYTON 2100 Series packages a range of
products and services, which are new or have
significant enhancements. For example, production
improvements focused on statistical process
control have yielded greater consistency in all
product attributes.
The result? Clearly defined, differentiated pipe
pressure classes designed to meet evolving water
industry needs.

Scope
Ductile iron pipelines are used for the
transmission of water, wastewater, drainage, raw
water, effluents, slurries and various other fluids.
This manual deals essentially with water
industry applications. It has been compiled to
assist pipeline designers, specifiers and operators. Ductile Iron Pipeline Systems – Tyco Water
It is not intended to be a comprehensive
treatise on all aspects of ductile iron pipeline
design but a compendium of information, data,
useful guidelines and procedures.

DI:2
 AS/NZS 2280-2004 Included in the
Ductile Iron revised Standard are
details for:
Pipelines  Standard pipe
– a working pressure classifications
class revolution of PN 20 and PN 35;
 Flange Class pipe,
AS/NZS 2280 the a thick walled pipe for
Australian Standard for use with screw-on
ductile iron pipes and flanges.
fittings was published on
The old K9
the Standards Australia
classification pipe is
website on August 25th as
replaced largely by
AS/NZS 2280 : 2004. The
PN 20 and PN 35,
revision covers numerous
whilst the old K12 pipe
changes and improvements,
is replaced by Flange
the principal one however is
Class pipe. Fittings are
a ‘working class revolution’.
classified as PN 35,
The Standard moved to classify pipes and fittings by replacing the old K14
pressure rather than wall thickness. This change is classification.
somewhat of a revolution. Standard fittings are
Minimum wall thicknesses are determined by
classified PN 35 and fittings wall thicknesses remain
the Barlow formula. It describes the relationship
unchanged. The
between the internal fluid pressure and the stress
superseded K
in the pipe wall. Nominal wall thicknesses take into
classification was
account manufacturing tolerances.
first introduced into
Australia in 1978, AS/NZS 2280: 2004 Ductile iron pipes and
along with ductile fittings represents state-of-the-art ductile iron
iron pipes and pipe and fittings requirements defining fitness for
fittings. purpose. Since the previous revision of the Standard
The changes in 1999, significant advancements have been made
contained in the in manufacturing technology to allow improved
Standard have been process control. Extensive application of
endorsed by a programmable logic controllers has reduced
variety of industry variability and led to improved product.
stakeholders, The water industry is constantly demanding
including peak continuous improvement and the changes included
industry bodies, in this Standard set the scene for significant
manufacturers, benefits. More efficient use of materials, decreased
designers, pipeline mass, bigger bores, reduced head loss, increased
installers, operators flows and lower pumping costs will deliver those
and asset owners. savings for our vital infrastructure.
Ductile Iron Pipeline Systems – Tyco Water

DI:3
 It demonstrates
compliance with
environmental laws and
regulations and undergoes
certification by an external
third party organisation.
ISO 14001 is an
internationally recognised
system for environmental
management and is a key
plank in Tyco Water's
business management.

Quality
Assurance
To consistently satisfy
the expectations of our
customers, Tyco Water
places great importance
on the maintenance of
product quality through
Green the operation of Quality Systems in accordance
with ISO 9001.
credentials
Our Quality Systems have
In August 2005, the Tyco been assessed and accredited by an
Water Yennora Ductile Iron Pipe independent certified body who, as part
Plant received certification of its of the Supplier Assessment Scheme,
Environmental Management System to audit each plant annually.
AS/NZS ISO 14001:2004. Certification marked the end In 1987, the Yennora facility was the
of the formal process of structuring and documenting first manufacturing plant in the water
ISO 9001 Lic 0015
the existing environmental management system to industry to be registered to AS 1822 - SAI Global

meet the requirements of the international standard. Suppliers Quality Systems. It is currently registered
It also capped the site’s commitment to environmental to AS/NZS ISO 9001 - Quality Systems for Production
improvement over the past 15 years. Certification and Installation producing pipes to product standards
ensures that all the gains achieved during this time AS/NZS 2280 and BS/EN 545 and BS/EN 598.
are locked in place. Documented procedures are followed for all
In over 40 years of operation, the manufacturing aspects of a plant’s operation from receipt of order
facility has recycled 2.5 million tonnes of scrap and through design, purchasing, manufacture, inspection
waste steel – enough to fill 2,000 football fields – to and delivery. Adherence to these procedures is
produce 55,000 kilometres of iron pipe which has been determined by internal Quality Assurance Audits
laid in more than a dozen countries around the world. conducted by trained auditors.
Ductile Iron Pipeline Systems – Tyco Water
Striving for a greener future Lean manufacture – ‘Six Sigma’

