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PORTLAND CEMENT ASSOCIATION 33 West Grand Avenue, Chicago, Illinois 60610 Tho activities of tho Portland Cement Association are limitod to scientific research, (he development of new or improved products and methods, technical service, promotion and educational effort (including saicty work), and arc primarily designed to improve and extend the uses of Portland cement and concrete. The manifold program of the Association and Us varied services to cement users are made possible by (he financial support of lit member companies in the United States and Canada, engaged in the manufacture and safe of a very (aroe proportion of afi Portland cement used in those two countries. A current list of member companies will be furnished on request. O Portland Cement Association 1M7 Printed in U.S.A. 2 PIPE INTRODUCTION A combination of portland cement, asbestos fibers, and silica produces the unique pipe material, asbestoscement. Asbestos-cement pipe can be manufactured in all the sizes and strengths needed to meet the varied service requirements of the public-works, irrigation, industrial, and home-building industries. An Italian engineer, A. Mazza, first developed an asbestos-cement pipe in 1913. Successful performance in fire protection systems led to rapid acceptance throughout Italy and the spread of asbestos-cement pipe manufacture to England in 1925 and to America in 1929. The strength and durability of asbestos fibers have been known for centuries. The ancient Asiatics, Greeks, and Egyptians used asbestos for its resistance to fire, heat, most acids, the weather, and for its strength and durability. They learned to separate the fibers and weave cloth for clothing and other items. The intimate combination of portland cement and asbestos fibers develops a material that retains many of the inherent characteristics of the separate com ponents. Major uses of asbcstos-ccmcnt pipe arc in water distribution systems and sewage and waste-water col lection and disposal systems for municipal and private utilities; in irrigation and drainage systems for agri culture; and in manufacturing process systems, po table and cooling water lines, and fire protection and waste collection systems for industry. Other important uses are for cable conduits in the electric power and communications fields and for heating, venting, and air-conditioning ducts in industrial and residential construction. Asbestos-cement pipe offers outstanding advantages for use in all types of water conveyance systems. The inherent characteristics of asbestos-cement pipe con tribute to overall economy from design to installation, operation, and maintenance, The long lengths, simple and efficient coupling details, strength, light weight, and corrosion resistance add up to construction and performance satisfaction at minimum cost. The first manufactured pipe were used in gravity iiow systems. Use of asbestos-cement pipe extended to pressure systems as the techniques of manufacture improved to increase the strength characteristics of the pipe. CAPCO JEN 0020890 m.W Above. Watte disposal of acidic mining wator is pumped through asbeslos>coment pipe to an alkaline tailing pond. Courloty Canadian Johns-ManvilU Co. Ltd. Right. Storm drain water installation utilizing a pliant plastic sleeve coupling. Perforated asbestos-cement drain pipe also adapts to this type of joint construction. Coutiaiy Johm-Manrillt. MANUFACTURE Asbestos-cement pipe is manufactured from port- land cement, asbestos fibers, and silica flour. Portland cement is finely ground powder composed of certain chemical compounds. When water is mixed with portland cement, it forms a cementitious paste that, upon hardening, binds materials together into a product with excellent compressive strength. Just as steel re inforcement is used to improve the tensile strength of hardened concrete, asbestos fiber is the reinforcement that provides the necessary tensile strength of asbestoscement pipe. Years of experience have proved that chrysotilc asbestos is most suitable for pipe production, although asbestos mode of other fibers is used to some extent. Individual chrysotilc fibers, derived from a fibrous magnesium silicate, have a diameter of approximately 1 millionth of an inch. The strength of good asbestos fibers is equivalent to the strength of piano wire or to steel threads having a diameter of 40 millionths of an inch. Portland cement, asbestos fillers, and finely ground silica are the ingredients of 20th-Century asbestoscement pipe. The portland cement is