ductile iron pipes and fittings_electrosteel casting ltd.pdf

7/27/2019 Ductile Iron Pipes and Fittings_Electrosteel Casting Ltd.pdf

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DUCTILE IRON PIPES

AND FITTINGS

ELECTROSTEEL CASTINGS LIMITED

S E W E R A G E

P O T A B L E W A T E R

KI

T

EM

A

R

K

B S E N 5 4 5

B S E N 5 9 8

I S O 2 5 3 1

IS

O

9

0

0

1

I S O 7 1 8 6

I

SO

1

4

00

1

D

V

GW

S

IR

IM

K

S

A


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This Ductile Iron pipes and Fittings catalogue willillustrate how pipes and fittings are made, their

principal features and the extensive quality that

is built into every stage of the production

process. Electrosteel castings is committed tooffering advice to customers on the technical

specifications and the internal and external pro-

tection systems. This service extends to handlingand installing ductile iron pipes and fittings.

Electrosteel Castings recommendations come

with the experience accumulated over fourdecades of pipe-making. Since local conditions

may vary from country to country Electrosteel

castings encourages its customers to make con-tact for any assistance. This catalogue is not a

technical manual. Electrosteel Castings advises

its customers to strictly follow the relevantapplicable standards for selection, specification,

installation and testing.

Note. : Further additional information will become available as the need dictates. This will be as separate information documents.

Oct, 2006


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CONTENTS

Vision and Quality Policy 2

Environmental Policy 3

Achievements 4

Quality assurance 5

Quality checks & manufacturing process 6

Ductile iron and its advantages 8

Push-on flexible joint 9

Restrained joint 12

Mechanical joint 13

Socketed fittings 14

Flanged pipes and fittings 18

Coating and lining 26

Packing 29

Handling 30

Stacking 32

Pipe Cutting 35

Ovality Correction 36

Repair of Damaged Cement Mortar Lining 37

Laying and Jointing 38

Relevant standards 40


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2

QUALITY

POLICYECL is committed to providing goods and services which meet customers expectations and needs.The aim is to achieve Quality Right the First Time.

ECL is committed to complying with the requirements and to continually improve the effectivenessof quality management system through teamwork, training and motivation.

ECL shall formulate Quality goals for all functions and involve employees in fulfilment of the same.

VISIONECL aims to be world class, committed to

customer satisfaction and to encourage the

spirit of leadership amongst our dedicated

team by creating a healthy environment for

continuous growth, profit and prosperity.

Centrifugal casting


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3

Electrosteel Castings Limited is

committed to :

Meet environmental legislation andregulation as applicable, on an on-

going basis, with an aim to improve

the quality of life.

Strive for prevention of pollution

through continuous improvement of

process, Technology & equipment,

wherever applicable.

Aim to achieve continuous

improvement of environmental

performance through setting of

objectives and targets and reviewing

results.

Promote conservation of resources.

Communicate environmental policyto all employees and to ensure that

this policy is available to all interested

parties.

ENVIRONMENTALPOLICY


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4

ACHIEVEMENTS

1994 Set up a 60,000 tpa ductile iron spun pipe plant at Khardah near Calcutta, thefirst ever in India.

1995 Accredited with ISO 9002 from Indian Register Quality System an Accreditedbody of Raad Voor de Certificate of Netherlands for our ductile Iron pipes.

1996 Obtained KITEMARK license from British Standard Institute for our ductileiron pipes as per ISO 2531, BS EN 545, BS EN 598. Commissioned own mini blast

furnace for better quality control.

1999 ISO 9002 accredition from British Standard Institute for DI pipes and fittings.

2000 Capacity increased progressively to 130,000 tpa for ductile iron pipes,125,000 tpa for cast iron pipes.

Obtained KITEMARK License from British Standards Institution, UK for Ductile Iron

Fittings at our manufacturing facilities in Elavur, near Chennai as per ISO 2531, BS EN

545, BS EN 598.

1994-2000 ECL is regularly exporting DI Pipes and Fittings to Singapore,Malaysia, Hong Kong, Brunei, Vietnam in South East Asia & Indo-China; Nepal, Bangladesh,

Sri Lanka in South Asia ; Qatar, Oman, Kuwait, Bahrain in the Gulf ; Lebanon, Syria in the

Middle East ; Algeria, Ethiopia, Namibia and Egypt in Africa.

2003 Accredited with ISO 9001-2000 and ISO 14001-2004 from Indian RegisterQuality Systems, an Accredited body of Raad Voor de Certificate of Netherlands for our

ductile Iron pipes. Electrosteel increased its DI pipe manufacturing capacity from 1,50,000

tpa to 2,00,000 tpa.

2004 Accredited with ISO 9001:2000 for the manufacture and supply of D.I.Pipes,Fittings, Accessories and their joints, from British Standard Institute.

2005 Backward integration has been further achieved by setting up a Captive Cokeoven plant at Haldia, West Bengal. Electrosteel achieves three star export house status.

2006 Electrosteel set up 12mw captive power plant at Haldia using waste gas fromCoke Oven plant. Electrosteel increases its DI pipe manufacturing capacity from 2,00,000

to 2,50,000 tpa.


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CERTIFICATIONS

Certificate of approval from the British Standards Institution ( BSI) certifying that

our quality management system complies with the requirements of ISO 9001:2000.

ECL is committed to providing goods and services which meet customers expectations and needs.

The aim is to achieve Quality right the first time.

ECL shall constantly strive for continuous improvement through teamwork, training and motivation.

QUALITY ASSURANCE

ISO 9001 APPROVED BY IRQS

IRQSA DEPARTMENT OF INDIAN

REGISTER OF SHIPPING

RvCACCREDITED BY THE

DUTCH COUNCIL FORACCREDITATION

Licensed to use KITEMARK

KM 34577

KM 39560

KM 52142

KM 39166

KM 39167

KM 39168

Certificate of approval, from Indian Register Quality Systems an

Accredited body of Raad Voor de Certificate of Netherlands certifying

that our quality management system is in accordance with the

requirements of ISO 9001-2000.

We also have KSA ( South Korea), DVGW ( Germany) and SIRIM ( Malaysia) approvals for our products.

5British Standards Institution has granted the Right & License to use KITEMARK on

Ductile Iron Pipes & Fittings manufactured and supplied in conformity with ISO 2531 /

BS EN 545 / BS EN 598.


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Strict selection of raw material is an indispensable requirement to produce

quality ductile iron pipes & fittings. Electrosteel endeavours to achieve Quality

right the first time with strict quality control on raw material selection and

procurement.

Electrosteel commissioned its Mini Blast Furnace (MBF) at its plant at

Khardah using TKES technology. The MBF produces l iquid metal suited tomanufacture ductile iron pipes. The liquid metal is further processed and super

heated in induction furnaces. It is then treated with Magnesium for nodularisation

and transferred to the centrifugal spun casting machines.

The pipes are heat treated, zinc coated, hydrostatically tested, cement mortar

lined and finished with a layer of bitumen coating / epoxy.

The in-process inspection and quality control at all points during the

production cycle is strictly maintained and documented as per ISO 9001 quality

systems.

6

QUALITY CHECKS AT EVERY

STAGE OF MANUFACTURING


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7

PROCESS

Blast Furnace Analysis of Raw Materials Zinc Coating Thickness

Chemical Composition Dimensional checks

Micro & Chemical Composition

Internal lining ThicknessTemperature

External coating ThicknessMicro structure Flattening

Hydraulic Test

Induction Furnace

Mg Treatment

Pipes spinning

Heat treatment

TESTING PROCESS TESTING

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Pressure

Thickness & Dia

DE

e


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8

GREY CAST IRON VS DUCTILE IRON

DUCTILE IRON AND ITS

ADVANTAGES

Micro-structure of Ductile IronMicro-structure of Grey Cast Iron

Cast iron is an alloy of carbon and iron where the graphite is

solidified out of the matrix. In grey cast iron the graphite is in the

form of flakes. In 1948 it was discovered that the flake graphite

structure could be modified where the graphite was in the form of

spheroid or nodules by the addition of magnesium to the molten

metal. This iron is now typically known as Ductile Iron or S.G. Iron.

The mechanical properties of ductile iron as compared to grey cast

iron show superior tensile strength, yield strength, ductility and

impact resistance. The use of ductile iron has grown at a rapid rate

over the past fifty years. The much improved properties were

recognised to be of particular benefit in the centrifugal pipe industry

and as such most of the pipe production is now in ductile iron.

PROPERTIES & ADVANTAGES OF DUCTILE IRON PIPE

High tensile strength High yield strength High impact

resistance High elongation (ductility) High fatigue

resistance Resistance to handling / transportation damage

Resistance to second cover damage Simple to join having

agreed joint deflection Resists longitudinal joint withdrawal.