Ductile Iron Pipeline Systems are a significant Tyco Water has long been focused on continuous
contributor to the sustainability of our environment, improvement in its people, processes, products and
with the base iron for pipes and fittings being sourced services. Today the philosophy of TQM is carried on
from 100% scrap steel. We’re turning scrap into assets in the business under the principles, practices and
using less energy and thereby minimising greenhouse methodologies of ‘Lean Manufacturing’ and ‘Six Sigma’.
gas emissions. Lean production is aimed at the elimination of waste. Its
goal is to minimise consumption of resources and to
become highly responsive to customer demand while
ISO 14001
producing top quality products in the most efficient and
The Yennora Manufacturing Facility is certified to economical manner possible. The goal of Six Sigma is to
ISO 14001 by SAI Global. The facility operates within an eliminate variability, defects and failures that undermine
environmental management system applied to those customer loyalty. Six Sigma provides Tyco Water with
environmental aspects that it controls and influences. the tools to improve the capability of its business
It implements, maintains and improves the processes. This increase in performance and decrease in
environmental management system to ensure process variation leads to defect reduction and vast
conformance with its own stated environmental policy. improvement in employee morale and quality of product.
DI:4
 The Tyco Water
ductile iron pipe
manufacturing
facility at Yennora,
New South Wales

Yennora manufacturing facility Century Plus II

Located about 35 kilometres west of Sydney, the Through the Century Plus® Accreditation
Yennora facility commenced production in 1962 making Programme for pipelayers, Tyco Water is ensuring
grey cast iron pipes and converted to ductile iron pipe that its products are installed and maintained to
manufacture in 1976 to take advantage of the superior achieve the highest probability of providing a service
mechanical properties of ductile iron. life of at least 100 years.
TYTON joint pipes are
produced by the centrifugal
casting process to a standard
length of 5.5 metres, in the
range DN 100 to DN 750.
Ductile Iron Pipeline Systems – Tyco Water

Currumbin valves
and fittings
manufacturing
facility
The Tyco Water pipeline
components manufacturing
facility utilises modern
automatic moulding and
coremaking equipment together
with induction melting facilities
in the production of ductile iron
fittings and valves. Quality
control is assisted by means of
spectrometer analysis for metal
specification and final
mechanical property verification.
DI:5
TYTON® 2100 Series
D U C T I L E I R O N P I P E L I N E S Y S T E M S

Over the past 40 years, there have been many

significant developments in TYTON Ductile Iron
Pipeline Systems covering the full spectrum of
materials, manufacturing, quality assurance,
products, services, feedback systems, design,
distribution, along with handling & installation.
TYTON 2100 Series packages a range of
products and services, which are new or have
significant enhancements. For example, production
improvements focused on statistical process
control have yielded greater consistency in all
product attributes.
The result? Clearly defined, differentiated pipe
pressure classes designed to meet evolving water
industry needs.

TYTON pipe and

TYTON fittings
rubber ring joint
The TYTON rubber ring push-in joint is the most
robust flexible pipe joint available. It features a
single, specially shaped rubber gasket, in which the
heel of hardened rubber locates and anchors itself
in the groove of the TYTON pipe socket. The rubber
ring also has a sealing bulb of softer rubber, firmly

TYTON 2100 Series – Ductile Iron Pipeline Systems – Tyco Water

bonded to the heel. This achieves the required seal
against the inserted pipe spigot. This tried
and proven jointing system has
been used worldwide
for more than
50 years.

DI:6
 TYTONXTEND
When it comes to mine subsidence, embankment
TYTONXCEL slippage, soil settlement or ground movements,
TYTONXTEND is without comparison. Based on
Driven by pressure the quintessential TYTON pipe joint, TYTONXTEND
classification, TYTONXCEL is an exciting new concept incorporates an extended socket throat, accommodating
in ductile iron pipe design reflecting state-of-the-art erratic and unpredictable ground strain in axial and
manufacture and evolving water industry needs. rotational movement. The pipeline’s integrity is
By introducing pressure classes PN 20 and PN 35, preserved and that vital water or sewer line remains
TYTONXCEL provides efficiency gains and cost savings uncompromised.
TYTON 2100 Series – Ductile Iron Pipeline Systems – Tyco Water

without sacrificing the time proven superior

performance capabilities associated with
ductile iron pipeline systems. TYTONXCEL
delivers …
 Increased bores
• increased flows
• reduced head loss
• lower pumping costs,
 Decreased mass
• more pipes per truck
• faster laying
 Increased efficiency
• reduced cost
• more savings