thoroughly drymixed with the silica and selected asbestos fibers. Water is added and the wet-mix slurry is moved to a vat. There a rotating cylinder mold picks up a thin film of the mixture and transfers it to a felt conveyor where excess water is removed. Next, the well-mixed, smooth slurry is fed in a thin layer onto revolving steel mandrels and compressed under pressure into a tough, homogeneous structure. The size of the mandrel determines the internal diam eter of the pipe. When the desired wall thickness has been reached, the mandrel is loosened from the newly formed pipe. Up to this point operations for all asbestos-cement pipe, regardless of size, length, or type, are the same except for the mix proportions. The blend used and thickness of the pipe wall depend on the strength re quirements of the finished pipe. After loosening, the pipe and mandrel move slowly along a conveyor until an initial pre-cure hardness is attained. Then the mandrels arc removed and the pipe placed in curing trays in a controlled temperature-humidity room to develop a primary hardness. The pipe is then ready for autoclave curing. In the autoclave curing process, the pipe is placed in a pressure steam curing vessel. The pressure is built up to about 100 lb. per square inch and left under saturated steam conditions for several hours. This causes the finely ground silica to combine chemically with the free lime in the cement to form calcium sili cates. Calcium silicates are highly stable, corrosionresistant compounds. Autoclave curing also imparts maximum strength to the pipe. After curing, the pipe ends are trimmed and ma chined on finishing lathes to exact dimensions to match couplings, thereby ensuring both tightness and case of assembly. All couplings and fittings arc made to the same rigid standards. Quality control is adhered to in all steps of manu facture. All pipe arc checked for compliance with speci fications. Various strength tests arc performed at the factory to assure that the pipe meets the requirements of its intended service. 3 CAPCO JEN 0020891 SPECIFICATIONS In the United States and Canada, rigid specifications for the manufacture of asbestos-cement pipe were de veloped from practically the beginning of pipe produc tion. Today's manufacturers make pipe of various strengths to meet many different design conditions. Asbestos-cement pipe is manufactured to satisfy the chemical and physical properties required for a par ticular service with an ample margin of safety. Precisely controlled dimensions assist materially in installation economy and performance. Users of asbestos-cement pipe arc ensured of a quality product for the job by selecting pipe to fit the job's specific needs. A partial list of specifications of several organiza tions is provided in Table 1. The omission of specifica tions and organizations in this table has no signifi cance. There are many specifications and space docs not permit listing them all. The American Society for Testing and Materials is nationally recognized for, its specifications for many construction materials and processes. The American Water Works Association has developed nationally recognized standards for asbestos-cement pressure pipe usage in the waterworks industries. Other organi zations also prepare specifications for various uses of asbestos-cement pipe. For further information on speci- ficalions, contact the local asbestos-cement pipe repre sentative or a district office of the Portland Cement Association. USES OF ASBESTOS-CEMENT PIPE The type of materials and the manufacturing process give asbestos-cement pipe many advantages in water supply, waste water, irrigation, drainage, and other liquid and air conveyance systems. The many uses of the pipe arc directly related to two distinct categories: pressure pipe and nonpressure pipe, both having ex cellent flow properties. TABLE 1. SPECIFICATIONS CONCERNING ASBESTOS-CEMENT PIPE Organization AWWA AWWA AWWA ASTM ASTM ASTM ASTM ASTM ASTM ASTM AASHO* Federal Spec. Federal Spec. Specification number H2 C40Q C603 C296 C428 C458 C460 C50CC508 Cl 869 M189 SS-P-351a SS-P-331a Title Standard Practice (or the Selection of Asbestos-Cement Water Pipe Tentative AWWA Standard for AsbestosCement Water Pipe Installation of Asbostos-Cement Water Pipe Asbestos-Cement Pressure Pipe Asbostos-Cement Nonpressure Sewer Pipe Organic Fiber Content of Asbestos- * Cement Products Terms Relating to Asbostos-Cement and Related Products Asbestos-Cement Pipe Asbestos-Cement Perforated Underdrain Pipe Asbestos-Cement Pipe, Rubber Rings for Perforated