DUCTILE IRON

DUCTILE IRON
See also: page
MANUFACTURE 31
Ductile iron is distinguished from ordinary grey iron by its remarkable
SAFETY FACTORS 62
mechanical properties (elasticity, impact strength, elongation...). These
are due to the spheroidal nature of the graphite particles.

Definition A ferrous product classification can be established in terms of the carbon content of the basic metal:
iron: 0 to 0.1% C,
of irons steel: 0.1 to 1.7% C,
cast iron: 1.7 to 5% C.
Below 1.7 % carbon, solidification produces an austenitic single phase material, with the carbon present in
the structure in solid solution.
Above 1.7% carbon, the carbon cannot all be dissolved in the iron structure and consequently solidifies in the
form of a secondary phase, either as graphite (pure C), or iron carbide (Fe3C). Iron is a multi-phase material,
of complex structure: the most common constituents are ferrite (Fe) and pearlite (Fe + Fe3C).
Other elements present in iron in very low proportions have an effect on the structure, mechanical properties
and casting of the metal. Silicon (usually 1 to 3 %) plays a particular part and makes the iron in reality a
ternary alloy: iron, carbon, silicon.
Different types of cast iron
The term Cast iron covers a wide variety of Fe-C-Si alloys. It is usual to class them in groups according to
the graphite condition, making an additional differentiation based on the structure of the metal matrix
(ferritic, pearlitic).

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 DUCTILE IRON
In so called grey irons the graphite is present in the form of flakes, Effect
hence their metallurgical name: flake graphite irons (sometimes called
lamellar graphite irons). By concentrating abnormal stresses at certain of graphite
points, each of these flakes may initiate cracking. shape
Metallurgists have therefore sought to diminish, or eliminate, this effect
by changing the size or distribution of the flakes.
In a first stage, the adoption of the centrifugal process to cast flake
graphite iron pipes (so called grey iron pipes), led to an appreciable
improvement, by producing very fine graphite flakes.
A decisive advance was then made in 1948, when research in both the
U.S.A. and Great Britain led to the discovery of spheroidal graphite
iron, more commonly known as ductile iron.
The graphite no longer exists in flake form but precipitates in a spherical
form. The possibility of crack propagation lines is therefore eliminated.
Graphite precipitation in spheroidal form is obtained by the controlled
addition of a small amount of magnesium to the previously desulfurized
base iron.

S.G. iron
properties

Ductile iron owes its remarkable mechanical properties to the sphe-

roidal shape of its graphite:
tensile strength,
impact resistance,
high elastic limit (yield stress),
good elongation.

29
 DUCTILE IRON
These properties are further enhanced by control of the chemical anal-
ysis and heat treatment of the metal matrix.
Ductile iron maintains the traditional qualities of cast irons, resulting
from the high carbon content:
compression strength,
castability,
abrasion resistance,
machinability,
fatigue strength.

SAINT-GOBAIN All SAINT-GOBAIN PAM pipes and fittings are manufactured

from S.G. iron complying with Standards ISO 2531 and
PAM EN 545.
ductile iron Minimum tensile Minimum elongation
strength at failure
Type of product Rm A
MPa (in %)
DN 40 to 2 000 DN 40 to 1 000 DN 1 100 to 2 000
Pipes centrifugally cast 420 10 7
Pipes not
centrifugally cast 420 5 5
fittings and accessories

Note 1:
By agreement between the manufacturer and the customer, the conven-
tional elastic limit at 0.2 % (Rp0.2) can be measured. It should not be less
than:
270 MPa when A 12 % for DN 40 to 1000 or 10 % for DN > 1 000;
300 MPa in all other cases.

Comparison
of properties
of different types
of cast iron
for spun pipes

The Brinell hardness should not exceed 230 HB for pipes and 250 HB for fittings and accessories. For
welded components, a higher Brinell hardness is admissible in the area affected by heat adjacent to the weld.

30
 MANUFACTURE

MANUFACTURE

Three stages are involved in the manufacture of pipes and fittings: See also: page
metal preparation: blast furnace, cupola, metal treatment, DUCTILE IRON 28
QUALITY CONTROL 42
pipe spinning/foundry casting,
WORKS TESTING 40
finishing/coatings.

31
 MANUFACTURE

Metal preparation

Pipe spinning

Finishing/coatings

32
 MANUFACTURE

Metal preparation Pipe

Molten metal can be obtained directly by reduction of iron ore in a blast furnace, or by melting pig iron and manufacture
scrap in a cupola (or electric furnace). In all cases the materials have to be selected and checked carefully, in
order to produce a very high purity base metal suitable for the treatments described below.
After desulfurization, the iron temperature is adjusted in an electric furnace, to provide the optimum casting
temperature. At this stage, corrections can be made to the chemical composition by additions of scrap metal,
or specific ferro-alloys. Magnesium is introduced into the molten metal, to render it ductile (see DUCTILE
IRON).

