DUCTILE IRON PIPES AND FITTINGS

B S

E N

5 4 5 B S E N

5 9 8

I S O

2 5 3 1 I S O D V G W I M 7 1 8 6 S E W E R A G E

S I R

P O T A B L E K S A

W A T E R

9 0 0 1

ELECTROSTEEL CASTINGS LIMITED

S O

1 4 0 0 1

K I T E M A R K

I S O

Oct, 2006

This Ductile Iron pipes and Fittings catalogue will illustrate 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 to offering advice to customers on the technical specifications and the internal and external protection systems. This service extends to handling and installing ductile iron pipes and fittings. Electrosteel Castings recommendations come with the experience accumulated over four decades of pipe-making. Since local conditions may vary from country to country Electrosteel castings encourages its customers to make contact for any assistance. This catalogue is not a technical manual. Electrosteel Castings advises its customers to strictly follow the relevant applicable 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.

CONTENTS Vision and Quality Policy Environmental Policy Achievements Quality assurance Quality checks & manufacturing process Ductile iron and its advantages Push-on flexible joint Restrained joint Mechanical joint Socketed fittings Flanged pipes and fittings Coating and lining Packing Handling Stacking Pipe Cutting Ovality Correction Repair of Damaged Cement Mortar Lining Laying and Jointing Relevant standards 2 3 4 5 6 8 9 12 13 14 18 26 29 30 32 35 36 37 38 40

VISION
ECL 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.

QUALITY POLICY

Centrifugal casting

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 is committed to complying with the requirements and to continually improve the effectiveness of quality management system through teamwork, training and motivation. ECL shall formulate Quality goals for all functions and involve employees in fulfilment of the same.

ENVIRONMENTAL POLICY
Electrosteel Castings Limited is committed to : Meet environmental legislation and regulation as applicable, on an ongoing 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 policy to all employees and to ensure that this policy is available to all interested parties.
3

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

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

1996 Obtained KITEMARK license from British Standard Institute

for our ductile iron 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 Register
Quality 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.

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

2004

2005 Backward integration has been further achieved by setting up a Captive Coke
oven 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 from
Coke Oven plant. Electrosteel increases its DI pipe manufacturing capacity from 2,00,000 to 2,50,000 tpa.

QUALITY ASSURANCE
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.

CERTIFICATIONS
Certificate of approval from the British Standards Institution ( BSI) certifying that our quality management system complies with the requirements of ISO 9001:2000. 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.

IRQS A DEPARTMENT OF INDIAN REGISTER OF SHIPPING

RvC ACCREDITED BY THE DUTCH COUNCIL FOR ACCREDITATION ISO 9001 APPROVED BY IRQS

5
British 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.

Licensed to use KITEMARK

KM 34577 KM 39560 KM 52142 KM 39166 KM 39167 KM 39168

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

QUALITY CHECKS AT EVERY STAGE OF MANUFACTURING

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 liquid metal suited to manufacture 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.

PROCESS
1. Blast Furnace

TESTING
Analysis of Raw Materials 6.

PROCESS
Zinc Coating

TESTING
Thickness

2.

Induction Furnace

Chemical Composition

7. Dimensional checks

Thickness & Dia

e

DE

3.

Mg Treatment

Micro & Chemical Composition 8.

Hydraulic Test

Pressure
7

4.

Pipes spinning

Temperature

9.

Internal lining

Thickness

5.

Heat treatment

Micro structure

Flattening

10.

External coating

Thickness

DUCTILE IRON AND ITS ADVANTAGES

GREY CAST IRON VS DUCTILE 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.

Micro-structure of Grey Cast Iron

Micro-structure of 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

PUSH-ON FLEXIBLE JOINT

PUSH-ON FLEXIBLE TYPE
The 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.

Flexible Push-on Joint

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.

Ductile Iron Pipes for Water Conveyance

Product Standards : BS EN 545 : 2002. ISO 2531 : 1998. IS 8329 : 2000.
e

DE

External Dia. DE Iron thickness 'e' for K9. Minimum Nominal Tolerance Nominal Tolerance Works test mm mm mm mm mm Pressure Bars (K9) 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000 98.0 118.0 170.0 222.0 274.0 326.0 378.0 429.0 480.0 532.0 635.0 738.0 842.0 945.0 1048.0 ( +1 to -2.2 ) ( +1 to -2.8 ) ( +1 to -2.9 ) ( +1 to -3.0 ) ( +1 to -3.1 ) ( +1 to -3.3 ) ( +1 to -3.4 ) ( +1 to -3.5 ) ( +1 to -3.6 ) ( +1 to -3.8 ) ( +1 to -4.0 ) ( +1 to -4.3 ) ( +1 to -4.5 ) ( +1 to -4.8 ) ( +1 to -5.0 ) 6.00 6.00 6.00 6.30 6.80 7.20 7.70 8.10 8.60 9.00 9.90 10.80 11.70 12.60 13.50 -1.3 -1.3 -1.5 -1.5 -1.6 -1.6 -1.7 -1.7 -1.8 -1.8 -1.9 -2.0 -2.1 -2.2 -2.3 50 50 50 50 50 50 40 40 40 40 40 32 32 32 32

DN

Internal Pressure Rating (K9) PFA PMA PEA Max. Max. Max. Bars Bars Bars 64 64 64 62 54 49 45 42 40 38 36 34 32 31 30 77 77 77 74 65 59 54 51 48 46 43 41 38 37 36 96 96 96 79 70 64 59 56 53 51 48 46 43 42 41

10

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.