Asbestos-Cement Pipe for Underdrainage Pipe: Asbestos-Cement Pipe: Asbestos-Cement, Nonprossuro AASHO--American Association of State Highway Officials Major subject Loading conditions for wator distribution systems Pressure flow systems Water distribution systems Water, sewage, and other fluids carried under pressure Gravity flow systems Methods of testing Definitions of terms Methods of testing Subsurface drainage systems Pressure and gravity systems Subsurface drainage systems Pressure flow systems Gravity flow systems such as sowors 4 CAPCO JEN 0020892 Asbestos-cement pipo adapt* to winter inttaliation for thi* gravity sewer system. The pipe is bedded on a pea gravel bate in the reeky trench. Covrltiy Altai Asbestos C*. Lid., Canada A cajt-iron valve it a itandard, readily assembled control unit in asbestos-cement pressure water main*. Courtesy ./obits-Manrilta. o The Canton, III., Country Club irrigation system being in stalled with asbestos-cement pipe without interruption to the gelf enthusiast. Courtesy Certain-Teed Products Corp. Pressure-pipe installation shows how readily asbestos-cement pipe adapts in following the contours of the rolling landscape and avoiding obstacles. Courtesy Certoin-Teed Products Corp. CAPCO JEN 0020893 The flow equation most widely used by engineers in pipeline design is the Manning formula, which ex press the relationship of velocity to pipeline charac teristics : V = Id rhs* n where n = measure of surface roughness R = hydraulic radius S = slope of energy gradient V = average velocity The Ilazen-Williams formula is often used in pres sure systems: V = 1.318Cft0li:1Suw where C = measure of surface roughness Asbcstos-ccmcnt pipe has a roughness value of n = 0.010 for the Manning formula and C = 140 for the Hazen-Williams formula. The low roughness value provides the designer a minimum energy loss due to resistance, and therefore maximum economy. Equally important to the designer are the many classes of pipe for both internal and external loading. The pipe is designed, produced, and tested to meet definite strength criteria. The designer can select a pipe with the strength necessary to do the job and be assured of satisfactory performance. Internal pressure strengths are known from hydrostatic tests. External strengths, flexural and crushing, are factory-tested to ensure the required performance. Pressure Pip* Asbestos-cement pressure pipe is designed to carry liquids under pressure. It is widely used in municipal and private water utility service, in industrial service for both underground and overhead supply and waste lines, and in irrigation systems. Special applications include salt water collection and disposal lines in oil fields. Asbcstos-ccmcnt pressure pipe has proved its performance under severe environmental conditions as drainage conduits for mining operations and as force mains in sewage lines. Pressure pipe is manufactured to meet three internal pressure ratings. Each pipe and coupling is designed for sufficient strength to withstand an internal hydro static pressure of four times the rated working pressure for the class of pipe. Class of pipe denotes the internal working pressure. Therefore, Class 100 pipe, is made to withstand internal pressures up to 100 psi; Class 150, 150 psi; and Class 200, 200 psi. A convenient re lationship of pressure and waterhead is provided in Table 2. In addition to the internal pressure, the pipe must withstand both flexural loads and crushing loads. These minimum loads are listed in Tables 3 and 4 for the three classes of pressure pipe. Design criteria for both internal and external loads are specified in AWWA II2, Standard Practice for the Selection of Asbestos-Cement Water Pipe. The method of manufacture of asbestos-cement pipe ensures that the chemical and physical properties will meet the user's specification. Autoclaving virtually eliminates uncombined calcium hydroxide which en sures chemical stability and increases its resistance to corrosive elements. The cured pipe is trimmed and ma chined to required dimensions. Precisely controlled di mensions assist materially in installation economy and performance. i TABLE 2. HYDROSTATIC PRESSURE FOR DIFFERENT WATERHEADS Waterhead, ft. Hydrostatic pressure, psi 10 20 30 40 ! SO 60 : 70 80 90 100 150 ; 200 \ i__ _____ ____ . . -- 4.33 8.67 13.00 17.33 21.67 26.00 30.33 34.67 39.00 43.33 65.00 86.67 i TABLE 3. FLEXURAL STRENGTH OF ASBESTOS-CEMENT PRESSURE PIPE (AWWA C400-64T) Nominal diameter, in. Total applied load, lb.