Section One: Introduction

SPI RALWELD PI PE
History of Steel Pipe
Pipelines in one form or another have been
used since the early days of civilization.
Thousands of years ago, the Chinese used
bamboo to transport water. In the United
States, pipelines made of bored-out logs
were placed in service as early as 1652.
The use of ferrous materials for piping systems in the
United States began with the use of gray iron pipe in 1804. Gray iron pipe
played a key role in the development of many major cities. It was eventually replaced by pipes
made of ductile iron, which offered improved metallurgical properties.
Early growth and expansion of steel pipe
manufacturing came with the development of
processes for refining iron into steel. The Bessemer
process developed in 1855 and the open-hearth
process developed in 1861 not only yielded steel,
but also made it stronger, more ductile, and more
cost effective. It was then possible to cold form
steel sheets into large diameter pipes. Virtually all
the early steel pipes were produced by rolling
lengths of steel plate, usually 4-to-8 ft. (1.2 to 2.4 m)
long, into cylinders and riveting the seams and
joints to fabricate lengths of steel pipe up to 30 ft.
(9.1 m) in length.
The first recorded installation of steel pipe with riveted seams occurred in Railroad Flat, California,
in 1858. Records show that some installations of steel pipe in San Francisco laid in 1863 are still
in use today. Large diameter riveted steel pipes supplied the needs of our growing nation for more
than 50 years. The labor intensive assembly of riveted pipe seams and joints was replaced by the
development of the lock seam method in 1905. In the early 1900s, electric welding processes were
being developed and, by 1932, replaced the lock seam joining method for forming steel pipe.
The next major breakthrough for steel pipe manufacturing was the spiral-weld seam process. This
process allowed coiled or sheet steel to be fed into a machine that cold formed the flattened sheet
into a pipe cylinder with helically welded seams. This allowed the length of a pipe to be almost
unlimited, instead of relying on the length of the forming rolls or plate.
Spiral-welded steel pipe today is made from the highest quality steels and manufactured by modern
helical forming machines using electric double submerged arc welding.
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Common Uses
Steel pipe meeting the requirements of AWWA C200 has been used for applications such as:
Transmission Mains Force Mains
Penstocks Power Plant Circulating Lines
Aqueducts Aerial Pipe Crossings
Intakes and Outfalls Treatment Plant Piping
Pump Station Piping Trenchless Installations
An Introduction to AMERICAN SpiralWeld Pipe
To meet growing demand in the marketplace,
AMERICAN Cast Iron Pipe Company expanded its
product line in 2000 to include spiral-welded steel
pipe in diameters up to 144 in. (3,600 mm). Made by
AMERICAN SpiralWeld Pipe Company, LLC in
Columbia, South Carolina, this product line
complements AMERICANs ductile iron pipe and
steel pipe product lines.
As the population growth of the United States
continues to trend upward, so does the demand for
utility infrastructure, including larger pipelines to serve the water, wastewater, hydroelectric, and
power generation industries. Spiral-welded steel pipe is used as water transmission and
distribution lines; outfall lines for wastewater; penstocks for hydroelectric facilities; and cooling
water lines by power generation facilities. In addition, spiral-welded steel pipe is used as structural
pipe piling and casing pipe by the construction industry.
AMERICAN SpiralWeld is housed in a state of-the-
art facility on a 150-acre site in Columbia, South
Carolina. The manufacturing plant encompasses
290,000 square ft. (27,000 square m) and is laid out
in three contiguous buildings, allowing the pipe to
be produced under roof from start to finish.
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Facility Mission
Our mission is to produce premium quality steel pipe in diameters up to 144 in. (3,600 mm) for the
water, wastewater, power, structural and industrial markets.
Strategic Location
AMERICAN SpiralWeld Pipe is located just eight miles (13 km) from downtown Columbia, South
Carolina, a major transportation hub for three major interstate highways, I-20, I-77 and I-26. Within
a 100-mile (160-km) radius, there is access to other major interstate highways, including I-95 and
I-85. In addition, AMERICAN has rail access to CSX and Norfolk-Southern railroads that border its
site and can ship from the Port of Charleston to its international customers and others with water
access. With excellent rail access and AMERICANs network of distribution centers across the
country, AMERICAN is able to serve a large portion of the country.
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AMERICAN Cast Iron Pipe Company
Company Philosophy
Organized in 1905, AMERICAN Cast Iron Pipe Company,
located in Birmingham, Alabama, USA, is a renowned
manufacturer of ductile iron pipe, spiral-welded pipe,
hydrants and valves for the waterworks industry and steel
pipe for the oil and natral gas industries. AMERICANs
diversified product line also includes static castings
and high-performance fire pumps.