Ductile Iron Pipes for Sewerage Application

Product Standards : BS EN 598 : 1995. ISO 7186 : 1996.

DE

DN (mm) 100 150 200 250 300 350 400 450 500 600 700 800 900 1000

External Diameter DE (mm) Nominal Tolerance on Diameter 118.0 +1 / - 2.8 170.0 +1 / - 2.9 222.0 +1 / - 3.0 274.0 +1 / - 3.1 326.0 +1 / - 3.3 378.0 +1 / - 3.4 429.0 +1 / - 3.5 480.0 +1 / - 3.6 532.0 +1 / - 3.8 635.0 +1 / - 4.0 738.0 +1 / - 4.3 842.0 +1 / - 4.5 945.0 +1 / - 4.8 1048.0 +1 / - 5.0

Minimum Iron Thickness. e (mm) 2.5 2.5 3.0 3.5 4.0 4.3 4.6 4.9 5.2 5.8 7.6 8.3 9.0 9.7

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RESTRAINED JOINT
NUT GLAND BOLT GASKET

LOCKING RING

WELD BEAD

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This is a joint where restraining mechanism is incorporated to normal flexible Push-OnJoints. 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-OnJoints 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 marshy grounds, 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. Details of Accessories Nominal Size (DN) (mm) 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000 No. of Holes 4 4 6 8 6 8 8 10 16 16 20 24 30 30 30

JOINT PROFILE

GLAND

LOCKING RING

NUT

BOLT

GLANDS Hole Dia. (mm) 28 28 28 28 30 30 30 30 30 30 30 30 30 30 30 No. per Joint 4 4 6 8 6 8 8 16 16 16 20 24 30 30 30

BOLTS Size (mm) M24 M24 M24 M24 M27 M27 M27 M27 M27 M27 M27 M27 M27 M27 M27 Length (mm) 70 70 70 70 102 102 102 102 102 102 102 123 123 123 123

* For guidance only.

MECHANICAL JOINT
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 the joint 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.

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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.

Ductile Iron Socket Fittings

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

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.

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.

14

Double Socket 900 Bend

Double Socket 450 Bend

Nominal size mm 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000

e mm 7.0 7.2 7.8 8.4 9.0 9.6 10.2 10.8 11.4 12.0 13.2 14.4 15.6 16.8 18.0

L mm 100 120 170 220 270 320 370 420 470 520 620 720 820 920 1020

Nominal size mm 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000

e mm 7.0 7.2 7.8 8.4 9.0 9.6 10.2 10.8 11.4 12.0 13.2 14.4 15.6 16.8 18.0

L mm 55 65 85 110 130 150 175 195 220 240 285 330 370 415 460

Double Socket 22 /20 Bend

Double Socket 11 /40 Bend

Double Socket 900 Duck foot Bend

Nominal size mm 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000

e mm 7.0 7.2 7.8 8.4 9.0 9.6 10.2 10.8 11.4 12.0 13.2 14.4 15.6 16.8 18.0

L mm 40 40 55 65 75 85 95 110 120 130 150 175 195 205 210

Nominal size mm 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000

e mm 7.0 7.2 7.8 8.4 9.0 9.6 10.2 10.8 11.2 12.0 13.2 14.4 15.6 16.8 18.0

L mm 30 30 35 40 50 55 60 65 70 75 85 95 110 115 120

Nominal size mm 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000

e mm 7.0 7.2 7.8 8.4 9.0 9.6 10.2 10.8 11.4 12.0 13.2 14.4 15.6 16.8 18.0

L mm 110 130 180 230 280 325 380 430 480 530 630 735 830 930 1035

c mm 110 125 160 190 225 255 290 320 355 385 450 515 580 645 710

d mm 180 200 250 300 350 400 450 500 550 600 700 800 900 1000 1100

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Nominal Dia (DN) mm 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000

e mm 7.0 7.2 7.8 8.4 9.0 9.6 10.2 10.8 11.4 12.0 13.2 14.4 15.6 16.8 18.0

L mm 160 160 165 170 175 180 185 190 195 200 210 220 230 240 250

d mm 109 130 183 235 288 340 393 445 498 550 655 760 865 970 1075

Collars

For operational convenience collars are with mechanical joints only.

