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GUI DELI NES

Field Welding
and Cutting
Ductile Iron Pipe

Last Revised:
May 2016
 Ductile Iron Pipe Manufacturers have been successfully welding
Ductile Iron Pipe for many years and should be consulted on their
recommendations for field welding and torch cutting their product.
The Ductile Iron Pipe Research Association (DIPRA) does not
support indiscriminate field welding of Ductile Iron Pipe. However,
unforeseen circumstances might require field welding of retainer
rings, thrust collars, etc., onto the barrels of Ductile Iron Pipe.
This manual is intended as a guide for field welding and cutting cement-mortar lined and unlined Ductile Iron
Pipe. For welding or cutting special lined pipe, consult the pipe manufacturer. The procedures described are
intended to be used only by qualified welders having adequate skill and experience in the practice of the
appropriate welding and cutting methods for cast ferrous materials. Only such qualified welders should be
allowed to field weld and field cut restrained joints for Ductile Iron Pipe. Pipe manufacturers’ recommended
procedures shall be followed while exercising reasonable care. Care should also be exercised in the application
of the principles contained herein. DIPRA assumes no responsibility and disclaims liability for the design or
performance of pipe joints or pipe systems fabricated with this approach. Also, DIPRA assumes no responsibility
and disclaims liability for injury or damage to persons or property arising from the use of these procedures.

Introduction
Welding is a very important fabrication method in modern industry. If an alloy can be welded successfully,
its usefulness is clearly enhanced. Ductile Iron can be welded successfully to produce welds that have
mechanical properties comparable to those of the base iron. As with any base material, the success of
welding Ductile Iron depends on suitable equipment, correct procedures, qualified welders, and effective
quality control procedures.

Ductile Iron Pipe

The first Ductile Iron Pipe was cast experimentally in 1948. Years of metallurgical, casting, and quality control
refinement followed, and in 1955 Ductile Iron Pipe was introduced into the marketplace.

Its phenomenal strength and impact resistance compared to Gray Iron, along with many other advantages,
created a rapid increase in demand for this product as engineers and utility officials realized that it could be
transported, handled, and installed with virtually no damage to the pipe. In service, Ductile Iron Pipe showed
that expense of repair was practically eliminated.

Ductile Iron is usually defined as a Cast Iron with primary graphite in the nodular or spheroidal form. This
change in the graphite form is accomplished by adding an alloy, usually magnesium, to molten iron of
appropriate composition. Properly treated iron will solidify with the graphite in the form of nodules or
spheroids. The distribution and shape of the graphite nodules are set when the metal solidifies in the mold
and will remain essentially unchanged during subsequent processing. Because of the mold cooling and rapid
iron solidification, the pipe must be annealed (heat treated) to produce the necessary proportion of ferrite
that imparts strength, ductility, and impact properties required by specifications for water service.

The annealing treatment relieves casting stresses and produces the microstructural transformation that
increases the toughness and improves ductility of the iron while maintaining the required strength. The
effectiveness of the magnesium treatment of the iron as well as the annealing treatment of the pipe is proven
by means of physical tests. The types of tests, test frequencies, and acceptance limits that are required are

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 specified in ANSI/AWWA C151/A21.51 Standard, “Ductile-Iron Pipe, Centrifugally Cast, for Water.” The
acceptance test requirements of the ANSI/AWWA C151/A21.51 Ductile Iron Pipe Standard are:

1. Tensile properties of specimens machined from the pipe wall: ultimate strength, 60,000 psi minimum;
yield strength, 42,000 psi minimum; elongation, 10 percent minimum.
2. Charpy V-Notch impact strengths on specimens cut from the pipe wall: 7 ft-lb minimum at 70°F; 3 ft-lb
minimum at -40°F.

Ferritic Ductile Iron, as compared to Gray Iron, will have about twice the strength as determined by a tensile
test, beam test, ring bending test, and bursting test. The tensile elongation and impact strength of Ductile
Iron is many times that of Gray Iron.

Gray Iron Ductile Iron

As these photomicrographs show, Ductile Iron differs from Gray Iron in that its graphite is spheroidal, or nodular, instead of the flake form found in
Gray Iron. Ductile’s greater strength, ductility, and toughness are due to this change in microstructure

The annealing treatment for Ductile Iron Pipe relieves casting stresses and produces the microstructural transformation that increases the pipe’s toughness
and improves the ductility of the iron while maintaining the required strength.