Proven and cost effective internal and external corrosion

protection. Impermeable to gas and organic contaminant

Imported back-fill not normally required Full range of ductile

iron fittings available Easy pipe location when buried Low

skill level for jointing Under pressure connections are not

complicated Resistant to stray current effect due to electrical

discontinuity at joints

APPLICATION OF DUCTILE IRON PIPE

Transmission of raw, potable and sea water at high pressures

Distribution of potable water and gas.

Transmission of domestic and industrial effluent.

Fire-fighting systems - on-shore and off-shore

Ground conditions which are susceptible to subsidence and

movement

Under major carriage-ways

Piling

Hilly Terrains


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PUSH-ON FLEXIBLE

JOINT

Flexible Push-on Joint

PUSH-ON FLEXIBLE TYPEThe push-on flexible joint is an extremely strong and efficient joint,

extensively used throughout the world. Apart from normal anchoring

precautions on bends and tees, no bolt tightening is necessary and the

simple push-on connection with a single separate component - rubber

gasket - allows rapid, low cost pipe laying even in wet conditions.

The push-on joint assembly is supplied along with the accessories -

Rubber Gaskets (SBR / EPDM conforming Standards BS : EN 681- 1996/ ISO 4633 : 1996 / BS 2494 / 1990 and Lubricants.)

Rubber Gaskets and Lubricants shall be suitable for Potable Water as per

BS 6920 : 1996.

9


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Pipes are supplied in standard length of 5.5 metres. Short length pipes as per respective standards can be supplied.

In addition to Class K9 pipes, Electrosteel supplies C40, K7, K8, K10, and K12 classes of pipes

The thickness can be determined by the formula -

e = K ( 0.5 + 0.001DN )

PFA (allowable operating pressure) is the internal pressure, exclusive of surge, that a component can safely withstand in permanent service.

PMA (allowable maximum operating pressure) is the maximum internal pressure, including surge, that a component can safely withstand in service.

PEA (allowable test pressure) is the maximum hydrostatic pressure that a newly installed component can withstand for a relatively short duration,

when either fixed above ground level or laid and back-filled underground in order to measure the integrity and leak tightness of the pipe.

10

DN External Dia.DE Iron thickness 'e' for K9. Minimum Internal Pressure Rating (K9)

Nominal Tolerance Nominal Tolerance Works test PFA PMA PEAmm mm mm mm mm Pressure Max. Max. Max.

Bars (K9) Bars Bars Bars

80 98.0 ( +1 to -2.2 ) 6.00 -1.3 50 64 77 96

100 118.0 ( +1 to -2.8 ) 6.00 -1.3 50 64 77 96

150 170.0 ( +1 to -2.9 ) 6.00 -1.5 50 64 77 96

200 222.0 ( +1 to -3.0 ) 6.30 -1.5 50 62 74 79

250 274.0 ( +1 to -3.1 ) 6.80 -1.6 50 54 65 70

300 326.0 ( +1 to -3.3 ) 7.20 -1.6 50 49 59 64

350 378.0 ( +1 to -3.4 ) 7.70 -1.7 40 45 54 59

400 429.0 ( +1 to -3.5 ) 8.10 -1.7 40 42 51 56450 480.0 ( +1 to -3.6 ) 8.60 -1.8 40 40 48 53

500 532.0 ( +1 to -3.8 ) 9.00 -1.8 40 38 46 51

600 635.0 ( +1 to -4.0 ) 9.90 -1.9 40 36 43 48

700 738.0 ( +1 to -4.3 ) 10.80 -2.0 32 34 41 46

800 842.0 ( +1 to -4.5 ) 11.70 -2.1 32 32 38 43

900 945.0 ( +1 to -4.8 ) 12.60 -2.2 32 31 37 42

1000 1048.0 ( +1 to -5.0 ) 13.50 -2.3 32 30 36 41

L

e

DE

Ductile Iron Pipes for Water ConveyanceProduct Standards : BS EN 545 : 2002.

ISO 2531 : 1998.

IS 8329 : 2000.


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DN External Diameter DE (mm) Minimum Iron

(mm) Nominal Tolerance on Thickness. e (mm)

Diameter

100 118.0 +1 / - 2.8 2.5

150 170.0 +1 / - 2.9 2.5

200 222.0 +1 / - 3.0 3.0

250 274.0 +1 / - 3.1 3.5

300 326.0 +1 / - 3.3 4.0

350 378.0 +1 / - 3.4 4.3

400 429.0 +1 / - 3.5 4.6450 480.0 +1 / - 3.6 4.9

500 532.0 +1 / - 3.8 5.2

600 635.0 +1 / - 4.0 5.8

700 738.0 +1 / - 4.3 7.6

800 842.0 +1 / - 4.5 8.3

900 945.0 +1 / - 4.8 9.0

1000 1048.0 +1 / - 5.0 9.7

Ductile Iron Pipes for Sewerage ApplicationProduct Standards : BS EN 598 : 1995.

ISO 7186 : 1996.

1

L

e

DE


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12

This is a joint where restraining mechanism is

incorporated to normal flexible Push-On-

Joints. In some site conditions or laying

profile, axial pull-out forces are generated by

internal pressure at cross-sectional and

directional changes. Normal flexible Push-On-

Joints are incapable of withstanding such axial

forces, even with the help of conventional

thrust blocks. As a result, there are chances

of pull out of the pipe from the joints leading

to leakages.

Such joints ideally suit the following site or

laying conditions :

Directional changes in pumping.

Unstable ground conditions like marshygrounds, subsidence areas, seismic zones etc.

Hilly terrains.

Electrosteel offers such joints in size ranging

DN 80 to DN 1000. The mechanism adopted

by Electrosteel for restrained joint involves a

welding bead at the spigot end, glands, locking

ring and bolts & nuts. The gland and locking

ring, connected with socket collar by bolts &

nuts, create the restraining force against the

weld bead of the spigot, as the accessories

are supplied generally in DI.

Restrained joints of Electrosteel offers the

same degree of deflection as that of flexible

Push-On-Joints.

The performance of this joint will however

depend on by following the correct

procedures, as suggested by the

manufacturer. Electrosteel provides all the

details of such procedures to its customers.

GLAND

NUTBOLT

LOCKING RING

Details of Accessories

Nominal GLANDS BOLTS

Size (DN)

(mm) No. of Hole Dia. No. per Size Length

Holes (mm) Joint (mm) (mm)

80 4 28 4 M24 70

100 4 28 4 M24 70

150 6 28 6 M24 70

200 8 28 8 M24 70

250 6 30 6 M27 102

300 8 30 8 M27 102

350 8 30 8 M27 102

400 10 30 16 M27 102

450 16 30 16 M27 102

500 16 30 16 M 27 1 02

600 2 0 3 0 2 0 M27 102

700 24 30 24 M27 123

800 30 30 30 M27 123

900 30 30 30 M27 123

1000 30 30 30 M27 123

* For guidance only.

NUT GLAND

BOLT

GASKET

LOCKING RINGWELD BEAD

JOINT PROFILE

RESTRAINED JOINT


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13

Mechanical Jointing system is an easy to assemble bolted Flexible Jointing system. The sealing is obtained by applying pressure to the gasket by

mechanical means, viz. a separate gland. The gland when bolted with the pipe exerts pressure on the sealing rubber gasket and makes thejoint leak-proof. Accessories consist of gasket, a follower gland and Hook bolts with hexagonal covered nuts. The gland and bolts are made

from ductile iron. The advantage of mechanical joint is that the joint does not need extra equipment to push the spigot into the socket. Only

a ratchet type spanner is needed to tighten the nuts on the Hook bolt.

Main advantages of Mechanical joints are :

(a) In case the joint leaks the bolts can be tightened to stop leakage

(b) In case of failure of the joint the gasket can be changed from outside and again the joint can be redone without taking out the pipe, which

is essential for Push-on joint.

(c) The joints offer higher angle of deflection than push-on joint without leakage.

JOINTING PROCEDURE

Clean the spigot end of the pipe or fitting with a brush alongwith the socket of the pipe or fittings to be assembled.

Slide the gland over the spigot end followed by the gasket with the tip pointing towards the spigot end.

Introduce the spigot with the gasket and gland into the full depth of the socket and check the assembly for alignment

Slide the gasket along the spigot and engage it in its recess. Then slide the gland along into contact with the gasket.

Now engage the hook bolts and tighten the bolts in suitable sequence.

MECHANICAL JOINT


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Ductile Iron Socket Fittings

Double Socket 90 deg. Bend

Double Socket 45 deg. Bend

Double Socket 221/2 deg. Bend

Double Socket 111/4 deg. Bend

Duck-foot Bend.

Collars (Mechanical Joint)

Double Socket Taper

All Socket / Double Socket Flange Branch Tee.

Flange Socket

Double Socket Flange Branch Level Invert Tee.