All Socket and Flange on Double Socket Tees Double Socket Concentric Tapers
Nominal Dia (DN) Body mm Branch mm mm mm e e1 L Branch All Socket Flange on double socket mm mm Flange on double socket mm H All Socket mm

80 100 100 150 200 200

80 80 100 100 80 100 150 200 80 100 150 200 250 100 200 300 100 200 350 80 100 150 200 300 400 100 250 450 100 200 400 500 200 400 600 200 400 700 200 400 600 800 200 400 600 900 200 400 600 1000

7.0 7.2 7.2 7.8 8.4 8.4 8.4 8.4 9.0 9.0 9.0 9.0 9.0 9.6 9.6 9.6 10.2 10.2 10.2 10.8 10.8 10.8 10.8 10.8 10.8 11.4 11.4 11.4 12.0 12.0 12.0 12.0 13.2 13.2 13.2 14.4 14.4 14.4 15.6 15.6 15.6 15.6 16.8 16.8 16.8 16.8 18.0 18.0 18.0 18.0

7.0 7.0 7.2 7.2 7.0 7.2 7.8 8.4 7.0 7.2 7.8 8.4 9.0 7.2 8.4 9.6 7.2 8.4 10.2 7.0 7.2 7.8 8.4 9.6 10.8 7.2 9.0 11.4 7.2 8.4 10.8 12.0 8.4 10.8 13.2 8.4 10.8 14.4 8.4 10.8 13.2 15.6 8.4 10.8 13.2 16.8 8.4 10.8 13.2 18.0

170 170 190 195 175 200 255 315 180 200 260 315 375 210 325 440 205 325 495 185 210 270 325 440 560 215 390 620 215 330 565 680 340 570 800 345 575 925 350 580 1045 1045 355 590 1170 1170 360 595 1290 1290

170 170 190 195 175 200 255 315 180 200 260 315 375 210 325 440 -

165 175 180 210 235 240 250 260 265 270 280 290 300 300 320 340 330 350 380 355 360 370 380 400 420 390 420 460 420 440 480 500 500 540 580 525 555 600 585 615 645 675 645 675 705 750 705 735 765 825

85 95 95 120 145 145 150 155 170 170 175 180 190 220 220 220 -

Nominal Diameter (DN)

e1

e2

200 200 250

Larger End mm 100 150 150 200 200 250 250 300 300 300 350 350 350 400 400 400 450 450 500 500 600 600 700 700 800 800 900 900 1000 1000

Smaller End mm 80 80 100 100 150 150 200 150 200 250 200 250 300 250 300 350 350 400 350 400 400 500 500 600 600 700 700 800 800 900

mm 7.2 7.8 7.8 8.4 8.4 9.0 9.0 9.6 9.6 9.6 10.2 10.2 10.2 10.8 10.8 10.8 11.4 11.4 12.0 12.0 13.2 13.2 14.4 14.4 15.6 15.6 16.8 16.8 18.0 18.0

mm 7.0 7.0 7.2 7.2 7.8 7.8 8.4 7.8 8.4 9.0 8.4 9.0 9.6 9.0 9.6 10.2 10.2 10.8 10.2 10.8 10.8 12.0 12.0 13.2 13.2 14.4 14.4 15.6 15.6 16.8

mm 90 190 150 250 150 250 150 350 250 150 360 260 160 360 260 160 260 160 360 260 460 260 480 280 480 280 480 280 480 280

250 250 250 250 300 300 300 350 350 350 400 400 400 400 400 400 450 450 450 500 500 500 500 600 600 600 700 700 700 800 800

16

All Socket and Flange on Double Socket Tees

800 800 900 900 900 900 1000 1000 1000 1000

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

Flanged Socket

Double Socket Level Invert Tee with Flanged Branch

e1

Nominal Dia (DN) mm 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000

e mm 7.0 7.2 7.8 8.4 9.0 9.6 10.2 10.8 11.4 12.0 13.2 14.4 15.6 16.8 18.0

L mm 130 130 135 140 145 150 155 160 165 170 180 190 200 210 220

d mm 109 130 183 235 288 340 393 445 498 550 655 760 865 970 1075

PN16 is the preferred flange. PN 10, PN 25 and PN 40 flanges are supplied when specified.

