DESIGN

Critical Buckling Pressure

for Ductile Iron Pipe

Last Revised:
March 2022
 Critical Buckling Pressure for Ductile Iron Pipe

by Richard W. Bonds, P.E.

DIPRA Research/Technical Director

When external pressure is increased on a pipeline, it may reach a level (the critical buckling

pressure, PCR) where the structure becomes suddenly unstable and collapses due to general

buckling. Collapse is sudden inversion of curvature of the pipe wall. The more flexible the pipe,

the more unstable the wall structure will be in resisting buckling. In the case of buried pipes, the

surrounding soil generally provides some support to the pipe, creating a higher critical buckling

pressure than in unsupported applications.

While to our knowledge there has never been buckling collapse failure of a Ductile

iron pipeline, the new larger sizes may suggest an examination of bucking design in certain
situations. Therefore, in applications where a Ductile iron pipeline may be subject to internal

negative pressure conditions (vacuum*) and/or external hydrostatic pressure, a prudent design

engineer will want to include calculations to assure that the pipe will not collapse due to

buckling.

Buckling with No Support from Surrounding Soil Structure

The worst case (lowest critical bucking pressure) occurs when the pipeline is exposed to

the atmosphere or liquid media with no support for surrounding soil structure.

* Vacuum is a common expression for internal negative pressure and/ or external fluid pressure.

2
 For this case the critical buckling pressure is given by1 :

2E ⎛ t ⎞3
1
PCR = ⎯⎯⎯ ⎜ ⎯⎯ ⎟ (Eq.1 )
(1 - γ2) ⎝ DM ⎠

where:

PCR = Critical buckling pressure (psi)

E = Modulus of elasticity of the pipe material (24 x106 psi for ductile iron)
γ = Poisson's ratio for the pipe material (0.28 for ductile iron)
DM = Mean diameter of the pipe
t1 = Minimum manufacturing thickness of the pipe (inch)

3
 TABLE 1
Standard Pressure Classes and Nominal Thicknesses
of Ductile Iron Pipe

Pressure Class
Outside
Size (inches) Diameter
(inches)
150 200 250 300 350

3 3.96 - - - - 0.25*
4 4.80 - - - - 0.25*
6 6.90 - - - - 0.25*
8 9.05 - - - - 0.25*
10 11.10 - - - - 0.26
12 13.20 - - - - 0.28
14 15.30 - - 0.28 0.30 0.31
16 17.40 - - 0.30 0.32 0.34
20 21.60 - - 0.33 0.37 0.38
24 25.80 - 0.33 0.37 0.40 0.43
30 32.00 0.34 0.38 0.42 0.45 0.49
36 38.30 0.38 0.42 0.47 0.51 0.56
42 44.50 0.41 0.47 0.52 0.57 0.63
48 50.80 0.46 0.52 0.58 0.64 0.70
54 57.56 0.51 0.58 0.65 0.72 0.79
60 61.61 0.54 0.61 0.68 0.76 0.83
64 65.67 0.56 0.64 0.72 0.80 0.87

* Calculated thicknesses for these sizes and pressure ratings are less than those shown above. These are the lowest nominal thicknesses
currently available in these sizes.

Pressure classes are defined as the rated water working pressure of the pipe in psi. The thicknesses shown are adequate for the rated
water working pressure plus a surge allowance of 100 psi. Calculations are based on a minimum yield strength in tension of 42,000 psi
and 2.0 safety factor times the sum of working pressure and 100 psi surge allowance.

Thickness can be calculated for rated water working pressure and surges other than the above by use of the design procedure detailed
in ANSI/AWWA C150/A21.50.

Ductile iron pipe can be utilized for water working pressure greater than 350 psi and is available in thicknesses greater than Pressure
Class 350. Contact DIPRA member companies regarding specific requirements.

4
 Table 2
Allowances for Casting Tolerance

Size (inches) Casting Tolerance (inches)

3-8 0.05

10-12 0.06

14-42 0.07

48 0.08

54-64 0.09

The lowest critical buckling pressure (PCR) corresponds to the smallest t1/DM value
with no support from surrounding soil structure. The smallest value of t1/DM for domestically
manufactured Ductile iron pipe corresponds to 64-inch Pressure Class 150 (see Table 1).