TYTONXTREME
Gravity sewers are one of the toughest
environments in the water game. H2SO4 is
a dark master. Other industries offer similar
nasties, including the extremes of pH and
abrasion, all handled by TYTONXTREME.
It also carries extremes of pressure, from
positive to negative, sealing in the nasties
and keeping out infiltration. Peerless!
DI:7
 The TYTON gasket All these challenges can be overcome with the
TYTON-LOK Restrained Joint System. TYTON-LOK is
TYTON JOINT ductile iron pipes and fittings are the key to fast track design and construction of ductile
normally jointed with the TYTON gasket manufactured iron pipeline systems.
to AS 1646 - Elastomeric seals for waterworks
purposes. The TYTON JOINT pipe compresses an
elastomeric sealing ring between the spigot and socket
ends of individual pipe lengths. TYTON gaskets consist
of two elastomeric compounds, a soft ‘bulb’ to provide
the compression sealing ring and a hard ‘heel’ to anchor
the ‘bulb’ in the pipe socket during installation and any
subsequent pressurisation of the pipeline.

TYTON gaskets are formed from the elastomeric

compounds by chemically linking long chain polymers in
a thermal process called vulcanisation or curing.
Appropriately cured elastomers exhibit resilient
elastomeric behaviour allowing long life positive jointing
to cope with pipe tolerances and misalignment.

BLUEBOSS®
TYTON-LOK
Sleeving is the most cost
Would you like to eliminate thrust blocks? effective external protection system. Continued
… realise construction savings in time and materials? improvements including the move to Linear Low
Imagine … negotiating crowded service Density Polyethylene, CENTURY PLUS and Pipeline
trenches, meeting impossible deadlines Installation Quality System (PIQS), have bolstered its
for hydrotesting, avoiding late reputation. Enter BLUEBOSS, the new generation of
commissioning and Loose Polyethylene Sleeving (LPS). Formulated with
the nightmare metallocenes, BLUEBOSS is tougher, with higher

TYTON 2100 Series – Ductile Iron Pipeline Systems – Tyco Water

of weak soils tensile and impact strength combined with higher
that cannot resistance to ultra violet radiation. BLUEBOSS offers
bear any even more security for ductile iron pipelines in
pressure. aggressive soil environments. Protection for a lifetime!

DI:8
 HYDROLINE®
HYDROLINE is a registered name for a family of
linings that protect and enhance the bore of ductile
iron pipeline systems. They range from proven systems
such as ordinary Portland cement and bituminous
coatings to new developments such as calcium
aluminate cement and polymeric coatings for
aggressive conveyants.
The HYDROLINE family of internal
linings offers reduced costs,
increased benefits and
increased
customer
satisfaction.

CENTURY PLUS II
Tyco Water places a major emphasis on quality
pipeline systems and supports the total quality of
ductile iron pipeline systems by way of quality
TYTON 2100 Series – Ductile Iron Pipeline Systems – Tyco Water

installation training and accreditation for pipeline

installers.
The CENTURY PLUS pipeline installation course was
introduced over 15 years ago and to date has trained in
excess of 5,000 pipelayers, designers, project
managers and asset owners.
CENTURY PLUS II is an ever evolving training course
that includes the latest in industry improvements and
safety legislation.

DI:9
The Development of
Ductile Iron Pipeline Systems
D U C T I L E I R O N P I P E L I N E S Y S T E M S

Cast iron pipe has been used to carry water

for centuries. In fact, the earliest authentic
recorded use of cast iron in a water main was in
Germany in 1455. An
outstanding example of an
early cast iron main is one
laid between the years 1664
and 1668 to supply water to
the fountains in the Palace
Gardens at Versailles and
the town of Versailles. The
pipeline provided more than
300 years of continuous
service.

