Electro Steel Casting SA

ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
Ductile Iron
Pipe
&
Fittings
Specification
EN 545 - 2006
EN 545 - 2010
ISO 2531 - 1998
ISO 2531 - 2009
EN 598
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ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
DUCTILE IRON -PROPERTIES
Ductile cast iron is a material with substantially improved
mechanical properties of cast iron. Its minimum elongation of
10% before failure offers adequate strength to bear traffic and
top load without being brittle.
DI pipes are very robust, can withstand mechanical stress and
physical abuse, can be laid in unfavorable terrain and
operating conditions and work without failure offering a very
long service life.
QUALITY CHECKS AT EVERY STAGE OF MANUFACTURING
Strict selection of raw materials is an indispensable requirement for production of Quality Ductile Iron pipes & fittings. Electrosteel
endeavors to achieve 'Quality right the first time' with strict quality control on raw material selection and procurement.
Electrosteel has a Mini Blast Furnace (MBF) at its plant at Khardah using TKES technology. MBF produces liquid metal suited to the
manufacture of Ductile Iron pipes. The liquid metal is further processed and superheated in induction furnaces. It is then treated with
magnesium for nodularisation and transferred to the centrifugal spun casting machines.
The pipes are then heat treated and hydrostatically tested. Various types of coatings and linings are applied depending on soil corrossivity
and aggressivity of the fluid to transmitted. Special coating/lining like PU coating or Ceramic lining is also available. 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 / TEST
1. Blast furnace/Analysis
of raw materials
6. Zinc coating /
Thickness
2. Induction furnace /
Chemical composition
7. Dimensional checks/
Thickness and Dia
3. Magnesium
treatment/Micro and
chemical composition
8. Hydraulic test /
Pressure
4. Pipes spinning /
Temperature
9. Internal
lining/Thickness
5. Heat treatment /
Microscopic structure
and mechanical
strength
10.External
coating/Thickness
1
ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
QUALITY POLICY
QUALITY ACCREDUTUIBS
Electrosteel is committed to providing goods and services
which meet customer's expectations and needs.
The aim is to achieve "Quality right at the first Time".
INDIA
UK
UK
UK
Electrosteel is committed to complying with the requirements
and to continually improve the effectiveness of quality
management system through teamwork, training and
motivation.
Electrosteel shall formulate Quality objectives for all functions
and involve employees in fulfillment of the same.
UK
The quality policy and the quality objectives will be reviewed
for continuing suitability.
Total Productive Maintenance (TPM)
FRANCE
TPM and the Kaizen culture have percolated, both upward and
downward and continuously maintained with all the
enthusiasm involving and motivating personnel at all levels.
'Award in TPM excellence' achieved by Khardah works has
further motivated the teams to take up the challenge of
GERMANY
competing with best in the industry worldwide.
GERMANY
EU
Use of JIPM - In 2010 JIPM Japan has awarded 'Award for
excellence in consistent TPM commitment'. TPM
methodology of KYT (Danger Prediction Drill) is being
continuously enhanced to further improve the conciousness of
USA
USA
USA
SINGAPORE
MALAYSIA
BRASIL
PERU
BULGARIA
INDIA
workmen and supervisors. In addition, to avoid failure, mistake
proof (Pokayoke) and safety assurance perfect line (SAPL)
are also vigorously practiced.
2
ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
PRODUCT RANGE
Ÿ
Electrosteel produces pipes and fittings in the range DN80mm
DN 1000mm in accordance with the following standards:
Ÿ
ISO 2531 / EN545 for Water
Ÿ
ISO 7186 / EN 598 for Sewerage
Ÿ
IS 8329 / IS 9523 for water and sewerage
Ÿ
AWWA C151
Ÿ
RANGE OF PIPES
Ÿ
Socket and spigot pipes with flexible Push on joint pipes
Ÿ
Restrained flexible joint pipes
Ÿ
Flange pipes
Ÿ
Piling pipes
Ÿ
RANGE OF FITTINGS
Ÿ
Electrosteel produces comprehensive range of fittings and
ancillaries including:
Ÿ
Push on joint socketed fittings
Ÿ
Flanged fittings
Ÿ
Rotating flange fittings
Ÿ
Mechanical joint fittings
Ÿ
Express Type Mechanical joint fittings
Ÿ
Restrained joint fittings
OUR BRANDS
Ÿ
Electrosteel brand of pipes, fittings and flanged pipes
Ÿ
Electrofresh brand of pipes
Ÿ
Electrofresh Plus brand of pipes
Ÿ
Electrolock Joint
3
ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
APPLICATION
Ÿ
Raw and Clear water transmission (pumping and gravity
main)
Ÿ
Distribution network of potable water
Ÿ
Water supply for industrial /process plant application
Ÿ
Ash-Slurry Handling & Disposal system
Ÿ
Fire-fighting systems - on-shore and off-shore
Ÿ
Desalination Plants
Ÿ
Sewerage and waste water force main
Ÿ
Gravity sewerage collection and disposal system
Ÿ
Storm water drainage piping
Ÿ
Effluent disposal system for domestic and industrial
application
Ÿ
Recycling system
Ÿ
Piping work inside water and sewage treatment plants
Ÿ
Vertical connection to utilities and reservoirs
Ÿ
Piling for ground stabilization
Ÿ
Protective piping under major carriage-ways
VARIOUS JOINTING SYSTEMS
PUSH ON JOINT
JOINTING PROCEDURE
Socket and spigot push-on joints
1. Clean: Clean the inside of the socket and outside of the
spigot end of the two pipelines to be joined.
The socket and spigot push fit joint is a simple male-female
flexible joint that uses the compression of a synthetic rubber
2. Install the gaskets: Insert the rubber gasket into the
gasket to provide the water tight seal. The simplicity of the joint
groove of the socket.
and its flexible nature accommodates angular defection and
some longitudinal withdrawal without any loss in
3. Lubrication: Apply a thin layer of lubricant on the visible
performance. The design of the gasket incorporating a hard
surface of gasket and the plain end of pipe.
'heel' and softer 'bulb' ensures that gasket compression is
achieved without it being displaced on insertion of the spigot.
Rubber Gaskets
4. Assembly: Align the two pipes and insert the plain end
into the socket.
Gaskets are normally made of EPDM Rubber as per ISO
4633 / EN 681. These gaskets are approved by WRc (Water
5. Check: Verify that the gasket is properly seated in its
Research Centre) UK for safe use with potable drinking water.
housing around the perimeter.
4
ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
Electrosteel Ductile Iron Pipe joint designs are Type
Tooth Gasket Restrained Joint
Tested
Ÿ
Can be used on any Push on Joint Socket & Spigot pipe
Electrosteel's design of the socket and the rubber gasket
ensures leak-tight joint through Type Tests as per BSEN:545
and ISO:2531. Type Test is testing the pipe and pipe joint at
extreme working conditions (the product and use) to ensure
satisfactory performance.
Ÿ
A specially manufactured Steel teeth Inserted Gasket can
be used in place of normal Gasket
Ÿ
The special gasket can to be set in the Socket Groove like
any other gasket
Ÿ
Like any other pipe the steel teeth allow the spigot to be
pushed into the socket
Ÿ
Once the Spigot is fully inserted, teeth bite in to the spigot
and restrict the spigot to come out
Ÿ
This specially designed gasket performs the dual role of
water sealing and restraining
RESTRAINED JOINT
Normal Push-on Mechanical Joint in DI Pipes and Fittings
does not provide significant restraint against longitudinal
separation. Hydraulic thrust forces are created due to change
of direction, reduction in diameter and at the end of pipelines
under pressure during operation. These forces may cause
joint separation if anchor blocks or anchoring devices are not
provided in the pipeline.
One of the most common methods of providing resistance to
thrust forces is the use of thrust blocks. Resistance is provided
by transferring the thrust force to the soil through this thrust
block.
In many cases the site condition does not allow the space
required to construct concrete thrust block and time to cure the
concrete of the Thrust Block to be effective.
So, Electrosteel offers different designs of self restrained joints
to replace the concrete thrust block.
These include:
Ÿ
Tooth gasket Restrained Joint
Ÿ
Bolted Restrained Joint
Ÿ
Electrolock Restrained Joint
Remember...
Ÿ
Restrained joints are for Underground Application.
Ÿ
All pipes in the pipeline need not be with Restrain and
joints
Ÿ
Ÿ
Ÿ
Restraining length depends on Soil type, backfill
compaction, Pipeline Profile and Working Pressure.
All Bends, Reducers End blocks and Tees with its adjacent
restraining lengths are to be with Restrained Joints.
Joints on both sides of the fittings are to be Restrained.