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 General Welding of Iron Pipes Weld Joint Design
Most weld joint designs commonly used for welding
Weldability of Ductile Iron carbon steels are generally suitable for welding
Due to their high carbon content, all cast irons have Ductile Iron (butt welding is not recommended).
a common factor affecting their weldability. During
the welding of cast irons, the iron immediately Preheating
adjacent to the weld metal is heated to its fusion or Preheating involves raising the temperature of the base
melting point. After welding, the entire heat-affected metal in the region to be welded to a predetermined
zone cools very rapidly. During this heating and temperature prior to carrying out the welding process.
cooling, some of the graphitic carbon dissolves and Preheating may be applied to help prevent cold-
diffuses into the iron, and, as a result, carbides tend cracking, reduce hardness in the heat-affected zone,
to form at the edge of the fusion zone, and high- reduce residual stresses, and reduce distortion.
carbon martensite and bainite tend to form in the
remainder of the heat-affected zone. The formation Normally, preheating of Ductile Iron Pipe is not necessary
and is impractical to do in the field. However, in extreme
of these hard, brittle microconstituents increases
cold weather one may find it advantageous to warm
the susceptibility to cracking. The lower surface-to-
the pipe weld area with a torch.
volume ratio of the nodular graphite in Ductile Iron as
compared to that for the flake graphite in Gray Iron
Shielded Metal-Arc Welding
results in less carbon dissolution and the formation of
Shielded metal-arc welding is the most common
fewer carbides and less high-carbon martensite.
welding process used on Ductile Iron Pipe in the
field. The equipment necessary for shielded metal-
Also, because of its localized nature, welding
arc welding is as follows:
produces thermal stresses in the weld area. Ductile
Iron Pipe, having a predominantly ferritic matrix, is
1. D.C. arc welder using reversed polarity.
capable of local plastic deformation to accommodate
2. Suitable welding electrodes.
these welding stresses and is therefore better
3. Welding cable, work-piece cable, electrode holder,
suited to absorb welding stresses than is Gray Iron.
gloves, shield and protective clothing.
Successful welds can be made by minimizing the
stress from contraction of the weld metal as it cools,
Electrodes for metal-arc welding are normally
the pick-up of carbon by the weld metal, and by covered with a flux coating. The coating can fulfill
controlling the rate of cooling. the following functions:

Preparation for Welding 1. Stabilize the arc by ionization.

The success of any welding operation is affected 2. Provide protection for the molten metal from
by how effectively the preparation and cleaning the atmosphere by evolution of gases such as
operations are carried out prior to welding. The carbon dioxide and by hydrogen and also by the
welding area on the pipe and connecting piece must formation of a protective slag or flux.
be untarnished, dry, and grease-free. It has been 3. Influence the properties of the weld metal by
found that the asphaltic coating on the pipe can most de-oxidation and alloying.
easily be removed with a torch. An alternate method 4. Control the arc characteristics.
is to wash and wipe the area with a well-soaked rag
containing mineral spirits or other solvents. (Safety Recommended Electrodes
precautions must be observed when using flammable Some electrodes recommended for welding
materials.) After the asphaltic coating and any Ductile Iron are the 44- and 55-percent nickel-
grease, etc., have been removed from the weld area, iron electrodes. Consult pipe manufacturer for
the area should be ground to bright metal to remove recommendations. These electrodes provide
all annealing oxide. Also, the corresponding surface weld metal strength and toughness properties
of the Ductile Iron or alloy steel connecting piece to that are comparable to those of the base iron.
be welded should be cleaned and ground to bright The 44- and 55-percent nickel-iron electrodes
metal. A shot-blasted surface alone is not adequate should be in conformance with class designation
for welding. AWS A5.15 (ERNi-CI) and (ENiFe-CI) respectively.

