Draft – May 1, 2010

Indian Standard 9523

DUCTILE IRON FITTINGS FOR PRESSURE PIPES FOR
WATER & SEWER – SPECIFICATION

(Second Revision)

1
FOREWORD

This standard was first published in 1980 and then revised in 2000. In the light of the experience gained
during these years and the changes that had taken place in the international context, the committee has
decided to update this standard taking into account the modern trend to omit the use of DI Pipes for Gas.
This standard will also follow the trend in other international specifications, particularly the ISO and CEN.

Ductile Iron, also called nodular iron or spheroidal graphite iron is characterized by the presence of
graphite in nodular or spheroidal form in the resultant casting. It differs from cast iron by greater tensile
strength and its significant elongation at break.

Ductile Iron Pipe offers:

I. high resistance against breakage due to impact;

II. high tensile strength comparable to that of cast iron and mild steel so that the pipes can be used for
higher working pressure.
III. traditional corrosion resistance of cast iron, having high percentage of free graphite;
IV. lighter in mass.
V. coating of sprayed Zinc and inside cement mortar lining, which increases the life at least by 50 years
extra.
VI. smooth Cement Mortar Lining/ Epoxy Lining reduces frictional head loss.

In this revision the following main modifications have been made:

a) A new classification system is being introduced for DI Fittings based on pressure, with wall
thickness have been determined by allowable operating pressures.
b) The design of joints is not given in this standard; Type test of joints has been incorporated which
proves the efficacy of the joint design.
c) For additional corrosion protection, outside of the pipe Zinc, or Zinc Alloy Coating with finishing
layer of bitumen and alternatively Epoxy coating has also been included.
d) For smoother hydraulic flow and prevention of tuberculation and corrosion, inside lining by
Cement Mortar has been retained, other types of linings such as Epoxy, and Polyurethane have
been included which provide corrosion protection and at the same time a smooth internal surface.
e) For Ductile Iron Pipes & Fittings, ISO and CEN have two different standards, one for Water and
the other for Sewage. This Indian Standard has been drafted for one combined standard for Water
and Sewage with a section which for gravity sewers only. The classification of fittings is based on
working pressure of the pipeline irrespective of whether used in gravity or pumping mains
transmitting Water
f) Since the International Specification ISO: 2531, ISO 7186, EN 545, EN 598, AS/NZS 2280 are all
composite specification for DI Pipes and Fittings, the Indian Standard Specification IS: 9523 has
been issued only for fittings because the method of manufactures are different and BIS issues
separate licenses for Pipe and Fittings manufacturers.

In order to have International co-ordination and interchangeability with other International Standards,
assistance has been derived from the following publications:

ISO: 2531/2009 Ductile Iron Pipes, Fittings, Accessories & their joints for water or gas application,
issued by the International Organization for Standardization (ISO).
ISO:4179/2005 Ductile Iron Pipes for pressure and non-pressure pipelines – Centrifugal Cement
Mortar Lining General requirements.
ISO:8179-1/2004 Ductile Iron Pipes- External coating Part-I Metallic Zinc with finishing layer.
ISO:8179-2/2004 Ductile Iron Pipes External Coating Part 2 Zinc rich paint with finishing layer.
ISO: 8180 / 2006 Ductile Iron Pipes – Polyethylene Sleeving.
ISO:10803 (under rev) Design method for Ductile Iron Pipes.
ISO/DIS:10804:Part-I Restrained joint system for Ductile Iron Pipelines Part-I Design Rule and Testing.
ISO: 10802/1992 Ductile Iron Pipelines- Hydrostatic Testing after installation
ISO: 4633/ 1996 Rubber seals, joint rings for water supply, drainage and sewerage pipelines-
specification for materials
ISO:16132/2004 Seal Coat on Cement Mortar Lining
EN545/2007 Ductile Iron pipes, fittings accessories and their joints for water pipelines.
AS/NZS 2280/2004 Ductile Iron Pipe & Fittings

2
For the purpose of deciding whether a particular requirement of this standard is complied with, the final
value, observed or calculated, expressing the result of a test, shall be rounded off in accordance with IS
2:1960 “Rules for rounding off numerical values (revised)”. The number of significant places retained in
the rounded off value should be the same as that of the specified value in this standard.

Indian Standard

DUCTILE IRON FITTINGS FOR PRESSURE PIPES FOR WATER & SEWER –
SPECIFICATION
(Second revision)

1. Scope

This Indian Standard specifies the requirements and test methods applicable to
ductile iron, fittings, accessories and their joints for the construction of pipelines:

to convey water (e.g. for human consumption, raw water);

operated with or without pressure;

installed below or above ground.

NOTE In this Indian Standard, all pressures are relative pressures expressed in bars1).

This Indian Standard gives specifications for materials, dimensions and

tolerances, mechanical properties and standard coatings of fittings and
accessories. It also gives performance requirements for all components including
joints.
This Indian Standard covers fittings and accessories cast by any type of
foundry process or manufactured by fabrication of cast components, as well as
corresponding joints in the size range DN 80 to DN 2000 inclusive.

It is applicable to, fittings and accessories which are:

manufactured with socketed, flanged or spigot ends for jointing by means of various types of
gaskets which are not within the scope of this Indian Standard;

normally delivered internally and externally coated.

Fittings are classified according to pressure.

2.0 REFERENCES

The following Indian Standards contain provisions, which through reference in this text, constitute
provisions of this standard. At the time of the publication, the editions indicated below were valid. All the
standards are subject to revision, and parties to agreement based on this standard are encouraged to
investigate the possibility applying the most recent editions of the standards.

1) 100 kPa = 1 bar

3
 IS No. Title

1387:1993 General requirements for supply of metallurgical materials (second

revision).
1500:1983 Methods for Brinell hardness test for metallic materials (second revision).
1608:1995 Mechanical testing of metals - Tensile Testing (second revision).
5382 : 1985 Rubber Sealing Ring for Water Mains and Sewers (first revision).
9523:2000 Ductile iron fittings for pressure pipes for water and sewage.
12288: 1987 Code of Practice for use and Laying of Ductile Iron pipes

3.Terms and definitions

3.0 Definitions

For the purposes of this document, the following terms and definitions apply.
3.1.1
ductile iron
type of iron used for pipes, fittings and accessories in which graphite is present primarily in
spheroidal form

3.1.2
pipe
casting of uniform bore, with straight axis, having either socket, spigot or flanged ends, except
for flanged sockets, flanged spigots and collars which are classified as fittings

3.1.3
fitting
casting other than a pipe, which allows pipeline deviation, change of direction or bore. In
addition, flanged sockets, flanged spigots and collars are also classified as fittings

3.1.4
accessory
any casting other than a pipe or fitting, which is used in a pipeline, such as:

glands and bolts for mechanical flexible joints (see 3.1.13);

glands, bolts and locking rings or segments for restrained joints see 3.1.14)

Valves and hydrants of all types are not covered by the term accessory.

3.1.5
flange
end of a pipe or fitting, extending perpendicular to its axis, with bolt holes equally spaced on a
circle

NOTE A flange may be fixed (e.g. integrally cast, threaded-on or welded-on) or adjustable; an
adjustable flange comprises a ring, in one or several parts bolted together, which bears on an end
joint hub and can be freely rotated around the pipe axis before jointing.

3.1.6
spigot
male end of a pipe or fitting

3.1.7
spigot end
maximum insertion depth of the spigot plus 50 mm
4
3.1.8
socket
female end of a pipe or fitting to make the connection with the spigot of the next component

3.1.9
gasket
sealing component of a joint

3.1.10
joint
connection between the ends of pipes and/or fittings in which a gasket is used to effect a seal

3.1.11
flexible joint
joint which provides significant angular deflection and movement parallel and/or perpendicular to
the pipe axis

3.1.12
push-in flexible joint
flexible joint assembled by pushing the spigot through the gasket into the socket of the mating
component

3.1.13
mechanical flexible joint
flexible joint in which sealing is obtained by applying pressure to the gasket by mechanical means,
e.g. a gland

3.1.14
restrained joint
joint in which a means is provided to prevent separation of the assembled joint

3.1.15
flanged joint
joint between two flanged ends

3.1.16
nominal size (DN)
alphanumeric designation of size for components of a pipework system, which is used for reference
purposes. It comprises the letters DN followed by a dimensionless whole number which is indirectly related
to the physical size, in millimeters, of the bore or outside diameter of the end connections.

3.1.17
nominal pressure (PN)
numerical designation expressed by a number which is used for reference purposes. All components
of the same nominal size DN designated by the same PN number have compatible mating
dimensions.

3.1.17a
pressure class
allowable operating pressure of pipe including their joint as verified by all the performance tests
described in this standard.
3.1.17b
works test pressure (WTP)
hydrostatic pressure applied to a component during manufacturing to ensure leak-tightness.