* Class 100 Class 150 Class 200 4 1,200 1,460 1,860 6 2,800 3,700 4,900 8 5,330 7,600 10,130 'Loads applied according to AWWA (C400) lloxural test procedure. 6L CAPCO JEN 0020894 TABLE 4. CRUSHING STRENGTH OF ASBESTOS-CEMENT PRESSURE PIPE (AWWA C400-64T) . Nominal diameter, in. Applied load, lb per foot* Class 100 Class 150 Class 200 t TABLE 5. NOMINAL SIZE AND CRUSHING STRENGTH OF ASBESTOS-CEMENT NONFJRESSURE SEWER PIPE (ASTM C428-64T) Pipe class Applied load. lb. per foot* * Nominal diameter, in. 4 6 8 10 12 14 IS 18 , 20 24 [ 30 38 4,100 4,000 4,000 4,400 5,200 5,200 5,800 6,500 7,100 8,100 9,700 11,200 5,400 5,400 5,500 7,000 7,600 8,600 9,200 10,100 10,900 12,700 15,900 19,600 8,700 9,000 1 .1,500 9,300 11,000 2,400 11,800 13,500 3,300 15,400 17,400 19,400 ; 4,000 22,600 28,400 5,000 33,800 1,500 2,400 3,300 4,000 5,000 6, 8,10, 12,1.4,16 . \ 6,8,10,12,14,16,18, 20, 24 6, 8, 10, 12, 14, IS, 18, t 20, 24, 30 ; 10, 12, 14, 16, 18, 20, 24, 30, 36 10, 12,14, 16, 16, 20, 24, 30, 36 7 ...- . Load* applied according to AWWA (C400) crushing toal procedure. i `Load* applied according to ASTM (C500) crushing itrength tost procedurs. Nonpressure Pipe There arc many classes and types of nonpressure pipe produced for private, municipal, federal, and in dustrial use. Nonpressure pipe serve many functions, such as gravity flow sewage conduits, underdrain pipe, storm drains, gas and plumbing vents, air ducts, and electrical transmission cable conduits. The pipe is pro duced to best fit the job application, including its chem ical and physical requirements. The ASTM C428 specification for asbestos-cement nonpressure sewer pipe can be used as a guide to the properties of nonpressure pipe. Aslicstos-ccmcnt pipe in this specification arc designated as Classes 1,500, 2,400, 3,300, 4,000, and 5.000. The numbers refer to the minimum crushing strength in pounds per foot for each class. Pipe sizes, classes, and strength require ments arc given in Table 5. Another ASTM strength test determines the ability of asbestos-cement nonpressure pipe to withstand bending or flexure. Each standard length of 6- and 8- in.-diameter pipe is required to withstand a minimum total flexural load as indicated in Table 6. In addition to external strength requirements, the pipe must have sufficient internal strength to with stand hydrostatic pressure of 50 psi. In the hydrostatic pressure test the pipe must show no signs of leaking, weeping, or cracking. In each class designation three types of pipe arc available with different allowable percentages of uncombincd calcium hydroxide. Type I pipe cannot have more than 3 percent uncombined calcium hydroxide; Type II, 1 percent; and Type III, no limitation. These allowances arc particularly im portant in corrosive water-sewerage conditions. Variations of nonpressure pipe requirements can be specified when pipe is for use other than in gravity sewer systems. Reference can be made to manufac turers' specifications for the strength characteristics of pipe used in air ducts, electrical conduits, and many other systems. 7 CAPCO JEN 0020895 TABLE 6. FLEXURAL STRENGTH OF ASBESTOS-CEMENT NONPRESSURE SEWER PIPE (ASTM C428-64T) Nominal diamotor, in. Length, ft. Class 1,500 Total appliod load, lb.* Class 2,404 Class 3,300 6 16 8 8 10 1,500 1,700 2,100 13 2,000 2,200 2,600 . 10 2,700 3,000 3,900 13 3,600 4,100 4,800 - `Load* applied according to ASTM (CSOO) flexure ilrength tett procedure. Joinlt Joints and jointing methods are important in any pipe installation. Manufacturers of asbestos-cement pipe supply a complete range of accessories for quick installation and safe, efficient performance of a pipe system. Couplings for high-pressure systems are machined from the same pipe stock as the various classes of pipe. Straight-line joints are made virtually watertight`by a rubber sealing ring that fits the machined pipe and couplings. Equally as important as the joints is the easy adaption of cast iron valves, elbows, tees, etc., into an asbestos-cement pipeline. Use of plastic and rubber formed materials assists in construction of air duct pipe systems and storm drains. Asbestos-cement fittings also are available from these systems. Joint material and details are selected from the manufacturers' lists to best fit the needs of the installation. INSTALLATION Installation of asbestos-cement pipe proceeds swiftly. The combination of light weight, standard long lengths, and efficient couplings permits rapid construction. The pipe is easy to handle when trucking, moving, and installing, often resulting in small work crews. Pipe installations are further simplified with flexible joints that let the pipe