Double Socket 900 Bend

Nominal

size e L

mm mm mm

80 7.0 55

100 7.2 65

150 7.8 85

200 8.4 110

250 9.0 130

300 9.6 150

350 10.2 175

400 10.8 195

450 11.4 220

500 12.0 240

600 13.2 285

700 14.4 330

800 15.6 370

900 16.8 415

1000 18.0 460

Double Socket 450 Bend

Nominal

size e L

mm mm mm

80 7.0 100

100 7.2 120

150 7.8 170

200 8.4 220

250 9.0 270

300 9.6 320

350 10.2 370

400 10.8 420

450 11.4 470

500 12.0 520

600 13.2 620

700 14.4 720

800 15.6 820

900 16.8 920

1000 18.0 1020

Product standards : BS-EN-545 : 2002 / ISO-2531:1998 / IS-9523 : 2000

Push on type socketed fittings are offered for 80mm to 1000 mm. sizes. Mechanical Joint socketed fittings are offered for sizes

DN 80-600 mm.

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15

Double Socket 221

/20 Bend Double Socket 11

1

/40 Bend

Nominal

size e L

mm mm mm

80 7.0 40

100 7.2 40150 7.8 55

200 8.4 65

250 9.0 75

300 9.6 85

350 10.2 95

400 10.8 110

450 11.4 120

500 12.0 130

600 13.2 150

700 14.4 175

800 15.6 195

900 16.8 205

1000 18.0 210

Nominal

size e L

mm mm mm

80 7.0 30

100 7.2 30

150 7.8 35

200 8.4 40

250 9.0 50

300 9.6 55

350 10.2 60

400 10.8 65

450 11.2 70

500 12.0 75

600 13.2 85

700 14.4 95

800 15.6 110

900 16.8 115

1000 18.0 120

Nominal

size e L c d

mm mm mm mm mm

80 7.0 110 110 180

100 7.2 130 125 200

150 7.8 180 160 250

200 8.4 230 190 300

250 9.0 280 225 350

300 9.6 325 255 400

350 10.2 380 290 450

400 10.8 430 320 500

450 11.4 480 355 550

500 12.0 530 385 600

600 13.2 630 450 700

700 14.4 735 515 800

800 15.6 830 580 900

900 16.8 930 645 1000

1000 18.0 1035 710 1100

Double Socket 900 Duck foot Bend

Nominal Dia

(DN) e L d

mm mm mm mm

80 7.0 160 109

100 7.2 160 130

150 7.8 165 183

200 8.4 170 235

250 9.0 175 288

300 9.6 180 340

350 10.2 185 393

400 10.8 190 445450 11.4 195 498

500 12.0 200 550

600 13.2 210 655

700 14.4 220 760

800 15.6 230 865

900 16.8 240 970

1000 18.0 250 1075

For operational convenience collars are with

mechanical joints only.

Collars


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16

All Socket and Flange on Double Socket Tees

Nominal Diameter (DN) e1 e2 L

Larger Smaller

End End

mm mm mm mm mm

100 80 7.2 7.0 90

150 80 7.8 7.0 190

150 100 7.8 7.2 150

200 100 8.4 7.2 250200 150 8.4 7.8 150

250 150 9.0 7.8 250

250 200 9.0 8.4 150

300 150 9.6 7.8 350

300 200 9.6 8.4 250

300 250 9.6 9.0 150

350 200 10.2 8.4 360

350 250 10.2 9.0 260

350 300 10.2 9.6 160

400 250 10.8 9.0 360

400 300 10.8 9.6 260

400 350 10.8 10.2 160

450 350 11.4 10.2 260

450 400 11.4 10.8 160

500 350 12.0 10.2 360

500 400 12.0 10.8 260

600 400 13.2 10.8 460

600 500 13.2 12.0 260

700 500 14.4 12.0 480

700 600 14.4 13.2 280

800 600 15.6 13.2 480

800 700 15.6 14.4 280

900 700 16.8 14.4 480

900 800 16.8 15.6 280

1000 800 18.0 15.6 480

1000 900 18.0 16.8 280

Double Socket Concentric Tapers Nominal Dia (DN) e e1 L HBody Branch Branch All Socket Flange on All Socket

Flange on doubledouble socket socket

mm mm mm mm mm mm mm mm

80 80 7.0 7.0 170 170 165 85

100 80 7.2 7.0 170 170 175 95

100 100 7.2 7.2 190 190 180 95

150 100 7.8 7.2 195 195 210 120

200 80 8.4 7.0 175 175 235 145

200 100 8.4 7.2 200 200 240 145

200 150 8.4 7.8 255 255 250 150

200 200 8.4 8.4 315 315 260 155

250 80 9.0 7.0 180 180 265 170

250 100 9.0 7.2 200 200 270 170

250 150 9.0 7.8 260 260 280 175

250 200 9.0 8.4 315 315 290 180

250 250 9.0 9.0 375 375 300 190

300 100 9.6 7.2 210 210 300 220

300 200 9.6 8.4 325 325 320 220

300 300 9.6 9.6 440 440 340 220

350 100 10.2 7.2 205 - 330 -

350 200 10.2 8.4 325 - 350 -

350 350 10.2 10.2 495 - 380 -

400 80 10.8 7.0 185 - 355 -

400 100 10.8 7.2 210 - 360 -

400 150 10.8 7.8 270 - 370 -

400 200 10.8 8.4 325 - 380 -

400 300 10.8 9.6 440 - 400 -

400 400 10.8 10.8 560 - 420 -

450 100 11.4 7.2 215 - 390 -

450 250 11.4 9.0 390 - 420 -

450 450 11.4 11.4 620 - 460 -

500 100 12.0 7.2 215 - 420 -

500 200 12.0 8.4 330 - 440 -

500 400 12.0 10.8 565 - 480 -

500 500 12.0 12.0 680 - 500 -

600 200 13.2 8.4 340 - 500 -

600 400 13.2 10.8 570 - 540 -

600 600 13.2 13.2 800 - 580 -

700 200 14.4 8.4 345 - 525 -

700 400 14.4 10.8 575 - 555 -

700 700 14.4 14.4 925 - 600 -

800 200 15.6 8.4 350 - 585 -

800 400 15.6 10.8 580 - 615 -

800 600 15.6 13.2 1045 - 645 -

800 800 15.6 15.6 1045 - 675 -

900 200 16.8 8.4 355 - 645 -

900 400 16.8 10.8 590 - 675 -

900 600 16.8 13.2 1170 - 705 -

900 900 16.8 16.8 1170 - 750 -

1000 200 18.0 8.4 360 - 705 -

1000 400 18.0 10.8 595 - 735 -

1000 600 18.0 13.2 1290 - 765 -

1000 1000 18.0 18.0 1290 - 825 -

NOTE : PN 16 is the preferred flange. PN 10, PN 25 and PN 40 flanges aresupplied when specified.

All Socket and Flange on Double Socket Tees


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17

Nominal Dia

(DN) e L d

mm mm mm mm

80 7.0 130 109

100 7.2 130 130

150 7.8 135 183

200 8.4 140 235

250 9.0 145 288

300 9.6 150 340

350 10.2 155 393

400 10.8 160 445

450 11.4 165 498

500 12.0 170 550

600 13.2 180 655

700 14.4 190 760

800 15.6 200 865900 16.8 210 970

1000 18.0 220 1075

PN16 is the preferred flange. PN 10, PN 25 and

PN 40 flanges are supplied when specified.

Flanged Socket

Nominal size

Body Branch e e1 L HDN dn

mm mm mm mm mm mm

100 80 8.4 8.1 185 195150 80 9.1 8.1 190 220200 80 9.8 8.1 190 250200 100 9.8 8.4 215 250250 80 10.5 8.1 220 275250 100 10.5 8.4 220 275300 80 11.2 8.1 220 305300 100 11.2 8.4 220 305300 150 11.2 9.1 335 305350 80 11.9 8.1 225 340350 100 11.9 8.4 225 340350 150 11.9 9.1 340 340400 80 12.6 8.1 225 365400 100 12.6 8.4 225 365

400 150 12.6 9.1 340 365400 200 12.6 9.8 340 365450 80 13.3 8.1 230 380450 100 13.3 8.4 230 380450 150 13.3 9.1 345 380450 200 13.3 9.8 345 380500 80 14.0 8.1 230 400500 100 14.0 8.4 230 400500 150 14.0 9.1 350 400500 200 14.0 9.8 350 400600 80 15.4 8.1 355 435600 100 15.4 8.4 355 435600 150 15.4 9.1 355 450600 200 15.4 9.8 355 450700 150 16.8 9.1 360 500

700 200 16.8 9.8 360 500800 150 18.2 9.1 360 540800 200 18.2 9.8 360 540900 150 19.6 9.1 370 580900 200 19.6 9.8 370 5801000 150 21.0 9.1 370 6301000 200 21.0 9.8 370 630

e

e1

Double Socket Level InvertTee with Flanged Branch


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SPECIFICATIONS APPLICABLE : Refer Table : 1

FLANGED PIPES AND FITTINGS

DIMENSIONS OF FLANGES - PN10 & PN16 : Refer Tables : 2 & 3

Dimensions of pipes centrifugally cast with welded on flanges. Flanged pipes shall be of barrel with shrunk fit and welded on flanges under factory conditions.