Pipe spinning
The pipe spinning process consists of deposition of a layer of molten iron inside a rapidly rotating cylindrical
mold, and solidification of the metal by continuous mold cooling.
The principal methods used are the de LAVAUD process and the WET SPRAY process.
In the de LAVAUD process, molten metal is poured into an uncoated steel mold and is subjected to rapid
cooling. A graphitizing, then ferritizing heat treatment is necessary to obtain pipes with the required structure
and mechanical properties.
In the WET SPRAYprocess, before the iron is poured, the internal surface of the mold is coated with a fine
layer of powdered refractory silica, which reduces the thermal conductivity of the molten metal / mold inter-
face. The pipe therefore cools at a slower rate than in the de LAVAUD process and consequently only a
ferritizing heat treatment is required.

Finishing/Coatings
On leaving the heat treatment furnace, the pipes receive an external coat of pure metallic zinc, applied by
electric arc melting of zinc wire and spraying with compressed air.
Many types of inspections and tests to guarantee quality are carried out: checking the structure and mecha-
nical properties of the metal, visual inspection, dimensional checks, individual hydrostatic tests.
Particular attention is paid to spigots and sockets because of their importance in joint sealing.
The mortar lining is centrifugally applied. In the method used by SAINT-GOBAIN PAM, the mortar is
poured into the pipe and then spun at high speed, which has the effect of giving the lining good
compaction.
The cement mortar is then cured under controlled temperature and humidity conditions.
After the mortar has cured, the pipes move on to the coating lines. A layer of bituminous paint is then applied
by spraying on top of the zinc.
The pipes are then bundled (DN 300) and put into stock to await dispatch.

33
 MANUFACTURE

Fittings Production of ductile iron fittings and accessory items follows the same pattern (metal preparation, casting,
finishing and coating), except for the fact that sand castings do not require heat treatment.
manufacture
Casting
Various molding processes are used in casting, depending on the dimensions and type of casting being made.
The principal processes used by SAINT-GOBAIN PAM are:
compacted sand molding (flaskless or box) on high output automatic lines, for small diameters,
vacuum sand molding (V Process) on an automatic line for medium diameters,
self-setting sand molding, for large diameters.
Finishing/Coatings
On leaving the casting shop, the castings have their running systems removed, then are shotblasted and
fettled. Finally they are air tested before being given a dipped or sprayed bituminous coating.

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 STANDARDS

STANDARDS
SAINT-GOBAIN PAM products comply with French, European and See also: page
International standards. CERTIFICATES 45
QUALITY CONTROL 42

SAINT-GOBAIN PAM ductile iron pipeline products comply with:

French standards,
European standards,
International standards,
and specifically with the following standards:

Standards
Specifications
French European International

General technical specification for ductile iron pressure pipelines NF EN 545 EN 545 ISO 2531
EXPRESS Joint NF A 48-860
STANDARD Joint NF A 48-870
Socket pipes NF EN 545 EN 545 ISO 2531
Flanged pipes NF EN 545 EN 545 ISO 2531
Socket fittings NF EN 545 EN 545 ISO 2531
Flanged fittings NF EN 545 EN 545 ISO 2531
Fittings for PVC pressure pipes NF A 48-830
Flange dimensions (fixed and loose) NF A 48-840 ISO 7005-2
Joint gaskets. Material specifications NF EN 681-1 EN 681-1 ISO 4633
Pipe zinc coating NF EN 545 EN 545 ISO 8179-1
Polyethylene sleeving NF EN 545 EN 545 ISO 8180
Polyethylene external coating for pipes NF EN 545 EN 545 ISO 2531
Polyurethane external coating for pipes NF EN 545 EN 545 ISO 2531
NF A 48-851
Cement mortar pipe lining NF EN 545 EN 545 ISO 4179
Model for quality assurance in design/development, production, NF EN 29001 EN 29001 ISO 9001
installation and servicing (NF X 50-131)
Model for quality assurance in production and installation NF EN 29002 EN 29002 ISO 9002
(NF X 50-132)

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 DIMENSIONS

DIMENSIONS
See also: page The principal ductile iron pipes and fittings dimensions and tolerances
CUTTING PIPE 219 are standardized:
PRESSURES - nominal wall thickness (pipes and fittings)
MAXIMUM
PERMISSIBLE 51 nominal cement mortar lining thickness (pipes)
SAFETY FACTORS 62 pipe length
STANDARDS 35 pipe external barrel diameter.