The Development of Ductile Iron Pipeline Systems – Ductile Iron Pipeline Systems – Tyco Water
At left, cast iron pipe
installed in the 1660’s
in Versailles. At right,
Louis XIV, Le Roi Soleil.
The production of iron
for the Versailles pipeline
required the use of
expensive charcoal for the reduction of the iron
ore. However, by 1738 success had been achieved
in the production of lower cost iron through the
use of coke instead of charcoal. From this date the
more progressive cities installed cast iron mains.
Cast iron has also enjoyed a lengthy service
record in Australia. Cast iron pipe was used as
early as the 1840s in Sydney to supply water
from local swamps.
A far more extensive water distribution system
consisting of cast and wrought iron was well under
way in Sydney by 1880. In Melbourne, the Morang-
Preston main connecting Yan Yean Reservoir to
the city was laid in 1857 as part of Melbourne’s
first permanent water supply and after almost 150
years was replaced in 2006.
Other mains of similar vintage are still in
service. In the Hunter District of NSW the major
portion of a line laid in 1885 is still operational.
In fact, cast iron mains that were laid around the
turn of the century are still in use in many areas.
All early pipes were cast horizontally in sand
moulds but in 1846 the improved technique of
vertical casting was introduced.
The use of centrifugal force in the manufacture
of hollow metal bodies was known in 1809, but
it was not until 1914 that Fernando Arens Jr. and
Dimitri Sensaud de Lavaud proved the commercial
feasibility of centrifugally casting iron pipes in long
lengths. The production of spun iron pipe in water-
cooled steel moulds began in 1921.
DI:10
The Development of Ductile Iron Pipeline Systems – Ductile Iron Pipeline Systems – Tyco Water

Vertical sand-casting in a pipe pit.

Pipes are cast by introducing molten metal

into a revolving water-cooled steel mould, in which
centrifugal force holds the metal against the sides of
the mould. As the mould requires no preparation
between casting one pipe and the next, casting is
practically continuous and in this way, a very high
level of production is maintained.
Spun cast iron pipe was first produced in
Australia in 1929 at A.I. & S., Port Kembla in the
size range DN 80 to DN 500, with an effective length
of 3.66 metres. Production continued at this plant
until 1962 when Tubemakers (today Tyco Water)
established a modern plant at Yennora, New South
Wales to produce spun grey cast iron pressure pipe
in the size range DN 80 to DN 600, with an effective
length of 5.5 metres. The Yennora pipe plant was
converted to the production of ductile iron pipe in
1976.

DI:11
 TYTON 2100 Series
Ductile Iron Pipeline Systems
Design Manual 5
This document has been prepared as a revision of the Tyco Water
Ductile Iron Pipeline Systems Design Manual, Fourth Edition, 2000 and
incorporates the TYTON 2100 Series products and services.
It has been prepared by Tyco Water to assist qualified engineers
and contractors in the selection of the Company's product, and is not
intended to be an exhaustive statement on pipeline design, installation
or technical matters. Any conclusions, formulae and the like contained
in the manual represent best estimates only and may be based on
assumptions which, while reasonable may not necessarily be correct
for every installation.
Successful installation depends on numerous factors outside
the Company's control, including site preparation and installation
workmanship. Users of this manual must check technical developments
from research and field experience, and rely on their knowledge, skill and
judgement, particularly with reference to the qualities and suitability of the
products and conditions surrounding each specific installation.
The Company disclaims all liability to any person who relies on the
whole or any part of this manual and excludes all liability imposed by
any statute or by the general law in respect of this manual whether
statements and representation in this manual are made negligently or
otherwise except to the extent it is prevented by law from so doing.
The manual is not an offer to trade and shall not form any part of
the trading terms in any transaction. Tyco Water’s trading terms contain
specific provisions which limit the liability of Tyco Water to the cost of
replacing or repairing any defective product.

Previous Editions
First Edition 1981
Second Edition 1986
Third Edition 1995
Fourth Edition 2000
Addendum 1 2004
Addendum 2 2005

Copyright Tyco Water Pty Ltd

This manual is a publication of Tyco Water Pty Ltd,
ABN 75 087 415 745, and must not be copied or reproduced in whole
or part without the Company's prior written consent.
This manual is and shall remain as the Company's property and shall
be returned to the Company on its request. The Company reserves the
right to make changes to any matter at any time without notice.
The words TYTON®, TYTON-LOK® and TYTON JOINT® are United
States Pipe and Foundry Co. Inc. trademarks and are registered as such
in the United States Patent Office and some 45 other countries. Tyco
Water is an exclusively authorised and licensed user of these trademarks
within Australia and New Zealand. BLUEBOSS® and HYDROLINE® are
registered trademarks of Tyco Water Pty Ltd. Ductile Iron Pipeline Systems – Tyco Water
September 2008

DI:12
 Tyco Water
Ductile Iron Pipeline Systems
Design Manual

Registration of Volume No.