Nominal size Body Branch DN dn mm mm 100 80 150 80 200 80 200 100 250 80 250 100 300 80 300 100 300 150 350 80 350 100 350 150 400 80 400 100 400 150 400 200 450 80 450 100 450 150 450 200 500 80 500 100 500 150 500 200 600 80 600 100 600 150 600 200 700 150 700 200 800 150 800 200 900 150 900 200 1000 150 1000 200

e mm 8.4 9.1 9.8 9.8 10.5 10.5 11.2 11.2 11.2 11.9 11.9 11.9 12.6 12.6 12.6 12.6 13.3 13.3 13.3 13.3 14.0 14.0 14.0 14.0 15.4 15.4 15.4 15.4 16.8 16.8 18.2 18.2 19.6 19.6 21.0 21.0

e1 mm 8.1 8.1 8.1 8.4 8.1 8.4 8.1 8.4 9.1 8.1 8.4 9.1 8.1 8.4 9.1 9.8 8.1 8.4 9.1 9.8 8.1 8.4 9.1 9.8 8.1 8.4 9.1 9.8 9.1 9.8 9.1 9.8 9.1 9.8 9.1 9.8

L mm 185 190 190 215 220 220 220 220 335 225 225 340 225 225 340 340 230 230 345 345 230 230 350 350 355 355 355 355 360 360 360 360 370 370 370 370

H mm 195 220 250 250 275 275 305 305 305 340 340 340 365 365 365 365 380 380 380 380 400 400 400 400 435 435 450 450 500 500 540 540 580 580 630 630

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FLANGED PIPES AND FITTINGS

Product standards : BS-EN-545 : 2002 / ISO-2531:1998 / IS-8329-2000 / IS-9523 : 2000.
SPECIFICATIONS APPLICABLE : Refer Table : 1 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

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 PFA

PN 10 PMA PEA PFA 16 16 12 12 17 17 16 16

PN 16 PMA 20 20 20 20 PEA 25 25 25 25 PFA

PN 25 PMA PEA PFA 40 35 35 35 40 40 -

PN 40 PMA 48 48 48 PEA 53 53 53 -

18

80 100 to 150 200 to 600 700 to 1000

see PN 16 see PN 16 10 10

see PN 40 25 25 25 30 30 30

TABLE : 1 FLANGES SPECIFICATIONS PRESSURE CLASS SIZE RANGE NUTS AND BOLTS. GALVANISED MS OR HIGH TENSILE. FLAT GASKETS. RUBBER GASKETS 3 MM THICK.

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

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

screwed on

welded on

PN16 FLANGES (SUPPLIED AS STANDARD)

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

DN 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000 D 200 220 285 340 400 455 505 565 615 670 780 895 1015 1115 1230 E 132 156 211 266 319 370 429 480 530 582 682 794 901 1001 1112 19.0 19.0 19.0 20.0 22.0 24.5 24.5 24.5 25.5 26.5 30.0 32.5 35.0 37.5 40.0 a b 16.0 16.0 16.0 17.0 19.0 20.5 20.5 20.5 21.5 22.5 25.0 27.5 30.0 32.5 35.0 PCD (C) 160 180 240 295 350 400 460 515 565 620 725 840 950 1050 1160 HOLES. Nr. 8 8 8 8 12 12 16 16 20 20 20 24 24 28 28 Dia (d) 19 19 23 23 23 23 23 28 28 28 31 31 34 34 37 Bolt Size. M16 M16 M20 M20 M20 M20 M20 M24 M24 M24 M27 M27 M30 M30 M33 f 3 3 3 3 3 4 4 4 4 4 5 5 5 5 5

19

TABLE : 3 PN 16 FLANGES FOR WORKING PRESSURE UPTO AND INCLUDING 16 BAR.

DN mm 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000 D mm 200 220 285 340 400 455 520 580 640 715 840 910 1025 1125 1255 E mm 132 156 211 266 319 370 429 480 548 609 720 794 901 1001 1112 a mm 19.0 19.0 19.0 20.0 22.0 24.5 26.5 28.0 30.0 31.5 36.0 39.5 43.0 46.5 50.0 b mm 16.0 16.0 16.0 17.0 19.0 20.5 22.5 24.0 26.0 27.5 31.0 34.5 38.0 41.5 45.0 PCD (C) mm 160 180 240 295 355 410 470 525 585 650 770 840 950 1050 1170 HOLES. Nr. 8 8 8 12 12 12 16 16 20 20 20 24 24 28 28 Dia (d) mm 19 19 23 23 28 28 28 31 31 34 37 37 41 41 44 Bolt Size. M16 M16 M20 M20 M24 M24 M24 M27 M27 M30 M33 M33 M36 M36 M39 f 3 3 3 3 3 4 4 4 4 4 5 5 5 5 5

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.

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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.