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 These electrodes are capable of producing suitable for vertical welding and 5 to 15 amps for overhead
welds without preheating or postheating the welding with Inco Alloys International’s Ni-Rod
pipe or connecting piece. Nickel-iron electrodes 55X. The arc length should be kept as short as
are available from most of the leading electrode possible consistent with obtaining smooth operation
manufacturers and, although composition with and sufficient penetration and wash at the side
reference to nickel and iron content remains broadly of the joint. A slight weave of the electrode is
the same, differences in slag-stripping qualities and recommended, although this should not exceed
operation may be found in electrodes obtained three times the diameter (i.e., corewire diameter)
from different sources. Two nickel-iron electrodes of the electrode. When mild-steel components are
are Inco Alloys International’s Ni-Rod 44 and Ni- being joined to Ductile Iron Pipe, the center line of
Rod 55. Mild-steel, arc-welding electrodes are not the arc should be concentrated as far as possible
recommended for use with Ductile Iron because of onto the mild-steel component, which is thereby
the high risk of cracking at the interface of weld and made to absorb as much heat as possible from
base metal. the arc. The relatively low arc intensity associated
with the nickel-iron electrodes, coupled with the
Deposited metal from the ENiFe-CI electrode has sluggish metal-transfer characteristic, is conducive
a carbon content well above the solubility limit. to minimum heat input, giving minimum fusion and
The excess carbon is rejected as graphite during minimum carbide formation in the base iron.
solidification of the weld metal. This reaction causes
an increase in volume that tends to minimize weld By depositing narrow beads in short lengths one
shrinkage during solidification. This, in turn, reduces can reduce the cumulative effect of the stresses
residual stresses in the weld metal and the iron’s from shrinkage of weld metal. Each length of bead
heat-affected zone. should be allowed to cool until it can be touched
by hand before another deposit is made within
Care of Electrodes the area heated by the first bead. While one bead
Electrodes must be completely free from moisture is cooling, others are deposited at other locations
when used. Porosity in the weld can and often throughout the joint. All beads should be deposited
does originate because of moisture pick-up by the in the same direction. Another method to reduce
electrode coating. It is invariably due to the fact that shrinkage stresses is to peen a deposited bead of
the electrodes have been stored in unsatisfactory weld metal while it is still hot. Peening should be
conditions. Ideally, electrodes should be stored in an done with repeated moderate blows using a round-
oven maintained at a temperature of at least 250°F. nose tool and sufficient force to deform the weld
If they have not been stored under these conditions metal but without rupturing it. Effective peening
they should be baked for at least 1 hour at 480°F stretches the weld metal to help compensate for the
in a well-ventilated electric oven prior to use. The shrinkage that occurs during cooling. The peened
practice of drying electrodes by shorting them out metal is then allowed to cool before another bead
is not recommended. Excessive heating by this is deposited near it. By using a low welding current,
method, apart from having adverse effects on the a small-diameter electrode, and depositing multiple
power source, can damage the coatings and thus narrow beads, only the lower layer of weld metal
reduce their shielding efficiency when used. has a very high carbon content. Subsequent layers
of weld metal tend to temper and reduce hardness
Welding Procedures of the first layer. Complete flux removal is essential
Welding current for a particular electrode size after each weld pass before depositing further
should be within the range recommended by the weld metal since entrapped slag can impair the
manufacturer but as low as possible, consistent strength properties of the weld. Flux removal, in the
with smooth operation, desired head contour, case of nickel-iron electrodes, can usually be easily
and good fusion. When used in other than the flat accomplished with a pointed welder’s hammer or by
horizontal position, an electrode recommended wire-brushing.
for out of position welding, such as Inco Alloys
International’s Ni-Rod 55X, should be used. The
welding current should be reduced 10 to 20 amps

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 Metal Inert Gas (MIG) Welding FIGURE 1
Metal inert gas and pulsed-metal inert gas arc
welding using argon or argon-helium shielding-gas Shielded Metal-Arc Welding Process
with short-circuiting transfer is suitable for joining
Ductile Iron to itself and to mild steel. Because of
the relatively low heat input with this process, the
hard portion of the heat-affected zone is usually
confined to a thin layer next to the weld metal. As a
result, the strength and ductility of the welded joint
are about the same as those of the base metal.

Recommended Filler Material

It has been established that the most satisfactory
filler metal for MIG shortarc welding of Ductile Iron
is nickel (ENi-1).