Ductile iron To obtain the admissible pressures stipulated in Annex A of Standard

NF EN 545, December 1994, the nominal thickness of the iron for pipes
nominal and fittings is calculated as a function of the DN using the following
thickness formula:
eiron = K (0.5 + 0.001 DN)
Where:
eiron : nominal wall thickness in mm
DN : nominal diameter
K : coefficient used to designate the thickness class, selected from
the series of whole numbers: ... 8, 9, 10, 11, 12...

Pipes
For pipes, K = 9 in compliance with Standard NF EN 545, December
1994, with a minimum of 6 mm.
For a given DN, the outside diameter of a pipe must be identical,
whatever the wall thickness class.

Fittings
For fittings, K = 12.

36
 DIMENSIONS

Tolerances for iron thickness to Standards NF EN 545,

December 1994, and ISO 2531.1998

Type Thickness Tolerance*

of piece mm mm

Spun 6 1.3
pipes
>6 (1.3 + 0.001 DN)

Non-spun pipes 7 2.3

and fittings >7 (2.3 + 0.001 DN)
* Standards NF EN 545 and ISO 2531 do not stipulate an upper limit.

The thickness is to ISO 4179 and NF EN 545.

Pipe cement
mortar lining
Lining thickness, emortor
thickness
DN Nominal Tolerance*
mm mm

60 to 300 3.5 1.5

350 to 600 5 2
700 to 1 200 6 2.5
1 400 to 2 000 9 3

* There is no upper limit.

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 DIMENSIONS

Pipe working
length

The pipe working length is used for linear calculations. It is the length
of the pipe excluding the socket.
Socket pipes have the following working lengths:

Pipe working length

STANDARD UNIVERSAL STANDARD
DN
EXPRESS STANDARD PAMLOCK
m m m
60 to 300
6
350 to 600 5.97
700
800 7
900
7*
1 000
8.27*
1 100 8.27
1 200 8.26
1 400 8.19 8.14
1 500 8.18 8.13
1 600 8.18 8.12
1 800 8.17 8.10
2 000 8.13 Please consult us
* The working length depends on the production shop.

The tolerance for these lengths is 30 mm.

The percentage of pipes delivered with a shorter working length must not exceed 10 % of the total number
for each diameter of socket and spigot pipes supplied. (Standards NF EN 545 and ISO 2531.)

38
 DIMENSIONS
The external diameter of the spigot end of socket pipes is indicated in Barrel external
the corresponding product sheets.
See PIPES and FITTINGS.
diameter

External diameter tolerances

The tolerances for pipe external diameters comply with French
standards NF A 48-860 for the EXPRESS joint, and NF A 48-870 for
the STANDARD joint, that is:

DE
{ +1

(1.5 + 0.004 DN)

For DN 300: the pipe barrel external diameter measured with a
circumference tape must be such that at least two thirds of the pipe
length from the spigot end can be used for assembly when the pipe has
to be cut on site.
For DN > 300, this rule also applies to a percentage of the pipes agreed
between the manufacturer and the purchaser.

Ovality tolerance
Ovality of pipe and fitting spigot ends must:
remain within the OD tolerance limit for DN 60 to 200;
not exceed 1 % for DN 250 to 600 or 2 % for DN > 600
(NF EN 545 and ISO 2531).
A procedure exists to correct ovality. See OVALITY RE-ROUNDING.
Recommendation: When cutting a pipe, it is recommended you use a
circumference tape to first check the outside diameter of the area where
the pipe is to be cut. See CUTTING PIPES.

The pipe internal diameter, expressed in millimetres, corresponds Barrel internal

to the DN number (nominal diameter).
diameter
Standard NF EN 545 authorises the following tolerances:
DN 60 to 1000: 10 mm,
DN 1 100 to 2 000: 0.01 DN.

39
 WORKS TESTING

WORKS TESTING
See also: page Every SAINT-GOBAIN PAM pipe and fitting undergoes a works internal
PRESSURES pressure test, in accordance with French and International Standards.
(TERMINOLOGY) 48
MANUFACTURE 31
STANDARDS 35

Socket pipes Works hydraulic test pressure

DN (bar)

K9
60 to 300 50
350 to 600 40

700 to 1 000 32

1 100 to 2 000 25

Every pipe is subjected to a works hydraulic pressure test at the

pressure indicated in the table above.
Standards NF EN 545 and ISO 2531.