DUCTILE IRON FLANGED JOINT FITTINGS

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, 22 /2 deg. & 11 /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.
1 1

21
Flanged Spigot Double Flanged 900 Bend Double Flanged 450 Bend

Nominal Dia (DN) mm 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000

DE mm 98 118 170 222 274 326 378 429 480 532 635 738 842 945 1048

e mm 7.0 7.2 7.8 8.4 9.0 9.6 10.2 10.8 11.4 12.0 13.2 14.4 15.6 16.8 18.0

L mm 350 360 380 400 420 440 460 480 500 520 560 600 600 600 600

Nominal size DN mm 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000

e mm 7.0 7.2 7.8 8.4 9.0 9.6 10.2 10.8 11.4 12.0 13.2 14.4 15.6 16.8 18.0

L mm 165 180 220 260 350 400 450 500 550 600 700 800 900 1000 1100

Nominal size DN mm 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000

e mm 7.0 7.2 7.8 8.4 9.0 9.6 10.2 10.8 11.4 12.0 13.2 14.4 15.6 16.8 18.0

L mm 130 140 160 180 350 400 298 324 350 375 426 478 529 581 632

Double flanged 22 1/20 bend

L L

Double flanged 11 1/40 bend

L L

Double Flanged concentric Tapers

221/20

111/40

Nominal size DN mm 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000

e mm 7.0 7.2 7.8 8.4 9.0 9.6 10.2 10.8 11.4 12.0 13.2 14.4 15.6 16.8 18.0

L mm 130 140 160 180 350 400 298 324 349 375 426 478 529 581 632

Nominal size DN mm 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000

Nominal Diameter (DN)

e1

e2

e mm 7.0 7.2 7.8 8.4 9.0 9.6 10.2 10.8 11.4 12.0 13.2 14.4 15.6 16.8 18.0

L mm 130 140 160 180 350 400 298 324 349 375 426 478 529 581 632

Larger End Smaller End

(Body) mm 100 200 250 300 350 400 450 500 600 700 800 900 1000

(branch) mm 80 150 200 250 300 350 400 400 500 600 700 800 900

mm 7.2 8.4 9.0 9.6 10.2 10.8 11.4 12.0 13.2 14.4 15.6 16.8 18.0

mm 7.0 7.8 8.4 9.0 9.6 10.2 10.8 10.8 12.0 13.2 14.4 15.6 16.8

mm 200 300 300 300 300 300 300 600 600 600 600 600 600

22

All Flanged Radial Tee

All Flanged Y Pipe

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

e B

r
900

A A e
A L B

Nominal size Body Branch DN DN mm mm 80 100 150 200 250 300 350 400 450 500 600 80 100 150 200 250 300 350 400 450 500 600

L mm 545 580 670 760 900 1000 1100 1200 1300 1400 1600

A mm 165 180 220 260 350 400 450 500 550 600 700

B mm 380 400 450 500 550 600 650 700 750 800 900

r approx. mm 330 340 385 430 475 515 560 605 650 690 780

Nominal size DN mm 80 100 150 200 250 300 350 400 450 500 600

A mm 165 180 220 260 350 400 450 500 550 600 700 Nominal Dia DN mm 200 350 400 700 900 1000 Larger End D b mm 340 340 520 580 580 900 1125 1255 1255 mm 17 17 22.5 24 24 34.5 41.5 45 45 c1 mm 3 3 4 4 4 5 5 5 5 Smaller End Nominal Dia c2 DN mm mm 80 100 250 250 300 500 700 700 800 3 3 3 3 4 4 5 5 5 a mm 40 40 54 54 55 67 73 73 73

Double Flanged 900 Duck-foot Bend

All Flanged Tees

Nominal Dia (DN) Body Branch mm mm 80 100 100 150 150 150 200 200 200 200 250 250 250 250 300 300 300 350 350 350 400 400 400 450 450 450 500 500 500 500 600 600 600 700 700 700 800 800 800 800 900 900 900 1000 1000 1000 1000 80 80 100 80 100 150 80 100 150 200 100 200 200 250 100 200 300 100 200 350 100 200 400 100 200 450 100 200 400 500 200 400 600 200 400 700 200 400 600 800 200 400 600 200 400 600 1000 e mm 7.0 7.2 7.2 7.8 7.8 7.8 8.4 8.4 8.4 8.4 9.0 9.0 9.0 9.0 9.6 9.6 9.6 10.2 10.2 10.2 10.8 10.8 10.8 11.4 11.4 11.4 12.0 12.0 12.0 12.0 13.2 13.2 13.2 14.4 14.4 14.4 15.6 15.6 15.6 15.6 16.8 16.8 16.8 18.0 18.0 18.0 18.0 e1 mm 7.0 7.0 7.2 7.0 7.2 7.8 7.0 7.2 7.8 8.4 7.2 8.4 8.4 9.0 7.2 8.4 9.6 7.2 8.4 10.2 7.2 8.4 10.8 7.2 8.4 11.4 7.2 8.4 10.8 12.0 8.4 10.8 13.2 8.4 10.4 14.4 8.4 10.8 13.2 15.6 8.4 10.8 13.2 8.4 10.8 13.2 18.0 L mm 330 360 360 440 440 440 520 520 520 520 700 700 700 700 800 800 800 850 850 850 900 900 900 950 950 950 1000 1000 1000 1000 1100 1100 1100 650 870 1200 690 910 1350 1350 730 950 7500 770 990 1650 1650 H mm 165 175 180 205 210 220 235 240 250 260 275 325 325 350 300 350 400 325 325 425 350 350 450 375 375 475 400 400 500 500 450 550 550 525 555 600 585 615 645 675 645 675 705 705 735 765 825