To calculate the critical buckling pressure for this size Ductile iron pipe exposed to the

atmosphere, apply Equation 1:

2E ⎛ t ⎞3
1
PCR = ⎯⎯⎯ ⎜ ⎯⎯ ⎟
(1 - γ2) ⎝ DM ⎠

where:

E = 24 x106 psi
γ = 0.28
t1 = 0.56 - .09 = 0.47 inch (from Tables 1 & 2)
DM = 65.67 - 0.47 = 65.20 (from Table 1)

(2) (24 x 106) ⎛ 0.47 ⎞3

∴ PCR = ⎯⎯⎯⎯⎯ ⎜ ⎯⎯ ⎟ = 19.51psi
(1 - 0.282) ⎝ 65.20 ⎠

Therefore, 64-inch Pressure Class 150 Ductile iron pipe exposed to the atmosphere

and subjected to 10 psi internal vacuum would have a safety factor of approximately 2.0
19.51
(Sf = ⎯⎯ = 1.95)
against failure due to buckling. Higher pressure rated 64-inch diameter
10
pipe as well as all smaller diameter Ductile iron pipe would have an even higher safety factor.

5
 For example, 24-inch diameter pressure Class 200 Ductile iron pipe would have a critical

buckling pressure (PCR) of 54.95 psi, giving it a safety factor of 5.5 against failure due to

buckling when exposed to the atmosphere and subjected to 10 psi internal vacuum. The stiffness

and buckling resistance of all sizes of Ductile iron pipe with minimum wall thicknesses are

significantly greater than that of flexible pipe of other materials. Table 3 shows the lowest critical

buckling pressure of pressure class Ductile iron pipe when exposed to the atmosphere or liquid

media (worst case).

TABLE 3
Minimum Critical Buckling Pressure of Ductile Iron Pipe
Exposed to the Atmosphere or Liquid Media
(worst case)
Pressure Class

150 200 250 300 350

Critical Buckling Pressure (psi)

Size (in)

3 - - - - 7,838.36

4 - - - - 4,280.70

6 - - - - 1,385.37

8 - - - - 601.12

10 - - - - 321.74

12 - - - - 210.79

14 - - 140.37 185.16 210.79

16 - - 125.19 161.33 203.95

18 - - 100.78 144.16 179.19

20 - - 94.20 131.26 160.79

24 - 54.95 84.81 113.28 147.59

30 32.09 48.75 70.43 90.40 122.52

36 28.30 40.86 61.23 81.76 113.36

42 23.77 38.87 55.53 76.43 107.82

48 22.30 34.74 51.16 72.13 98.24

54 20.68 32.97 49.39 70.58 97.18

60 20.75 32.12 47.08 69.22 93.58

64 19.51 31.38 47.33 68.00 90.46

6
Buckling of Buried Ductile Iron Pipe
Ulrich Luscher studied the case of thin, cylindrical tubes surrounded by a concentric ring of soil

and found that the surrounding soil tremendously increases the buckling resistance of a flexible

tube over that of an unsupported tube4. He found that the modulus of elastic support provided
by the soil is mathematically equivalent to the modulus of resistance of the soil cylinder to

uniform pressure applied at the inner boundary. Luscher also found that elastic buckling occurs

when the uniform applied pressure on the outside of the soil ring exceeds a critical value

(the critical buckling pressure, PCR) expressed as:

⎡ ⎤1/2
PCR = ⎢ 32EIBES
⎥ (Eq.2 )
⎢ ⎯⎯⎯⎯⎯ ⎥
⎢ DM3 ⎥
⎣ ⎦

where:

PCR = Critical buckling pressure (psi)

E = Modules of elasticity of the pipe material (24 x 106 psi for Ductile Iron)
I = Moment of inertial of the pipe per inch (in.4/in.)
DM = Mean diameter of the pipe (in.)
ES = Soil modulus of elasticity (psi)
B = Coefficient of elastic support:

⎡ DM ⎤ 2

1 - ⎯⎯⎯⎯⎯ ⎥
⎢ ⎥
⎢ D + 2h
⎣ M ⎦
B = ⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯⎯
⎡ DM ⎤2
1.3 + 0.52 ⎢ ⎯⎯⎯⎯⎯ ⎥ ⎥
⎢ D + 2h
⎣ M ⎦

where:

h = Depth of cover (inch)

'
Glascock proposed substituting the modulus of soil reaction (E ) for ES in Luscher's equation

and, in order to make predictions agree with results of soil box and buried vacuum tests,

proposed modification of B as follows5 :