3.1.18

allowable operating pressure (PFA)

5
maximum internal pressure, excluding surge, that a component can safely withstand in permanent
service

3.1.19
allowable maximum operating pressure (PMA)
maximum internal pressure, including surge, that a component can safely withstand in service

3.1.20
allowable site test pressure (PEA)
maximum hydrostatic pressure that a newly installed component can withstand for a relatively short
duration, when either fixed above ground level or laid and backfilled underground, in order to measure
the integrity and tightness of the pipeline

NOTE This test pressure is different from the system test pressure which is related to the design
pressure of the pipeline.

3.1.20a
site test pressure(STP)
actual site test pressure that a newly installed pipeline system should be tested for an agreed period,
for a relatively short duration to the actual working pressure and surge, if any, in order to ensure the
integrity and leak tightness of the pipeline.

3.1.21
diametral stiffness of a pipe
characteristic of a pipe which allows it to resist diametral deflection under loading

3.1.22
batch
quantity of castings from which a sample may be taken for testing purposes during manufacture

3.1.23
type test
proof-of-design test which is done once and is repeated only after change of design

3.1.24
laying length of a socket and spigot pipe
laying length Le, equal to the overall length of pipe (OL) minus the maximum spigot insertion depth
(X) as given by the manufacturer as shown in Figure 4

NOTE For flanged pipes and fittings, the effective length L (/ for branches) is equal to the overall
length. For socketed pipes and fittings, the effective length Lu. (lu for branches) is equal to the overall
length minus the spigot insertion depth as indicated in the manufacturer's catalogues.

3.1.25
standardized length
standardized length of socketed pipes and fittings (Lu or lu for branches), as shown in Figure 4 for
pipes and Figure 4 to 13 for fittings

3.1.26
spigot end
maximum insertion depth of the spigot plus 50 mm

3.1.27
component
any product defined in 3.1.2 to 3.1.4

6
3.1.28
deviation
amount by which the design length may differ from the standardized length of a pipe or a fitting

NOTE Pipes and fittings are designed to a length selected in the range of standard length plus or
minus the deviation (see Table 6); they are manufactured to this length plus or minus the tolerance
given in Table 7.

3.1.29
ovality
out of roundness of a pipe section, equal to:

A1 A2
100
A1 A2

where
A1 is the maximum axis, in millimetres, and

A2 the minimum axis of the pipe cross-section, in millimetres.

3.1.30
hoop stress ( )
stress in a pipe or fitting under pressure, acting tangentially to the perimeter of a transverse section

3.28 Calculated Diametral thickness: Calculated by a formula on the basis of the local minimum
thickness and the nominal diameter of the pipe in order to calculate the diametral stiff of the pipe.

3.32 Coating: Corrosion preventing barrier applied to the external surface of a pipe.

3.33 Lining: Corrosion preventing barrier applied to the internal surface of a pipe.

3.34 Laitance: Smooth internal surface layer of mortar consisting of very fine particles.(This does not
include the cement rich layer, which is an integral part of the lining and cannot be easily removed.)
3.35 Hoop stress: Stress in a pipe or fitting under pressure, acting tangentially to the perimeter of a
transverse section.

4.Technical requirements

4.1 General

4.1.1 Fittings

Nominal sizes, thicknesses, lengths and coatings are specified in 4.1.1, 4.2.3, 4.2.4,
4.4 and 4.5, respectively.

Essential Special Ductile Iron Fittings:

DI Fittings which are not covered in Table 15 to 31 under Section 3 of this standard, but are supplied against specific
requirement of the Purchaser for use in water and sewage transmission, against agreement between the manufacturer
and the purchasers, with different shapes, lengths and other combinations of nominal diameters than those given in
the above noted Tables, should generally conform to the Nominal Sizes, Wall thickness, external diameters and flange
dimension given in Table 3,4,5,6 and 7 of Section 2 and should also comply with all the other requirements of this
Indian Standard. Such fittings which generally conform to this standard and are put use for water and sewage
transmission may also bear the Quality Certification mark of the licensee
7
The standard nominal sizes DN of pipes and fittings are the following:
80, 100, 125, 150, 200, 250, 300, 350, 400, 450, 500, 600, 700, 800, 900, 1000,
1100, 1200, 1400, 1500, 1600, 1800, 2000,
The stiffness and diametral deflection of ductile iron fittings are those given in
Annex D.

The pressures PFA, PMA and PEA (see 3.1.18, 3.1.19 and 3.1.20) are those
indicated in this standards or regulations.

NOTE When installed and operated under the conditions for which they are designed (see annexes
A and B), ductile iron, fittings, accessories and their joints maintain all their functional
characteristics over their operating life, due to constant material properties, to the stability of their
cross-section and to their design with high safety factors.

4.1.2 Surface condition and repairs

Fittings and accessories shall be free from defects and surface imperfections which
could impair their compliance with the requirements of Clauses 4 and 5.
Minor defects arising out of manufacturing process fittings, may be rectified, for
example by welding, sealing compounds or by other means at the discretion of the
manufacturer in order to remove surface imperfections and localized defects which
do not affect the entire wall thickness provided that the repairs are carried out in
accordance with a written assurance system provided that the repaired fittings
comply with all the requirements of Clauses 4 and 5.
4.1.3 Types of joints and interconnection

4.1.3.1 General

Joint design and gasket shapes are beyond the scope of this Indian Standard.

Rubber gasket materials shall conform to the requirements of IS 5382 for water
applications. When materials other than rubber are necessary (e.g. high
temperature flanged joints), they shall conform to the appropriate IS standards.

4.1.3.2 Flanged joints

Flange joints shall be designed such that they can be attached to flanges whose
dimensions and tolerances comply with ISO 7005-2 . This ensures interconnection
between all flanged components (pipes, fittings, valves, etc.) of the same DN and PN
and adequate joint performance. Bolts and nuts shall comply as a minimum with
the requirements of IS and IS . Where washers are required they shall
comply with IS .
In addition, each type of flange joint shall be designed to meet the performance
requirements of 5.3.

8
Although it does not affect interconnection, the manufacturer shall indicate in his
catalogue whether his products are normally delivered with fixed flanges or loose
flanges.

4.1 3 .3Flanged joints are designed for working pressure ratings of 1.0, 1.6, 2.5 and 4.0 MPa.

4.1.3.4The flange can be either Fixed or rotatable type to facilitate easy alignment. Rotatable type flange
comprises of a ring, in one or several parts assembled together, which bears on an end joint hub
and can be freely rotated around the pipe axis before jointing. Flanges may be of screwed on or
may be welded on plain ended ductile iron pipes. The flange shape can either be solid or hollow
back type as shown in Fig. below. Details of hollow back flange may be given in the manufacturer’s
catalogue.

Solid Back Flange

Rotatable Flange in two parts Hollow back Flange

4.1.3.5 In case of ductile iron fittings with cast on, screwed on flanges or welded flanges, the flanges shall
be generally at right angle to the axis of the pipe and machined, if required. The bolt holes shall be either
cored or drilled.

4.1.3.6 The bolt hole circle shall be concentric with the bore and holes of the two flanges of the fittings
shall be correctly aligned.

4.1.3.7 The ductile iron fittings having screwed on flanges shall be sealed at the threaded joint between
the pipe and the flange by a suitable sealing compound. Unless otherwise specified, the sealing compound
applied to the threaded joint shall be suitable for use with ‘raw’ and potable water.

Alternative types of sealing compound, for pipes used for other duties shall be compatible and shall be the
subject of agreement between the manufacturer and the purchaser.

4.1.3.7 For screwed on or welded on flange fittings the thickness of the parent fitting after screwing or
welding must be maintained to the minimum thickness allowed for in the specification as per Table 2
(clause 12.2).

4.1.3.8 Dimensions of screwed on flanges and welded on flanges for Ductile Iron fittings shall conform to
the requirement of Tables 3, 4, 5, & 6.