Nominal Size (DN) mm 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000

e mm 7.0 7.2 7.8 8.4 9.0 9.6 10.2 10.8 11.4 12.0 13.2 14.4 15.6 16.8 18.0

L&t mm 155 175 230 280 335 385 440 495 545 600 705 810 915 1020 1130

c mm 110 125 160 190 225 255 290 320 355 385 450 515 580 645 710

d mm 180 200 250 300 350 400 450 500 550 600 700 800 900 1000 1100

23

All Flanged Tees

All Flanged Level Invert Tees

Flanged Bell-mouth

e1

L e

= L

e2 H

R B

Nominal size Body DN Branch DN mm 100 150 200 200 250 250 300 300 300 350 350 350 400 400 400 400 450 450 450 450 500 500 500 500 600 600 600 600 700 700 800 800 900 900 1000 1000 mm 80 80 80 100 80 100 80 100 150 80 100 150 80 100 150 200 80 100 150 200 80 100 150 200 80 100 150 200 150 200 150 200 150 200 150 200

e1 mm 8.4 9.1 9.8 9.8 10.5 10.5 11.2 11.2 11.2 11.9 11.9 11.9 12.6 12.6 12.6 12.6 13.3 13.3 13.3 13.3 14.0 14.0 14.0 14.0 15.4 15.4 15.4 15.4 16.8 16.8 18.2 18.2 19.6 19.6 21.0 21.0

e2 mm 8.1 8.1 8.1 8.4 8.1 8.4 8.1 8.4 9.1 8.1 8.4 9.1 8.1 8.4 9.1 9.8 8.1 8.4 9.1 9.8 8.1 8.4 9.1 9.8 8.1 8.4 9.1 9.8 9.1 9.8 9.1 9.8 9.1 9.8 9.1 9.8

L mm 360 440 520 520 700 700 800 800 800 850 850 850 900 900 900 900 950 950 950 950 1000 1000 1000 1000 1100 1100 1100 1100 600 650 670 690 720 730 770 770

H mm 195 220 250 250 275 275 305 305 305 340 340 340 365 365 365 365 380 380 380 380 400 400 400 400 435 435 450 450 500 500 540 540 580 580 630 630

24

Nominal size DN mm 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000

L mm 135 140 155 170 190 210 225 245 260 280 300 340 380 420 440

D mm 160 185 245 310 340 435 495 560 620 685 810 945 1055 1165 1290

B mm 80 85 95 110 120 135 145 160 170 185 210 225 270 255 240

R mm 100 106 119 137 150 169 181 200 212 231 262 281 300 319 337

All Flanged Cross

All Flanged 450 Angle Branch

e1 e2 B
e2 e2

e1

e1

Nominal Size Body Branch DN DN mm mm 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000

e1 mm 8.1 8.4 9.1 9.8 10.5 11.2 11.9 12.5 13.3 14.0 15.4 16.8 18.2 19.6 21.0

e2 mm 8.1 8.4 9.1 9.8 10.5 11.2 11.9 12.5 13.3 14.0 15.4 16.8 18.2 19.6 21.0

L mm 330 360 440 520 700 800 850 900 950 1000 1100 1200 1350 1500 1650

B mm 13 5 180 220 260 350 400 425 450 475 500 550 600 675 750 825 Nominal size Body Branch DN DN mm mm 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000 Type mm N N N N N N N M M M M M M M M e1 mm 8. 8.4 9.1 9.8 10.5 11.2 11.9 12.6 13.3 14.0 15.4 16.8 18.2 19.6 21.0 e2 mm 8.1 8.4 9.1 9.8 10.5 11.2 11.9 12.6 13.3 14.0 15.4 16.8 18.2 19.6 21.0 L mm 500 540 640 735 830 930 880 970 1060 1140 1310 1550 1700 1850 2050 K mm 375 405 480 560 640 715 790 870 950 1025 1180 1430 1570 1700 1900

25

Nominal Dia DN mm 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000

a mm 19.0 19.0 19.0 20.0 22.0 24.5 26.5 28.0 30.0 3105 36.0 39.5 43.0 46.0 50.0

b mm 16.0 16.0 16.0 17.0 19.0 20.5 22.5 24.0 26.0 27.5 31.0 34.5 38.0 41.5 45.0

e mm 3 3 3 3 3 4 4 4 4 4 5 5 5 5 5

K&R mm 325 375 425 475 575 675 775 875 975

h mm 71 80 88 97 114 131 148 165 182

Blank Flanges, Type PN 16

k h R

b a

Bitumen coating

26

COATING AND LINING

POTABLE WATER Coatings
Ductile iron pipes : Electrosteel offers ductile 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. - 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.