7
 ⎡ ⎛ h ⎞ ⎤
⎢ h
⎢ 0.015 + 0.041 ⎜ ⎯⎯ ⎟ for 0 ≤ ⎯⎯ ≤ 5 ⎥⎥
⎝ DM ⎠ DM
B' =
⎢ ⎥
⎢ ⎥
⎢ ⎛ h ⎞ h ⎥
⎢ 0.015 + 0.041 ⎜ ⎯⎯ ⎟ for 5 ≤ ⎯⎯ ≤ 80 ⎥
⎢ ⎝ DM ⎠ DM ⎥
⎣ ⎦

'
Standard laying conditions and conservative E values for Ductile iron pipe from

ANSI/AWA C150/A21.50 are given in Table 4.

TABLE 4

Standard Pipe Laying Conditions

Laying Bedding
E'
Description Angle KO Kx
Conditions † (psi)
(degrees)

Flat-bottom trench.††† Loose back- 150 30 0.235 0.106

Type 1†† fill.

Flat-bottom trench. Backfill lightly

300 45 0.210 0.105
Type 2 consolidated to centerline of pipe.

Pipe bedded in 4-in. minimum loose

soil.†††† Backfill lightly consolidated 400 60 0.189 0.103
Type 3 to top of pipe.

Pipe bedded in sand, gravel, or

crushed stone to depth of 1/8 pipe
diameter, 4-in. minimum. Backfill
500 90 0.157 0.096
compacted to top of pipe. (Approx.
Type 4
80 percent Standard
Proctor, AASHTO T-99-†††††

Pipe bedded to its centerline in

compacted granular material,
4-in. minimum under pipe.
Compacted granular or select †††† 700 150 0.128 0.085
Type 5 material to top of pipe. (Approx. 90
percent Standard Proctor, AASHTO
T-99.†††††

† Sec Figure 1.
†† For pipe 14-inch and larger, consideration should be given to the use of laying conditions other
than Type 1.
††† Flat-bottom is defined as "undisturbed earth."
†††† Loose soil or select material is defined as "native soil excavated from the trench, free of rocks,
foreign material, and frozen earth."
††††† AASHTO T-99, "Moisture Density Relations of Soils Using a 5.5-pound Rammer 12-inch Drop."

8
 In order to reduce E' when the pipeline was submerged, Glascock also introduced a
groundwater buoyancy reduction factor (RW):

hw
RW = 1 - 0.33 ⎯
h

where: hW = Height of groundwater above pipe (inch)

h = Depth of cover (inch)

Glascock and Cagle later reanalyzed the buckling tests based on new data on much

larger pipes and concluded that B' may be more a function of soil depth (h) than of the depth-
'
to-diameter ratio and revised B as follows6 :

1
B' = ⎯⎯⎯⎯⎯⎯
1 + 4e -0.065H

where: H = Depth of cover (feet)

Therefore, the critical buckling pressure (PCR) for buried pipe becomes:

⎡ ⎤1/2
⎢ 32 Rw E I B'E'
⎢ ⎥
PCR = ⎥ (Eq.3 )
⎢ ⎯⎯⎯⎯⎯ ⎥
⎢ DM3 ⎥
⎣ ⎦

where: PCR = Critical buckling pressure (psi)

Rw = Water buoyancy factor

⎛h ⎞
= 1 - 0.33 ⎜⎯W
⎟ ; 0 ≤ hW ≤ h
⎝ h ⎠

where:

hW = Height of groundwater above pipe (inch)

h = Depth of cover (inch)
E = Modulus of elasticity of the pipe material
(24 x 106 psi for Ductile iron pipe)

9
 I = Moment of inertia of the pipe per inch (in.4/in.)

B' = Empirical coefficient of elastic support

1
= ⎯⎯⎯⎯⎯⎯
1 + 4e -0.065H

where:

H = Depth of cover (feet)

E' = Modulus of soil reaction (psi)
DM = Mean diameter of the pipe (inch)

For Ductile iron pipe this equation reduces to :