9
Table 3 Dimensions of Standard Flange Drilling for Screwed Flanges and Welded Flange, (PN10)
(Clauses 6.2.7 & 9.3)

All dimensions in millimetres

Nominal Dimensions Holes Bolt
Dia Size
DN D E C b f s r Number Dia (d) Metric
80 200 132 160 19 3 15 6 8 19 M16
100 220 156 180 19 3 15 6 8 19 M16
125 250 184 210 19 3 15 6 8 19 M16
150 285 211 240 19 3 15 8 8 23 M20
200 340 266 295 20 3 15 8 8 23 M20
250 395 319 350 22 3 16 10 12 23 M20
300 445 370 400 24.5 4 17.5 10 12 23 M20
350 505 429 460 24.5 4 19.5 10 16 23 M20
400 565 480 515 24.5 4 19.5 10 16 28 M24
450 615 530 565 25.5 4 20 12 20 28 M24
500 670 582 620 26.5 4 21 12 20 28 M24
600 780 682 725 30 5 24 12 20 31 M27
700 895 794 840 32.5 5 24 12 24 31 M27
750 960 857 900 34 5 24 12 24 31 M27
800 1015 901 950 35 5 24.5 12 24 34 M30
900 1115 1001 1050 37.5 5 26.5 12 28 34 M30
1000 1230 1112 1160 40 5 28 12 28 37 M33
1100 1340 1231 1270 43 5 30 12 28 37 M33
1200 1455 1328 1380 45 5 31.5 12 32 40 M36
1400 1675 1530 1590 46 5 32 12 36 43 M39
1600 1915 1750 1820 49 5 34.5 12 40 49 M45
1800 2115 1950 2020 52 5 36.5 15 44 49 M45
2000 2325 2150 2230 55 5 38.5 15 48 49 M45

10
 Table 4 Dimensions of Standard Flange Drilling for Screwed Flanges and Welded Flange, (PN16)
(Clauses 6.2.7 & 9.3)

All dimensions in millimetres

Nominal Bolt
Dia Dimensions Holes Size
DN D E C b f s r Number Dia (d) Metric
80 200 132 160 19 3 15 6 8 19 M16
100 220 156 180 19 3 15 6 8 19 M16
125 250 184 210 19 3 15 6 8 19 M16
150 285 211 240 19 3 15 8 8 23 M20
200 340 266 295 20 3 16 8 12 23 M20
250 400 319 355 22 3 17.5 10 12 28 M24
300 455 370 410 24.5 4 19.5 10 12 28 M24
350 520 429 470 26.5 4 21 10 16 28 M24
400 580 480 525 28 4 22.5 10 16 31 M27
450 640 548 585 30 4 24 12 20 31 M27
500 715 609 650 31.5 4 25 12 20 34 M30
600 840 720 770 36 5 29 12 20 37 M33
700 910 794 840 39.5 5 27.5 12 24 37 M33
750 970 857 900 41 5 28 12 24 37 M33
800 1025 901 950 43 5 30 12 24 40 M36
900 1125 1001 1050 46 5 32.5 12 28 40 M36
1000 1255 1112 1170 50 5 35 12 28 43 M39
1100 1355 1218 1270 53.5 5 37.5 12 32 43 M39
1200 1485 1328 1390 57 5 40 12 32 49 M45
1400 1685 1530 1590 60 5 42 12 36 49 M45
1600 1930 1750 1620 65 5 45.5 12 40 56 M52
1800 2130 1950 2020 70 5 49 15 44 56 M52
2000 2345 2150 2230 75 5 52.5 15 48 62 M56

NOTES :

1. The method of screwing and/or welding of the flanges are left to the discretion of the manufacturer.
2. If so required the screwed flanges may be spot-welded on the backside after screwing.
3. Dimension ‘b’ & ‘s’ are for guidance only tolerances would be as per IS:.
4. Unless otherwise specified, Flanges will be of Ductile Iron.

11
 Table 5 Dimensions of Standard Flange Drilling for Screwed Flanges and Welded Flange, (PN25)
(Clauses 6.2.7 & 9.3)

All dimensions in millimetres

Nominal Dimensions Holes Bolt
Dia Size
DN D E C b f s r Number Dia (d) Metric
80 200 132 160 19 3 15 6 8 19 M16
100 235 156 190 19 3 15 6 8 23 M20
125 270 184 220 19 3 15 6 8 28 M24
150 300 211 250 20 3 16 8 8 28 M24
200 360 274 310 22 3 17.5 8 12 28 M24
250 425 330 370 24.5 3 19.5 10 12 31 M27
300 485 389 430 27.5 4 22 10 16 31 M27
350 555 448 490 30 4 24 10 16 34 M30
400 620 503 550 32 4 25.5 10 16 37 M33
450 670 548 600 34.5 4 27.5 12 20 37 M33
500 730 609 660 36.5 4 29 12 20 37 M33
600 845 720 770 42 5 33.5 12 20 40 M36
700 960 820 875 46.5 5 33.5 12 24 43 M39
750 1020 883 940 50 5 34 12 24 43 M39
800 1085 928 990 51 5 35.5 12 24 49 M45
900 1185 1028 1090 55.5 5 39 12 28 49 M45
1000 1320 1140 1210 60 5 42 12 28 56 M52
1100 1420 1240 1310 65.5 5 45 12 32 56 M52
1200 1530 1350 1420 69 5 48.5 12 32 56 M52
1400 1755 1560 1640 74 5 52 12 36 62 M56
1600 1975 1730 1860 81 5 56.5 12 40 62 M56
1800 2195 1980 2070 88 5 61.5 15 44 70 M64
2000 2425 2210 2300 95 5 66.5 6
15 48 70 M64

NOTES :

1. The method of screwing and/or welding the flanges shall be left to the discretion of the manufacturer.
2. If so required the screwed flanges may be spot-welded on the backside after screwing.
3. Dimension ‘b’ & ‘s’ are for guidance only Tolerances would be as per IS:.
4. Unless otherwise specified, Flanges will be of Ductile Iron.

12
 Table 6 Dimensions of Standard Flange Drilling for Screwed Flanges and Welded Flange, (PN40)
(Clauses 6.2.7 & 9.3)

All dimensions are in millimetres

Nominal Dimensions Holes Bolt
Dia Size
DN D E C b f s r Number Dia (d) Metric
80 200 132 160 19 3 15 6 8 19 M16
100 235 156 190 19 3 15 6 8 23 M20
125 270 184 220 23.5 3 16.5 6 8 28 M24
150 300 211 250 26 3 18 8 8 28 M24
200 375 284 320 30 3 21 8 12 31 M27
250 450 345 385 34.5 3 24 10 12 34 M30
300 515 409 450 39.5 4 27.5 10 16 34 M30
350 580 465 510 44 4 31 10 16 37 M33
400 660 535 585 48 4 33.5 10 16 40 M36
450 685 560 610 50 4 35 12 20 40 M36
500 755 615 670 52 4 36.5 12 20 43 M39
600 890 735 795 58 5 40.5 12 20 49 M45

NOTES :

1. The method of screwing and /or welding of the flanges shall be left to the discretion of the manufacturer.
2. If so required the screwed flanges may be spot-welded on the backside after screwing.
3. Dimension ‘b’ & ‘s’ are for guidance only tolerances would be as per IS:.
4. Unless otherwise specified, Flanges will be of Ductile Iron.

4.1.3.3 Flexible joints

Pipes and fittings with flexible joints shall be in accordance with 4.2.2.1 for their
spigot external diameters DE and their tolerances. This provides the possibility of
interconnection between components equipped with different types of flexible joints.
In addition, each type of flexible joint shall be designed to meet the performance
requirements of 5.2.

13
NOTE 1 For interconnection with certain types of joints operating within a tighter tolerance range
on DE, the manufacturer's guidance should be followed as to the means of ensuring adequate joint
performance up to the highest pressures (e.g. measurement and selection of external diameter).

NOTE 2 For interconnection with existing pipelines which can have external diameters not
in accordance with 4.2.2.1, the manufacturer's guidance should be followed as to the appropriate
means of interconnection (e.g. adaptors).

4.1.3.4 Restrained Flexible joints

4.1.3.5.For pipelines where probability of axial movement is high, the flexible joint may be restrained with
suitable restraining mechanism.

4.1.3.5The design safety factors with respect to failure against axial forces due to internal pressure shall
be such that the joints shall withstand a type test of 1.5 times allowable operating pressure (PMA)
plus 5 bars.
6.4.3 All restrained joints shall be designed to be at least semi-flexible; consequently, the allowable
angular deflection declared by the manufacture shall be not less than half of the value shown in
6.1
6.4.4 All restrained joint designs shall be type tested in accordance with 19.1.1, 19.1.2 and 19.2 except
that there shall be no external axial restraint in positive internal pressure tests so that the joint is
subjected to the full end thrust.

6.4.5 During the positive internal pressure tests, the axial movement shall reach a stable value and
cease.
6.4.6 When the restraining mechanism and sealing component of a restrained joint are independent,
such a joint does not need to be subjected to Type test 19.3 and test 19.4, if the unrestrained
version of the joint has passed these tests.
6.4.7 Ductile Iron pipelines with restrained joints are well suited for use in seismic zones. However,
certain locations, such as fault crossings. Liquefaction zones, connection to structures etc. may
require specialized design.
Restrained joints for ductile iron pipelines shall be designed in accordance with
ISO 10804-1. Their spigot external diameters DE and their tolerances shall comply
with 4.2.2.1.

4.1.4. Materials in contact with water intended for human consumption

When used under the conditions for which they are designed, in permanent or in
temporary contact with water intended for human consumption, ductile iron
fittings and their joints shall not have detrimental effects on the properties of that
water for its intended use.