Flux-Cored Wire Arc Welding

This process is similar to MIG welding insofar as FIGURE 2
a consumable wire electrode is used. However, Metal Inert Gas (MIG) Welding Process
whereas MIG welding uses an inert gas shield to
protect the weld pool, the flex-cored wire process
derives its protection from the slag formed from the
flux materials contained in the core of the tubular
wire. A Ni-Rod FC55 cored wire electrode is available
that produces weld metal with a composition and
micro-structure similar to that deposited by ENiFe-
CI covered electrodes. The principle of graphite
precipitation and the associated volume increase is
the same for both electrodes.

The flux-cored electrode is a self-shielding design

but it may be used with carbon dioxide (CO2)
shielding or as a submerged arc welding electrode.
The electrode producer should be consulted for
recommendations on usage and procedures for
specific applications.

Oxyacetylene Welding FIGURE 3

Oxyacetylene welding procedures require large Flux-Cored Wire Arc Welding Process
amounts of heat input during both the pre-
heating and the welding operations. The extensive
heating is a limiting factor in the application of this
process. The process is not considered suitable
for fabrication work as the high heat input can
cause excessive distortion; and in the as-deposited
condition, the weld area is likely to contain a high
proportion of iron carbide.

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 Field Welding Procedure For Field-Cut Procedure
Restrained Joint Ductile Iron Pipe 1. Measure the candidate pipe diameter (or
circumference) at the location of the cut to
Many restrained joint designs rely on a welded- be made to ensure that the pipe diameter and
on retainer ring around the spigot of the pipe to circumference are within the tolerance shown in
provide part of the means of restraint. This retainer Table 2. (Note: There are minimum laying lengths
ring is furnished factory-welded in position on the for restrained joint pipe. Consult manufacturer.)
pipe. The welding is performed by welders qualified
to produce high-quality, dependable welds. By
planning ahead, necessary field cuts of Ductile Iron
Pipe can normally be positioned in unrestrained
sections of the pipeline. However, if field cuts are
required in restrained joint pipe sections utilizing the
welded-on retainer ring, a loose factory-supplied
ring can be field-welded onto the barrel of the field-
cut Ductile Iron Pipe.

Welds should be applied using a D.C. arc welder

employing reversed polarity and operating at Step 1. Measure the pipe diameter (or circumference) at the location of the
cut to ensure that it is within the tolerance shown in Table 2 on page 10 of
amperage ranges recommended by the electrode this brochure.
manufacturer. General ranges of amperages for various
diameter electrodes are shown in Table 1. 2. Mark the pipe at sufficient intervals around the
circumference by measuring from a reference
TABLE 1 (usually the spigot end) such that a square cut can
General Amperage Ranges for Various Electrodes be made.

Electrode Diameter Recommended Current (amp)

3/32-in 40–65

1/8-in 75–95

5/32-in 100–135

3/16-in 120–155

The weld electrodes used should be in conformance

with Class designation AWS 5.15 (ENiFe-CI). Three Step 2. Mark the pipe at sufficient intervals around the circumference by
such electrodes are Inco Alloys International’s measuring from a reference — usually the spigot end of the pipe.

Ni-Rod 44, Ni-Rod 55 and 55X (consult pipe

manufacturer for recommendations). The electrode 3. Cut the pipe at the desired location. It is important
and electrode diameter recommended by pipe that field cuts for restrained joint welding be
manufacturers for their retainer ring should be used 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 the manufacturer’s recommendations
using a grinder or file to prevent damage to the
gasket during assembly.

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 6. Re-mark the location of the weld-on retainer ring
on the pipe as was done in Step 4.
7. Some restrained joint designs require the weld-
on retainer ring to be cut to length in the field. If
such is employed, fit the ring around the pipe and
mark and cut the ring to the length recommended
by the manufacturer. Normally the ring will be cut
“short” to accommodate lengthening during the
welding operation.
8. Clamp the weld-on retainer ring securely on
the pipe in the correct location.* This may be
Step 3. Cut the pipe at the desired location. Following the cut, the outside of the
cut end should be beveled smooth per the manufacturer’s recommendations. accomplished using the manufacturer’s special
welding jigs, fixtures, and/or C-clamps. If the
4. Mark the location of the weld-on retainer ring from clamping device bears on the inside of the pipe,
the cut end of the pipe per the manufacturer’s care should be taken to minimize damage to the
specifications. pipe lining. If welding fixtures and/or C-clamps
are used, the weld deposit should be applied in
circumferential intervals corresponding to the
movement of the clamps as recommended by the
pipe manufacturer.