The company was founded by John J. Eagan, a devotedly
religious man who adopted as the companys governing
philosophy the Golden Rule: treat others the way you want
to be treated. Upon his death in 1924, Mr. Eagan willed
ownership of the company in a trust to the employees.
Today, the Golden Rule remains the companys guiding
principle, ensuring strong relationships with our customers,
each other and our community. Its how we do business:
The Right Way.
AMERICAN Cast Iron Pipe Company
Divisions and Subsidiaries:
AMERICAN Ductile Iron Pipe
AMERICAN Flow Control
AMERICAN Valve & Hydrant
Waterous Company
American Steel Pipe
AMERICAN SpiralWeld Pipe Company, LLC
Specification Rubber Products, Inc
AMERICAN Castings
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John Joseph Eagan,1870-1924
First president of the American Cast Iron Pipe
Company from 1905 to 1915, chairman of the
Board of Directors from 1915 to 1921, and
president again from 1921 until a few days
before his death on March 30, 1924.
Building on Experience, Growing on Success
AMERICAN SpiralWeld Pipe complements the AMERICAN
family of companies.
AMERICAN Ductile Iron Pipe is a leader in ductile iron pipe,
having a significant number of industry firsts. These firsts
include development of the cement mortar lining process,
co-development of ductile iron, and development of large
diameter pipe casting up to 64 in. (1,600 mm) in diameter.
AMERICAN was also the first ductile iron pipe manufacturing
plant in North America to achieve ISO 9000 certification.
AMERICAN Flow Control is a leading
manufacturer of resilient seated gate valves,
check valves, and fire hydrants. It has
manufacturing plants in South St. Paul,
Minnesota, and Beaumont, Texas.
AMERICAN Steel Pipe produces high quality
API electric resistance welded (ERW) piping in
pressures to 3,000 psi (21 MPa) for the
petrochemical industry. Formed as a division
of AMERICAN in 1963, AMERICAN Steel Pipe
has produced more than 36,000 miles
(58,000 km) of ERW pipe enough to encircle the earth one-and-a-half times. AMERICAN Steel
Pipes state-of-the-art production facility is ISO 9001Certified, offering the highest quality assurance.
It also enjoys the benefits of strong relationships with its steel suppliers throughout the United States.
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State of the Art Manufacturing Facility A Pictorial Tour
Coil Steel
The manufacture of AMERICAN SpiralWeld
Pipe begins with high quality steel received
in coils up to 80 in. (2,000 mm) wide and
weighing as much as 50 tons. Dual rail
access allows AMERICAN to cost effectively
obtain the materials from across the country
that meet or exceed customers quality
requirements.

Spiral-welded Pipe Mills
AMERICANs twin spiral mills have the capacity
to handle coils of steel from 0.1875 in. (4.8 mm)
to 1 in. (25.4 mm) in thickness, with yield
strengths up to 70,000 psi (482 MPa), to produce
high-quality, spiral-welded steel pipe up to 144 in.
(3,600 mm) diameter. This flexibility offers
AMERICANs customers a wide variety of options.
Pipe forming begins when the coils are loaded
into the forming section. The steel coil is unwound
and fed through the first of four sets of flattening
rolls. The flattened coil continues through the
forming section that is set at the required angle,
based on the diameter of the finished cylinder,
and the coil thickness and width.
The flattened sheet is then reformed by a series
of three sets of rollers and becomes a spiral-weld
seamed cylinder. High quality interior and exterior
submerged-arc welds, precisely controlled by
programmable logic controllers (PLCs), are
positioned by the mill operator using remote video
monitoring. At the customers request, these welds
may be tested using Kraut-Kramer ultrasonic
inspection equipment.
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Coil Steel
Twin Spiral-Welded Pipe Mills
Forming Section

The finished spiral-welded pipe cylinder feeds to
the run out section of the mill where the pipe is cut
to exact length. Steel cylinders fabricated for
structural pipe may be cut to standard lengths up
to 80 ft. (24 m). Cylinders fabricated for either C200
or structural pipe requiring hydrostatic testing may
be cut to nominal lengths from 20 ft. (6 m) to 55 ft.
(17 m).
Material Handling System
Finished pipe cylinders are moved through the
production process by an efficient and
ergonomically-friendly pipe handling system.
Remote controlled, hydraulic pipe pushers and
stops move the pipe on storage racks. Between
the storage racks, the pipe is moved and indexed
for the next process by carts capable of moving
large diameter, thick-walled pipe.