Flanges are of raised face type conforming to ISO 7005-2 / EN 1092-2 / BS 4504 and other required specifications

FLANGES

SPECIFICATIONS PRESSURE CLASS SIZE RANGE NUTS AND BOLTS. GALVANISED MS OR HIGH TENSILE.

ISO 7005 / EN - 1092-2/BS 4504. PN 10, PN16, PN25 AND PN 40. 80 1000 MM. FLAT GASKETS. RUBBER GASKETS 3 MM THICK.

TABLE : 1

L

Allowable pressures for Ductile Iron Flanged Pipes and Fittings : Fitting with one flange such as double socket tees with flanged branch, flanged spigot and flanged

sockets their PFA, PMA and PEA are limited by their flange : they are same as that of flange pipes and flange fittings as per the following table :

DN PN 10 PN 16 PN 25 PN 40

PFA PMA PEA PFA PMA PEA PFA PMA PEA PFA PMA PEA

80 see PN 16 16 20 25 see PN 40 40 48 53

100 to 150 see PN 16 16 20 25 25 30 35 40 48 53

200 to 600 10 12 17 16 20 25 25 30 35 40 48 53

700 to 1000 10 12 17 16 20 25 25 30 35 - - -

Product standards : BS-EN-545 : 2002 / ISO-2531:1998 / IS-8329-2000 / IS-9523 : 2000.

PN 16 flanges are supplied as standard. PN 10, PN 25 & PN 40 are supplied on request.

screwed on welded on

18


21/44

PN16 FLANGES (SUPPLIED AS STANDARD)

80 200 132 19.0 16.0 160 8 19 M16 3100 220 156 19.0 16.0 180 8 19 M16 3

150 285 211 19.0 16.0 240 8 23 M20 3

200 340 266 20.0 17.0 295 8 23 M20 3

250 400 319 22.0 19.0 350 12 23 M20 3

300 455 370 24.5 20.5 400 12 23 M20 4

350 505 429 24.5 20.5 460 16 23 M20 4

400 565 480 24.5 20.5 515 16 28 M24 4

450 615 530 25.5 21.5 565 20 28 M24 4

500 670 582 26.5 22.5 620 20 28 M24 4

600 780 682 30.0 25.0 725 20 31 M27 5

700 895 794 32.5 27.5 840 24 31 M27 5

800 1015 901 35.0 30.0 950 24 34 M30 5

900 1115 1001 37.5 32.5 1050 28 34 M30 5

1000 1230 1112 40.0 35.0 1160 28 37 M33 5

PN 10 FLANGES FOR WORKING PRESSURES UPTO AND INCLUDING 10 BAR.TABLE : 2

DN D E a b HOLES.

PCD (C) Nr. Dia (d) Bolt Size. f

PN 16 FLANGES FOR WORKING PRESSURE UPTO AND INCLUDING 16 BAR.

mm mm mm mm mm mm mm

80 200 132 19.0 16.0 160 8 19 M16 3

100 220 156 19.0 16.0 180 8 19 M16 3

150 285 211 19.0 16.0 240 8 23 M20 3

200 340 266 20.0 17.0 295 12 23 M20 3

250 400 319 22.0 19.0 355 12 28 M24 3

300 455 370 24.5 20.5 410 12 28 M24 4

350 520 429 26.5 22.5 470 16 28 M24 4

400 580 480 28.0 24.0 525 16 31 M27 4

450 640 548 30.0 26.0 585 20 31 M27 4

500 715 609 31.5 27.5 650 20 34 M30 4

600 840 720 36.0 31.0 770 20 37 M33 5

700 910 794 39.5 34.5 840 24 37 M33 5

800 1025 901 43.0 38.0 950 24 41 M36 5

900 1125 1001 46.5 41.5 1050 28 41 M36 5

1000 1255 1112 50.0 45.0 1170 28 44 M39 5

TABLE : 3

DN D E a b HOLES.

PCD (C) Nr. Dia (d) Bolt Size. f

19


22/44

20

DI FITTINGS WITH ROTATING FLANGE

The latest addition to Electrosteels range of DI pipe accessories are DI Flanged fittings with rotating or Loose Flange. Unlike As cast Flanged

fitting, in this case, separately cast loose Flanges are mounted on the fittings.

A loose Flanged Fittings is comprised of a Flange ring, ( in one or more parts bolted together) which can be fixed on the fittings end. This

loose Flange can be freely rotated around the axis of the fittings. The critical dimensions are however same with As Cast Flanged fittings.

Advantages of Loose Flange Fittings

Since the flange can be freely rotated, bolt-hole alignment with the mating Flange becomes very easy.

As it can be fixed and removed easily, dismantling of adjoining accessories becomes easier.

The PN rating of the Fittings can be changed at will, just by changing the loose flange.


23/44

2

Nominal

size e L

DNmm mm mm

80 7.0 165

100 7.2 180

150 7.8 220200 8.4 260

250 9.0 350

300 9.6 400

350 10.2 450

400 10.8 500

450 11.4 550

500 12.0 600

600 13.2 700

700 14.4 800

800 15.6 900

900 16.8 1000

1000 18.0 1100

Double Flanged 900 Bend

Nominal Dia

(DN) DE e Lmm mm mm mm

80 98 7.0 350

100 118 7.2 360

150 170 7.8 380200 222 8.4 400

250 274 9.0 420

300 326 9.6 440

350 378 10.2 460

400 429 10.8 480

450 480 11.4 500

500 532 12.0 520

600 635 13.2 560

700 738 14.4 600

800 842 15.6 600

900 945 16.8 600

1000 1048 18.0 600

Flanged Spigot

Nominal

size e L

DNmm mm mm

80 7.0 130

100 7.2 140

150 7.8 160200 8.4 180

250 9.0 350

300 9.6 400

350 10.2 298

400 10.8 324

450 11.4 350

500 12.0 375

600 13.2 426

700 14.4 478

800 15.6 529

900 16.8 581

1000 18.0 632

Double Flanged 450 Bend

Fixed flange fittings are offered for all sizes. Rotating flange joint fittings are offered for DN 80-600mm

Flange spigot

Double Flanged Bends - 90, 45, 221

/2 deg. & 111

/4 deg.

Double Flanged Concentric Taper.

All Flanged Radial Tee.

All Flanged Y Pipe.

Reducing Flanges - PN16.

Double Flanged Duck-foot Bend - 90 deg.

All Flanged Tee.

All Flanged Level Invert Tee.

Flanged Bell-mouth.

All Flanged Cross.

All Flanged 45 deg. Angle Branch.

Blank Flanges - PN16.

DUCTILE IRON FLANGED JOINT FITTINGS


24/44

22

Nominal Diameter (DN) e1 e2 L

Larger End Smaller End

(Body) (branch)

mm mm mm mm mm

100 80 7.2 7.0 200

200 150 8.4 7.8 300

250 200 9.0 8.4 300300 250 9.6 9.0 300

350 300 10.2 9.6 300

400 350 10.8 10.2 300

450 400 11.4 10.8 300

500 400 12.0 10.8 600

600 500 13.2 12.0 600

700 600 14.4 13.2 600

800 700 15.6 14.4 600

900 800 16.8 15.6 600

1000 900 18.0 16.8 600

Double Flanged concentric TapersDouble flanged 221/20 bend

Nominalsize DN e L

mm mm mm

80 7.0 130

100 7.2 140

150 7.8 160

200 8.4 180250 9.0 350

300 9.6 400

350 10.2 298

400 10.8 324

450 11.4 349

500 12.0 375

600 13.2 426

700 14.4 478

800 15.6 529

900 16.8 581

1000 18.0 632

Double flanged 11 1/40 bend

Nominalsize DN e L

mm mm mm

80 7.0 130

100 7.2 140

150 7.8 160

200 8.4 180250 9.0 350

300 9.6 400

350 10.2 298

400 10.8 324

450 11.4 349

500 12.0 375

600 13.2 426

700 14.4 478

800 15.6 529

900 16.8 581

1000 18.0 632

221/20

L L

111/40

L L

Nominal size r

Body Branch L A B approx.