Ductile iron fittings : Electrosteel offers ductile iron fittings, externally coated with zinc rich paint and finishing layer of bituminous paint.

With a low resistivity, less than 1500 ohm - cm above the water table or less than 2500 ohm - cm below the water table. With low pH, below 6, With contamination by certain wastes, organic or industrial effluent. Stray currents.

Special coatings : Other special type of external

coatings can be supplied as mentioned below :

- Applicable Standards :

BS EN 545 : 2002. ISO 2531 : 1998.

Zinc coating with extra thickness. Coal tar coating. Bitumen pigmented with materials for high temperature and
UV resistance. Liquid epoxy coating. Zinc - aluminium (85Zn-15Al) pseudo alloy coating having a minimum mass of 400gm/m2 with finishing layer of epoxy coating

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

Sulphate resisting portland cement. Blast furnace slag cement.

HJHJHHHHKHKHK

Special types of linings : The following

types 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. Zinc coating

27
Note : All materials used for internal lining is suitable for potable water applications as per BS 6920.

Linings
Ductile iron pipes : Electrosteel offers internal cement mortar lining, centrifugally applied as per the following standards :
- Applicable Standards : ISO 4179 : 1985. BS EN 545 : 2002.

The thickness is maintained as per the following table : DN (mm) Nominal Value 80 - 300. 350 - 600. 700 - 1000. 3.5 5.0 6.0 Thickness (mm) Tolerance -1.5 -2.0 -2.5

Coatings
Ductile iron fittings : Ductile iron fittings are also supplied with internal cement mortar lining.
Fusion Bonded Epoxy Coating

SEWERAGE APPLICATIONS

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

Coatings
Ductile iron pipes : ECL offers ductile iron
pipes, 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.

Linings
Ductile iron pipes : ECL offers internal cement 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) 100 - 300. 350 - 600. 700 - 1000. Thickness (mm) Nominal Value Tolerance 3.5 5.0 6.0 -1.5 -2.0 -2.5

Ductile iron fittings : ECL offers ductile iron

fittings, externally coated with zinc rich paint and finishing layer of epoxy paint. - Applicable Standards : ISO 8179 : 2004 part - 2. BS EN 598 : 1995.

28

Ductile iron fittings : Ductile iron fittings are supplied with linings as per the following standards.
- Applicable Standards : a) High Alumina cement b) Epoxy Range of Application High Alumina cement Epoxy - pH 4 to pH 12 - pH 1 to pH 14 BS EN 598 : 1995. ISO : 7186 : 1996

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

external 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 external metallic structures. Possible contamination of the soil by industrial effluent. The characteristics of the soil for the above mentioned special type of coating With a low resistivity, less than 1500 ohms - cm above the water table or less than 2500 ohms - cm below the water-table.

Ductile iron fittings are also offered with Fusion Bonded Epoxy(FBE) coating ( inside and outside) from our latest state of the art FBE line.

PACKING
BUNDLED PIPES
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.

29

LOOSE PIPES
Pipe 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 & ACCESSORIES

Fittings 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.

HANDLING
Handling Bundled Pipes

GENERAL
Ductile 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.
BUNDLE / PIPE Fig. - 1 200

30
On receipt, pipes and fittings should be inspected for damage to : The pipe or fitting itself. Cement mortar Linings. External protection system. Jointing surfaces. 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 offloaded 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).

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 CONTAINER

In 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 the pipes 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 or with 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 TRANSPORTATION
In 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. Pipes should 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

31

Handling Loose Pipes

STACKING
Square stacking of loose pipes

Parallel stacking using timbers

32

Pyramidal stacking

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

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

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.

All these factors should be taken into consideration and the stacking heights should not exceed those in table given below. Stacking Heights Dia (mm) 80 100 150 200 250 300 350 & 400 450 & 500 600 700 800 & above Maximum No. of layers 18 16 14 12 10 8 7 6 4 3 2

Parallel stacking using timbers

For this method of stacking two timber battens of sufficient strength should be placed across the pipes between each tier, approximately 600 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 stability.

A competent supervisor shall determine the maximum height for a particular site / location.

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 of pipes having special external protection

Wherever possible, pipes with special external protection should not 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.

33

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.

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

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 pipe bundles

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) 80 100 150 200 250 300 350 400 450 500 600 700 800 & above Max. stack layers (No. of pipes) 18 18 18 12 6 6 8 8 4 6 6 4 4

34

Stacking of Pipes

PIPE CUTTING
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. 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.