5
Nom. Dia
PFA [Bar]
80
100
125
150
200
250
300
400
500
600
700
16
16
16
16
16
10
10
10
10
10
10
Max. Angular *
Deflection
2.0°
2.0°
2.0°
2.0°
2.0°
2.0°
1.5°
1.5°
1.5°
1.5°
1.5°
ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
Bolted Restrained Joint
Electrolock Restrained Joint
1.
Can withstand very high pressure.
1.
Can withstand very high pressure.
2.
Need specially manufactured pipes, with Factory
manufactured Hood on the socket and Weld
Bead on spigot.
2.
Need Factory manufacture Long Socket Pipes with two
chambers one for normal sealing and the other for
restraining axial movement.
3.
Need special accessories like Gland, Split Retainer
Ring and Nuts/ Hook Bolts.
3.
The water sealing is done by Push-on gasket and re-
4.
The water sealing and restraining are in two
different systems.
4.
Normal Push on joint gasket to be used for sealing.
5.
5.
Normal gasket to be used for sealing.
6.
The Hook Bolts with the support from socket
hood hold the gland and the socket together.
The welding bead on the other pipe's spigot
cannot pass through Retainer Ring housed in
the gland, ensures restraining axial movement
between the two pipes.
After assembly, the locking bars in parts are to be
inserted in the Locking Chamber. The weld bead on the
spigot gets locked with the locking
bar against
separation force.
6.
Can be used for trenchless applications where all pipes
with such joints are used in the trenchless portion.
7.
Easy to assemble and disassemble when required.
7.
straining is done by Weld Bead and Locking Bar.
Easy to assemble and disassemble when required.
Nom.
Dia
80
100
150
200
250
300
350
400
450
500
600
700
750
800
900
1000
Gland Bolts
PFA bar
64
55
44
39
37
32
30
27
25
20
16
Hole
size
25
25
25
25
30
30
30
30
30
30
30
30
30
30
30
30
No. of
Hole
4
4
6
8
6
8
8
10
12
16
20
24
28
30
30
30
Tightening
Torque (Nm)
PRE
20
20
20
20
20
20 .
10
10
10
10
10
10
10
20
10
10
Final
(Max)
100
80
60
60
70
60
20
20
20
30
20
10
30
90
30
10
100/110*
No. of
Locking
Bar
2
No. of
Rubber
Segment
1
100
75/100*
4
2
125
63/100*
4
2
150
63/75*
4
2
200
42/63*
4
2
250
40/44*
4
2
300
40
4
2
400
30
4
2
500
30
8
4
600
30
8
4
700
25
8
4
Nom. Dia
PFA bar
80
Max
Angular**
Deflection
5.0°
4.0°
3.0°
* With high pressure locking bar
** For higher angular deflection please contact the manufacturer
Max
Angular*
Deflection
2.0°
1.5°
1.0°
6
ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
FLANGED JOINT
Remember...
Over ground and specialized applications require restrained
joints where Flanged pipes are used. Flanged Pipes have the
following advantages:
Ÿ
Buried installation is not recommended.
Ÿ
Flanged joint being a rigid joint, perfect alignment of the
flange faces during jointing and bolt tightening is
absolutely vital.
Ÿ
Use of duck foot bend at bottom of vertical flange pipe line
is necessary.
Ÿ
For high pressure application, flanged pipeline needs
thrust block / support at bends / tees.
1. A c t s a s s e l f - r e s t r a i n e d J o i n t r e d u c i n g t h e
requirement of thrust blocks.
2. Ideal for over-ground and Exposed Installations.
3. Flanged Pipes are ideal for Vertical pipelines.
4. Used for Temporary Installations (over pillars)
where pipelines need to be disengaged or
displaced.
5. Widely used for interconnection in Pump House
and Treatment Plant.
Type of Pipe
Dia Range and lengths
PN Ratings
WELDED FLANGED PIPES
Flanges are welded From 80 to 1000 mm
PN10,PN16,PN
on either side of a
diameter, in lengths upto
25,PN40
Class K9 barrel
5.3 m.
SCREWED FLANGED PIPES
Flanged are
From 80 to 300 diameter,
screwed-fit on either
PN10
in lengths upto 5.0 m.
side of a Class K9
CAST FLANGED PIPES
Ranged Pipe is cast
From 80 to 700 mm
PN10,PN16,PN
as a single unit
diameter, in lengths upto
25,PN40
using advanced Lost
1.2 m.
Foam method.
JOINTING PROCEDURE
Ÿ Proberly align the pipes
Ÿ Clean flange faces and remove rust and dirt
Ÿ Position the gasket. Use 3mm thick moulded rubber
gaskets with quality conforming to ISO 4633
Ÿ Use automotive grade oil/grease to lubricate bolt threads
etc.
Ÿ
Insert the nut-bolts one by one. Tighten diametrically
opposite bolts to the recommended torque. If necessary
re-tighten bolts before pressure testing.
Electrosteel manufactures Flanged Pipes using all the three
methods, that is, Welded Flanged Pipes, Screwed Flanged
Pipes and integrally Cast Flanged Pipes (short lengths). Other
types of coating and lining to the Flanged Pipes are also
available. All flanged pipes are normally lined with Cement
Mortar and has outside Zinc and Bitumen Coating. Other types
of coating and lining to the Flanged Pipes are also available.
7
ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
Dimention of Socket & Spigot pipes
As per ISO 2531 - 2009 / en 545-2010
Dimention of Socket & Spigot pipes
As per ISO 2531 - 1998 / EN 545-2007
PIPE DIMENSIONS
PUSH ON JOINT
Nominal
Dia.
Ext.
Dia.
Tol. On
*Nom.
Thickness
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
DE
(mm)
+1/-2.8
+1/-2.8
+1/-2.9
+1/-3
+1/-3.1
+1/-3.3
+1/-3.4
+1/-3.5
+1/-3.6
+1/-3.8
+1/-4
+1/-4.3
+1/-4.5
+1/-4.8
+1/-5
K7
(mm)
Nominal
Dia.
DN
(mm)
80
100
150
200
250
300
350
400
450
500
600
700
800
900
1000
Ext.
Dia.
DE
(mm)
98
118
170
222
274
326
378
429
480
532
635
738
842
945
1048
Tol. On
Nominal
Dia.
(mm)
Ext.
Dia. DE
(mm)
Tol. On
DE
(mm)
80
100
150
200
250
300
350
400
450
500
600
700
800
900
1000
98
118
170
222
274
326
378
429
480
532
635
738
842
945
1048
+1/-2.8
+1/-2.8
+1/-2.9
+1/-3
+1/-3.1
+1/-3.3
+1/-3.4
+1/-3.5
+1/-3.6
+1/-3.8
+1/-4
+1/-4.3
+1/-4.5
+1/-4.8
+1/-5
DE
(mm)
+1/-2.8
+1/-2.8
+1/-2.9
+1/-3
+1/-3.1
+1/-3.3
+1/-3.4
+1/-3.5
+1/-3.6
+1/-3.8
+1/-4
+1/-4.3
+1/-4.5
+1/-4.8
+1/-5
6.0
6.0
6.0
6.0
6.3
6.6
7.0
7.7
9.0
10.4
11.2
12.0
ECL
Works Test
Pressure
K7
(kg/cm²)
40
40
40
40
40
40
32
32
32
32
32
25
25
25
25
Preferred Class #
Pressure
Class
C40
C40
C40
C40
C40
C40
C30
C30
C30
C30
C30
C25
C25
C25
C25
Nominal
Thickness
(mm)
4.4
4.4
4.5
4.7
5.5
6.2
6.3
6.5
6.9
7.5
8.7
8.8
9.6
10.6
11.6
*Nom.