DN DN

mm mm mm mm mm mm

80 80 545 165 380 330

100 100 580 180 400 340

150 150 670 220 450 385

200 200 760 260 500 430

250 250 900 350 550 475

300 300 1000 400 600 515

350 350 1100 450 650 560

400 400 1200 500 700 605

450 450 1300 550 750 650

500 500 1400 600 800 690

600 600 1600 700 900 780

All Flanged Radial Tee

B

r

L

A B

e

e

All Flanged Y Pipe

Nominalsize DN A

mm mm

80 165

100 180

150 220

200 260

250 350

300 400

350 450

400 500

450 550

500 600

600 700

A

A

900

e

Larger End Smaller End

Nominal Dia D b c1 Nominal Dia c2 aDN DN

mm mm mm mm mm mm mm

200 340 17 3 80 3 40

340 17 3 100 3 40

350 520 22.5 4 250 3 54

400 580 24 4 250 3 54

580 24 4 300 4 55

700 900 34.5 5 500 4 67

900 1125 41.5 5 700 5 73

1000 1255 45 5 700 5 73

1255 45 5 800 5 73

Reducing Flange PN 16b=10+0.035 DN with a minimum value of 16

ee


25/44

23

Nominal e L & t c d

Size (DN)

mm mm mm mm mm

80 7.0 155 110 180

100 7.2 175 125 200150 7.8 230 160 250

200 8.4 280 190 300

250 9.0 335 225 350

300 9.6 385 255 400

350 10.2 440 290 450

400 10.8 495 320 500

450 11.4 545 355 550

500 12.0 600 385 600

600 13.2 705 450 700

700 14.4 810 515 800

800 15.6 915 580 900

900 16.8 1020 645 1000

1000 18.0 1130 710 1100

Double Flanged 900 Duck-foot Bend All Flanged Tees

All Flanged Tees

mm mm mm mm mm mm

80 80 7.0 7.0 330 165

100 80 7.2 7.0 360 175

100 100 7.2 7.2 360 180

150 80 7.8 7.0 440 205

150 100 7.8 7.2 440 210

150 150 7.8 7.8 440 220

200 80 8.4 7.0 520 235

200 100 8.4 7.2 520 240

200 150 8.4 7.8 520 250

200 200 8.4 8.4 520 260

250 100 9.0 7.2 700 275

250 200 9.0 8.4 700 325

250 200 9.0 8.4 700 325

250 250 9.0 9.0 700 350

300 100 9.6 7.2 800 300

300 200 9.6 8.4 800 350

300 300 9.6 9.6 800 400

350 100 10.2 7.2 850 325

350 200 10.2 8.4 850 325

350 350 10.2 10.2 850 425

400 100 10.8 7.2 900 350

400 200 10.8 8.4 900 350

400 400 10.8 10.8 900 450

450 100 11.4 7.2 950 375

450 200 11.4 8.4 950 375

450 450 11.4 11.4 950 475

500 100 12.0 7.2 1000 400

500 200 12.0 8.4 1000 400

500 400 12.0 10.8 1000 500

500 500 12.0 12.0 1000 500

600 200 13.2 8.4 1100 450

600 400 13.2 10.8 1100 550

600 600 13.2 13.2 1100 550

700 200 14.4 8.4 650 525

700 400 14.4 10.4 870 555

700 700 14.4 14.4 1200 600800 200 15.6 8.4 690 585

800 400 15.6 10.8 910 615

800 600 15.6 13.2 1350 645

800 800 15.6 15.6 1350 675

900 200 16.8 8.4 730 645

900 400 16.8 10.8 950 675

900 600 16.8 13.2 7500 705

1000 200 18.0 8.4 770 705

1000 400 18.0 10.8 990 735

1000 600 18.0 13.2 1650 765

1000 1000 18.0 18.0 1650 825

Nominal Dia (DN) e e1 L H

Body Branch


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24

Nominal size

Body DN Branch DN e1 e2 L H

mm mm mm mm mm mm

100 80 8.4 8.1 360 195150 80 9.1 8.1 440 220

200 80 9.8 8.1 520 250

200 100 9.8 8.4 520 250

250 80 10.5 8.1 700 275

250 100 10.5 8.4 700 275

300 80 11.2 8.1 800 305

300 100 11.2 8.4 800 305

300 150 11.2 9.1 800 305

350 80 11.9 8.1 850 340

350 100 11.9 8.4 850 340

350 150 11.9 9.1 850 340

400 80 12.6 8.1 900 365

400 100 12.6 8.4 900 365

400 150 12.6 9.1 900 365400 200 12.6 9.8 900 365

450 80 13.3 8.1 950 380

450 100 13.3 8.4 950 380

450 150 13.3 9.1 950 380

450 200 13.3 9.8 950 380

500 80 14.0 8.1 1000 400

500 100 14.0 8.4 1000 400

500 150 14.0 9.1 1000 400

500 200 14.0 9.8 1000 400

600 80 15.4 8.1 1100 435

600 100 15.4 8.4 1100 435

600 150 15.4 9.1 1100 450

600 200 15.4 9.8 1100 450

700 150 16.8 9.1 600 500700 200 16.8 9.8 650 500

800 150 18.2 9.1 670 540

800 200 18.2 9.8 690 540

900 150 19.6 9.1 720 580

900 200 19.6 9.8 730 580

1000 150 21.0 9.1 770 630

1000 200 21.0 9.8 770 630

All Flanged Level Invert Tees

HL

= =e2

Nominal

size L D B R

DN

mm mm mm mm mm

80 135 160 80 100100 140 185 85 106

150 155 245 95 119

200 170 310 110 137

250 190 340 120 150

300 210 435 135 169

350 225 495 145 181

400 245 560 160 200

450 260 620 170 212

500 280 685 185 231

600 300 810 210 262

700 340 945 225 281

800 380 1055 270 300

900 420 1165 255 319

1000 440 1290 240 337

Flanged Bell-mouth

B

R

D

L

e

e1


27/44

25

Nominal Size

Body Branch e1 e2 L B

DN DN

mm mm mm mm mm mm

80 80 8.1 8.1 330 13 5

100 100 8.4 8.4 360 180150 150 9.1 9.1 440 220

200 200 9.8 9.8 520 260

250 250 10.5 10.5 700 350

300 300 11.2 11.2 800 400

350 350 11.9 11.9 850 425

400 400 12.5 12.5 900 450

450 450 13.3 13.3 950 475

500 500 14.0 14.0 1000 500

600 600 15.4 15.4 1100 550

700 700 16.8 16.8 1200 600

800 800 18.2 18.2 1350 675

900 900 19.6 19.6 1500 750

1000 1000 21.0 21.0 1650 825

All Flanged Cross

B

B

e1

L

e2

Nominal size

Body Branch Type e1 e2 L K

DN DN

mm mm mm mm mm mm mm80 80 N 8. 8.1 500 375

100 100 N 8.4 8.4 540 405

150 150 N 9.1 9.1 640 480

200 200 N 9.8 9.8 735 560

250 250 N 10.5 10.5 830 640

300 300 N 11.2 11.2 930 715

350 350 N 11.9 11.9 880 790

400 400 M 12.6 12.6 970 870

450 450 M 13.3 13.3 1060 950

500 500 M 14.0 14.0 1140 1025

600 600 M 15.4 15.4 1310 1180

700 700 M 16.8 16.8 1550 1430

800 800 M 18.2 18.2 1700 1570

900 900 M 19.6 19.6 1850 17001000 1000 M 21.0 21.0 2050 1900

All Flanged 450 Angle Branch

D

e b

a

k

h

R

Blank Flanges, Type PN 16Nominal Dia a b e K & R hDN

mm mm mm mm mm mm

80 19.0 16.0 3

100 19.0 16.0 3

150 19.0 16.0 3

200 20.0 17.0 3

250 22.0 19.0 3 300 24.5 20.5 4

350 26.5 22.5 4 325 71

400 28.0 24.0 4 375 80

450 30.0 26.0 4 425 88

500 3105 27.5 4 475 97

600 36.0 31.0 5 575 114

700 39.5 34.5 5 675 131

800 43.0 38.0 5 775 148

900 46.0 41.5 5 875 165

1000 50.0 45.0 5 975 182

e1

e2

e2

e1


28/44

26

Coatings

Ductile iron pipes : Electrosteel offersductile iron pipes, metallic zinc sprayed, with a finishing layer of

bituminous paint.

- Applicable Standards : ISO 8179 : 1995 PART - 1.

BS EN 545 : 2002.

BS 3416 : Type 2.

Ductile iron fittings : Electrosteeloffers ductile iron fittings, externally coated with zinc

rich paint and finishing layer of bituminous paint.

- Applicable Standards : ISO 8179 : 2004 PART - 2.

BS EN 545 : 2002.

BS 3416 : Type 2.

Field of use, characteristics of soil:Ductile iron pipes and fittings supplied with the above

mentioned external coatings can be buried in contact with majority

of soils. For special type of soils, as mentioned below, additional and

/ or special coatings are recommended.

With a low resistivity, less than 1500 ohm - cm above the watertable or less than 2500 ohm - cm below the

water table.

With low pH, below 6, With contamination by certain wastes, organic or industrialeffluent.

Stray currents.

COATING AND LININGPOTABLE WATER

Bitumen coating


29/44

27

Special coatings : Other special type of externalcoatings can be supplied as mentioned below :

Zinc coating with extra thickness. Coal tar coating. Bitumen pigmented with materials for high temperature andUV resistance.

Liquid epoxy coating.

HJHJHHHHKHKHK

Linings

Ductile iron pipes : Electrosteel offers internalcement mortar lining, centrifugally applied as per the following

standards :

- Applicable Standards : ISO 4179 : 1985.