Ductile iron pipeline systems, including pipes, fittings and accessories, are comprised of various
materials. When used for conveying water intended for human consumption, the materials in contact
with the water shall meet the relevant requirements of the Indian standards or regulations in India of
use with respect to effect on water quality.

4.2 Pressure classification and dimensional requirements

4.2.1 Pressure classifications

4.2.1.1. General

Components with flexible joints shall be classified by the allowable operating

pressure in bar (PFA), prefixed by the letter C.
Components with flanged joints shall be classified by the PN number of the flange.
Allowable pipeline pressures relationships shall be as follows:
14
a) Allowable operating pressure (PFA) = (C), in bars

b) Maximum allowable operating pressure (PMA) = 1.20 (PFA), in bars

a) Allowable site test pressure (PEA) = 1.20 (PFA) + 5, in bars

The allowable pressures within a pipeline system shall be limited to the lowest
pressure classification of all, components within the system.
4.2.1.2 Standard pressure classes

Standard pressure classes of components with flexible joints are C25, C30, and
C40. Other pressure classes are allowable, including C20, C50, C64 and C100.
Pressure classes for components with flanged joints are PN10, PN16, PN25 and
PN40.
4.2.1.3 Allowable pressures

Allowable pressure for fittings given in Table 18 to Table 36 are as follows:

- socketed fittings, except tees, are given in Table 1;

- socketed tees may be less than those given in Table 3 and shall be given in
the manufacturer’s catalogues;

- fittings with one flange, such as double-socketed tees with flanged branch,
flanged spigots and flanged sockets are limited by the flange PN and are given
in Table 2.

Allowable pressures of components are as given in Table 1 and 2.

Table 1
Allowable pressures for socketed fittings given in Tables 18 - 36
DN Allowable Maximum Allowable
operating allowable test pressure
pressure operating
(PFA) pressure (PEA)
(PMA)
80 to 200 64 77 82
250 to 350 50 60 65
400 to 600 40 48 53
700 to 1400 30 36 41
1500 to 2000 25 30 35

Table 2
Allowable pressures of components with flanged joints

Pressure class Allowable operating Maximum allowable Allowable site test

PN pressure operating pressure pressure

PFA PMA PEA

bar bar bar
10 10 12 17

15
 16 16 20 25
25 25 30 35
40 40 48 53

4.2..2 Diameter

4.2.2.1 External diameter

Table 14 in 8.1 specifies the values of the external diameter DE of the spigot end of
fittings, when measured circumferentially using a circumferential tape in
accordance with 6.1.1. The positive tolerance is + 1 mm and applies to all pressure
classes of flanged spigot fittings.
The negative tolerance depends on the design of each type of joint and shall be as
specified in national standards, or, when not so specified, in manufacturers'
catalogues, for the type of joint and the nominal size considered.
In addition, the ovality (see 3.1.26) of the spigot end of fittings shall:

remain within the tolerances on DE for DN 80 to 200;

not exceed 1 % of DE for DN 250 to DN 600 or given in the following table.

Allowable Ovality for Push-on-Joint Pipes

Nominal Diameter Allowable Difference Between

DN Monor Axis and DE, Min

80 to 300 mm 1.00 mm
350 to 600 mm 1.75 mm
700 mm 2.0 mm
900 to 1000 mm 3.5 mm
1100 to 1200 mm 4.0 mm
1400 to 1600 mm 4.5 mm

NOTE The manufacturer's recommendations should be followed with respect to the

necessity and means of ovality correction; certain types of flexible joints can accept the maximum
ovality without the need for spigot re-rounding prior to jointing.

4.2.2.2 Internal diameter

The nominal values of the internal diameters of centrifugally cast pipes, expressed
in millimetres, are approximately equal to the numbers indicating their nominal
sizes DN.
4.2.3 Wall thickness

4.2.3.1. Fittings with flexible joints

The minimum wall thickness for pipes shall be determined from the following
equation:
emin = PFA x SF x DE and shall not be < 3.0 mm.
20Rm+(PFA x SF)
where:

emin is the minimum fittings wall thickness, in millimetres;

16
PFA is the allowable operating pressure in bars (see 3.1.18);

SF is the safety factor for PFA (= 3);

DE is the nominal pipe external diameter (see Table 14), in millimetres;

Rm is the minimum tensile strength of ductile iron, in megapascals (Rm = 420 MPa;
see Table 8).

NOTE The above equation is derived from Barlow's equation, i.e., hoop stress, = PD/2t (see
3.1.27)

4.2.3.2 Flanged fittings

Flanged fittings shall be classified by PN number. The pressure class of the barrel of
the flange fittings shall be equal to or greater than a value in bar equal to the PN of
the flanges. The pressure class of the flange fitting barrel to be used for fabricated
flanged fittings shall be as indicated in Clause 8.2 for welded on flanges, screwed on
flanges, and integrally cast flanges.

NOTE Pipe threads are regarded as loss of wall thickness.

4.2.3.2.1 Fittings with weld bead

The minimum wall thickness for spigots of fittings delivered with weld beads for
restrained joints shall not be less than 4.7 mm.
4.2.3.3. Fittings

Nominal wall thicknesses (enom) are given for fittings in Table 18 to Table 36, with
allowable pressures given in 4.2.1.3. The minimum wall thicknesses (emin) for
fittings is: emin = enom – (2.3 + 0.001DN).
Fittings with other pressure classifications are allowed. The manufacturer shall be
aresponsible for the design of the fittings including the determination of wall
thickness.

The design shall be carried out either by:

- A calculation method using the tensile strength of the material divided by a
safety factor, or finite element analysis or

- An experimental method by means of pressure tests subjected to a constant

hydrostatic pressure equal to 3 times a safety factor with respect to PFA.

4.2.4. Length

4.2.4.3 Fittings

Fittings shall be supplied to the lengths as given in 8.3 and 8.4 except that
alternatively, socket fittings may be supplied to the lengths mutually agreed
between the manufacturers and the purchasers.

17
 © ISO
NOTE Two series of dimensions are shown, series A and series B which is generally limited up to
DN 450.

The permissible deviations (see 3.1.25) on the lengths of series A fittings shall be as
given in Table 6.

Table 6 – Permissible deviations on length

Dimensions in millimetres
Type of fitting DN Deviation
Flanged sockets 80 to 1200 25
Flanged spigots
1400 to 2000 35
Collars, tapers
80 to 1200 +50
Tees — 25
1400 to 2000 +75
—35
Bends 90° (1/4) 80 to 2000 (15 + 0,03 DN)
Bends 45° (1/8) 80 to 2000 (10 + 0,025 DN)
Bends 22° 30' (1/16) and 11°15' 80 to 1200 (10 + 0,02 DN)
(1/32) 1400 to 2000 ( 10 + 0,025 DN)

2. TOLERANCES

12.1 The tolerance on the barrel wall thickness fittings shall be as follows :

Wall thickness Tolerance in mm

7 -2.3
Greater than 7 -(2.3+0.001 DN)

The tolerance value on External diameter & barrel wall thickness is given in Table-3.

12.2 Tolerances for the various dimensions of flanges shall be as given in Table 8, 9, 10 and 11.

Table 8

Tolerances on the external diameter ‘D & E'

Dimensions are in mm
DN 80 100 125 150 200 250 300 350 400 450 500 600 700 750
Tolerance ± 4.5 +5.5, -2.5 + 6.5, -3.5 + 7.5, -4
on D
Tolerance ± 4.0 ± 4.5 ± 5.0 ± 5.5
on E

Dimensions are in mm
DN 800 900 1000 1100 1200 1400 1600 1800 2000
Tolerance on D + 7.5, -4 + 8.5, -4 +10, -5 +12, -6
Tolerance on E ± 5.5 ± 5.5 ± 6.0 ± 6.0

Table 9

18
 Tolerances on raised face height (f)
Dimensions are in mm
Height of raised face (f) Tolerance
3 +1.5, -2.0
4 +2, -3.0
5 +2.5, -4.0

Table 10
Tolerances on thickness of flange
Dimensions are in mm
Type of Flange Tolerance
Integrally Cast Flanges ± (3 + 0.05 b)
Welded and screwed on flanges ± (2 + 0.05 b)

Table – 11 Tolerances on flange drilling

Dimensions are in mm
Dimension Bolt hole diameter
dia. 19 to dia. 28 dia. 31 to dia 56 above dia. 62
Tolerance
Bolt hole diameter, d +2, -0 +3, -0 +4, -0
Pitch circle diameter, C ±2 ± 2.8 ± 4.8
Centre to centre of adjacent ±2 ± 2.8 ± 4.8
bolt holes

12.3 Tolerance on Ovality

12.3.1 Fittings shall be as far as possible circular internally and externally. The tolerance for out of
roundness of the socket and spigot ends in the jointing zone for Push-on-joint are given in Table-
12 and for Mechanical Joint are given in Table-13.