Organisation

Address

e-mail

Telephone

Facsimile

Registrant Name

Position
Ductile Iron Pipeline Systems – Tyco Water

Date Registered

This volume consists of pages

Introduction – DI:1 to DI:15
Component Data – 1:1 to 1:66
Design Guidelines – 2:1 to 2:80
Handling and Installation – 3:1 to 3:62
Appendix

DI:13
 Contacts
D U C T I L E I R O N P I P E L I N E S Y S T E M S

Web site Regional marketing offices

Members area
Brisbane
This Manual, related literature and interactive
software are available from the Tyco Water Ductile For Queensland
Iron Pipeline Systems – Members Area web site. 39 Silica Street, Carole Park 4300
Application for membership can be iniated through PO Box 162 Carole Park, Queensland 4300
the website. A subsequent security check protects
Telephone 07 3712 3666
the site from ill-intentioned parties. Membership
assessment normally takes two working days. This Facsimile 07 3271 3128
can be expedited on request. e-mail rmob@tycowater.com
http://www.tycowater.com/ductile_iron_pipelines
Sydney

Divisional office For New South Wales

& Australian Capital Territory
Tyco Water Pty Ltd 1-21 Percival Road, Smithfield 2164
ABN 75 087 415 745 PO Box 141 Fairfield, New South Wales 1860
1-21 Percival Road, Smithfield 2164 Telephone 02 9612 2470
PO Box 141 Fairfield, New South Wales 1860

Contacts – Ductile Iron Pipeline Systems – Tyco Water

Facsimile 02 9612 2471
Telephone 02 9612 2470 e-mail rmos@tycowater.com
Facsimile 02 9612 2471
e-mail info@tycowater.com Melbourne
For Victoria, Tasmania,
www.tycowater.com
South Australia & Northern Territory
60A Maffra Street, Coolaroo 3048
PO Box 42 Dallas, Victoria 3047
Telephone 03 9301 9115
Facsimile 03 9309 0577
e-mail rmom@tycowater.com

Perth
For Western Australia
70 Cleaver Terrace, Belmont 6104
PO Box 385 Cloverdale, Western Australia 6105
Telephone 08 9346 8555
Facsimile 08 9346 8501
e-mail rmop@tycowater.com
DI:14
 Customer centres Melbourne
– Australia 60A Maffra Street, Coolaroo 3048
PO Box 42 Dallas, Victoria 3047
Townsville Telephone 03 9309 9133
19-29 Corporate Crescent, Garbutt 4814 Facsimile 03 9309 6237
PO Box 7860 Garbutt, Queensland 4814 e-mail ccm@tycowater.com
Telephone 07 4725 5940
Adelaide
Facsimile 07 4725 4995
20 Taminga Street, Regency Park 5010
e-mail cct@tycowater.com
PO Box 644 Enfield Plaza, South Australia 5085
Brisbane Telephone 08 8340 3411
88 Frederick Street, Northgate 4013 Facsimile 08 8340 3422
PO Box 308 Virginia, Queensland 4014 e-mail cca@tycowater.com
Telephone 07 3266 2255
Perth
Facsimile 07 3260 5221
70 Cleaver Terrace, Belmont 6104
e-mail ccb@tycowater.com
PO Box 385 Cloverdale, Western Australia 6105
Gold Coast Telephone 08 9346 8500
63 Currumbin Creek Road, Currumbin 4223 Facsimile 08 9346 8501
PO Box 150 Currumbin, Queensland 4223 e-mail ccp@tycowater.com
Telephone 07 5589 4400
Facsimile 07 5534 7079 Customer centres
e-mail ccg@tycowater.com – New Zealand

Newcastle Auckland
14 Yangan Drive, Beresfield
8 Fisher Crescent, Mt Wellington, Auckland
New South Wales. 2322
PO Box 12169, Penrose, Auckland
Telephone 02 4966 0140
Telephone 9 921 7230
Facsimile 02 4966 8776
Facsimile 9 921 7231
e-mail ccn@tycowater.com
email dtonge@tycoflow.co.nz
Sydney Wellington
1-21 Percival Road, Smithfield 2164
54 Hutt Road, Petone, Lower Hutt, Wellington
Contacts – Ductile Iron Pipeline Systems – Tyco Water

PO Box 141 Fairfield, New South Wales 1860

Telephone 04 913 8510
Telephone 02 9612 2400
Facsimile 02 9612 2499 Christchurch
e-mail ccs@tycowater.com 44 Mandeville Street, Riccarton, Christchurch
Telephone 03 968 3260

Dunedin
32-34 McBride Street, Dunedin
Telephone 03 455 5143

DI:15