ACIPCO Ductile Iron pipe is easily cut in the field by any of several methods, the most generally used being as follows: ABRASIVE WHEEL A rotary-type abrasive wheel saw is probably one of the most popular tools used for cutting ductile iron pipe. This equipment is commercially available with gasoline engines as well as pneumatic motors. Cutting time is usually no more than one minute per 25mm of pipe diameter with most commonly used class thicknesses. TORCH CUTTING Ductile iron pipe can be cut in the field or shop by using an oxyacetylene torch. Best results are obtained by using a No. 8 or No. 10 tip with approximately 5 bar oxygen and 1 bar acetylene. For cement-lined ductile pipe, the best results are normally obtained when the torch head is inclined approximately 60° to the direction of cutting. Metallurgical studies have shown that the heat-affected zone in pipe cut by this method exists within only 6mm from the cut face. The hardening of the metal in the 6mm affected heat zone causes some difficulty in threading or machining in this particular portion of the pipe, but such hardening does not interfere with push-on or mechanical joint assembly or performance. Cutting speed for pipe cut by oxyacetylene methods is approximately one minute per 25mm of diameter for cement-lined pipe and even less for unlined pipe. MILLING CUTTER Several types of milling pipe cutters are available which operate hydraulically, pneumatically, or electrically, or are self-powered by a gasoline engine. The milling-type cutter will normally cut pipe from 150mm - 1600mm diameters. This type of cutter is usually supplied with an air motor which also makes submarine cuts possible. The set-up time for this cutter is usually less than ten minutes; it requires a minimum clearance of 300mm and has a cutting speed of approximately one minute per 25mm of pipe diameter. OTHER CUTTING METHOD Portable guillotine saws are available for cutting pipe from 80mm - 450mm diameters. Caution: Hydraulic squeeze cutters are not suitable for cutting ductile iron pipe.

Cutting ductile iron pipe with abrasive wheel. Cutting ductile iron pipe with torch. Torch cutting ductile iron pipe. Cutting ductile iron pipe with milling cutter.

PROCEDURE FOR FIELD CUTTING DUCTILE IRON PIPE 1. Measure the candidate pipe diameter (or circumference) at the location of the cut to be made to ensure that the pipe diameter and circumference are within the tolerance. (Note: There are minimum laying lengths for restrained joint pipe. Contact ACIPCO.) 2. Mark the pipe at sufficient intervals around the circumference by measuring from a reference (usually the spigot end) such that a square cut can be made. 3. Cut the pipe at the desired location. It is important that field cuts for restrained joint welding be smooth, regular, and as square as possible with the axis of the pipe because the cut end will be used as a reference to position the retainer ring. The outside of the cut end should be beveled smooth per manufacturer's recommendations using a grinder or file to prevent damage to the gasket during assembly. FIELD GAUGING ACIPCO factory gauges the spigot ends of every ductile iron pipe before shipment to the customer. Accordingly, pipe selected for cutting in the field should be field-gauged. A circumferential "pi" tape can be used for this. Also, a mechanical joint gland inserted over the barrel of the pipe might serve as a convenient indicator for field cutting. Some pipe, especially in the largest diameters, may be out-of-round to the degree that they will need to be rounded after cutting by jacking or other methods to facilitate making the joint. This is a normal occurrence and does not in any way affect the serviceability of ductile iron pipe. Instructions for the rounding operation are described in this section. PREPARATION OF FIELD CUT JOINTS Field cuts that will be assembled with mechanical joints will require little or no preparation other than cleaning. When a torch cut is made, the last few inches of the plain end need to be cleaned of any oxides, slag, or other protrusions. When the cut end is to be assembled in a Fastite® bell, an adequate smooth (without sharp edges) bevel should be ground or filed on the cut edge to prevent damage to or dislodgement of the gasket during assembly. Note: Generous bevels are advantageous in the assembly of field-prepared ends. To confirm the effectiveness of pipe end preparation and the subsequent assembly of a field-prepared end, a thin "automotive" or other feeler gauge can be effectively used to check (probe) for proper and uniform gasket positioning all around the assembled joints.

Step 1. Measure the pipe diameter (or circumference) at the location of the cut to ensure that it is within the tolerance. Step 2. Mark the pipe at sufficient intervals around the circumference by measuring from a reference--usually the spigot end of the pipe. Step 3: Cut the pipe at the desired location. Following the cut, the outside of the cut end should be beveled smooth. Bevel for Fastite® Joint.

INSTRUCTIONS FOR FIELD ROUNDING OF DUCTILE IRON PIPE FOR JOINT ASSEMBLY Need for rounding in assembly of mechanical joints can be predetermined by a difficulty in sliding the gland or end ring over the end of the pipe. Rounding may be accomplished in the following manner using a mechanical jack and shaped blocks. (Note: This procedure may also be used with assemblies involving Fastite® joint pipe, fittings, valves, etc.; however, rounding is less frequently necessary for assembly of Fastite® joints.) 1. Determine the minimum diameter of the ends to be rounded. 2. Place the jack and the shaped blocks in line with the minimum diameter, as shown in the sketch, using a sound 100mm x 100mm spacer timber cut square to the required length to take up the space. 3. Apply a load carefully with the jack only until the minimum diameter equals the maximum diameter, or until the gland will easily slip over the end. No more jacking should be attempted or necessary--DO NOT ATTEMPT TO PERMANENTLY ROUND END. 4. After the joint is completely assembled and the bolts (if involved) are uniformly tightened to the required torque, carefully relax and remove the jack and timbers from the pipe.

TAPPING DUCTILE IRON PIPE ACIPCO Ductile Iron pipe is readily tapped either dry or under pressure by using conventional tapping equipment utilized by most contractors and water utilities. Taps made directly into the pipe result in clean, sharp, strong threads, making tapping saddles unnecessary for small diameter taps. Teflon tape or a commercial thread compound which is suitable to the service is recommended to be used on threads.

Above is shown a 150mm ACIPCO Ductile Iron pipe that has been tapped for a 25mm corporation stop, showing the excellent threading properties of ductile iron pipe.