12.3.2 In case of oval spigot ends for Push-on joints (DE), the minor axis is permitted to be less than the
minimum allowable diameter by the value given below provided the mean diameter DE measured
by circumferential tape, comes within the minimum allowable dimensions of DE (Table-3) after
applying the tolerance.

Table-12
ALLOWABLE OVALITY FOR PUSH-ON-JOINT FITTINGS (Clause 12.4.1 )

Nom. Diameter Allowable Difference Nom. Diameter Allowable Difference

DN (mm) between Minor Axis DN (mm) between Minor Axis
and DEMin.(mm) and DEMin.(mm)
80 - 300 1.0 900 - 1000 3.5
350 - 600 1.75 1100 - 1200 4.0
700 2.0 1400 - 1600 4.5
750 - 800 2.4

12.3.3 Mechanical Joint will accept some degree of spigot ovality but the measured difference between the
maximum and minimum axis of individual spigots shall not exceed the following values.

Table-13
ALLOWABLE OVALITY FOR MECHANICAL JOINT FITTINGS (Clause 12.4.1)

Nom. Diameter Maximum Ovality of Nom. Diameter Maximum Ovality of

DN (mm) Spigot on External DN (mm) Spigot on External
Diameter DE ( mm ) Diameter DE ( mm )
80 - 150 5 900 - 1000 40
200 - 350 10 1100 - 1400 50
400 - 500 20 1600 - 2000 60
600 - 800 30

12.4 Lengths of Fittings

19
The permissible deviations on the lengths of fittings shall be as given in table-14.

TABLE-14- PERMISSIBLE DEVIATION (Clause 12.4)

Types of Fittings Nominal Diameter DN Deviation in L and H

mm mm
Flanged sockets , Flanged spigots 80 to 1200 ± 25
Collars, tapers 1400 to 2000 ± 35
Tees 80 to 1200 +50/-25
1400 to 2000 +75/-35
Bends 90° (1/4) 80 to 2000 ± (15 + 0.03 DN)
Bends 45° (1/8) 80 to 2000 ± (10 + 0.025 DN)
Bends 22° 30’ and 11° 15’ 80 to 1200 ± (10 + 0.02 DN)
(1/16 and 1/32) 1400 to 2000 ± (10 + 0.025 DN)

12.5 Tolerance of lengths

The limit Deviation or tolerance on length of Fittings is given in the table below

Type of fittings Tolerance

Fittings for Socketted joint 20
Fittings for Flanged joint 10 *

4.3.Material characteristics

4.3.1 Tensile properties

Fittings and accessories made of ductile iron shall have the tensile properties given
in table 8.
During the manufacturing process the manufacturer shall carry out suitable tests
to verify these tensile properties; these tests may be:

a) either a batch sampling system whereby samples are obtained from samples cast separately or
integrally with the fitting casting concerned. Test bars shall be machined from these samples and
tensile tested in accordance with 6.3; or

b) a system of process control testing (e.g. non-destructive) where a positive correlation can be
demonstrated with the tensile properties specified in Table 8. Testing verification procedures
shall be based on the use of comparitor samples having known and verifiable properties. This
system of testing shall be supported by tensile testing in accordance with 6.3.

20
 Table 8 – Tensile properties

Type of casting Minimum tensile strength, Minimum percent elongation after fracture, A
Rm
MPa
DN 80 to DN 2 000 DN 80 to DN 1 000 DN 1 100 to DN 2 000

Fittings and accessories 420 5 5

1. By agreement between manufacturer and purchaser, the 0.2% proof stress may be measured. It shall be not less
than: 270 MPa when A > 12 % for DN 80 to 1000 or A > 10% for DN > 1000; 300 Mpa in other cases
2. For ductile iron fittings up to DN 1000 if the tensile strength of specimen is not found within limits, and
microstructure reveals 75 percent ferrite with spheroidal graphite and percentage elongation > 7, it shall be
taken as meeting the requirements of this standard.
3. The frequency of testing is related to the system of production and quality control used by the manufacturer.

4.3.2 Brinell hardness

The hardness of the various components of the fittings shall be such that they can
be cut, tapped, drilled and/or machined with standard tools. In case of dispute, the
hardness shall be measured according to 6.4.

The Brinell hardness shall not exceed 230 HBW for centrifugally cast pipes and
250 HBW for fittings and accessories. For components manufactured by welding, a
higher Brinell hardness is allowed in the heat-affected zone of the weld.
4.5 Coatings and linings for fittings and accessories

Fittings and accessories shall normally be delivered internally and externally coated.
4.5.1 External coatings

Ductile iron pipeline systems can be installed in a wide range of external operating
environments. These environments can be characterized according to their
aggressivity. Relevant factors are given in Annex A.1.

Where protection against aggressive external environments is deemed necessary,

coatings specified by IS standards are available as outlined in Annex A.3. Where IS
and ISO standards do not exist, coatings shall comply with CEN standards, or with
an agreed technical specification.
4.5.2 Internal linings

Ductile iron pipeline systems can be used to convey a wide range of raw waters and
potable waters. These internal environments can be characterized according to their
aggressivity. Relevant factors to be considered for cement mortar linings without
seal coats are given in Annex B.1.
Where protection against aggressive internal environments is deemed necessary,
linings specified by IS standards are available as outlined in Annex B-3. Where IS
and ISO standards do not exist, linings shall comply with CEN standards, or with
an agreed technical specification.

21
4.6 Marking

All pipes and fittings shall be durably and legibly marked and shall bear at least the
following indications:
the manufacturer's name or mark;

the identification of the year of manufacture;

the identification as ductile iron;

the DN;

the PN rating of flanges when applicable;

the C pressure class of socket and spigot fittings;

the reference to this Indian Standard;

ISI certification mark and the License No.

The first five markings above shall be cast-on or cold stamped. The last two
indications can be applied by any method, e.g. painted on the castings.

5. Leaktightness requirements

5.1 Fittings

Fittings shall be designed to be leak-tight at their allowable test pressure (PEA).

They shall be tested in accordance with 6.5 and shall exhibit no visible leakage,
sweating or any other sign of failure.
5.2 Flexible joints

5.2.1 General

All flexible joints for ductile iron fittings and components shall be designed in
compliance with the requirements of 5.2. If the design has been tested and
documented by the manufacturer and successfully used for a minimum of ten
years, the performance of a type test in accordance with 5.2.2 for internal pressure,
in accordance with 5.2.3 for external pressure and in accordance with 5.2.4 for
negative internal pressure is only required for significant changes in design which
could adversely affect the performance of the joint.
Joint designs shall be type tested to demonstrate leak-tightness to both internal and
external pressure under the most un-favorable conditions of castings tolerances and
joint movements.
There shall be a type test for at least one DN for each of the groupings given in
Table 9. One DN is representative of a grouping when the performances are based
on the same design parameters throughout the size range.
Table 9 – DN groupings for type tests

DN groupings 80 to 250 300 to 700 to 1000 1100 to

600 2000
Preferred DN in each grouping 200 400 800 1600

22
If a grouping covers products of different designs and/or manufactured by different
processes, the grouping shall be subdivided.

NOTE If for a manufacturer a grouping contains only one DN, this DN may be considered as part
of the adjacent grouping provided that it is of identical design and manufactured by the same
process.

The type tests shall be carried out in the configuration of maximum design radial
gap between the components to be jointed (smallest spigot end of the Flanged
Spigot Adaptor together with largest socket of the Flanged Socket Adaptor).
In the type test, the maximum gap shall be equal to the maximum design radial gap
with a tolerance of plus 0 % minus 5 %. The internal socket diameter may be
machined to achieve this, even if the resulting diameter is slightly outside the
normal manufacturing tolerance.

All joints shall be performance tested with a spigot having an average iron wall
thickness (over a distance of 2 DN, in mm from the spigot end face) equal to the
specified minimum value for the pipe for which the joint is designed plus 10 %,
minus 0 %. It is permissible to machine the spigot end of the pipe bore to achieve
the required thickness.

Restrained flexible joints shall be designed and tested in accordance with

ISO 10804-1.
5.2.2 Internal pressure

The leak-tightness of joints to internal pressure shall be type tested in accordance

with 7.1 at a test pressure which shall be not less than their allowable test pressure
PEA; the joints shall exhibit no visible leakage in the two following positions:

a) joint aligned and subjected to shear: the shear force across the joint, expressed in N, shall be
not less than 30 times DN;

b) joint deflected: the test angular deflection shall be the maximum allowable deflection
indicated in the manufacturers catalogue, but not less than 3° 30’ for DN 40 to DN 300, 2°
30’ for DN 350 to DN 600, 1° 30’ for DN 700 to DN 2600.

5.2.3 External pressure

The leak-tightness of joints to external pressure shall be type tested in accordance

with 7.2; the joints shall exhibit no visible leakage when subjected to a shear load,
expressed in newtons, not less than 30 times DN.
The test pressure shall be not less than 1 bar.