Thickness
K9
(mm)
6.0
6.0
6.0
6.3
6.8
7.2
7.7
8.1
8.6
9.0
9.9
10.8
11.7
12.6
13.5
Minimum
Thickness*
Allowable
Deflection
(mm)
(Degree)
3
3
3
3.1
3.9
4.6
4.7
4.8
5.1
5.6
6.7
6.8
7.5
8.4
9.3
5
5
5
4
4
4
3
3
3
3
3
2
2
1.5
1.5
Dimention of Socket & Spigot pipes
As per ISO 7186 / EN 598
Pressure Sewer
Note: All dimensions are in millimeter
Nominal
Thickness
(mm)**
Nominal
Thickness
(mm)#
4.4
4.4
4.5
4.7
4.9
5.1
5.7
6.3
6.4
6.5
7.5
8.5
9.6
10.6
11.6
4.8
4.8
4.8
4.9
5.3
6.6
6.0
6.3
6.7
7.0
7.7
9.6
10.4
11.2
12.0
8
ECL
Allowable
Works Test Deflection
Pressure
K9
(kg/cm²)
(Degree)
60
5.0
60
5.0
60
5.0
60
4.0
60
4.0
60
4.0
50
3.0
50
3.0
50
3.0
50
3.0
50
3.0
42
2.0
42
2.0
42
1.5
42
1.5
Allowable
Deflection
Degree
5.0
5.0
5.0
4.0
4.0
4.0
3.0
3.0
3.0
3.0
3.0
2.0
2.0
1.5
1.5
ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
FLANGED JOINT
PN - 10
PN - 16
PN - 25
PN - 40
Symmary of minimum tightening torque for
flanged joints
Dimensions of Flanges
DN Outside Die. Of Pitch Flange Outside Dia. Of Pitch Flange Outside Die. Of Pitch Flange Outside Die. Of Pitch Flange
raised Circle
raised Circle
raised Circle
raised Circle
Dia
Width
Dia
Width
Dia
Width
Dia
Width
face
Dia
face
Dia
face
Dia
face
Dia
80
200
132
160
100
125 See PN 16 Dimension
150
200
250
395
319
350
300
445
370
400
350
505
429
460
400
565
480
515
450
615
530
565
500
670
582
620
600
780
682
725
700
895
794
840
750
960
857
900
800
1015
901
950
900
1115
1001 1050
1000 1230
1112 1160
DN
80
100
125
150
200
250
300
350
400
450
500
600
700
750
800
900
1000
Bolt
size
N
16
16
16
20
20
20
20
20
24
24
24
27
27
27
30
30
33
PN - 10
No.
Tight
of
Torque
bolts
N.m
8
7.8
8
11.9
8
18.5
8
32.7
8
39.4
12
40.7
12
58.4
16
59.4
16
91.6
20
92.2
20
113.7
20
185.8
24
209.4
24
240.3
24
300.8
28
325.6
28
437.8
16.0
19.0
20.5
20.5
20.5
21.0
22.5
25.0
27.5
29.0
30.0
32.5
35.0
Bolt
size
N
16
16
16
20
20
24
24
24
27
27
30
33
33
33
36
36
39
PN - 10
DN
200
220
250
285
340
400
455
520
580
640
715
840
910
970
1025
1125
1255
132
156
184
211
266
319
370
429
480
548
609
720
794
857
901
1001
1112
PN - 16
No.
Tight
of
Torque
bolts
N.m
8
7.8
8
11.9
8
18.5
8
32.7
12
38.6
12
71.2
12
102.2
16
103.8
16
153.0
20
154.1
20
209.0
20
327.9
24
369.5
24
424.1
24
530.9
28
574.6
28
772.6
160
180
210
240
295
355
410
470
525
585
650
770
840
900
950
1050
1170
Bolt
size
N
16
20
24
24
24
27
27
30
33
33
33
36
39
39
45
45
52
PN - 16
16.0
16.0
16.0
16.0
17.0
19.0
20.5
22.5
24.0
26.0
27.5
31.0
34.5
36.0
38.0
41.0
45.0
200
235
270
300
360
425
485
555
620
670
730
845
960
1020
1085
1185
1320
PN - 25
No.
Tight
of
Torque
bolts
N.m
8
16.6
8
20.5
8
37.9
8
54.4
12
64.3
12
113.4
16
121.9
16
181.7
16
257.1
20
258.9
20
319.2
20
504.9
24
620.8
24
712.4
24
923.4
28
999.5
28
1427.1
132
156
184
211
274
330
389
448
503
548
609
720
820
883
928
1028
1140
Bolt
size
N
16
20
24
24
27
30
30
33
36
36
39
45
PN - 25
160
190
220
250
310
370
430
490
550
600
660
770
875
940
990
1090
1210
16.0
16.0
16.0
17.0
19.0
21.5
23.5
26.0
28.0
30.5
32.5
37.0
41.5
45.0
46.0
50.5
55.0
PN - 40
No.
Tight
of
Torque
bolts
N.m
8
16.6
8
31.1
8
57.4
8
82.4
12
110.6
12
188.8
16
203.0
16
300.2
16
428.3
20
431.2
20
580.0
20
950.0
PN - 40
Nuts and Bolts for Flanged Pipes
Nom.
Bolt size/ Total
Bolt size/ Total
Bolt size/ Total
Bolt size/ Total
No. of
No. of
No. of
No. of
Dia.
length/ Thread
length/ Thread
length/ Thread
length/ Thread
Bolts
Bolts
Bolts
Bolts
(mm)
length (mm)
length (mm)
length (mm)
length (mm)
80
100
125
150
200
250
300
350
400
450
500
600
700
750
800
900
1000
4.8
8
8
8
8
12
12
16
16
20
20
20
24
24
24
28
28
M16 x
M16 x
M16 x
M20 x
M20 x
M20 x
M20 x
M20 x
M24 x
M24 x
M24 x
M27 x
M27 x
M27 x
M30 x
M30 x
M33 x
70/38
70/38
70/38
80/46
80/46
80/46
90/46
90/46
90/54
90/54
100/54
100/60
110/60
110/60
120/66
120/66
130/78
8
8
8
8
12
12
12
16
16
20
20
20
24
24
24
28
28
M 16 x 70/38
M 16 x 70/38
M 16 x 70/38
M20 x 80/46
M20 x 80/46
M24 x 90/54
M24 x 90/54
M24 x 90/54
M27 x 100/60
M27 x 100/60
M30 x 110/66
M33 x 120/78
M33 x 130/78
M33 x 130/78
M36 x 140/84
M36 x 150/84
M39 x 160/103
8
8
8
8
12
12
16
16
16
20
20
20
24
24
24
28
28
M16 x 70/38
M20 x 80/46
M24 x 80/54
M24 x 90/54
M24 x 90/54
M27 x 100/60
M27 x 100/60
M30x 110/66
M33 x 120/78
M33 x 120/78
M33 x 120/78
M36 x 140/84
M39 x 150/90
M39 x 160/90
M45 x 180/102
M45 x 180/102
M52 x 200/116
9
8
8
8
8
12
12
16
16
16
20
20
20
-
M16 x
M20 x
M24 x
M24 x
M27 x
M30 x
M30 x
M33 x
M36 x
M36 x
M39 x
M45 x
70/38
80/46
90/54
100/54
100/60
120/66
130/72
140/78
l50/84
l50/84
l60/90
l80/102
-
200
235
270
300
375
450
515
580
660
685
755
890
132
166
184
211
284
345
409
465
535
560
615
735
160
190
220
250
320
385
450
510
585
610
670
795
16.0
16.0
20.5
23.0
27.0
31.5
35.5
40.0
44.0
46.0
48.0
53.0
ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
DUCTILE IRON FITTINGS
Loose Flange Fittings
Electrosteel has also introduced fittings with Adjustable
Flange or Loose Flange. Unlike 'As cast' Flanged fitting, in this
case, separately cast loose Flanges are mounted on the
fittings. A loose Flanged Fittings comprises of a Flange ring (in
two 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.
Advantages
Ÿ Since the flanges can be freely rotated, bolthole alignment
with the mating Flange becomes easier.
Ÿ As it can be fixed and removed easily, dismantling of
adjoining accessories becomes easier. Small angles can
be adjusted.
Ÿ The PN rating of the Fittings can be changed at will, just by
changing the loose flange.
Special fittings
Apart from push-on joint and mechanical joint fittings we also
manufacture some special fittings, which are extremely useful
for practical applications which would have same wall
thickness, material and quality tests of standard fittings. Few
of these are mentioned below:
Ÿ 4 way Crosses
Ÿ Double Socket Branch Flange level Invert Tee (Scour
Tee)
Ÿ Puddle flange of required
length
Ÿ Special variation of
Ÿ conventional Fittings such as:
Ÿ Fittings with one side Flange & one side plain-ended
/socketed of a particular length.
Ÿ Tees and Reducers with other non standard DN x dn
combinations.
Ÿ In fact due to the immense flexibility of our manufacturing
process by Lost Foam method, virtually any combination of
socket/ flange/plain-end is possible.
Manufacturing Procedure
The lost foam' process used for manufacturing DI fittings is an
advanced technique and it scores over other conventional
processes.
Lost Foam Technique
Ÿ
First an exact replica of the fitting is made with 'Styro-foam'
popularly known as Thermo-cole.
Ÿ This replica, moulded in special machines, acts as a
pattern for the casting. The patterns are then kept in
mechanized moulding box and then packed with sand.