BS EN 545 : 2002.

Ductile iron fittings : Ductile iron fittings arealso supplied with internal cement mortar lining.

- Applicable Standards : BS EN 545 : 2002.

ISO 2531 : 1998.

The type of cement used for internal lining, that can be

supplied are :

Sulphate resisting portland cement. Blast furnace slag cement.

Special types of linings : The followingtypes of special linings are also offered :

Cement mortar lining with bitumen seal coat.

Cement mortar lining with epoxy seal coat. Bituminous paint. Liquid epoxy.

Ductile iron fittings are also offered with Fusion Bonded Epoxy(FBE)

coating ( inside and outside) from our latest state of the art FBE line.

Note : All materials used for internal lining is suitable for potable

water applications as per BS 6920.

Coatings

Zinc coating

Fusion Bonded Epoxy Coating

The thickness is maintained as per the following table :

DN (mm) Thickness (mm)

Nominal Value Tolerance

80 - 300. 3.5 -1.5

350 - 600. 5.0 -2.0

700 - 1000. 6.0 -2.5

Zinc - aluminium (85Zn-15Al) pseudo alloy coating having aminimum mass of 400gm/m2 with finishing layer of epoxy coating


30/44

Coatings

Ductile iron pipes : ECL offers ductile ironpipes, metallic zinc sprayed, with a finishing layer of red / brown

bitumen paint on the body and red / brown epoxy paint on the end

surface of spigot and inside the socket which may come in contact

with effluent.

- Applicable Standards : ISO 8179 : 1995 part - 1.

BS EN 598 : 1995.

Ductile iron fittings : ECL offers ductile ironfittings, externally coated with zinc rich paint and finishing layer of

epoxy paint.

- Applicable Standards : ISO 8179 : 2004 part - 2.

BS EN 598 : 1995.


coating from our latest state of the art FBE line.

Field of use, characteristics of soil:Ductile iron pipes and fittings supplied with the above mentioned

external coatings can be buried in contact with majority of soils.

Special coatings : Other special type ofexternal coatings can be applied as mentioned below :

Zinc coating with extra thickness. Bitumen coating. Bitumen pigmented with aluminium. Liquid Epoxy coating for pipes and fittings.

The choice of coating to be applied depends mainly on :

Resistivity of the soil. pH of the soil. Presence of water-table at the pipe level. Presence of stray currents or of macrocells due to externalmetallic structures.

Possible contamination of the soil by industrialeffluent.

The characteristics of the soil for the above mentioned

special type of coating -

With a low resistivity, less than 1500 ohms - cm above thewater table or less than 2500 ohms - cm below the water-table.

With a low pH, below pH6. With contamination by certain wastes, organic orindustrial effluent.

Linings

Ductile iron pipes : ECL offers internalcement mortar lining with high alumina cement, centrifugally applied

as per the following standards :

- Applicable Standards : ISO 7186 : 1996.

BS EN 598 : 1995.

The thickness is maintained as per the following table :

DN (mm) Thickness (mm)

Nominal Value Tolerance

100 - 300. 3.5 -1.5

350 - 600. 5.0 -2.0

700 - 1000. 6.0 -2.5

Ductile iron fittings : Ductile iron fittings aresupplied with linings as per the following standards.

- Applicable Standards : BS EN 598 : 1995.

ISO :7186 : 1996

a) High Alumina cement

b) Epoxy

Range of Application

High Alumina cement - pH 4 to pH 12

Epoxy - pH 1 to pH 14


coating ( inside and outside) from our latest state of the art FBE

line.

SEWERAGE APPLICATIONS

28


31/44

For break bulk shipment

ECL generally follows the practice of bundling ductile iron pipes upto 150 mm dia to

facilitate loading, unloading and handling. For details on bundling, buyers are requested

to contact ECL as the pattern might change on case to case basis depending on mode of

shipment.

Each bundle has two number-base wood placed parallel to each other. Seperator wood

is provided between two rows / layers of pipes to provide stability to the bundle. The

pipes are bundled such that the successive pipes have sockets in opposite direction,

viewed vertically or horizontally. The pipes are strapped with adequate number of steel

straps to ensure that the straps do not snap even during multiple handling. Bundles

should not be lifted by the steel straps.

Shipping marks are provided in each bundle with the help of metal tags or self adhesive

stickers.

PACKINGBUNDLED PIPES

LOOSE PIPESPipe sizes above DN 150 mm are generally shipped in loose condition. These pipes

require careful handling to avoid damages. Shipping marks are provided by stencilling or

pasting adhesive stickers on the pipes.

PACKING OF FITTINGS & ACCESSORIESFittings are packed in sea worthy wooden crates/pallets and are placed inside the top of

the container or sent along with the pipes in conventional vessels.

Rubber gaskets are packed in corrugated card board boxes properly sealed in PE bags

(so that they are not exposed to air and light) when shipped in containers and in

wooden cases, when shipped by conventional vessels.

Lubricants are packed in plastic jars/tins which are further packed in corrugated card

board boxes or wooden cases, as the case may be.

29


32/44

30

GENERALDuctile iron pipes and fittings are not susceptible to breakage by impact during handling but

improper handling can result in damaged linings, coatings and sleeving and in severe cases, in bruising

and deformation of the spigot.

Damage to pipes and fittings may be caused by :

Insecure loading on lorry or wagon.

Improper use of handling equipment.

Use of unsuitable handling equipment.Incorrect storage in the hold of the boat/ship.

Incorrect stacking methods.

Improper storage of joint components.

Unloading on uneven or sloping ground.

Impact between pipes.

On receipt, pipes and fittings should be inspected for damage to :

The pipe or fitting itself.

Cement mortar Linings.

External protection system.

Jointing surfaces.

HANDLINGHandling

Bundled Pipes

It is important to bear in mind that pipes and

fittings are heavy objects and are dangerous

when handled unless particular care is paid to

aspects of safety. These instructions are

intended to give guidance to ensure that the

quality of pipes and fittings is not impaired

during handling. Proper regard must be paid to

all appropriate health and safety regulations in

handling pipes and fittings. It is essential that

only skilled and experienced personnel handle

pipes.

It is imperative that pipe weights, type of

stacking, outreach required and site conditions

are taken into account when determining the

suitability of the lifting equipment. The lifting

machine shall be of the type which retains the

load safely in the event of a power failure.

Off - loading shall be carried out smoothly and

without snatch. Where pipes have been

bundled, it is essential that the bundles be off-

loaded with slings around the complete bundle,

using the correct lifting angle on the slings (see

fig. 1). Use of nylon rope or nylon belt of

suitable capacity is recommended.

It is essential that the bundles are not lifted by

means of their retaining straps and

that stacked bundles are lowered to the ground

before the straps are cut. When cranes are

used for off-loading individual pipes, slings or

lifting beams with purpose designated

padded hooks shall always be used. Personnel

engaged in off loading operations are

recommended to wear suitable protective

clothing (helmet, safety boots/

shoes and gloves).

BUNDLE / PIPE

200

Fig. - 1


33/44

3

Handling

Loose Pipes

The pipes should be lifted smoothly, without

sudden jerking motions. Guide ropes should be

used where required to prevent damage

caused by pipes bumping together or against

surrounding objects. When lowering pipes,

timber battens placed on the ground about 600

mm from each end of the pipes shall be used

to absorb shock and to prevent damage to the

coating and any sleeving.

STUFFING & DE-STUFFING OF CONTAINERIn case of container shipment, each container is

brought to ECL stockyard for in - house

stuffing that is done in the presence of handling

supervisors. Each container is checked for

damages and cleaned before loading.

Customers must take care to de - stuff the

containers carefully to avoid damaging thepipes and the container walls. The bundles

must be taken out with a combination of two

forklifts (or one crane or one forklift) in case

of side open containers. A Zebra belt must be

used with one forklift to pull out the bundles

carefully and the second forklift must support

the bundle. Only one bundle must be pulled

out at a time. In case of top open containers,

overhead cranes with slings must be used.

Individual pipes must be de-stuffed from the

container at the destination with the help of a

combination of overhead crane and forklift orwith the help of two forklifts. The pipes must

be pulled out slowly and balanced with a

forklift. A boom is very helpful to de - stuff

pipes. Further advice on all aspects of unloading

containers is available by contacting ECL.

BREAK-BULK TRANSPORTATIONIn case of shipment by conventional vessels, the

bundles are transported by trucks and trailers

to the nearest port. The bundles are handled

with the help of overhead cranes using slings.

The bundles are lashed properly to the trucks

and trailers to avoid movement during transit.

At the port, the bundles are directly lifted by

port cranes / vessel derricks from the trucks

and trailers and then placed inside the holds.

Inside the hold, the bundles are properly

stabilised using suitable lashing to avoid

movement during sailing.