23
 5.2.4 Negative internal pressure

The leak tightness of joints to negative internal pressure shall be type tested in
accordance with 7.3 at a test pressure of 0,9 bar below atmospheric pressure
(approximately 0,1 bar absolute pressure). The maximum pressure change during
the test period shall not be more than 0,09 bar after 2 hours, when tested in the two
following positions:

a) joint aligned and subjected to shear: the shear force across the joint, expressed in N, shall not
be less than 30 times DN;

b) joint deflected: the test angular deflection shall be the maximum allowable deflection
indicated in the manufacturer’s catalogue, but not less than 3º 30’ for DN 40 to DN 300, 2º
30’ for DN 350 to DN 600, 1º 30’ for DN 700 to 2600.

5.3 Flanged joints as cast, screwed, welded and adjustable.

All flanged joints for ductile iron fittings and components shall be designed in
compliance with the requirements of 5.3. If the design has been tested and
documented by the manufacturer and successfully used for a minimum of ten
years, the performance of a type test in accordance with 5.3 is only required for
significant changes in design which could adversely affect the performance of the
joint.
In order to demonstrate their strength and leak tightness in service conditions,
flanged joints shall be subjected to a performance test. When tested in accordance
with 7.4, they shall show no visible leakage under the combined effects of a
hydrostatic internal pressure and of a bending moment given in Table 10, where:

the pressure is (1,5 PN + 5) bar;

the relevant bending moment is obtained by addition of the bending moments due to the weight
of the components and of the water in the test assembly and to a possible external load
calculated as a function of the length of the unsupported span of the testing arrangement (see
7.4).

A performance test shall be carried out on each type of flange joint available from the manufacturer
in accordance with Table 10.

NOTE The bending moments given in Table 10 are equal to those resulting from the weight of the
pipes and of the water over an unsupported pipe length L between simple supports, with:

- L = 8 m for DN 250;

- L = 12 m for DN 300.

Table 10 Bending moments for flange joint performance tests

DN Bending moment DN Bending moment
kN·m kN·m
40 0,7 500 63
50 0,9 600 87
60 1,3 700 116
65 1,4 800 146
80 1,8 900 181
100 2,3 1000 222
125 2,9 1100 265
24
 150 4,0 1200 313
200 6,0 1400 423
250 8,6 1500 475
300 26,0 1600 548
350 33,8 1800 625
400 42 2000 770
450 51

Test methods

6.1 Dimensions

6.1.1 External diameter

Adaptor Fittings with sockets and spigot ends shall be measured at their spigot end
by means of a circumferential tape for compliance with the outer diameter tolerance.
They can also be verified by means of go, no-go gauges.

In addition, the frittings shall be visually inspected at their spigot end for
compliance with the ovality tolerance and, in case of doubt, checked by
measurement of the maximum and minimum axes. This control may also be carried
out by go, no-go gauges.

The frequency of testing is related to the system of production and quality control
used by the manufacturer.
6.1.2 Wall thickness

Fittings wall thickness compliance shall be demonstrated by the manufacturer; he

may use a combination of various means, such as:

fittings weight control;

direct wall thickness measuring or gauging by suitable equipment, such as mechanical or

ultrasonic equipment. The frequency of testing is related to the system of production and quality
control used by the manufacturer.

6.3 Tensile test

6.3.1 Sampling

The thickness of the sample and the diameter of the test bar shall be as indicated in
Table 8.
6.3.1.2 Fittings and accessories

Samples shall be taken, at the manufacturers option, either from an integrally cast
sample, from a sample attached to the casting, or from a sample cast separately. In
the latter case, it shall be cast from the same metal as that used for the casting. If
the casting is subjected to heat treatment, the sample shall be subjected to the
same heat treatment.

25
6.3.2 Test bar

A test bar shall be machined from each sample to be representative of the metal at
the mid-thickness of the sample, with a cylindrical part having the diameters given
in Table 11. If the specified diameter of the test bar is greater than 60% of the
measured minimum thickness of the sample, it is allowed to machine a test bar
with a smaller diameter, or to cut another sample in a thicker part of the pipe.
The test bars shall have a gauge length at least five times the nominal test bar
diameter. The ends of the test bars shall be such that they will fit the testing
machine.
The surface roughness of the machined gauge length of the test bar shall be such
that Rz 6,3.
Two methods of measuring the tensile strength may be used at the manufacturers
option:

Method A:
Produce the test bar to a nominal diameter 10 %, measure the actual diameter
before the test with an accuracy of 0,01 mm and use this measured diameter to
calculate the cross-sectional area and the tensile strength;or

Method B:
Produce the test bar to a nominal area So within a specified tolerance on the
diameter (see Table 11) and use the nominal area to calculate the tensile strength.

26
 Table 11 – Dimensions of test bar

Type of casting Test bar Test bar, method B

method A
Nominal Nominal area Nominal Tolerance on
diameter S diameter diameter
mm mm2 mm mm

Fittings and accessories not centrifugally

cast:
integrally cast samples 5 20 5,05 ± 0,02
separately cast sample:
thickness 12.5 mm for casting thickness 6 30 6,18 ±0.03
less than 12 mm
Thickness 25 mm for casting thickness 12 12 or 14 - - -
mm and over

6.3.3 Equipment and test method

The tensile testing machine shall have suitable holders or grips to attach to the test
bar ends so as to positively apply the test load axially. The testing machine shall
have a force range suitable for testing the bars to failure whilst indicating the load
applied.
The rate of stressing shall be as constant as possible within the limits of 6 N/mm2
per second to 30 N/mm2 per second.
The tensile strength shall be calculated by dividing the maximum force sustained by
the test bar by the cross-sectional area of the test bar before testing. The elongation
shall be measured by piecing together the broken parts of the test bar and taking
the ratio of the extended gauge length to the original gauge length. Alternatively, the
elongation may be measured directly by means of an extensometer.
6.3.4.Test results

Test results shall comply with Table 8. If they do not comply, the manufacturer
shall:

a) in the case where the metal does not achieve the required mechanical properties, investigate
the reason and ensure that all castings in the batch are either re-heat-treated or rejected;
castings which have been re-heat treated are then re-tested in accordance with 6.3;

b) in the case of a defect in the test bar, carry out a further test. If it passes, the batch is
accepted; if not, the manufacturer has the option to proceed in accordance with a) above.

NOTE The manufacturer may limit the amount of rejection by making additional tests, in order of
manufacture, until the rejected batch of castings is bracketed by a successful test at each end of the
interval in question.

27
 6.3.6 Test frequency

The frequency of testing is related to the system of production and quality control
used by the manufacturer (see 4.3.1). The maximum batch sizes shall be as given in
Table 12.
Table 12 – Maximum batch size for tensile testing

Type of casting DN Maximum batch size

Batch sampling Process control
system testing system

Fittings and accessories All sizes 4 ta 48 ta

a Mass of crude castings, excluding risers.

6.4 Brinell hardness

When Brinell hardness tests are carried out (see 4.3.2), they shall be performed
either on the casting in dispute or on a sample cut from the casting. The surface to
be tested shall be suitably prepared by slight local grinding, and the test shall be
carried out in accordance with IS 1500 using a ball of 2,5 mm or 5 mm or 10 mm
diameter.
6.5 Works leak-tightness test of fittings

6.5.1 General

Fittings shall be tested in accordance with 6.5.2 and 6.5.3 respectively. The test
shall be carried out on all fittings before the application of their external and
internal coatings.

The test apparatus shall be suitable for applying the specified test pressures to the
fittings. It shall be equipped with an industrial pressure gauge with an error limit of
3 %.
6.5.3 Fittings

At the manufacturer's option, they shall be submitted to a hydrostatic pressure test,

or air test. The test pressures, which shall be as given in Table 13.

28
ISO 2531:1998(E) © ISO
Table 13 – Works test pressure for fittings and accessories

DN Pipes not centrifugally cast, fittings and accessories

80 to 300 25
350 to 600 16
700 to 2000 10
a The works hydrostatic test pressure is less than for pipes because of the difficulty providing sufficient
restraint to high internal pressure during test.
b 16 bar for fittings with PN 10 flanges.

When the air test is carried out it shall be with an internal pressure of at least 1 bar
and a visual inspection time not less than 10 s; for leak detection, the castings shall
be either uniformly coated on the external surface by a suitable foaming agent or
submerged in water.