Hydraulic Expander
Formed bell ends require use of a hydraulic
expander to accurately expand the bell end of the
cylinder. This allows a precision joint fit in the field,
which means easier assembly and increased
production. The pipe expansion processing area
includes a remote-controlled pipe turnstile that
allows the operator to expand each end of the
cylinder as required.
AMERICAN hydrostatically tests cylinders to AWWA
C200. Structural pipe may also be hydrostatically
tested when requested by the customer. The
hydrostatic testing machine is designed to
accommodate nominal joint lengths from 20 ft.
(6 m) to 55 ft. (17 m), pressures up to 3,700 psi
(26 MPa) and thrusts up to 6,000,000 lbs.
(27,000 kN). The process is controlled by a PLC.
A sequence of pumps efficiently fill, then test pipe cylinders to a pressure that induces a
circumferential stress of at least 75% of the materials specified minimum yield strength. This
testing ensures quality cylinder fabrication.
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Pipe Forming and OD Stabilizers
Hydraulic Expander
Hydrostatic Tester
Cement Mortar Lining (AWWA C205)
After successful hydrostatic testing, the pipe is
moved by remote control carts into the lining
preparation area. The approach to the lining
processing area is used to prepare the pipe for
application of cement mortar. This preparation
includes the installation of the rubber dams that
are placed in both ends of the pipe to keep the
joint areas free of cement mortar. It can also
include the application of round-up rings secured
to the exterior of the pipe to maintain dimensional
stability during application of the lining, which is
applied using centrifugal force.
AMERICANs belt-driven cement mortar lining
machine can process pipe up to 120 in. (3,000 mm)
in diameter with cement mortar linings up to 1 in.
(25.4 mm) thick. The belt-driven machine rotates
the pipe at high speed to create a centrifugal force
equivalent to about 70 gs on the applied mortar. As
the pipe spins, cement is poured along the interior
of the pipe. Centrifugal force ensures even
distribution of the cement.
After lining, the pipe is moved to the curing area
where the ends are capped before curing the lining with steam. The densely compacted cement
mortar allows excellent flow through the pipe and provides additional structural rigidity for buried
pipe installation. At AMERICAN, the standard for steel pipe with a cement mortar lining is a finished
inside diameter equal to or greater than the nominal pipe diameter.
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Cement Lining Staging Area
Cement Mortar Liner
Tape Coating (AWWA C214)
The tape coating area includes two parallel pipe
translators, or conveyors. The first set of translators
move the pipe through a pre-heating cabinet to
eliminate any moisture on the pipe and elevate the
temperature of the pipe for application of the three-
layer tape system. Immediately after the pipe exits
the pre-heating cabinet, the pipe enters the blast
cabinet where the surface is prepared for
application of the tape.
The second translator moves the pipe through a
second pre-heating cabinet which continues to
heat the pipe to the appropriate level for application
of the tape. Next, the pipe enters a spray booth
where a liquid adhesive is sprayed onto the exterior
surface. The pipe then receives a 20-mil dielectric
tape, which is tested for holidays, or flaws, using a
high voltage sensor. Next, the pipe receives a 30-mil
mechanical protective layer of high-density
polyethylene. The pipe coating system is completed
when a final 30-mil mechanical layer of high-density
polyethylene is applied. The pipe temperature, and
the temperature and application pressure of each
tape layer are monitored during the coating process.
The pipe then exits the facility.
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Pipe entering Pre-Heat Cabinent
Three Layer Polyethylene Tape Wrap System
Completed Pipe exiting Facility to Pipe Storage
Polyurethane Coating (AWWA C222)
The polyurethane area includes two parallel pipe
translators, or conveyors. The first set of translators
move the pipe through a pre-heating cabinet to
eliminate any moisture on the pipe and elevate the
temperature of the pipe for application of the
polyurethane. Immediately after the pipe exits the
pre-heating cabinet, the pipe enters the blast
cabinet where the surface is prepared for the
application process.
The second translator moves the pipe through a
second pre-heating cabinet which continues to
heat the pipe to the appropriate level for application
of the polyurethane. Next, the pipe enters a spray
booth where liquid polyurethane is sprayed onto
the exterior surface. The pipe temperature, and the
temperature and mix ratio of the polyurethane
material are monitored during the coating process.
Immediately after application the coating is tested
for holidays, or flaws, using a high voltage sensor,
followed by in-line thickness verification. The pipe
then exits the facility.
Fitting Fabrication
AMERICAN supplies a full line of fittings, including
fittings fabricated from spiral-welded pipe cylinders,
and/or cylinders rolled and welded from plate steel
up to a thickness of 3 in. (76 mm).