Ÿ When hot metal is poured, the Styro-foam pattern
vaporizes and the metal takes the shape of the fitting by
filling up the cavity.
Ÿ After cooling, castings are taken out, shot blasted, fettled
and cleaned.
Ÿ After thorough inspection and fettling, the castings
(Fittings) are subjected to hydrostatic testing.
Ÿ Tested fittings are then Zinc coated, cement lined and a
bituminous finishing coat is applied from outside.
Alternatively fittings are short blasted, fusion bonded
epoxy coated and lined in our special FBE plant.
Advantages of Lost Foam Technique
Ÿ Higher productivity. Casting process is much faster.
Ÿ No need of core setting. So no question of core
displacement resulting in uneven thickness.
Ÿ Much lower chances of having pinhole, slag inclusion or
blowhole.
Ÿ Maintains high dimensional tolerance, which is so vital for
proper fitment and leak -tightness. The castings have
excellent finish.
Ÿ In flanged fitting no drilling hole is necessary as all the
holes are as cast.
Hydrostatic Testing
D.I. fittings are tested at works at the following test pressure
as specified in ISO/EN.
Diameter
(mm)
80 - 300
350 - 600
700 - 1000
Works Test Presure
(Kg/cm²)
25
16
10
It may appear that test pressures of fittings are low, compared
to the allowable working pressures in pipes. But fittings with k12 higher factor of safety and do not fail at allowable working
pressure
10
ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
DOUBLE SOCKET 11¼º BEND
Nominal
Size mm
80
100
150
200
250
300
350
400
e
mm
7.0
7.2
7.8
8.4
9.0
9.6
10.2
10.8
L
mm
30
30
35
40
50
55
60
65
Nominal
Size mm
450
500
600
700
800
900
1000
e
mm
11.4
12.0
13.2
14.4
15.6
16.8
18.0
L
mm
70
75
85
95
110
115
120
Nominal
Size mm
80
100
150
200
e
mm
7.0
7.2
7.8
8.4
L
mm
40
40
55
65
Nominal
Size mm
450
500
600
700
e
mm
11.4
12.0
13.2
14.4
L
mm
120
130
150
175
250
9.0
75
800
15.6
195
300
9.6
85
900
16.8
205
350
10.2
95
1000
18.0
210
400
10.8
110
Nominal
Size mm
80
100
150
200
250
300
350
400
e
mm
7.0
7.2
7.8
8.4
9.0
9.6
10,2
10,8
L
mm
55
65
85
110
130
150
175
195
Nominal
Size mm
450
500
600
700
800
900
1000
e
mm
11.4
12.0
13.2
14.4
15,6
16.8
18.0
L
mm
220
240
285
330
370
415
460
Nominal
Size mm
80
100
150
200
250
300
350
400
e
mm
7.0
7.2
7.8
8.4
9.0
9.6
10.2
10.8
L
mm
100
120
170
220
270
320
370
420
Nominal
Size mm
450
500
600
700
800
900
1000
e
mm
11.4
12.0
13.2
14.4
15.6
16.8
18.0
L
mm
470
520
620
720
820
920
1020
DOUBLE SOCKET ½º BEND
DOUBLE SOCKET 45º BEND
DOUBLE SOCKET 90º BEND
11
ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
DOUBLE SOCKET 90º DUCK FOOT BEND
Nominal
Size
mm
80
100
150
200
250
300
350
400
e
L
H
D
mm
7.0
7.2
7.8
8.4
9.0
9.6
10.2
10.8
mm
110
130
180
230
280
325
380
430
mm
110
125
160
190
225
255
290
320
mm
180
200
250
300
350
400
450
500
DE
e
L
mm
98
118
170
222
274
326
378
429
mm
7.0
7.2
7.8
8.4
9.0
9.6
10.2
10.8
mm
350
360
380
400
420
440
460
480
e
L
d
mm
7.0
7.2
7.8
8.4
9.0
9.6
10.2
10.8
mm
130
130
135
140
145
150
155
160
mm
109
130
183
235
288
340
393
445
Nominal
Size
mm
450
500
600
700
800
900
1000
e
L
H
D
mm
11.4
12.0
13.2
14.4
15.6
16.8
18.0
mm
480
530
630
730
830
930
1030
mm
355
385
450
515
580
645
710
mm
550
600
700
800
900
1000
1100
Nominal
Size
e
L
H
450
500
600
700
800
900
1000
480
532
635
738
842
945
1048
11.4
12.0
13.2
14.4
15.6
16.8
18.0
500
520
560
600
600
600
600
Nominal
Dia (DN)
mm
450
500
600
700
800
900
1000
e
L
d
mm
11.4
12.0
13.2
14.4
15.6
16.8
18.0
mm
165
170
180
190
200
210
220
mm
498
550
655
760
865
970
1075
FLANGED SPIGOT
Nominal
Dia (DN)
mm
80
100
150
200
250
300
350
400
FLANGED SOCKET
Nominal
Dia (DN)
mm
80
100
150
200
250
300
350
400
DOUBLE SOCKET CONCENTRIC TAPER
Nominal Dia.
(DN)
e
Larger Smaller
End
End
mm
mm
mm
100
80
7.2
150
80
7.8
150
100
7.8
200
100
8.4
200
150
8.4
250
150
9.0
250
200
9.0
300
150
9.6
300
200
9.6
300
250
9.6
350
200
10.2
350
250
10.2
350
300
10.2
400
250
10.8
400
300
10.8
Nominal Dia.
(DN)
e1
L
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
mm
90
190
150
250
150
250
150
350
250
150
360
260
160
360
260
12
e
e1
Larger Smaller
End
End
400
350
10.8 10.2
450
350
11.4 10.2
450
400
11.4 10.8
500
350
12.0 10.2
500
400
12.0 10.8
600
400
13.2 10.8
600
500
13.2 12.0
700
500
14.4 12.0
700
600
14.4 13.2
800
600
15.6 13.2
800
700
15.6 14.4
900
700
16.8 14.4
900
800
16.8 15.6
1000
800
18.0 15.6
1000
900
18.0 16.8
L
160
260
160
360
260
460
260
480
280
480
280
480
280
480
280
ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
DOUBLE SOCKET COLLAR
Nominal
Dia (DN)
mm
80
100
150
200
250
300
350
400
e
L
d
mm
7.0
7.2
7.8
8.4
9.0
9.6
10.2
10.8
mm
160
160
165
170
175
180
185
190
mm
109
130
183
235
288
340
393
445
Nominal
Dia (DN)
mm
450
500
600
700
800
900
1000
e
L
d
mm
11.4
12.0
13.2
14.4
15.6
16.8
18.0
mm
195
200
210
220
230
240
250
mm
498
550
655
760
865
970
1075
ALL SOCKET TEE
Nominal Dia.
(DN)
e
e1
L
H
Body Branch mm mm mm mm
mm
mm
80
100
100
150
150
200
200
200
200
250
250
250
250
250
300
300
300
300
300
350
350
350
350
350
350
400
400
400
80
80
100
100
150
80
100
150
200
80
100
150
200
250
100
150
200
250
300
100
150
200
250
300
350
80
100
150
7.0
7.2
7.2
7.8
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
9.6
9.6
10.2
10.2
10.2
10.2
10.2
10.2
10.8
10.8
10.8
7.0
7.0
7.2
7.2
7.8
7.0
7.2
7.8
8.4
7.0
7.2
7.8
8.4
9.0
7.2
7.8
8.4
9.0
9.6
7.2
7.8
8.4
9.0
9.6
10.2
7.0
7.2
7.8
170
170
190
195
255
175
200
255
315
180
200
260
315
375
205
260
320
380
435
205
265
325
380
440
495
185
210
270
85
95
95
120
125
145
145
150
155
170
170
175
180
190
195
200
205
215
220
220
225
230
240
245
250
245
245
250
Nominal Dia.