⎡ ⎤1/2
⎢ ⎛ t ⎞3 ⎥
PCR = 8,000 ⎢ R B' E' ⎜ ⎯1 ⎟ ⎥ (Eq.4 )
⎢ w ⎝ DM ⎠ ⎥⎥
⎢
⎣ ⎦

When designing for buried installation, the critical buckling pressure divided by a safety

factor (normally 2), should be greater than or equal to the combined soil overburden pressure,

external hydrostatic pressure, and internal vacuum. Normally, simultaneous applications of live-

load and internal-vacuum transients need not be considered. Therefore, for vacuum conditions:

PCR ≥ Rw Pprism + Phydrostatic + Pvacuum

PCR ⎛ wH ⎞ γw Hw + P
≥ Rw ⎜ ⎯ ⎟ + ⎯⎯ vacuum
(Eq.5 )
Sf ⎝ 144 ⎠ 144

where:

w = Soil weight (120 lb./ft3)

H = Depth of cover (ft)
γw = Specific weight of water (62.4 lb./ft3)

10
 Hw = Height of groundwater above pipe (ft)
Sf = Safety factor (normally 2)

Example:

A 36-inch diameter Pressure Class 150 Ductile iron pipeline is to be installed with 4 feet of cover

and a Type 3 laying condition. The pipeline could be subjected to as much as 10 psi internal

vacuum and a water table 2 feet above the pipe. Using a design safety factor of 2, check for

collapse due to buckling. What is the actual safety factor against this type of failure?

Using Eq. 4:

⎡ ⎤1/2
⎢ ⎛ t ⎞3 ⎥
PCR = 8,000 ⎢ R B' E' ⎜ ⎯1 ⎟ ⎥
⎢ w ⎝ DM ⎠ ⎥⎥
⎢
⎣ ⎦

⎛h ⎞
Rw = 1 - 0.33 ⎜ ⎯w ⎟
⎝ h ⎠
⎛ 24 ⎞
= 1 - 0.33 ⎜ ⎯⎟
⎝ 48 ⎠
= 0.835

1
B' = ⎯⎯⎯⎯⎯⎯
1 + 4e -0.065H
1
= ⎯⎯⎯⎯⎯⎯
1 + 4e -0.065(4)
= 0.245

E' = 400 psi (From Table 4)

t1 = Nominal thickness - casting tolerance (from Tables 1 & 2)
= 0.38 - 0.07
= 0.31 inch

11
 DM = O.D. - t1 (O.D. from Table 1)
= 38.3 - 0.31
= 37.990 inch

⎡ ⎤1/2
⎢ ⎛ 0.31 ⎞3⎥
∴ PCR = 8,000 ⎢ (0.835) (0.245) (400) ⎜ ⎯⎯ ⎟ ⎥⎥
⎢
⎢ ⎝37.99 ⎠ ⎥
⎣ ⎦
= 53.344psi

Using Eq. 5:

PCR ⎛ wH ⎞ γw Hw + P
≥ Rw ⎜ ⎯ ⎟ + ⎯⎯ vacuum
Sf ⎝ 144 ⎠ 144

⎡ ⎤ ⎡ ⎤
53.344 ⎢
⎢
⎥
(120) (4) ⎥ ⎢
⎢(62.4) (2)⎥⎥
⎯⎯⎯ ≥ (0.835) ⎢ ⎯⎯⎯ ⎥ + ⎢ ⎯⎯⎯ ⎥ + 10
2 ⎢ 144 ⎥ ⎢ 144 ⎥
⎣ ⎦ ⎣ ⎦
26.672 ≥ 2.783 + 0.867 + 10
26.672 ≥ 13.65 ∴ OK

PCR
Actual Safety Factor =
Pactual
53.344
= ⎯⎯⎯
13.65
= 3.91

In the American National Standard for the Thickness Design for Ductile Iron Pipe (ANSI/

AWWA C150/A21.50)2, the wall thickness required for external load is based on two design

considerations: limitation of ring bending stress and ring deflection. Based on these design

considerations, Table 5 provides the maximum depth of cover for Ductile Iron pipe with cement

lining based on laying conditions and assumed earth prism/traffic loadings.