readily conform to gradual changes in alignment and grade. The precision couplings speed assembly and ensure watertightness in water and sewage lines. Rubber com pression rings and machined couplings are pushed or pulled together with little difficulty. In addition, the couplings are designed to provide joint flexibility in the line to absorb deflection, curvature, severe vibra tion, and subsidence--and still remain watertight. Asbestos-cement pipe can readily be drilled and tapped with ordinary waterworks tools to make service connections. When necessary, the pipe is easily cut and machined for connections to valves, fittings, hy drants, or other junctions. A wide range of shopfabricated tees, wyes, and elbows simplify sewer, drain, irrigation, building sewer, air duct, and conduit line connections. Watertightness is essential in water and sewage systems. The joint couplings and the pipe are thor oughly tested to ensure watertightness. The designed tightness, ensured with compression rubber rings, as sures the engineer that the pipeline will meet rigid field infiltration tests. Coupling assemblies for both pressure and non pressure pipe service are easily made. Other joints of tapered sections, plastic sleeves, and wraparound tapes have serviceability for other uses of asbestos-cement pipe. There is an asbestos-cement pipe and pipe cou pling specifically designed for each use. From highpressure water mains to air conduits, the pipe and pipe couplings assure easy, rapid, durable, and economic construction. 8V CAPCO JEN 0020896 I L- 1 * Plant-manufactured tees, wyes, and couplings permit rapid House sewer line connections are easily accomplished with installation of industrial sewer drains. Cevrluty The Plintkofu Co. asbestos-cement pipe. The machined end is lubricated. ou pling with rubber gasket is positioned and pushed on with pry bar and block of wood* Co*rtosy Corfain*T#d Products Corp. Lubricant being applied to the end of a water pressure pipe to facilitate assembly. Covriusy Thu Flintkotu Co. A rubber compression ring ensures watertightness and flexi- bility of the pipe system. Courtesy Thu FUntkoiu Co. 9 CAPCO JEN 0020897 A taction of pipa i easily aligned and assembied by two man. They are laying pipe at fast at th trench it being dug. Cowftiy Flintkatw Co. Thit bank of atbettat-mrtt pips will eniure watertightneti for oltctrical cabltl. Courftiy Canadian Jahnt-Mamillt Co. Ltd. OPERATIONAL ADVANTAGES Asbestos-cement pipe offers many operational ad vantages over steel or cast-iron pipe. In water supply systems, transmission costs are held to a minimum because asbestos-cement pipe offer little resistance to flow. Pumping efficiency is maintained because as bestos-cement pipe will not tuberculate or rust, which causes an increase in roughness and decrease in pump efficiency. Similar efficiency and savings are secured in force mains for sewage lines and in irrigation pump ing systems utilizing asbestos-cement pipe. Water sup ply lines arc secured against excessive water loss and pressure reductions. Water is delivered when needed and at the required pressure with optimum economy. Infiltration of water into sewage and storm drain lines often encroaches on the design capacity of the line. However, an asbestos-cement pipe system reduces the waste-water treatment plant load by keeping out this excess water that would have to be treated in systems of lesser quality construction. Moreover, wa tertightness prevents exfiltration of sewage and pollu tion of the groundwater through which many sewage lines must be built. In some areas the groundwater is used for residential, commercial, and industrial use; if it becomes polluted, it must have some type of treatment. The watertight asbestos-cement pipeline truly represents an operational saving. MAINTENANCE ADVANTAGES Watertight asbcstos-ccmcnt pipe keeps out tree roots, a perpetual maintenance problem in many under ground pipeline systems. Further maintenance econ omics are gained because asbcstos-ccmcnt pipe's strength, smooth interior surface, and tight flexible joints provide a pipeline that stays sound and tight, requiring less frequent inspections. 