(DN)
e
e1
L
H
Body Branch mm mm mm mm
mm
mm
400
400
400
450
450
450
500
500
500
500
600
600
600
700
700
700
800
800
800
800
900
900
900
900
1000
1000
1000
1000
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
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
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
325
440
560
215
385
620
215
330
565
680
340
570
800
345
575
925
350
580
815
1045
355
590
820
1170
360
595
825
1290
MJ COLLAR
Nominal
Dia (DN)
mm
80
100
150
200
250
300
350
400
e
mm
L
mm
d
mm
7.0
7.2
7.8
8.4
9.0
9.6
10.2
10.8
160
160
165
170
175
180
185
190
109
130
183
235
288
340
393
445
Nominal
Dia (DN)
mm
450
500
600
700
800
900
1000
13
e
mm
L
mm
d
mm
11.4
12.0
13.2
14.4
15.6
16.8
18.0
195
200
210
220
230
240
250
498
550
655
760
865
970
1075
255
270
280
270
290
310
295
305
330
340
355
380
400
405
430
460
455
480
500
525
505
530
550
585
555
580
600
645
ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
DOUBLE FLANGED 11 ¼º BEND
Nominal
Size (DN)
mm
80
100
125
150
200
250
300
350
e
mm
L
mm
7.0
7.2
7.5
7.8
8.4
9.0
9.6
10.2
113
115
111
113
132
165
175
191
Nominal
Size (DN)
mm
400
450
500
600
700
800
900
1000
e
mm
L
mm
10.8
11.4
12.0
13.2
14.4
15.6
16.8
18.0
205
349
375
426
478
529
581
632
e
mm
L
mm
10.8
11.4
12.0
13.2
14.4
15.6
16.8
18.0
239
349
375
426
478
529
581
632
e
mm
L
mm
10.8
11.4
12.0
13.2
14.4
15.6
16.8
18.0
324
350
375
426
478
529
581
632
e
mm
L
mm
10.8
11.4
12.0
13.2
14.4
15.6
16.8
18.0
500
550
600
700
800
900
1000
1100
DOUBLE FLANGED 22 ½º BEND
Nominal
Size (DN)
mm
80
100
125
150
200
250
300
350
e
mm
L
mm
7.0
7.2
7.5
7.8
8.4
9.0
9.6
10.2
105
110
105
109
131
190
210
210
Nominal
Size (DN)
mm
400
450
500
600
700
800
900
1000
DOUBLE FLANGED 45º BEND
Nominal
Size (DN)
mm
80
100
125
150
200
250
300
350
e
mm
L
mm
7.0
7.2
7.5
7.8
8.4
9.0
9.6
10.2
130
140
150
160
180
350
400
298
Nominal
Size (DN)
mm
400
450
500
600
700
800
900
1000
DOUBLE FLANGED 90º BEND
Nominal
Size (DN)
mm
80
100
125
150
200
250
300
350
e
mm
L
mm
7.0
7.2
7.5
7.8
8.4
9.0
9.6
10.2
165
180
200
220
260
350
400
450
Nominal
Size (DN)
mm
400
450
500
600
700
800
900
1000
14
ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
DOUBLE SOCKET LEVEL INVERT TEE WITH FLANGED BRANCH
Nominal Dia.
(DN)
Body Branch
mm
mm
100
80
150
80
150
100
200
80
200
100
200
150
250
80
250
100
250
150
250
200
300
80
300
100
300
150
300
200
300
250
350
80
350
100
350
150
350
200
350
250
400
80
Nominal Dia.
(DN)
Body Branch
mm
mm
400
100
400
150
400
200
400
250
400
300
450
80
450
100
450
150
450
200
450
250
450
300
450
400
500
80
500
100
500
150
500
200
500
250
500
300
500
350
500
400
500
450
e
e1
L
H
mm mm mm mm
7.2
7.8
7.8
8.4
8.4
8.4
9.0
9.0
9.0
9.0
9.6
9.6
9.6
9.6
9.6
10.2
10.2
10.2
10.2
10.2
10.8
7.0
7.0
7.2
7.0
7.2
7.8
7.0
7.2
7.8
8.4
7.0
7.2
7.8
8.4
9.0
7.0
7.2
7.8
8.4
9.0
7.0
170
170
195
175
200
255
180
200
260
315
180
205
260
320
380
185
205
265
325
380
185
175
205
210
235
240
250
265
270
280
290
295
300
310
320
330
325
330
340
350
360
355
e
e1
L
H
mm mm mm mm
10.8
10.8
10.8
10.8
10.8
11.4
11.4
11.4
11.4
11.4
11.4
11.4
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
7.2
7.8
8.4
9.0
9.6
7.0
7.2
7.8
8.4
9.0
9.6
10.8
7.0
7.2
7.8
8.4
9.0
9,6
10.2
10.8
11.4
210
270
325
385
440
190
215
270
330
385
445
560
195
215
275
330
390
450
505
565
620
360
370
380
390
400
385
390
400
410
420
430
450
415
420
430
440
450
460
470
480
490
Nominal Dia.
(DN)
Body Branch
mm
mm
600
80
600
100
600
150
600
200
600
250
600
300
600
350
600
400
600
450
600
500
700
80
700
100
700
150
700
200
800
150
800
200
900
150
900
200
1000
150
1000
200
DOUBLE SOCKET FLANGED BRANCH TEE
Nominal Dia.
(DN)
Body Branch
mm
mm
80
80
100
80
100
100
150
80
150
100
150
150
200
80
200
100
200
150
200
200
250
80
250
100
250
150
250
200
250
250
300
100
300
200
300
250
300
300
350
100
350
200
350
350
400
80
400
100
400
150
400
200
e
e1
L
H
mm mm mm 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
9.0
9.6
9.6
9.6
9.6
10.2
10.2
10.2
10.8
10.8
10.8
10.8
7.0
7.0
7.2
7.0
7.2
7.8
7.0
7.2
7.8
8.4
7.0
7.2
7.8
8.4
9.0
7.2
8.4
9.0
9.6
7.2
8.4
10.2
7.0
7.2
7.8
8.4
170
170
190
170
195
255
175
200
255
315
180
200
260
315
375
205
320
380
435
205
325
495
185
210
270
325
165
175
180
205
210
220
235
240
250
260
265
270
280
290
300
300
320
330
340
330
350
380
355
360
370
380
15
Nominal Dia.
(DN)
Body Branch
mm
mm
400
300
400
400
450
100
450
250
450
450
500
100
500
400
500
500
600
200
600
400
600
600
700
200
700
400
700
700
800
200
800
400
800
600
800
800
900
200
900
400
900
600
900
900
1000
200
1000
400
1000
600
1000
1000
e
e1
L
H
mm mm mm mm
10.8
10.8
11.4
11.4
11.4
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
9.6
10.8
7.2
9.0
11.4
7.2
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
440
560
215
385
620
215
565
680
340
570
800
345
575
925
350
580
815
1045
355
590
820
1170
360
595
825
1290
400
420
390
420
460
420
480
500
500
540
580
525
555
600
585
615
645
675
645
675
705
750
705
735
765
825
e
e1
L
H
mm mm mm mm
13.2
13.2
13.2
13.2
13.2
13.2
13.2
13.2
13.2
13.2
14.4
14.4
14.4
14.4
15.6
15.6
16.8
16.8
18.0
18.0
7.0
7.2
7.8
8.4
9.0
9.6
10.2
10.8
11.4
12.0
7.0
7.2
7.8
8.4
7.8
8.4
7.8
8.4
7.8
8.4
200
220
280
340
395
455
510
570
630
685
205
230
285
345
290
350
300
355
305
360
475
480
490
500
510
520
530
540
550
560
505
510
520
525
580
585
640
645
700
705
ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
DOUBLE FLANGED CONCENTRIC TAPERS
Nominal Dia.
Larger Smaller
End
End
100
80
125
80
125
100
150
80
150
100
150
125
200
80
200
100
200
125
200
150
250
80
250
100
250
125
250
150
250
200
300
80
300
100
300
125
300
150
300
200
300
250
350
80
350
100
350
125
350
150
350
200
350
250
350
300
e2
e1
L
7.2
7.5
7.5
7.8
7.8
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
9.6
9.6
9.6
10.2
10.2
10.2
10.2
10.2
10.2
10.2
7.0
7.0
7.2
7.0
7.2
7.5
7.0
7.2
7.5
7.8
7.0
7.2
7.5
7.8
8.4
7.0
7.2
7.5
7.8
8.4
9.0
7.0
7.2
7.5
7.8
8.4
9.0
9.6
200
180
200
230
300
200
335
290
240
300
440
400
350
295
300
550
510
460
405
300
300
655
615
565
510
410
305
300
L
mm
H
mm
D
mm
165
180
220
260
350
400
450
500
110
125
160
190
225
255
290
320
180
200
250
300
350
400
450
500
Nominal Dia.