At the destination port, bundles must be lifted

out of the hold again using the methods

described on page 30 with the help of port

cranes / vessel derricks and directly loaded on

trucks or trailers to be transported to the

warehouse / site. Adequate lashing on trucks

and trailers is essential. The bundles must be

taken off the trucks and trailers with the help

of overhead cranes.

In case of loose pipes, wooden sleepers are

provided on the vehicle platform with profiled

wooden chocks to arrest side movement while

transporting to the port. The pipes are loaded

in a pyramid formation on trucks with

successive layers / rows having sockets facing

opposite direction. When using trailers, loading

should be done to ensure that sockets of the

lowest tier face each other. The pipes must be

secured to the trucks and trailers with the help

of slings. Wire ropes and iron chains must not

to be used.

While unloading pipes from the hold at

destination port, be careful to avoid impact of

the pipes against the walls of the hold. Pipesshould be unloaded row after row. It is

recommended to first remove pipes in the

centre and then roll the pipes on the sides to

the centre for lifting by port cranes / vessel

derricks. The pipes must preferably be loaded

directly on trucks and trailers and transported

to the warehouse / site. Further advice on all

aspects of loading and unloading break-bulk

vessel is available by contacting ECL


34/44

32

STACKING OF LOOSE PIPES

Pipes taken to a warehouse for storage and held pending further

distribution should be arranged in stacks. The stacking area should

provide a firm foundation with a suitable approach road for vehicles.

Stacks should be arranged so as to provide safe vehicular and

pedestrian access. During stacking and removal operations, safe

access to the top of the stack is essential. In inclement weather

conditions, when pipe surfaces may become slippery, consideration

should be given to the use of light weight staging placed on top of

the stacks. Pipes should be stacked on a base of raised wooden

battens at least 100 mm thick x 225 mm wide. The battens should

STACKING

be positioned approximately 600 mm from each end of the pipe.

The bottom layer of the pipes should be securely anchored. Three

types of stacking are recommended :

Square stacking : suitable for pipes of all sizes.

Parallel stacking using timber : suitable for pipes of all sizes.

Pyramid stacking : suitable for pipes of all sizes.

Square stacking

Each tier of pipes should be positioned with their axes at right

Square stacking of loose pipes

Pyramidal stacking

Parallel stacking using timbers


35/44

33

angles to those of the preceding tier to form a stable and compact

stack. The sockets of the pipes in each tier should be at the same

end, except for the two end pipes which should be reversed to lock

the tiers in position. Alternatively, the sockets of alternate pipes in

each tier may be reversed. The pipes rest directly upon those

beneath and extra care should be exercised when lowering the

pipes into position to prevent damage to the protective coating.

Parallel stacking usingtimbers

For this method of stacking two timber battens of sufficient strength

should be placed across the pipes between each tier, approximately600 mm from pipe ends. The sockets of pipes in each successive

tier should be reversed and battens should be of sufficient thickness

to avoid metal to metal contact. An adequate number of chocks

should be wedged under the outer pipes of each tier and nailed to

the timber bearers to ensure s tability.

Pyramidal stacking

In pyramidal stacks, each pipe nestles between the two pipes

immediately beneath it and care should be exercised when lowering

pipes into position. It is essential that the end pipes of the bottom

tier be securely anchored along their length with chocks preferably

fixed to timbers running along the width of the stack. The axis of all

pipes should be in the same direction, and the sockets should be

reversed in successive tiers.

Stacking heights

For loose pipes the heights of stacks should be determined by

consideration of :

The stresses on the lowest layer of pipes in the stack ;

The total lift given by the available crane ; and

The facilities available to ensure stable stacking.

All these factors should be taken into consideration and the stacking

heights should not exceed those in table given below.

Stacking Heights

Dia (mm) Maximum No. of layers

80 18

100 16

150 14

200 12

250 10

300 8

350 & 400 7

450 & 500 6

600 4

700 3800 & above 2

A competent supervisor shall determine the maximum height for

a particular site / location.

Stacking of pipeshaving specialexternal protection

Wherever possible, pipes with special external protection shouldnot be stacked but should be laid out in a single layer and supported

on the shoulder of the socket and the unprotective spigot end, so

that the whole barrel is clear of the ground. If the space available is

limited, then reduced stacking may be permissible, in such

circumstances the manufacturer should be consulted. Care should

be exercised when handling such pipes to avoid damaging the

protection. They should be lifted by hooks engaging in socket and

spigot ends.

The hooks should be as wide as possible and padded with rubber to

minimize damage to the cement linings. Smaller sizes, upto DN 400,

may be lifted with wide fabric slings. Wire ropes or chain slings

should not be used.

STACKING OF BUNDLED PIPES

The stacking area should provide a firm foundation with a suitable

approach road for vehicles. Stacks should be arranged to provide


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34

safe vehicular and pedestrian access. Bundles are provided with base

timbers and these can be laid directly onto a good, level,

hardstanding surface. The bundles should be stacked one on top of

the other with the axes of pipes kept parallel.

Recommended stacking height on good, level, hardstanding surface

shall not exceed those given in the table below. However, the

maximum stacking height for any particular location should be

determined by a competent supervisor.

Breaking down of pipebundles

It is essential that bundles which have been stacked be lowered to

ground level before the straps are cut. Special precautions should

be taken when cutting the straps of the bundles and when removing

pipes from individual tiers.

Stacking height of bundled pipes

DN (mm) Max. stack layers (No. of pipes)

80 18

100 18150 18

200 12

250 6

300 6

350 8

400 8

450 4

500 6

600 6

700 4

800 & above 4

Stacking of Pipes


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35

For the installation of bends, branches and valves, pipelines require

pieces of pipes of varying lengths. The exact length can only be

determined on the site and one must be able to cut the pipes easily,

quickly and safely.

CUTTING MACHINESToday abrasive disc cutters with various kinds of power supply are

used to cut ductile iron pipes. These cutters are powered by

electric or compressed air connections or they can be driven

indirectly by internal combustion engines.

Many of the abrasive disc cutters in the market can be fitted with

both abrasive cut off discs for cutting and with roughing discs for

rounding off the cut edges. If only one machine is available on site

then it should be suitable for both types of discs.

Stages in cuttingoperation

The pipe should be placed on level ground or on square

timbers in such a way that during cutting, the cutting disc does not

become jammed and the remaining pipe wall does not prematurely

break away.

Marking : A line marked all around the pipe facilitates a

straight cut. The line is simply drawn along a steel band which is

bent around the pipe.

Cutting : Using the cutting disc, the ductile iron and

cement mortar pipe wall is cut through completely at

one point. The pipe is then cut along the marked line in a single

operation.

Rounding off : For jointing into sockets of the push - in type,

the new spigot end must be chamfered as the original spigot end.

Only thus the spigot end can be correctly inserted in the socket

without damaging the gasket or pressing it out of its seat. A

roughing disc is used for chamfering.

Re-coating : Subsequently, the bare metal surface should be

re-coated with zinc rich paint and a finishing layer of bitumen.

Marking the insertion depth : Before assembling the joint, lines

should be marked on the new spigot, showing the correct insertion

depth of the spigot end in the socket.

PIPE CUTTING

E x t e r n a l d i a m e t e r ( D E )

DN (mm) Max (Tape) Min (Tape) Max (circum Tape) Min (circum Tape)

350 1190.0 1177.0 379.0 374.6

400 1351.0 1337.0 430.0 425.5450 1511.0 1497.0 481.0 476.4

500 1674.0 1660.0 533.0 528.2

600 1998.0 1983.0 636.0 631.0

700 2321.0 2306.0 739.0 733.7

800 2648.0 2631.0 843.0 837.5

900 2972.0 2953.0 946.0 940.2

1000 3295.0 3276.0 1049.0 1043.0

General :The external diameter of > DN 300 at the cut area should conform to the following standards to ensure a satisfactory joint.


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Transport and handling can cause pipe ovality to affect correct

assembly of the pipe joints. Ovality is rare in small diameter pipes

less than 300 DN. Ovality correction can be carried out by either

of the following methods for pipes DN 350 and above :

METHOD AThe use of this method is recommended except where it is

impracticable to remove the re-rounding equipment after ovality

correction and subsequent joint. Position a timber strut and jack

(approximately 5 tonnes capacity) inside the spigot at 90 to the

major axis. Rubber pads should be placed in position to prevent

possible damage to the pipe lining. Extend the jack until the major

axis has been reduced to the appropriate limit specified in the table

shown on page 35.

Rotate the whole assembly through 90 and complete the jointing

operation with the major axis of the spigot vertical. After jointing,

remove the equipment.

METHOD BThe use of this method is recommended only where it would be

impracticable to remove the re-rounding equipment described in

Method A after ovality correction and subsequent jointing.

Place the equipment around the spigot and of the pipe at a position

approximately 450 mm from the pipe end and with the major axis

of the spigot vertical. Tighten the two nuts evenly until the major

axis has been reduced to the appropriate limit specified in the table

shown on page 35. Complete the jointing operation with the major

axis of the spigot vertical. After jointing, remove the tackle.