Loading and Transportation
After the pipe is manufactured, it is moved to a
staging area for delivery to the customer. Here, the
pipe will receive a thorough inspection before sets
of vertical and horizontal supports, called bracing,
are installed. The ends of cement mortar lined pipe
are then sealed to maintain an appropriate moisture
level inside the pipe.
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Pipe entering (l to r) Pre-Heat Cabinet and Blast Cabinet
Fitting Fabrication
Pipe being loaded for Shipment

When the pipe is ready for shipment, a Project Specialist with AMERICANs Customer Service
Department in Birmingham 866-442-ASWP (2797) releases the pipe and/or fittings for shipment
as determined by the customer. AMERICANs business systems software automatically prints the
necessary pick list and shipping documents to AMERICANs Traffic Department in Birmingham
and to AMERICAN SpiralWeld in Columbia. The Traffic Department orders the necessary number
and types of trucks or rail cars, while AMERICAN SpiralWeld makes final preparations for loading
and shipment.
ASWP Capabilities
AMERICAN SpiralWeld Pipe offers its customers the following capabilities:
Pipe meeting or exceeding the requirements of
AWWA C200, ASTM A139, or ASCE Manual No. 79
Sizes 24 to 144 in. (600 to 3,600 mm) diameter
Wall thickness up to 1 in. (25.4 mm)
Standard nominal lengths from 20 to 55 ft. (6 to 17 m)
Rubber gasket joints up to 84 in. (2,100 mm) diameter
Weld-bell joints up to 144 in. (3,600 mm) diameter
Butt-welded joints up to 144 in.(3,600 mm) diameter
Cement mortar lining meeting or exceeding the requirements
of AWWA C205; including the ability to apply the lining to a
thickness exceeding 1 in. (25.4 mm)
NSF/ANSI Standard 61 Certification
External polyethylene tape coating meeting or exceeding the
requirements of AWWA C214
Internal and external polyurethane coating meeting or exceeding
the requirements of AWWA C222
(Contact AMERICAN for a complete list of coatings and linings available.)
Structural pipe or pipe piling in the above dimensions meeting or
exceeding the requirements of ASTM A252
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Quality Assurance and Testing
AMERICAN SpiralWeld Pipe is a member of the Steel Tank Institute &
Steel Plate Fabricators Association (STI/SPFA), dedicated to the
promotion of steel as the choice material for quality piping for the
petroleum, chemical, food and water storage industries; steel tanks;
pressure vessels; and specialty products. AMERICANs production
facility in Columbia and the Customer Service Department in
Birmingham are quality accredited by the SPFA Quality Certification
Program. This accreditation certifies AMERICANs design and
fabrication processes meet the highest standards.
AMERICANs employees are dedicated to producing the highest quality products. All welders are
qualified per ASME Section IX, AWS B2.1, or AWS D1.1. AMERICANs Quality Assurance Depart-
ment is staffed with SNT-TC-1A certified NDE Technicians and AWS Certified Weld Inspectors.
AMERICAN Customer Service
866-442-ASWP (2797)
AMERICANs experienced Sales Engineers review initial and final designs to recommend solutions
to complex design and specification issues. AMERICAN Sales Engineers are located throughout
the US. Sales Engineers, Customer Service personnel and other support staff work together with
contractors, engineers and owners to ensure the sales order is accurately scheduled, properly
ordered, and delivered on time. Upon award of each order the project is assigned to a Project
Specialist who serves as the single point contact throughout the project life cycle.
AMERICANs Chief Engineer, Project Engineer, and Customer Service team provide customers with
a wealth of product design experience. This translates into customer confidence in AMERICANs
ability to develop and deliver complex steel pipe designs and fitting configurations.
While AMERICAN Customer Service personnel are involved in
numerous critical tasks, none is more important for our
customers than the preparation of the project specific submittal
package. This submittal includes: pipe design calculations, which
consist of a thorough analysis of internal pressure and external
loading conditions based on the engineers plans and
specifications; the pipeline layout drawings, which show the
layout of the pipeline in the horizontal and vertical planes,
detailing locations of all control points and appurtenances; and
detailed drawings of all straight pipes, pipe specials, pipe fittings,
etc., based on the pipeline layout drawings.
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These submittal materials are developed using Twister, a sophisticated, Windows-based software
program developed by AMERICAN. The program takes survey data, in most any format (baseline,
offset, centerline, etc.), and provides a three-dimensional rendering with optimized dimensions and
details of the pipeline, pipe specials and fittings needed for fabrication.