Larger Smaller
End
End
400
100
400
125
400
150
400
200
400
250
400
300
400
350
450
150
450
200
450
250
450
300
450
350
450
400
500
200
500
250
500
300
500
350
500
400
600
300
600
350
600
400
600
500
700
600
800
700
900
800
1000
900
e2
e1
L
10.8
10.8
10.8
10.8
10.8
10.8
10.8
11.4
11.4
11.4
11.4
11.4
11.4
12.0
12.0
12.0
12.0
12.0
13.2
13.2
13.2
13.2
14.4
15.6
16.8
18.0
7.2
7.5
7.8
8.4
9.0
9.6
10.2
7.8
8.4
9.0
9.6
10.2
10.8
8.4
9.0
9.6
10.2
10.8
9.6
10.2
10.8
12.0
13.2
14.4
15.6
16.8
720
670
615
510
410
300
300
715
610
510
410
305
300
725
625
520
420
600
730
625
525
600
600
600
600
600
e
mm
L
mm
H
mm
D
mm
11.4
12.0
13.2
14.4
15.6
16.8
18.0
550
600
700
800
900
1000
1100
355
385
450
515
580
645
710
550
600
700
800
900
1000
1100
DOUBLE FLANGED 90º DUCK-FOOT BEND
Nominal
e
Size (DN)
mm
mm
80
7.0
100
7.2
150
7.8
200
8.4
250
9.0
300
9.6
350
10.2
400
10.8
Nominal
Size
(DN) mm
450
500
600
700
800
900
1000
ALL FLANGED RADIAL TEE
Body
DN
mm
80
100
150
200
250
300
SIZE
Branch
DN
mm
80
100
150
200
250
300
e
A
B
H
L
mm
7.0
7.2
7.8
8.4
9.0
9.6
mm
165
180
220
260
350
400
mm
380
400
450
500
550
600
mm
380
400
450
500
550
600
mm
545
580
670
760
900
1000
16
ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
REDUCING FLANGES, TYPE PN16
b = 10+0.035 DN with a minimum value of 16
Larger End
ALL FLANGED TEES
Nominal
Dia.DN
D
b
mm
200
200
350
400
400
700
900
1000
1000
mm
340
340
520
580
580
910
1125
1255
1255
mm
17.0
17.0
22.5
24.0
24.0
34.5
41.5
45.0
45.0
Nom. Dia.
Body Branch
DN
DN
mm
mm
80
80
100
80
100
100
125
80
125
125
150
80
150
100
150
150
200
80
200
100
200
150
200
200
250
80
250
100
250
150
250
200
250
250
300
80
300
100
300
150
300
200
300
250
300
300
350
80
350
100
350
150
350
200
350
250
350
300
350
350
400
80
400
100
400
150
400
200
400
250
400
300
400
400
450
100
450
150
e
e1
mm
7.0
7.2
7.2
7.5
7.5
7.8
7.8
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
9.6
9.6
9.6
10.2
10.2
10.2
10.2
10.2
10.2
10.2
10.8
10.8
10.8
10.8
10.8
10.8
10.8
11.4
11.4
mm
7.0
7.0
7.2
7.0
7.0
7.0
7.2
7.8
7.0
7.2
7.8
8.4
7.0
7.2
7.8
8.4
9.0
7.0
7.2
7.8
8.4
9.0
9.6
7.0
7.2
7.8
8.4
9.0
9.6
10.2
7.0
7.2
7.S
8.4
9.0
9.6
10.8
7,2
7,8
L
Smaller End
Cl
Nominal
Dia. DN
c2
a
mm
3
3
4
4
4
5
5
5
5
mm
80
100
250
250
300
500
700
700
800
mm
3
3
3
3
4
4
5
5
5
mm
40
40
54
54
55
67
73
73
77
H
mm mm
330 165
360 175
360 180
400 190
400 200
440 205
440 210
440 220
520 235
520 240
520 250
520 260
700 265
700 275
700 300
700 325
700 350
800 290
800 300
800 325
800 350
800 375
800 400
850 325
850 325
850 325
850 325
850 325
850 425
850 425
900 350
900 350
900 350
900 350
900 350
900 450
900 450
950 375
950 375
17
Nom. Dia.
Body Branch
DN
DN
mm
mm
450
200
450
250
450
300
450
350
450
400
450
450
500
100
500
150
500
200
500
250
500
300
500
350
500
400
500
500
600
100
600
150
600
200
600
250
600
300
600
350
600
400
600
450
600
500
600
600
700
200
700
400
700
700
800
200
800
400
800
600
800
800
900
200
900
400
900
600
900
900
1000 200
1000 400
1000 600
1000 1000
e
e1
L
H
mm
11.4
11.4
11.4
11.4
11.4
11.4
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
13.2
13.2
13.2
13.2
13.2
13.2
13.2
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
mm
8.4
9.0
9.6
10.2
10,8
11.4
7.2
7.8
8.4
9.0
9.6
10.2
10.8
12.0
7.2
7.8
8.4
9.0
9.6
10.2
10.8
11.4
12.0
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
mm
950
950
950
950
950
950
1000
1000
1000
1000
1000
1000
1000
1000
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
650
870
1200
690
910
1350
1350
730
950
1500
1500
770
990
1650
1650
mm
375
375
475
475
475
475
400
400
400
400
500
500
500
500
450
450
450
450
550
550
550
550
550
550
525
555
600
585
615
645
675
645
675
705
750
705
735
765
825
ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
ALL FLANGED LEVEL INVERT TEES
Nom. Dia.
Body Branch
DN
dn
mm
mm
80
80
100
80
125
80
150
80
150
100
200
80
200
100
200
150
250
80
250
100
250
150
250
200
300
80
300
100
300
150
300
200
300
250
350
80
350
100
350
150
350
200
350
250
350
300
400
80
400
100
400
150
400
200
400
250
400
300
450
100
450
150
e
e1
mm
7.0
7.2
7.5
7.8
7.8
8.4
8.4
8.4
9.0
9.0
9.0
9.0
9.6
9.6
9.6
9.6
9.6
10.2
10.2
10.2
10.2
10.2
10.2
10.8
10.8
10.8
10.8
10.8
10.8
11.4
11.4
mm
7.0
7.0
7.0
7.0
7.2
7.0
7.2
7.8
7.0
7.2
7.8
8.4
7.0
7.2
7.8
8.4
9.0
7.0
7.2
7.8
8.4
9.0
9.6
7.0
7.2
7.8
8.4
9.0
9.6
7.2
7.8
L
H
mm mm
330 165
360 175
400 190
440 205
440 210
520 235
520 240
520 250
700 265
700 275
700 300
700 325
800 290
800 300
800 325
800 350
800 375
850 325
850 325
850 325
850 325
850 325
850 425
900 350
900 350
900 350
900 350
900 350
900 450
950 375
950 375
Nom. Dia.
Body Branch
DN
dn
mm
mm
450
200
450
250
450
300
450
350
450
400
500
80
500
100
500
150
500
200
500
250
500
300
500
350
500
400
500
450
600
80
600
100
600
150
600
200
600
250
600
300
600
350
600
400
600
450
600
500
700
150
700
200
800
150
800
200
900
150
900
200
1000 300
e
e1
L
H
mm
11.4
11.4
11.4
11.4
11.4
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
13.2
13.2
13.2
13.2
13.2
13.2
13.2
13.2
13.2
13.2
14.4
14.4
15.6
15.6
16.8
16.8
18.0
mm
8.4
9.0
9.6
10.2
10.8
7.0
7.2
7.8
8.4
9.0
9.6
10.2
1Q.S
11.4
7.0
7.2
7.8
8.4
9.0
9.6
10,2
10.8
11.4
12.0
7.8
8.4
7.8
8.4
7.8
8.4
9.6
mm
950
950
950
950
950
1000
1000
1000
1000
1000
1000
1000
1000
1000
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
595
650
635
690
675
730
880
mm
375
375
475
475
475
400
400
400
400
400
500
500
500
500
450
450
450
450
450
550
550
550
550
550
520
525
580
585
640
645
720
FLANGED BELL-MOUTH
Nominal
SIZE
mm
80
100
150
200
250
300
350
400
e
L
D
mm
7.0
7.2
7.8
8.4
9.0
9.6
10.2
10.8
mm
135
140
155
170
190
210
225
245
mm
160
185
245
310
370
435
495
560
Nominal
SIZE
mm
450
500
600
700
800
900
1000
18
e
L
D
mm
11.4
12.0
13.2
14.4
15.6
16.8
18.0
mm
260
280
300
340
380
420
440
mm
620
685
810
945
1055
1165
1290
ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
ALL FLANGED CROSS
Nom. Dia.