Step 4. Mark the location of the weld-on retainer ring from the cut end of the
pipe per the manufacturer’s specifications.

5. Remove the asphaltic coating on the pipe in

the area the retainer ring is to be welded with a
solvent wash or by burning with a torch. After Step 8. Clamp the weld-on retainer ring securely on the pipe in the correct
the asphaltic coating has been removed, grind location. *If the clamping device bears on the inside of the pipe, take care
to minimize damage to the pipe lining.
the retainer ring location to bright metal. Also,
the corresponding edge of the ring to be welded 9. With the retainer ring fitted closely to the pipe
should be cleaned and ground to bright metal. surface, weld on the side of the ring next to the
Place loose locking rings or glands (if required cut end of the pipe.* Weld according to the pipe
for the particular joint configuration) on the pipe manufacturer’s recommendations (electrode
barrel beyond the retainer ring location. diameter, weld size, weld passes required, welding
technique, etc). To minimize heat build-up that may
possibly cause thermal stresses and/or damage
to linings, skip welding techniques can be used.
Thorough peening of the weld passes before they
cool will minimize thermal stresses. The ends of
adjoining passes should be slightly overlapped
before the arc is broken. If weld cracks occur, they
should be ground away and repaired with a weld
overlay. After the entire ring has been welded to
the pipe, weld the ring ends to the pipe and weld
Step 5. Remove the pipe’s asphaltic coating on the area where the retainer
in the space remaining between the ring ends
ring will be welded with a solvent wash or by burning with a torch; then according to the pipe manufacturer’s instructions.
grind the retainer location to bright metal.

8
 12. Inspect the pipe lining for possible damage.
Cement-mortar linings are normally not adversely
affected by such welding procedures; however,
if cement lining damage occurs, it should be
patched in accordance with recommended
procedures as noted in ANSI/AWWA C104/A21.4
Standard, “Cement-Mortar Linings for Ductile-Iron
Pipe and Fittings for Water.” Contact the pipe
manufacturer for repair of special linings.

*The configuration of rings varies slightly from manufacturer to

Step 9. With the retainer ring fitted closely to the pipe surface, weld on the manufacturer. Contact your DIPRA member company regarding the ring
side of the ring next to the cut end of the pipe according to the manufacturer’s
configuration it recommends.
recommendations.* (Skip welding techniques can be used.) After the entire ring
has been welded to the pipe, weld the ring ends to the pipe and weld in the
space remaining between the ring ends.
Cutting Ductile Iron Pipe
10. Thoroughly clean the weld and ring* to remove Ductile Iron Pipe may be cut using an abrasive pipe
all weld flux and splatter. The pipe spigot should saw, a rotary wheel cutter, a guillotine pipe saw, or
be clean of weld splatter for proper gasket sealing a milling wheel saw. Cement-mortar lined or unlined
and joint assembly. Ductile Iron Pipe can also be cut with an oxyacetylene
torch if recommended by the pipe manufacturer for
its product.

Step 10. Thoroughly clean the weld and ring* to remove all weld flux and splatter
so the pipe spigot is clean for proper gasket sealing and joint assembly.

11. Coat the ring* weld and ground pipe surface with
a smooth uniform coat of brushable mastic.

In addition to being cut with an abrasive pipe saw, a rotary wheel cutter, a
guillotine pipe saw, or a milling saw, Ductile Iron Pipe can also be cut with an
oxyacetylene torch if recommended by the pipe manufacturer. Cut ends and
rough edges should be ground smooth. For push-on connections, the cut end
Step 11. Coat the ring*, weld, and ground pipe surface with a smooth uniform should be beveled to the approximate profile of the factory supplied end.
coat of brushable mastic.
The ANSI/AWWA standard for Ductile Iron Pipe
requires factory gauging of the spigot end.
Accordingly, pipes selected for cutting should be
field gauged in the location of the cut and be within
tolerance as shown in Table 2 (next page).