CUTTING MACHINES
Today 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 cutting operation

The pipe should be placed on level ground or on square timbers in such a way that during cutting, the cutting disc does not

35

General :
The external diameter of > DN 300 at the cut area should conform to the following standards to ensure a satisfactory joint. External diameter (DE) DN (mm) 350 400 450 500 600 700 800 900 1000 Max (Tape) 1190.0 1351.0 1511.0 1674.0 1998.0 2321.0 2648.0 2972.0 3295.0 Min (Tape) 1177.0 1337.0 1497.0 1660.0 1983.0 2306.0 2631.0 2953.0 3276.0 Max (circum Tape) 379.0 430.0 481.0 533.0 636.0 739.0 843.0 946.0 1049.0 Min (circum Tape) 374.6 425.5 476.4 528.2 631.0 733.7 837.5 940.2 1043.0

OVALITY CORRECTION
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 : 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 A
The 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.

METHOD B
The 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.

36

DE max

DE min

Method A DE min

Method B

DE max

REPAIR OF DAMAGED CEMENT MORTAR LINING

INSTRUCTIONS
When repairing damaged cement mortar linings, the following procedures should be used : Remove any areas of water accumulations. Apply repair mix to area and smooth off.

Preparation of area
Remove 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.

After-Treatment of Repair 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.

37

Composition of repair mix

Mix 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

Materials
Potable water. Cement - compatible to original lining as :

Ordinary portland cement Blast furnace slag cement Sulphate Resistant cement High Alumina cement

Repair procedure
Ensure repair area is wet.

Sand - Not coarser, having an average grain size of 270 - 300 microns.

LAYING AND JOINTING

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

38

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 the receiving 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.

39

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

DN 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000

Max. 80 80 80 87 94 101 98 109 103 113 121 140 145 155 155

Min. 53 53 53 60 66 68 68 75 76 81 83 94 89 89 89

Max. Joint deflection in Deg. 5 5 5 4 4 4 3 3 3 3 3 2 2 1 30

0 0

Max. 73 74 75 81 89 97 96 106 102 112 120 140 145 155 155

Min. 49 50 51 58 61 66 68 74 75 82 87 94 89 89 89

1 30

RELEVANT STANDARDS 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. SL. 1 2 3. 4 5 6 Standard BS EN 545 : 2002 ISO 2531 : 1998 BS EN 598 : 1995 ISO 7186 : 1996 BS 3416 : 1991 ISO 8179 : 2004 Description Ductile iron pipes, fittings, accessories and their joints for water pipelines-requirements and test methods. Ductile iron pipes, fittings, accessories and their joints for water or gas applications. Ductile iron pipes, fittings, accessories and their joints for sewerage applicationrequirements and test methods. Ductile iron products for sewerage applications. Specification for bitumen based coatings for cold application suitable for use in contact with potable water. Ductile iron pipes : external zinc coating. Part 1: Metallic Zinc with finishing layer. Part 2: Zinc rich paint with finishing layer

40

7 8 9 10 11 12 13 14 15

ISO 4179 : 1985 BS 2494 : 1990 ISO 4633 : 1996 BS 6076 : 1996 ISO 8180 : 1985 BS 8010 : Section 2.1 -1987 ISO 10802 :1992 ISO 10803 : 1999 BS EN 1092 : 1997 Part 2

Ductile iron pipes for pressure and non-pressure pipelines-centrifugal cement mortar lining -general requirements. Specification for elastomeric seals for joints in pipe-work and pipelines. Rubber seals-joint rings for water supply, drainage and sewerage pipelines-specification for materials. Specification for tubular polyethylene film for use as protective sleeving for buried iron pipes and fittings. Ductile iron pipes-polyethylene sleeving. Pipelines on land : design, construction and installation. Section 2.1 : Ductile iron. Ductile iron pipelines- hydrostatic testing after installation Design method for ductile iron pipes. Flanges and their joints. Circular flanges for pipes, valves, fittings and accessories, PN designated. Cast iron flanges. Flanges and their joints. Dimension of gaskets for PN-designated flanges. Non-metallic flat gaskets with or without inserts. Spiral bound gaskets for use with steel flanges. Non-metallic PTFE envelope gaskets. Corrugated, flat or grooved metallic and filled metallic gaskets for use with steel flanges. Metallic flangescast iron flanges.

16

BS EN 1514 : 1997 Part 1 part 2 part 3 part 4

17

ISO 70052 : 1988

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.

ESTABLISHMENTS
HEAD OFFICE : ELECTROSTEEL CASTINGS LIMITED 19, Camac Street, Kolkata - 700017, India Tel. : +91-33-2283-9990 Fax : +91-33-2289-4338

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

Website : www.electrosteel.com

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

Processed and printed at anderson printing (info@andersonindia.com)

IRQS CERTIFICATE NO : FM 45346 FM 58775

BS EN ISO 9001 : 2000 BY BRITISH STANDARD INSTITUTION A DEPARTMENT OF INDIAN REGISTER OF SHIPPING

RvC
ACCREDITED BY THE DUTCH COUNCIL FOR ACCREDITATION

KITEMARK

ISO 9001

APPROVED BY IRQS

www.electrosteel.com

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ELECTROSTEEL CASTINGS LIMITED