Body Branch
mm
mm
80
80
100
80
100
100
125
80
125
125
150
80
150
100
150
150
200
80
200
100
200
150
200
200
250
80
250
100
250
150
250
200
250
250
300
80
300
100
300
150
300
200
300
250
300
300
350
100
350
150
350
200
350
250
350
300
350
350
400
100
400
150
400
200
400
250
400
300
e
e1
L
H
mm
7.0
7.2
7.2
7.5
7.5
7.8
7.8
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
9.6
9.6
9.6
10.2
10.2
10.2
10.2
10.2
10.2
10.8
10.8
10.8
10.8
10.8
mm
7.0
7.0
7.2
7.0
7.0
7.0
7.2
7.8
7.0
7.2
7.8
8.4
7.0
7.2
7.8
8.4
9.0
7.0
7.2
7.8
8.4
9.0
9.6
7.2
7.8
8.4
9.0
9.6
10.2
7.2
7.8
8.4
9.0
9.6
mm
330
360
360
400
400
440
440
440
520
520
520
520
700
700
700
700
700
800
800
800
800
800
800
850
850
850
850
850
850
900
900
900
900
900
mm
165
175
180
190
200
205
210
220
235
240
250
260
265
275
300
325
350
290
300
325
350
375
400
325
325
325
325
425
425
350
350
350
350
450
Nom. Dia.
Body Branch
mm
mm
400
350
400
400
450
100
450
150
450
200
450
250
450
300
450
350
450
400
450
450
500
100
500
150
500
200
500
250
500
300
500
350
500
400
500
450
500
500
600
100
600
150
600
200
600
250
600
300
600
350
600
400
600
450
600
500
600
600
700
700
800
800
900
900
1000
1000
e
e1
L
H
mm
10.8
10.8
11.4
11.4
11.4
11.4
11.4
11.4
11.4
11.4
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
12.0
13.2
13.2
13.2
13.2
13.2
13.2
13.2
13.2
13.2
13.2
14.4
15.6
16.8
18.0
mm
10.2
10.8
7.2
7.8
8,4
9.0
9.6
10.2
10.8
11.4
7.2
7.8
8.4
9.0
9.6
10.2
10.8
11.4
12.0
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
mm
900
900
950
950
950
950
950
950
950
950
1000
1000
1000
1000
1000
1000
1000
1000
1000
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
1200
1350
1500
1650
mm
450
450
375
375
375
375
475
475
475
475
400
400
400
400
500
500
500
500
500
450
450
450
450
550
550
550
550
550
550
600
675
750
825
END CAPS
SIZE Body
DN
mm
80
100
125
150
200
250
300
350
SIZE Body
DN
mm
400
450
500
600
700
800
900
1000
e
mm
18
18
18
18
18
20
23
24
19
e
mm
25
26
27
30
31
33
35
37
ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
ALL SOCKET CROSS
SIZE
Body Branch
DN
DN
mm
mm
80
80
100
80
100
100
150
150
200
80
200
100
200
150
200
200
250
80
250
100
250
150
250
200
250
250
300
80
300
100
300
150
300
200
300
250
300
300
350
100
350
150
350
200
350
250
350
300
350
350
400
100
400
150
400
200
400
250
400
300
e
e1
L
H
mm
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
9.6
9.6
9.6
10.2
10.2
10.2
10.2
10.2
10.2
10.8
10.8
10.8
10.8
10.8
mm
7.0
7.0
7.2
7.8
7.0
7.2
7.8
8.4
7.0
7.2
7.8
8.4
9.0
7.0
7.2
7.8
8.4
9.0
9.6
7.2
7.8
8.4
9.0
9.6
10.2
7.2
7.8
8.4
9.0
9.6
mm
170
170
190
255
175
200
255
315
180
200
260
315
375
180
205
260
320
380
435
205
265
325
380
440
495
210
270
325
385
440
mm
85
95
95
125
145
145
150
155
170
170
175
180
190
195
195
200
205
215
220
220
225
230
240
245
250
245
250
255
265
270
SIZE
Body Branch
DN
DN
mm
mm
400
400
500
100
500
150
500
200
500
250
500
300
500
400
500
500
600
200
600
400
600
600
700
200
700
400
700
600
700
700
800
200
800
400
800
600
800
800
900
200
900
400
900
600
900
800
900
900
1000
200
1000
400
1000
600
1000
800
1000
1000
e
e1
L
H
mm
10.8
12.0
12.0
12.0
12.0
12.0
12.0
12.0
13.2
13.2
13.2
14.4
14.4
14.4
14.4
15.6
15.6
15.6
15.6
16.8
16.8
16.8
16.8
16.8
18.0
18.0
18.0
18.0
18.0
mm
10.8
7.2
7.8
8.4
9.0
9.6
10.8
12.0
8.4
10.8
13.2
8.4
10.8
13.2
14.4
8.4
10.8
13.2
15.6
8.4
10.8
13.2
15.6
16.8
8.4
10.8
13.2
15.6
18.0
mm
560
215
275
330
390
450
565
680
340
570
800
345
575
810
925
350
580
815
1045
355
590
820
1050
1170
360
595
825
1060
1290
mm
280
295
300
305
315
320
330
340
355
380
400
405
430
450
460
455
480
500
525
505
530
550
575
585
555
580
600
625
645
BLANK FLANGES, TYPE PN16
DN
mm
80
100
125
150
200
250
300
350
D
mm
200
220
250
285
340
400
455
520
a
mm
19.0
19.0
19.0
19.0
20.0
22.0
24.5
26.5
b
mm
16.0
16.0
16.0
16.0
17.0
19.0
20.5
22.5
c
mm
3
3
3
3
3
3
4
4
20
DN
mm
400
450
500
600
700
800
900
1000
D
mm
580
640
715
840
910
1025
1125
1255
a
mm
28.0
30.0
31.5
36.0
39.5
43.0
46.5
50.0
b
mm
24.0
26.0
27.5
31.0
34.5
38.0
41.5
45.0
c
mm
4
4
4
5
5
5
5
5
ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
EXTERNAL PROTECTION
The pipe is wrapped from just behind the socket to just prior to
the spigot insertion marks. Wrapping can be provided with
either a 25mm or 55% overlap. After jointing the jointing area is
also wrapped.
Selection of Suitable External Coating gms
1. Protection system for pipes
a) Metallic Zinc or Zinc alloy coating with
following options:
2
Ÿ Metallic Zinc coating having a mass of 130gm/m
or 200 gm/m2 or 400 gm/m2.
Ÿ Zinc Aluminium Alloy coating having a mass of 200
gm/m2 or 400 gm/m2.
The Metallic Zinc or Zinc alloy coating is covered with a
finishing layer of bitumen or Epoxy.
b) Aluminium pigmented Bitumen
Aluminium pigmented Bitumen - Normally applied over
Zinc inner coating
c) Epoxy coating : Normally applied over metallic
coating as a finishing coat. Compared to normal
bitumen coated pipes it offers:
Ÿ More resistance to external galvanic/soil corrosion in
aggressive soil.
Ÿ More resistance to external chemical (acid, alkali, organic)
attack.
Ÿ Higher scratch resistance. So more resistant to coating
damage during transportation/Handling /laying.
Ÿ The coating comes in attractive blue/green (for water) or
red (for sewerage) colour. Hence offers much better look
and aesthetics.
d) Polyethylene Sleeving : Loose Polyethylene
encasement is very effective for protection of Ductile
Iron Pipes and Fittings in corrosive environments and
widely practiced in USA, Europe and Australia.
Investigation of many field installations, where loose
polyethylene encasement has been used as protection
for Cast Iron and Ductile Iron pipelines indicates a high degree
of protection even in the highly corrosive soils. The dielectric
capability of polyethylene provides shielding for Ductile Iron
Pipes and Fittings from stray direct current at most levels
encountered in the field.
e) Polyurethane Coating: Polyurethane Coating
is normally factory applied on prepared pipe surface.
f) PE tape Wrapping: In highly aggressive soil
conditions, additional external protection in the form
of a spirally applied anti-corrosion mastic tape may
be required. This can either be applied at our works
prior to dispatch or, if the facility exists, it may be
site applied. The tape wrap provides high electrical
resistance and excellent corrosion protection in highly
aggressive environments.
* Soil resistivety above 2500 ohm.cm Metalilic Zinc (130 to 200
Slight
* Soil resistivity between 1500 and
gm/mtr² min.)
moderately
2500 ohm.cm without water table
with Bitumen or Epoxy as
aggressive
finishing layer
* Soil resistivity between 1500
Metalic Zinc-Aluminium
and 2500 ohm.cm with water table (400gms/mtr²) or
* Soil resistivity between 500
Metalic Zinc (200gms/mtr² min).