7. Type tests

7.1 Leak-tightness of joints to internal pressure

This type test shall be carried out on an assembled joint comprising two fittings
sections at least 1 m long each (see Figure 1).
The test apparatus shall be capable of providing suitable end restraints, whether the
joint is in the aligned position, or deflected, or subjected to a shear load. It shall be
equipped with a pressure gauge having an accuracy of 3 %.
The shear load W shall be applied to the spigot by means of a V-shaped block with
an angle of 120°, located at approximately 0,5 DN in millimetres or 200 mm from
the socket face (whichever is the largest); the socket shall bear on a flat support.
The load W shall be such that the resultant shear force F across the joint is equal to
the value specified in 5.2.2, taking into account the mass M of the pipe and its
contents and the geometry of the test assembly:
F c M c b
W
c a

where
W, F and M are expressed in newtons;

a, b and c are given in Figure 1.

29
 Figure 1 – Leak tightness of joints (internal pressure)

The test assembly shall be filled with water and suitably vented of air. The pressure
shall be raised steadily until it reaches the test pressure given in 5.2.2; the rate of
pressure increase shall not exceed 1 bar/s. The test pressure shall be kept constant
within 0,5 bar for at least 2 h during which the joint shall be thoroughly
inspected every 15 min.
7.2 Leaktightness of joints to external pressure

This type test assembly, which applies only to push-in flexible joints, shall comprise
two joints made with two fittings sockets connected together and one double-spigot
piece so as to create an annular chamber allowing to test one joint under internal
pressure and one joint under external pressure (see Figure 2).

Figure 2 – Leak tightness of joints (external pressure)

The test assembly shall be subjected to the shear load defined in 5.2.3; one half of
this load shall be applied to the spigot on each side of the test assembly, by means
of a V-shaped block with an angle of 120°, located at approximately 0,5 DN in
millimetres or 200 mm from the end of sockets (whichever is the largest); the
sockets shall bear on a flat support.

30
The test assembly shall then be filled with water and suitably vented of air. The
pressure shall be steadily increased until it reaches the test pressure given in 5.2.3
and then kept constant within 0,1 bar for at least 2 h, during which the internal
side of the joint subjected to external pressure shall be thoroughly inspected every
15 min.
7.3 Leaktightness of joints to negative internal pressure

The test assembly and test apparatus shall be as given in 7.1 with the fitting
sections axially restrained to prevent them moving towards each other.
The test assembly shall be empty of water and shall be evacuated to a negative
internal pressure of 0,9 bar (see 5.2.4) and then isolated from the vacuum pump.
The test assembly shall be left under vacuum for at least 2 h during which the
pressure shall not have changed by more than 0,09 bar. The test shall begin at a
temperature between 5 °C and 40 °C. The temperature of the test assembly shall not
vary by more than 10 °C for the duration of the test.
The internal pressure and the external load shall be kept constant for 2 h during
which the flanged joint shall be thoroughly inspected.
NOTE All necessary safety precautions should be taken for the duration of the pressure test.
7.5 Leak tightness of flexible joints to dynamic internal pressure

The test assembly and test apparatus shall be as given in Fig 1. The test assembly shall be filled with
water and suitably vented of air.The pressure shall be steadily increased up to PMA, the allowable
maximum operating pressure of the joint, then automatically monitored according to the following
pressure cycle:

c) steady pressure reduction to (MOP – 5) bar;

d) maintain (MOP – 5) bar for at least 5 secs;

e) steady pressure increase to MOP;

f) maintain MOP for at least 5 secs.

The number of cycles shall be recorded and the test stopped automatically in the occurrence of a failure of
the joint. For a restrained joint, the test assembly, the test apparatus and the test procedure are identical,
except that there shall be no end restraint so that the axial thrust is taken by the restrained joint under
test. In addition, any axial movement at the spigot shall be measured every 15 min.
NOTE All necessary safety precautions should be taken for the duration of the pressure test.

7.7 Leak tightness and mechanical resistance of pipe saddles

7.7.1 Positive internal pressure

The test shall be carried out on an assembly at least 1m long (see Figure). The pipe ends shall be suitably
capped and restrained to withstand the internal positive pressure.

The saddle shall be assembled such that the outlet is vertical and prior to pressurization the relevant
torque shall be applied to the saddle service valve

The test assembly shall be filled with water and suitably vented of air. The pressure shall be raised
steadily until it reaches the test pressure given in works hydrostatic test. The test pressure shall be kept
constant within +/- 0,5 bar for at least 2 h during which the saddle shall be inspected every 15 min.
The test shall be repeated with the saddle outlet horizontal and prior to pressurization the relevant load
shall be applied to the saddle service valve cap.

Saddles designed for use in only one direction (vertical or horizontal) shall only be tested in that
orientation.
31
NOTE All necessary safety precautions should be taken for the duration of the test.

Figure 4 – Leak tightness test for pipe saddles

7.7.2. Negative internal pressure

The test assembly and test apparatus shall be as given in 7.1, with the pipe ends capped.
The saddle shall be assembled such that the outlet is vertical and prior to pressurization the relevant
torque shall be applied to the saddle service valve.

The test assembly shall be empty of water and shall be evacuated to a negative internal pressure of 0.9
bar (see Table 13) and then isolated from the vacuum pump. The test assembly shall be left under vacuum
for at least 2 h during which the pressure shall not have changed by more than 0,09 bar.

The test shall be repeated with the saddle outlet horizontal and prior to pressurization the relevant load
shall be applied to the saddle service valve cap (see 5.5.1).

Saddles designed for use in only one direction (vertical or horizontal) shall only be tested in that
orientation.
7.8 Compressive strength of the cement mortar lining

The compressive strength shall be the arithmetic mean of six compressive strength tests performed on
three prism samples after 28 days of curing. The compressive strength shall be minimum 50 MPa as
determined by a performance test. It is to be ensured that:

the sand, the cement and the water used for the prism samples are identical with those used for the
mortar before application of the lining;

the sand/cement ratio used for the prism samples is equal to that used for the mortar before
application of the lining;

the water/cement ratio used for the prism samples is equal to that of the lining immediately after
application to the pipe wall;

the test samples are prepared using either an impact table or a vibrating table.

NOTE This takes into account the influence of the centrifugal spinning process which allows expelling the
excess water.

8. Initial performance testing

General

Initial performance testing shall be performed to show conformity with this standard. Tests previously
performed in accordance with the provisions of this standard (same product, same characteristic(s), test
method, sampling procedure, system of attestation of conformity, etc.) may be taken into account. In
addition, initial performance testing shall be performed at the beginning of the production of a new type of
product or at the beginning of a new method of production (where this may affect the stated properties).
32
Where components are used whose characteristics have already been determined by the component
manufacturer, on the basis of conformity with other product standards, these characteristics need not be
reassessed provided that the components' performance or method of assessment remain the same, that
the characteristics of the component are suitable for the intended end use of the finished product, and
insofar as the manufacturing process does not have a detrimental affect on the determined characteristics.
Components and raw materials ISI marked in accordance with appropriate harmonised Indian
specifications may be presumed to have the performances stated with the ISI marking, although this does
not replace the responsibility on the manufacturer of ductile iron pipeline product to ensure that the
product as a whole is correctly designed and its component products have the necessary performance
values to meet the design.

8.1.1 Characteristics

All characteristics in Clause 7 shall be subject to initial performance testing except for the release of
dangerous substances which may be assessed indirectly by controlling the content of the substance
concerned. Whenever a change occurs in the product, the raw material or supplier of the components, or
the production process (subject to the definition of a family), which would change significantly one or more
of the characteristics, the performance tests shall be repeated for the appropriate characteristics.

8.1.2 Treatment of calculated values and design

In those cases where conformity with this standard is based on calculations, performance testing will be
limited to the verification of the calculations made and that the resulting products correspond to the
assumptions made in the design.

8.1.3 Sampling, testing and conformity criteria

8.1.4 Sampling procedure

Initial performance testing shall be performed on samples of products representative for the manufactured
product type. The random sampling method shall be used, except for the assessment of the leak tightness
of joints which requires samples at the extreme of tolerances.

Testing and compliance criteria

The number of test samples to be tested (or assessed) shall be in accordance with clause 11.1 .The results
of all performance tests shall be recorded and held by the manufacturer for at least 10 years after the last
date or production of the product(s) to which they apply.

33
 Table 16 Number of test samples for initial performance testing

Test
Requirements
Items to be tested Number of samples (minimum)
/method in
accordance with
Internal pressure strength 1 per DN Appendix B.

Diametral stiffness of fitting 1of DN groups in Clause 6 Appendix D.

Leak tightness of flexible joints 1 of each DN grouping
To positive internal pressure DN 80 DN 300 DN 700 DN 1100 19.2
To negative internal pressure 19.3
to to To to
To positive external pressure 19.4
To dynamic internal pressure DN 250 DN 600 DN 1000 DN 2000 19.5
Strength and leak tightness of 1 of each DN grouping
flanged joints DN 80 DN 300 DN 700 DN1100 19.6
to DN to DN to DN to DN
250 600 1000 2000
Compressive strength of the Mean of 6 tests on 3 samples 19.7
cement mortar lining

8.3 Factory production control (FPC)

8.3.1 General

The manufacturer shall establish, document and maintain an FPC system to ensure that the products
placed on the market conform to the declared performance characteristics and to all requirements of this
standard. The FPC system shall consist of procedures (works' manual), regular inspections and tests
and/or assessments and the use of the results to control raw and other incoming materials or
components, equipment, the production process and the product. Records shall remain legible, readily
identifiable and retrievable.