OVALITY CORRECTION

Method A

Method B

DE min

DE max

DEmin

DEmax


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37

INSTRUCTIONS

When repairing damaged cement mortar linings, the following

procedures should be used :

Preparation of areaRemove damaged lining with hammer and chisel.

Do not disturb sorrounding lining.

Ensure edges are slightly undercut.

Brush off any loose mortar.

Thoroughly wet area to be repaired.

Composition of repairmixMix sand and cement dry in proportions of

Pipe = 1 sand : 1 cement

Fittings = 1.8 sand : 1 cement

Add sufficient potable water to form a thick paste which is

workable

Repair procedureEnsure repair area is wet.

Remove any areas of water accumulations.

Apply repair mix to area and smooth off.

After-Treatment ofRepair Area

After 20 minutes of completing the repair, dampen the repair

area.

Cover area with wet rags and leave to set in ambient

temperature - must be above 40 C.

In areas of high temperature and low humidity check

periodically for 4 hours that rags are wet.

Materials

Potable water.

Cement - compatible to original lining as :

Ordinary portland cement

Blast furnace slag cement

Sulphate Resistant cement

High Alumina cement

Sand - Not coarser, having an average grain size of

270 - 300 microns.

REPAIR OF DAMAGED CEMENT

MORTAR LINING


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38

GENERAL

Lifting and handling pipe and working in trenches are hazardous operations. The following

instructions are designed to ensure that during laying and jointing the quality of the pipes and

the fittings is not impaired, nor the actual jointing procedure compromised. It is essential that

these operations are carried out by persons skilled in these procedures. The work must be

supervised and conform to all relevant health and safety regulations.

ASSEMBLY OF PUSH ON JOINTS

Pipes should at all times be handled with care in accordance with the manufacturers

recommendations. Pipes should be lowered into the trench with tackle suitable for the mass of

the pipes. A mobile crane or a well designed set of shear legs should be used and the

positioning of the sling checked, when the pipe is just clear off the ground, to ensure a proper

balance. When lifting equipment is not available, smaller diameter pipes should be lowered using

suitable ropes.

All persons should vacate the section of the trench into which the pipe is being lowered.

All construction debris should be cleared from the inside of the pipe either before or just after

a joint is made. This can be done by passing a pull - through along the pipe, or by hand,

depending on a diameter of the pipe. When laying is not in progress, a temporary end closure

should be fitted securely to the open end of the pipeline. This may make the pipes buoyant in

the event of the trench becoming flooded, in which case the pipes should be held down either

by partial re - filling of the trench or by temporary strutting.

General instructions for jointing Push on joints are listed below, followed by the various

methods for closing the joint.

Before assembly, the outside of the spigot and the inside of the socket of the two pipeline

components to be joined must be thoroughly cleaned. Where there are no minimum and

maximum insertion distances on the pipe, these should be marked according to the table.

Insertion of the gasket can be facilitated by the prior application of a thin film of lubricant

to the bulb seating inside the socket. It is important not to apply lubricant to the anchor area of

the gasket.

The gasket should be inspected to ensure it is not deformed or damaged. The rubber

gasket should be cleaned, flexed and then placed in the bottom of the socket with the bulb

LAYING AND

JOINTING


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leading. Care must be taken to ensure that the groove in the ring is located on the retaining

bead in the socket and the heel of the ring is firmly bedded in its seat. Make sure the joint ring

fits evenly around the whole circumference and smooth out any bulges which would prevent

the proper entry of the spigot end.

In the larger diameters this operation may be assisted by forming two or four loops in the ring,

then pressing the loops flat one after the other.

Apply a thin film of lubricant to the inside surface of the joint ring where it will come into

contact with the entering spigot, which may also be covered with a thin film of lubricant for a

distance of 75 mm from the end.

The incoming spigot must be aligned and entered carefully into the socket until it makes

contact with the joint ring. Final assembly of the joint is completed from this position.

The joint is then made by forcing the spigot of the entering pipe past the joint ring of thereceiving pipe, thus compressing the ring, until the socket face is positioned between the

minimum and maximum insertion distances (see table below). Insertion distances should be

marked if they are not present.

If this final assembly cannot be attained by the application of reasonable force, the spigot should

be withdrawn and the position of the joint ring examined. Where necessary the spigot can be

withdrawn from the bottom of the socket by moving the far end of the pipe upwards and

sideways for a distance of about 150 mm, and then returning to the straight position.

INSERTION DEPTH FOR PIPES (mm) INSERTION DEPTH FOR FITTINGS (mm)

DN Max. Min. Max. Joint Max. Min.

deflection in Deg.

80 80 53 5 73 49

100 80 53 5 74 50

150 80 53 5 75 51

200 87 60 4 81 58

250 94 66 4 89 61

300 101 68 4 97 66

350 98 68 3 96 68

400 109 75 3 106 74

450 103 76 3 102 75

500 113 81 3 112 82

600 121 83 3 120 87

700 140 94 2 140 94

800 145 89 2 145 89

900 155 89 1030 155 89

1000 155 89 1030 155 89

Jointing Parameters


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The descriptions and illustrations contained in this catalogue are intendedmerely to present a general idea of the goods described therein.On account of continual improvement, we reserve the right to change, without prior notice, any of the descriptions, illustrations and data.

Please note that the recommendations in this catalogue only highlights the important points of the standards.Customers should study the following standards thoroughly for the selection specification, installation and testing.

RELEVANT STANDARDS

SL. Standard Description

1 BS EN 545 : 2002 Ductile iron pipes, fittings, accessories and their joints for water pipelines-requirements

and test methods.

2 ISO 2531 : 1998 Ductile iron pipes, fittings, accessories and their joints for water or gas applications.

3. BS EN 598 : 1995 Ductile iron pipes, fittings, accessories and their joints for sewerage application-

requirements and test methods.

4 ISO 7186 : 1996 Ductile iron products for sewerage applications.

5 BS 3416 : 1991 Specification for bitumen based coatings for cold application suitable for use in contactwith potable water.

6 ISO 8179 : 2004 Ductile iron pipes : external zinc coating.

Part 1: Metallic Zinc with finishing layer.

Part 2: Zinc rich paint with finishing layer

7 ISO 4179 : 1985 Ductile iron pipes for pressure and non-pressure pipelines-centrifugal cement mortar lining

-general requirements.

8 BS 2494 : 1990 Specification for elastomeric seals for joints in pipe-work and pipelines.

9 ISO 4633 : 1996 Rubber seals-joint rings for water supply, drainage and sewerage pipelines-specification for

materials.10 BS 6076 : 1996 Specification for tubular polyethylene film for use as protective sleeving for buried iron

pipes and fittings.

11 ISO 8180 : 1985 Ductile iron pipes-polyethylene sleeving.

12 BS 8010 : Section 2.1 -1987 Pipelines on land : design, construction and installation. Section 2.1 : Ductile iron.

13 ISO 10802 :1992 Ductile iron pipelines- hydrostatic testing after installation

14 ISO 10803 : 1999 Design method for ductile iron pipes.

15 BS EN 1092 : 1997 Flanges and their joints . Circular flanges for pipes , valves, fittings and accessories, PNdesignated.

Part 2 Cast iron flanges.

16 BS EN 1514 : 1997 Flanges and their joints. Dimension of gaskets for PN-designated flanges.

Part 1 Non-metallic flat gaskets with or without inserts.

part 2 Spiral bound gaskets for use with steel flanges.

part 3 Non-metallic PTFE envelope gaskets.

part 4 Corrugated, flat or grooved metallic and filled metallic gaskets for use with steel flanges.

17 ISO 70052 : 1988 Metallic flangescast iron flanges.


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ESTABLISHMENTS

HEAD OFFICE :

ELECTROSTEEL CASTINGS LIMITED

19, Camac Street, Kolkata - 700017, India

Tel. : +91-33-2283-9990

Fax : +91-33-2289-4338

Website : www.electrosteel.com

FACTORIES :

1) 30 B.T. Raod, Khardah, P.O. Sukchar

Dist. 24Parganas(N) Pin : 700115

Tel : +91-33-2553 2987 / 2991 / 3476

Fax : +91-33-2553 1893

2) Gummidipoondi Taluk, P.O. Elavur, Dist. Chengai MGR

Tamil Nadu, India. Pin : 601 211.

Tel : (+91) (04121) 22255 / 22803

For export enquiries please contact export department at head office address.

Processed and printed at anderson printing ([email protected])


44/44

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Carrying life to people.

CERTIFICATE NO : FM 45346 FM 58775

BS EN ISO 9001 : 2000 BY BRITISHSTANDARD INSTITUTION ISO 9001

IRQS

A DEPARTMENT OFINDIAN REGISTER OF

SHIPPING

RvC

ACCREDITED BY THEDUTCH COUNCILFOR ACCREDITATION

KITEMARKAPPROVED BY IRQS

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