Aggressive
and 1500 ohm.cm without water
With Bitumen or Epoxy as
table
finishing layer,
PE sleeving recommended
* Soil resistivity below 500 ohm.cm
Coating for Aggressive soil
without water table
plus tape wrap (25mm overlap)
* Soil resistivity below 1500 ohm.cm Alternately Polyeurethane
Highly
with water table
coating (Min. 750 micron)
aggressive
* Ground with light chemical
contamination
* Stray electrical currents
* Soil resistivity below 500 ohm/cm
Coating for Aggressive soil
with water table
plus tape wrap (55% overlap)
* Ground containing clinker, bricks, or Polyeurethane coating
flints etc. likely to cause
(Min. 1000 micron)
Special
mechanical damage
condition
* Ground with heavy chemical
contamination
* Tidal water e.g. estuaries,
shorelines
Note: The above table is only for guidance. User should
decide the type of coating depending on prevalling site
condition.
2. Protection system for fittings
a) Zinc rich paint and finishing layer of bituminous
paint or liquid epoxy
b) External polyethylene sleeving
c) Fusion Bonded Epoxy Coating
d) Polyurethane Coating
Fusion Bonded Epoxy Coating
FBE coating is applied in a state-of-the-art
automated facility to coat Dl fittings with
powdered epoxy by fusion bonding process.
This inert coating in attractive colors is suited for
aggressive soil condition.
Advantages
Ÿ Gives high Gloss and smooth coatings with excellent
adhesion.
Ÿ Difficult shapes can be coated evenly.
Ÿ Provides enhanced corrosion resistant properties.
Ÿ A choice of Blue or Red color for water or sewage
applications is available.
Ÿ Film thickness of 250 micron, can be specified as per EN
14901.
Ÿ Higher film thickness (above 250 micron) can also be
applied as per customer requirement.
21
ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
RECOMMENDATION FOR INTERNAL LINING
INTERNAL PROTECTION
1. Protection system for pipes
a) Cement Mortar Linings :
Pipes are generally supplied with centrifugally applied cement
mortar lining. This lining creates a mildly alkaline environment
at the internal metal surface and protects the pipe from
corrosion and tuberculation.
The different types of cement Lining offered are:
Ÿ Blast Furnace slag cement
Ÿ Sulphate resistant cement
Ÿ High Alumina Cement for sewage pipes
Water
Characteristics
Portland
Cement
Min value of pH
Max. content (mg/L) CO²
Sulfates (S0 ??)
Magnesium (Mg++)
Ammonium (NH?+)
6
7
400
100
30
Suphate
resisting
cements
5.5
15
3000
500
30
SI
1
2
3
High
alumina
cement
4
no limit
no litim
no limit
no limit
Advantages of Cement Mortar Lining (CML)
Centrifugally applied CML provides a higher Hazen
William's C value of 140 compared to 100 for bare metallic
pipes.
Ÿ Reduces frictional head loss and pumping cost.
Ÿ CML passivates the pipe wall against corrosion through the
alkaline reaction of cement.
Ÿ CML prevents pitting and tuberculation of pipes and stops
the production of red water.
Ÿ CML helps to maintain the same for area and coeffcient of
friction over a long period of time.
b) Seal coat on cement mortar lining
Seal coats if specified are applied on the inside cement mortar
lined surface of D.I. Pipes. Mainly two types of seal are offered:
Ÿ Bituminous seal coat
Ÿ Epoxy seal coat
The main purpose of providing seal coat is to stop leaching of
cement compounds from the linings, affecting the water's pH
and causing alkalinity to increase.
c) Ceramic Epoxy
Ceramic epoxy lining is a specialized lining which offers a hard
and stable surface with high abrasion resistance. Mainly used
for sewage conveyance or ash slurry conveyance or for
conveying corrosive fluids.
Ÿ
Fluid Condition
Potable Water/Raw water
with negative Langelier Index
(alkalinity) between 25 and
250 ppm CaCO³) and pH
between 5.5 and 13 content
in the input water
Domestic Sewage High
Sulphate content >3%
Very Soft Water with negative
Langelier Index (alkalinity
below 25 ppm CaCO³)
4
Sewage and Industrial
Effluent
having pH Minimum 3 to max
13 with aggressive CO²
Sulphates> 3000 mg/I,
magnesium > 500 mg/I
andammonium > 30 mg/I
5
Sea water and Ash slurry
Lining for Pipes
Cement Mortar Lining with
Blast Furnace Slag
Cement or Sulphate
resistant Cement,
depending on sulphate
Sulphate Resisting
Cement Lining
Sulphate Resisting
Cement
Lining or Blast Furnace
Slag Cement with Seal
Coat (Preferable with
epoxy)
High Alumina Cement
Mortar Lining
High Alumina Cement
Mortar Lining
2. Protection system for fittings
a) Cement Mortar Lining
By agreement between manufacturer and purchaser, any
one of the lining may be applied depending on the type
of liquid transported:
Ÿ
Blast furnace slag cement mortar
Ÿ
Sulphate resistant cement mortar
Ÿ
High alumina cement mortar. If required by the
customer, Fittings with bituminous or epoxy seal coat
over cement mortar is also available
b) Fusion Bonded Epoxy
Ÿ
Normally Fusion bonded epoxy is applied both on the
outer and inner surface of the fittings
c)
Ceramic Epoxy
Ceramic epoxy lining is also applied inside fittings which
are to be used with ceramic epoxy lined pipes.
All material coming in contact with potable water are certified
by various approving agencies like WRAS, DWI, WRc, DVGW
etc.
22
ELECTROSTEEL CASTINGS LIMITED
PRODUCT CATALOGUE
RELEVANT STANDARDS
Please not 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. They must also refer to our
User Guide for details regarding do’s and dont’s, handling, laying and installation
SI
STANDARD
DESCRIPTION
I
EN 545
Ductile iron pipes, fittings, accessories and their joints for water pipelines - requirements and test
methods.
2
ISO 2531
Ductile iron pipes, fittings, accessories and their joints for water or gas applications.
3
EN 598
Ductile iron pipes, fittings, accessories and their joints for sewerage application-requirements and test
methods.
4
ISO 7186
Ductile iron products for sewerage applications.
5
BS 3416
Specification for bitumen based coatings for cold application suitable for use in contact with potable water.
6
ISO 8179
Ductile iron pipes: external zinc coating. Part 1: Metallic Zinc with finishing layer. Part 2: Zinc rich paint
with finishing layer.
7
ISO 4179
Ductile iron pipes for pressure and non-pressure pipelines - centrifugal cement mortar lining -General
requirements.
8
BS 2494
Specification for elastomeric seals for joints in pipe-work and pipelines.
9
ISO 4633
Rubber seals-joint rings for water supply, drainage and sewerage pipelines-specification for materials.
10
BS 6076
Specification for tubular polyethylene film for use as protective sleeving for buried iron pipes and fittings.
11
ISO 8180
Ductile iron pipes-polyethylene sleeving.
12
BS 8010
Pipelines on land: design, construction and installation. Section 2.1 : Ductile iron.
13
ISO 10802
Ductile iron pipelines - hydrostatic testing after installation.
14
ISO 10803
Design method for ductile iron pipes.
15
EN 1092
Flanges and their joints. Circular flanges for pipes, valves, fittings and accessories, PN designated. Part 2
: Cast iron flanges.
16
EN 1514
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 : Nonmetallic PTFE envelope gaskets. Part 4 : Corrugated, flat or grooved metallic and filled metallic gaskets for
use with steel flanges.
17
ISO 7005
Metallic flanges - Cast iron flanges.
18
AWWA C151
Ductile Iron Pipe, Centrifugally Cast, for water.
19
AWWA C600
Installation of Ductile Iron Water Mains and their Appurtenances.
DISCLAIMER
Whilst every care was taken in compiling this data, information and related material contained herein are subject to change without notification. All detail that this document contains
are provided in good faith and therefore no representation or warranty whatsoever regarding the completeness, accuracy, “up to date”, or adequacy of, suitability, functionality,
ommission, or operation is specifically disclaimed of any liability for direct, indirect or consequential loss or damage, however so arising, from the use or reliance on information
herein thereafter provided.
INCLEDON
BLOEMFONTEIN Tel: 051 408 9200
KATHU
Tel: 053 723 2213
BURGERSFORT
LEPHALALE
RUSTENBURG
DURBAN
Tel: 014 591 7700
Tel: 031 716 2200
Tel: 013 231 7224
Tel: 014 763 5824
GERMISTON
Tel: 011 323 0800
NELSPRUIT
Tel: 013 752 3121
SECUNDA
Tel: 017 631 4200
UPINGTON
Tel: 054 332 1089
EAST LONDON
Tel: 043 736 6022
PORT ELIZABETH Tel: 041 409 8000
GEORGE
Tel: 044 874 2327
DPI TRADING (Western Cape)
CAPE TOWN
Tel: 021 957 5600