9
 Torch cutting of Ductile Iron Pipe normally results
TABLE 2
in a heat-affected zone extending less than 1/4-inch
Suitable Pipe Diameters for Field Cuts and
from the cut face but might result in small cracks in
Restrained Joint Field Fabrication
this area which should be removed by grinding. Some
Nominal Min. Pipe Max. Pipe Min. Pipe Max. Pipe
difficulty might result in threading or machining in this Pipe Size Diameter Diameter Circumference Circumference
particular portion of the pipe due to hardening of the In. In. In. In. In.

metal. Such hardening does not interfere with push- 4 4.74 4.86 14 29/32 15 9/32
on or mechanical joint assembly or performance.
6 6.84 6.96 21 1/2 21 7/8

Pipe manufacturers who recommend torch cutting of 8 8.99 9.11 28 1/4 28 5/8

their pipe report best results are obtained by using a 10 11.04 11.16 34 11/16 35 1/16
No. 8 or No. 10 tip with approximately 75 psi oxygen
12 13.14 13.26 41 9/32 41 21/32
and 10 to 15 psi acetylene. For cement-lined Ductile
14 15.22 15.35 47 13/16 48 7/32
Iron Pipe, the best results are normally obtained when
the torch head is inclined approximately 60 degrees 16 17.32 17.45 54 13/32 54 13/16
to the direction of cutting. Cutting time for pipe 18 19.42 19.55 61 61 13/32
cut by oxyacetylene methods is approximately one
20 21.52 21.65 67 19/32 68
minute per inch of diameter for cement-lined pipe
and even less for unlined pipe. 24 25.72 25.85 80 13/16 81 7/32

30 31.94 32.08 100 11/32 100 25/32

Cut ends and rough edges should be ground smooth
36 38.24 38.38 120 1/8 120 9/16
and for push-on connections, the cut end should be
42 44.44 44.58 139 5/8 140 1/16
beveled to the approximate profile of the factory
supplied end. 48 50.74 50.88 159 13/32 159 27/32

54 57.46 57.60 180 17/32 180 31/32

60 61.51 61.65 193 1/4 193 11/16

64 65.57 65.71 206 206 7/16

Above table based on ANSI/AWWA C151/A21.51

guidelines for push-on joints

References
1. American Cast Iron Pipe Company, “Instructions for Field Welding of American Restrained Ductile Iron Pipe Joints.”
2. ANSI/AWS D11.2 Standard, “Guide for Welding Iron Castings,” 1989.
3. ANSI/AWS A5.15 Standard, “Specification for Welding Electrodes and Rods for Cast Iron.”
4. ANSI/AWWA C151/A21.51 Standard, “Ductile-Iron Pipe, Centrifugally Cast, for Water.”
5. British Cast Iron Research Association, “The Joining and Fabrication of Nodular Iron Castings by Welding,” 1982.
6. INCO Alloys International, Ni-Rod 44 and Ni-Rod 55 Welding Electrodes.
7. INCO Alloys International, Ni-Rod 99X and Ni-Rod 55X Welding Electrodes.
8. Jefferson, T.B., “Metals and How to Weld Them,” Second Edition, Welding Engineer Publication, Inc.
9. The Lincoln Electric Company, “The Procedure Handbook of Arc Welding,” Twelfth Edition.
10. U.S. Pipe and Foundry Company, “Field Cutting and Welding Procedure for TR FLEX Pipe,” 1997 Edition.

10
For more information contact DIPRA or any
of its member companies.

Ductile Iron Pipe Research Association Member Companies

An association of quality producers AMERICAN Ductile Iron Pipe

dedicated to the highest pipe standards P.O. Box 2727
through a program of continuing research Birmingham, Alabama 35202-2727
and service to water and wastewater
professionals. Canada Pipe Company, Ltd.
1757 Burlington Street East
P.O. Box 19206 Hamilton, Ontario L8N 3R5 Canada
Golden, Colorado 80402
205.402.8700 Tel McWane Ductile
www.dipra.org P.O. Box 6001
Coshocton, Ohio 43812-6001
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