10 I V' CAPCO JEN 0020898 Because of the nature of its stable ingredients, as bestos-cement pipe resists many corrosive fluids and most aggressive soils. As a nonconductor, it is immune to electrolysis and electrochemical corrosion. Since u is corrosion-resistant throughout and will neither rust nor tuberculate, the design strength is maintained through years of maintenance-free service. Thousands of miles of asbestos-cement pipe now serving as sewer and water lines and in corrosive oil field and mining operations attest to its refnarkable physical and chem ical stability. These properties assure operation with minimum maintenance. Similarly, the inherent characteristics of asbestos-' cement pipe make it an ideal construction material for gas and plumbing vents, air ducts, and conduits for cables of various types. Heat, fire, corrosion, and rust resistance are essential to adequate safe and long serv ice performance of these systems. A large 30-in. asbestos-cement pipe is used for an air duct system. The pipeline it made virtually airtight with a pliant plastic sleeve coupling. This installation illustrates the various tees, elbows, and junction assemblies of an asbestos-cement pipe system. Co urtity Johnt-MantiKm* CAPCO JEN 0020899 Hot air duct* *f aib*it*s-m*nt pip* ar* cat! into th* floor tlab for thii horn* to giv* leng-laiting hooting and air-conditioning Cowrftf Johm'Manviffo. SUMMARY Proven in industries where the water carried is often highly aggressive, asbestos-cement pipe contin ues to have an enviable record for its outstanding economy. Its quality performance has been responsible for many new standards in the operation and main tenance of underground and exposed piping. A brief summary of asbestos-cement pipe perform ance characteristics is given in Table 7 (on page 13) to assist you in weighing the many important advantages of asbestos-cement pipe. OTHER ASBESTOS-CEMENT PRODUCTS There arc many other asbestos-cement products available for use in construction. Notable among these are siding and roofing products. Advanced manufac turing techniques provide siding and roofing sheets in many textures, colors, and a variety of shapes while maintaining the durability, corrosion resistance, strength, and workability characteristics of the pipe products. Standard and lightweight corrugated panels have been produced for commercial and industrial use. These too retain the asbestos-cement characteristics of resistance to corrosion, fire, acid fumes, gases, and salt air, while providing ease -in assembly and good strength properties. Asbcstos-ccmcnt has become a basic building mate rial. It can be used from the foundation up and in the interior to subdivide the space and provide a pleas ing, esthetic decor. 12 V- ' CAPCO JEN 0020900 i< j!ii ';;!: i C ~ Q. Wo to J U2 e5 ?-5 o '5 <uc | za 5 -8-S n2 r .5 *o fc c -o | i 4teo* nO-- v.Ms) 2=3 2 ,2 n 5.S-2J O u- -D " 1 %: s as: fcC * , SOr (mO | cu *o ! -S ' acj *; iii '4taSo** t"4r.t*1o *<1 o Q. , 12 *5 cc .2 a "S ' gsax' <e2* Hrc"* 1 Sri, v3 3. 3to ,S 4 - . i i ti CAPCO JEN 0020901 Characteristics Smooth surface Corrosion resistance Strength Adaptable couplings Construction workability Durability Dependable performance TABLE 7. ASBESTOS-CEMENT PIPE Applicability to pcrformanco i1 ]------------------------------------------------------------- Principal advantages Asbestos-cement pipo's roughness flow coefficient, Manning n = 0.010, Is recognized by engineers as approaching an ideal smooth-flow surface. High, efficient flow capacity i A long service life is assured because the pipe will not tuberculate or rust and reduce flow capacity; resists both corrosive natural waters and active soils; and is a noncon ductor. Maintained flow capacity; Immunity to electrolysis; ensured service life Wide range of pipe strengths allows the designer flexibility, with assurance of adequate safety factor. Each pipe and coupling is tested to pressures well above working stresses. Maintained strength; no costly overdesign Available for every purpose, couplings are designed to withstand internal and external loads assuring maximum tightness and rea sonable flexibility. Joint construction per mits rapid installation, laying around curves, absorption of ground settlement, and main tenance of tightness. Tightness and easy assembly Tho light weight, long lengths, and adapta ble couplings permit rapid, economical in stallations. The pipe Is easily field-cut with normal construction tools. Easy handling and assembly Corrosion resistance and maintained strength are inherent in the asbestos-cement combination. Proven service records attest* to satisfactory performance even In adverse soil-water-gas Installations. Long service life The inherent properties of asbestos-cement pipe make it ideally suited for water supply systems, waste water lines, storm drains, irrigation, mine lines, oil and brine lines, underdrains, gas vents, plumbing vents, air ducts, and conduits. Many and varied uses V CAPCO JEN 0020902