Socket fittings DN Leaktightness test

Air test at a minimum of 1 bar

60 to 2 000
Checked with foaming agent or water immersion

Every fitting is subjected to an air test of at least 1 bar.

Standards NF EN 545 and ISO 2531.

40
 WORKS TESTING

DN Leaktightness test Flanged pipes

Air test at 1 bar
and fittings
40 to 2 000
Checked with foaming agent or water immersion

Pipes are designed and individually works tested in compliance with

the above criteria.
Every fitting is subject to an air test at 1 bar.
Standards NF EN 545 and ISO 2531.

41
 QUALITY CONTROL

QUALITY CONTROL
See also: page SAINT-GOBAIN PAM has instituted a quality control organization
STANDARDS 35 complying with Standard ISO 9001.
CERTIFICATES 45
Its objective is to provide customers with products meeting perfectly
their stated requirements.

Quality policy The SAINT-GOBAIN PAM quality policy is based on improving products and services for its customers.

To meet this level of excellence, SAINT-GOBAIN PAM:

defines the specifications of, designs and improves products in order to adapt them to customer and
environmental requirements;
implements capable manufacturing means;
buys materials and manufactures products in compliance with specifications;
guarantees on-time delivery of its products and services.

To improve performance, the teams:

systematically measure results;
eliminate malfunctions;
undergo ongoing training.

SAINT-GOBAIN PAMs aim is to be the world leader in its area of business: this objective is reflected in
our Quality Policy.

42
QUALITY CONTROL

43
 QUALITY CONTROL

SAINT-GOBAIN The SAINT-GOBAIN PAM quality management system not only covers production and marke-
ting, but also product design. This is the best possible guarantee that our products meet their
PAM intended use.
quality The SAINT-GOBAIN PAM quality system is ISO 9001 certified. This standard is the reference for quality
assurance management applied to design/development, production, installation, and after-sales support.
For design, systematic project reviews are used to ensure that targeted new needs for the product being deve-
loped are met.
Each project involves three main phases prior to release on the market:
functional specifications,
technical definition of the product,
industrialisation and qualification of the product.
For production, the aims of the quality organisation are to:
check the consistency of incoming raw materials, constituents and other items required for the production
and usage of our products;
control the manufacturing process by formalising our expertise, automating process, and training opera-
tives while making ongoing improvements through analysis of the measurements made throughout the
manufacturing cycle;
check at every stage of production that the products meet the specifications, thus providing early detection
of any aberration, and enabling it to be corrected.
This QA organisation is founded on:
statistical control of processes which, based on regular measurements, allows process and product perfor-
mance to be quantified against established objectives;
self-monitoring, which is the basis of the system in production and consists in delegating to operatives the
monitoring of the results of their own work within pre-established parameters;
auditing, which ensures, in a systematic manner, that everyone is obeying the rules laid down, and checks
on their efficiency. This applies to SAINT-GOBAIN PAM and all its suppliers and sub-contractors, with
whom it collaborates on quality assurance;
checking, if necessary, of particular properties of products, raw materials or constituents, not covered by
the preceding arrangements.

44
 CERTIFICATES

CERTIFICATES

SAINT-GOBAIN PAM holds a number of certificates and endorsements See also: page
which guarantee its ability to design, manufacture and market ductile STANDARDS 35
iron pipe parts in accordance with very stringent quality assurance QUALITY 42
criteria and standards, as well as applicable French legislation. MATERIAL
IN CONTACT
These certificates are awarded by accountable outside organisations WITH DRINKING
which regularly check their validity. WATER 108

Organisation Certificate Subject

BVQI (Bureau Veritas These certificates attest that the SAINT-GOBAIN PAM quality assurance
Quality assurance system
Quality International, system complies with the requirements of the ISO 9001 Standard, for the design,
approval
United Kingdom, Netherlands) production and sale of pipes and accessories, valves and municipal castings.

This certificate recognises that:

TV (Technisher the SAINT-GOBAIN PAM organisation and its sand moulding practices are
SG iron foundry castings suitable for the production of castings intended for use under pressure;
berwachungs Verein Saarland,
certificate SAINT-GOBAIN PAM is proficient in ductile iron welding.
FRG)

Compliance to the requirements Manufacture and inspection of pipes and fittings.

Bureau Veritas
of the NF EN 545 Standard Tests of types of joints.

Compliance with the stipulations

Bureau Veritas of French Order dated 29 May Material in contact with drinking water.
1997

EN 29001/ISO 9001/BS 5750

EN 29001/ISO 9001/BS 5750 APPROVED BY BVQI LTD
APPROVED BY BVQI LTD

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