🧿1. Main Causes of Ductile Iron Pipe Leakage

The causes of ductile iron pipe leakage vary, but can be summarized as follows:

1. Joint Leakage (Most Common):

Rubber Ring Issues: Aging, deformation, misalignment during installation, or loose compression of the rubber ring in the socket joint can lead to seal failure.

Improper Installation: Misalignment of the socket joint, insufficient insertion depth, or excessive rotation angle during installation can result in a loose rubber ring seal.

Poor Support: Uneven settlement of the foundation beneath the pipe or inadequate backfill can lead to uneven stress on the pipe and cause the joint to pull apart.

2. Pipe Leakage:

Corrosion Perforation: Pipes buried underground for long periods of time are corroded by soil acids and alkalis, stray currents, or bacteria, causing the pipe wall to thin and eventually perforate.

External Damage: Careless digging or cracking of the pipe during other construction work (such as excavation).

Frost Cracks: In cold regions, water in the pipe freezes and expands, causing cracks in the pipe. Pressure shock: Water hammer, or a sudden, sharp increase in system pressure, impacts the pipe wall, causing cracks in weak spots.
Manufacturing defects: In rare cases, the pipe body may contain original casting defects such as pinholes and air holes.
3. Other causes:
Uneven settlement: Significant changes in geological conditions along the pipeline route or nearby large-scale construction can cause uneven settlement of the foundation, leading to pipe fractures.
Natural disasters: Earthquakes, landslides, and other natural disasters can cause pipe misalignment or fractures.

🧿2. Treatment methods for ductile iron pipe leaks

Different treatment methods are available depending on the location and severity of the leak:

1. Shut down and repair (traditional method)

For leaking joints: Drain the pipe, dig the work pit, remove the old rubber ring from the socket, clean it, and reinstall a new rubber seal. If necessary, use a stainless steel flange clamp to reinforce the joint. For small leaks in pipes: After shutting off the service, welding repairs can be performed (requiring professional welders and specialized welding rods, and is technically challenging) or using pipe clamps (metal clamps with rubber pads) to directly wrap the leak and tighten the bolts.
For severe ruptures: The service must be shut off, the damaged pipe section cut off, and then replaced with a double-disc straight pipe or short socket-and-spigot pipe. Flanges or socket-and-spigot joints are then required for reconnection.

2. Repair without Shutting Down the Service (Common Modern Method)

Using Pipe Leak Repair Clamps: This is currently the most popular and efficient repair method, particularly suitable for emergency repairs, significantly shortening service outages.

🧿 3. Advantages of Using Leak Repair Clamps

A leak repair clamp (also known as a leak repair clamp or pipe patch) is a device designed specifically for quickly plugging pipe leaks. It typically consists of two semicircular metal shells, an internal sealing rubber ring, and fastening bolts. Its advantages are significant:

1. Fast and efficient, significantly reducing water outage time:
From locating the leak to completing the repair, it can typically be completed within 1-2 hours, or even faster. This is crucial for ensuring water supply for residents and continuous production in factories.

2. No welding required, safe and easy to operate:
The entire repair process requires no hot work or welding, eliminating the risks of working in humid and flammable environments, making it extremely safe. Operators can easily master this product after simple training.

3. Wide range of applications and high versatility:
A single leak repair clamp can be used for a range of pipe diameters (e.g., a DN100 leak repair clamp can be used for pipes 98-102 mm in diameter), minimizing inventory requirements.

It can repair cracks and holes in pipes as well as leaks at joints, providing a versatile solution.

4. Excellent sealing performance and high reliability:
Using high-quality rubber sealing rings and high-strength bolts to apply uniform pressure, it achieves a 360° seal. Its pressure resistance typically exceeds the original design pressure of the pipe and offers excellent durability. 5. Significant Economic and Social Benefits:
Cost Savings: While the price of a single leak repair clamp may be higher than traditional materials, it saves significant labor costs, machine hours, and the significant indirect economic losses caused by water outages.
Impact Reduction: Minimizes the impact on water users, resulting in significant social benefits.

Using a Leak Repair Clamp (Brief Steps):

1. Locate and Excavate: Accurately locate the leak and dig a sufficiently large pit.

2. Clean the Surface: Thoroughly remove the anti-corrosion coating, rust, and debris from the pipe surface around the leak, leaving it smooth and flat.

3. Install the Leak Repair Clamp: Place the two pieces of the leak repair clamp on the leaking pipe, aligning the bolt holes.

4. Tighten the Bolts: Evenly tighten all bolts, alternating diagonally, until the seal is fully compressed and the leaking stops.

5. Backfill: Once the repair is complete, backfill and restore the road surface.

The housing is typically made of metals such as ductile iron and carbon steel, which are corrosion-resistant and high-strength. It can last the same life as the original pipe, eliminating the need for frequent repairs. Baoshuo brand carbon steel half joints are available in a variety of rubber materials, including NBR, EPDM, FKM, and silicone rubber. The half joint body is available in Q235 carbon steel and 304 and 316L stainless steel.

The following are Baoshuo brand oil-resistant pipe repair clamps, high-temperature-resistant pipe repair clamps, acid- and alkali-resistant pipe repair clamps, stainless steel pipe repair clamps, high-pressure-resistant pipe repair clamps, and large-diameter pipe repair clamps.

To summarize:

The main causes of ductile iron pipe leaks are joint problems and pipe corrosion/damage. Pipeline leak repair clamps (leak repair clamps) have become the preferred technology for modern pipe network repairs due to their significant advantages of speed, safety, reliability, and efficiency. They are particularly suitable for emergency repairs where water outage time is critical. For large or specialized damage, traditional pipe replacement procedures may still be necessary.