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 TABLE 5
Maximum Depth of Cover for Ductile
Iron Pipe with Cement Lining
Laying Condition
Pipe Pressure Nominal
size Class Thickness Type 1 Type 2 Type 3 Type 4 Type 5
(in) Class
Maximum Depth of Cover, ftA

3 350 0.25 78 88 99 B B
4 350 0.25 53 61 69 85 B
6 350 0.25 26 31 37 47 65
8 350 0.25 16 20 25 34 50
10 350 0.26 11** 15 19 28 45
12 350 0.28 10** 15 19 28 44
14 250 0.28 C 11** 15 23 36
300 0.30 13 17 26 42
350 0.31 14 19 27 44
16 250 0.30 C 11** 15 24 34
300 0.32 13 7 26 39
350 0.34 15 20 28 44
18 250 0.31 C 10** 14 22 31
300 0.34 13 17 26 36
350 0.36 15 19 28 41
20 250 0.33 C 10 14 22 30
300 0.36 13 17 26 35
350 0.38 15 19 28 38
24 200 0.33 C 8** 12 17 25
250 0.37 11 15 20 29
300 0.40 3 7 24 32
350 0.43 15 19 28 37
30 150 0.34 C - 9 14 22
200 0.38 8** 12 16 24
250 0.42 10 5 19 27
300 0.45 12 16 21 29
350 0.49 15 19 25 33
36 150 0.38 C - 9 14 21
200 0.42 8** 12 15 23
250 0.47 10 14 18 25
300 0.51 12 16 20 28
350 0.56 15 19 24 32
42 150 0.41 C - 9 13 20
200 0.47 8 12 15 22
250 0.52 10 14 17 25
300 0.57 12 16 20 27
350 0.63 15 19 23 32
48 150 0.46 C - 9 13 20
200 0.52 8 11 5 22
250 0.58 10 13 7 24
300 0.64 12 15 19 27
350 0.70 15 18 22 30
54 150 0.51 C - 9 13 20
200 0.58 8 11 14 22
250 0.65 10 13 16 24
300 0.72 13 15 19 27
350 0.79 15 18 22 30
60 150 0.54 C 5** 9 13 20
200 0.61 8 11 14 22
250 0.68 10 13 16 24
300 0.76 13 15 19 26
350 0.83 15 18 22 30
64 150 0.56 C 5** 9 13 20
200 0.64 8 11 14 21
250 0.72 10 13 16 24
300 0.80 12 15 19 26
350 0.87 15 17 21 29

** Minimum allowable depth of cover is 3 ft.

A These pipes are adequate for depth of cover from 2.5 ft up to the maximum shown
including an allowance for a single H-20 truck with 1.5 impact factor unless noted.
B Calculated maximum depth of cover exceeds 100 ft.
C For pipe 14-inch and larger, consideration should be given to the case of laying
conditions other than Type 1.
1. Ring deflection limited to 3%, minimum safety factor of 2.
2. Earth load (Pe ) is based on soil weight of 120 pcf.

13
 Although it may be unlikely to experience such a combination of adverse conditions in

practice, it is possible to calculate the allowable depth of cover for Ductile iron pipe classes by

the procedures outlined in this paper assuming an internal vacuum of 10 psi, water table even

with the surface of the ground, and a safety factor of 2. When this is done, invert case greater

depths of cover are allowed but this buckling design procedure than are allowed by current

standard ANSI/AWWA C150/A21.50 design procedures. Additionally, the stiffening effect of the

pipe bell cross-section and pipe joint overlap is conservatively ignored in this procedure. It is

obvious, therefore, that a designer need not normally be concerned with bucking collapse of

Ductile iron pipe. However, there are some extreme conditions, such as evacuation of a large

diameter pipeline installed under great depths of water, where buckling design may be necessary.

References

1. Timoshenko, S., “The Theory of Elastic Stability,” Eng. Society Monograph,

McGraw Hill (1936).

2. “American National Standard for the Thickness Design of Ductile Iron Pipe,”

ANSI/ AWWA C150/ A21.50.

3. “American National Standard for Ductile Iron Pipe, Centrifugally Cast,

for Water of Other Liquids,” ANSI/ AWWA C151/ A21.51.

4. Lusher, U., “Buckling of Soil-Surrounded Tubes,” Journal of the Soil Mechanics and

Foundations Division, ASCE, November 1966.

5. Glascock, B., “Design Method for Elastic Ring Buckling of Buried Flexible Pipes,” Amoco

Reinforced Plastics Company, Techite Technical Report No. ER-01052,

February 20, 1980.

6. Glascock, B. and Cable, L. L., “Recommendations for Elastic Buckling Design Requirements

for Buried Flexible Pipe,” AWWA Annual Conference Proceedings, 1982.

14
For more information contact DIPRA or any
of its member companies.

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