Field Service
To assist customers in the efficient, economical, and quality
installation of AMERICAN spiral-welded steel pipe, experienced
factory trained field representatives are on staff.
Field Welding (AWWA C206)
AMERICAN manufactures several joints configured for field
welding. Field welding should be completed using qualified
welders, following AWWA guidelines, and as required by
project specifications or governing codes.
Gasketed Joints
AMERICAN manufactures several different rubber-
gasketed joints to meet our customers requirements for
internal pressure and leak proof performance while
providing quick and efficient assembly. Joints are
manufactured per the requirements of the AWWA
standards.
Steel Pipe Design Overview
There is essentially one criterion for the design of a steel pipe: internal pressure. Once the
thickness for internal pressure has been determined analyses are performed to verify the pipes
adequacy with respect to external loads, buckling (or vacuum), and handling. For many projects,
the wall thickness recommended to allow reasonable handling of the pipe is adequate for all
anticipated loading concerns. AWWA M11 and AISI Volume 3 are excellent sources of information
for the design professional.
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Handling
The conservative wall thickness recommended for the handling
of steel pipe during the manufacturing, shipping, and
installation phases of a project is dependent on the type of
coating and lining specified by the owner or owners engineer.
Steel pipe with flexible coatings and linings (e.g., epoxies,
polyurethanes) should have a minimum diameter/wall thickness
ratio (D/t) of 288. For conventional cement mortar lined steel
water pipe, the recommended D/t ratio is no more than 240.
Internal Pressure
Internal pressure is the only condition for which design must be truly performed for buried steel
pipe. Design is based on the hoop stress formula t = PD/2S, where t is wall thickness, P is internal
pressure, D is pipe diameter, and S is the allowable stress. AWWA Manual M11 provides guidelines
for the design of pipe subject to various pressure conditions. For operating or working pressures,
S is generally 50% of the minimum specified yield strength of the steel. For temporary pressures,
such as transient or test pressures, S is generally 75% of the minimum specified yield strength of
the steel.
External Load
After the wall thickness has been calculated to withstand
handling and internal pressure conditions, the design should
be checked for allowable deflection. A cement mortar lined
pipe with a flexible coating should not exceed a design
deflection of 3%. While a compacted soil envelope of
approximately 85% standard Proctor is adequate for the
majority of installations, for deeper covers an improved soil
envelope may be warranted. Note: A steel pressure pipe will
tend to re-round after being placed in operation.
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Buckling
To date, modern steel pipe manufactured to recommended handling thicknesses has not experi-
enced a buckling failure in a compacted soil environment. As with external load, the soil envelope
should be designed and relied upon to provide the pipe adequate support to resist buckling. As
found in laboratory testing, buried steel pipe must first undergo approximately an 18% or greater
deflection before it is susceptible to a buckling failure. For an exposed or subaqueous pipe condi-
tion, however, design criteria established in AWWA M11 should be followed.
Design Detail
See Section II Steel Pipe Design (see AWWA Manual M11)
References
References for History of Steel Pipe:
History of Steel Pipe from Steel Plate Engineering Data-Volume 3, Welded Steel Pipe, pg. 2-3.
Early History and Development from The Handbook of Steel Pipe Committee of Steel Pipe
Producers and the American Iron and Steel Institute, pg.2.
Who Pioneered Bessemer Steel-Sir Henry Bessemer or William Kelly? and Steel Makers of
United States Pushed Open Hearth Process to Maturity from Articles on the History of Americas
Iron & Steel Industry. Articles appeared in Steel Facts from 1940 to 1948, pgs. 65-6 & 73-4.
Municipal Installations Report on Steel Pipe Lines for Underground Water Service conducted by
the Underwriters Laboratories, Inc., Special Investigation 888 on July 22, 1936, pg. 13.
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A Subsidiary of AMERICAN
P.O. Box 2727
Birmingham, AL 35202-2727
Phone: 1-866-442-ASWP (2797)
Email: [email protected]
WWW.AMERICAN-USA.COM
Note: The contents of this Field Service Guide are provided for informational purposes and convenience. It remains the responsibility of the installing
contractor to comply with the requirements of the projects plans and specifcations, and in the event of a confict, the terms of the plans and specifcations
shall govern and control. However, to the extent any sales representative or other agent or representative of AMERICAN makes any statement that
conficts with the contents of this Field Service Guide, the contents of the Field Service Guide shall govern and control, and it shall be the responsibility
of the installing contractor to comply with the terms of the Field Service Guide, subject, however, to the preceding sentence.