The FPC system may be part of a Quality Management System, e.g. in accordance with ISO 9001:2008. An
FPC system conforming with the requirements of ISO 9001:2008, and made specific to the requirements of
this standard, shall be considered to satisfy the above requirements. The results of inspections, tests or
assessments requiring action shall be recorded, as shall any action taken. The action to be taken when
control values or criteria are not met shall be recorded and retained for the period specified in the
manufacturer's FPC procedures.

If the manufacturer has the component designed, manufactured, assembled, packed, processed and/or
labelled by subcontracting, FPC of the original manufacturer may be taken into account. However, where
subcontracting takes place, the manufacturer shall retain the overall control of the component and ensure
that he receives all the information that is necessary to fulfill his responsibilities according to this
European Standard.

34
 8.4 FPC requirements for all manufacturers

8.4.1General

The manufacturer shall establish procedures to ensure that the production tolerances allow for the
products performances to be in conformity with the declared values, derived from initial performance
testing.

The characteristics, and the means of verification, are given in Table 17. The minimum testing frequencies
apply to permanent production in large quantities with a stable process. The actual testing frequencies to
be used in order to ensure permanent conformity of the products shall be fixed by the manufacturer's
FPC, taking into account the production rate and the process control measures which are implemented.

The manufacturer shall record the results of the tests specified above. These records shall at least include
the following information:
- identification of the product tested;
- the date of sampling and testing;
- the test methods performed;
- the test results.
Table 20 Minimum frequency of product testing as part of FPC

Items to be tested Test Requirements in Minimum frequency of

accordance with test
Dimensions
Wall thickness 10.3 , 15.4 & Table -2 1 per shift
External diameter of spigots 15.1, 15.2 & Table -2 10 % by pass/fail gauge
Internal diameter 10.2 & table B2 1 per shift
Length of fittings 15.5, 15.5.1 1% pipe after mould
change
Material characteristics
Tensile Tensile testing 12.1.1 & 12.1.6 see 11.1
Brinell hardness 12.2 See 11.1
Coating Coatings and linings of pipes
Zinc coating mass A.5 & A.6 1 per shift
Thickness of paint coatings A8 1 per shift
Thickness of cement mortar lining 16.3.1 , B6 & Table B2 1 per shift
Leak tightness for fittings
Works leak tightness test 13.1, 13.2 & Table 6 100 %

8.4.2 FPC for tensile testing

During the manufacturing process the manufacturer shall carry out suitable tests in order to verify the
tensile properties. These tests may be:

a) a batch sampling system whereby samples are obtained from the pipe spigot or, for fittings, from
samples cast separately or attached with the castings concerned. Test bars are machined from these
samples and tensile tested in accordance with 12.1; or

b) a system of process control (e.g. by non-destructive testing) where a positive correlation can be
demonstrated with the tensile properties specified in 12.1.6. Testing verification procedures are based on
the use of comparator samples having known and verifiable properties. This system is supported by
tensile testing in accordance with 12.1 and 12.1.6.

The frequency of testing is related to the system of production and quality control used by the
manufacturer. The maximum batch sizes shall be as given in 11.1.
35
8.5 Manufacturer-specific FPC system requirements
8.5.1. Personnel

The responsibility, authority and the relationship between personnel that manages, performs or verifies
work affecting product conformity, shall be defined. This applies in particular to personnel that need to
initiate actions preventing product non-conformities from occurring, actions in case of non-conformities
and to identify and register product conformity problems. Personnel performing work affecting product
conformity shall be competent on the basis of appropriate education, training, skills and experience for
which records shall be maintained.

8.5.2 Equipment

All weighing, measuring and testing equipment necessary to achieve, or produce evidence of, conformity
shall be calibrated or verified and regularly inspected according to documented procedures, frequencies
and criteria. Control of monitoring and measuring devices shall comply with the appropriate clause of ISO
9001:2000.

All equipment used in the manufacturing process shall be regularly inspected and maintained to ensure
use, wear or failure does not cause inconsistency in the manufacturing process. Inspections and
maintenance shall be carried out and recorded in accordance with the manufacturers written procedures
and the records retained for the period defined in the manufacturer's FPC procedures.

8.5.2 Design process

The factory production control system shall document the various stages in the design of the products,
identify the checking procedure and those individuals responsible for all stages of design. During the
design process itself, a record shall be kept of all checks, their results, and any corrective actions taken.
This record shall be sufficiently detailed and accurate to demonstrate that all stages of the design phase,
and all checks, have been carried out satisfactorily. Compliance with ISO 9001:2000, 7.3, shall be
deemed to satisfy the requirements of this sub-clause.

8.5.3 Raw materials and components

The specifications of all incoming raw materials and components shall be documented, as shall the
inspection scheme for ensuring their conformity. The verification of conformity of the raw materials with
the specification shall be in accordance with ISO 9001:2000, 7.4.3.

8.5.4 In-process control

The manufacturer shall plan and carry out production under controlled conditions. Compliance with ISO
9001:2000, shall be deemed to satisfy the requirements of this sub-clause.

8.5.5 Non-conforming products

The manufacturer shall have written procedures, which specify how non-conforming products shall be
dealt with. Any such events shall be recorded as they occur and these records shall be kept for the period
defined in the manufacturer’s written procedures. Compliance with ISO 9001:2000, Clause 8.3, shall be
deemed to satisfy the requirements of this sub-clause.

8.5.6 Corrective action

The manufacturer shall have documented procedures that instigate action to eliminate the cause of non-
conformities in order to prevent recurrence. Compliance with ISO 9001:2000, Clause 8.5.2,shall be
deemed to satisfy the requirements of this sub-clause.

36
 SECTION 3 DICTILE IRON FITTINGS

Ductile Iron Fittings of the following types with their ends either with socket (for mechanical joints or
push-on joints) or flanged shall conform to the dimensions as relevant to those given in Tables
mentioned below against each type. Tolerances shall be as per Tables 12, 13, 14 & Clause 12.5.

Double Socket 90° Bend Table 15

Double Socket 45° Bend Table 16
Double Socket 22½° Bend Table 17
Double Socket 11¼° Bend Table 18
Double Socket 90° Duckfoot Bend Table 19
Double Socket Tapers Table 20
All Socket, Flanged on Double Socket Tees Table 21
Collars Table 22
Flanged Socket Table 23
Flanged Spigot Table 24
Blank Flanges Table 25
90° Double Flanged Bend Table 26
45° Double Flanged Bend Table 27
22.5° Double Flanged Bend Table 32
11.25° Double Flanged Bend Table 33
90° Ducfoot Double Flanged Bend Table 28
All Flange Tee Table 29
Double Flanged Tapers Table 30
Reducing Flange Table 31

37
 Table-15 Table-16
90° DOUBLE SOCKET BEND 45° DOUBLE SOCKET BEND

Nominal e L Nominal e L
size size
mm mm mm mm mm mm
80 7.0 100 80 7.0 55
100 7.2 120 100 7.2 65
125 7.5 145 125 7.5 75
150 7.8 170 150 7.8 85
200 8.4 220 200 8.4 110
250 9.0 270 250 9.0 130
300 9.6 320 300 9.6 150
350 10.2 370 350 10.2 175
400 10.8 420 400 10.8 195
450 11.4 470 450 11.4 220
500 12.0 520 500 12.0 240
600 13.2 620 600 13.2 285
700 14.4 720 700 14.4 330
750 15.0 770 750 15.0 350
800 15.6 820 800 15.6 370
900 16.8 920 900 16.8 415
1000 18.0 1020 1000 18.0 460
1100 19.2 1130 1100 19.2 505
1200 20.4 1230 1200 20.4 550
1400 22.8 1430 1400 22.8 515
1600 25.2 1630 1600 25.2 565
1800 27.6 610
2000 30.0 660

NOTE : The figure is schematic. All dimensions are in mm.

90 degree bends are used up to DN 1600. Beyond DN 1600 two 45 degree bends with a barrel piece is
used. Normal international practice is to use 90 degree bends up to DN 300 only.

38
 Table-17 Table-18
22½° DOUBLE SOCKET BEND 11¼° DOUBLE SOCKET BEND

Nominal e L Nominal e L
size size
mm mm mm mm mm mm
80 7.0 40 80 7.0 30
100 7.2 40 100 7.2 30
125 7.5 50 125 7.5 35
150 7.8 55 150 7.8 35
200 8.4 65 200 8.4 40
250 9.0 75 250 9.0 50
300 9.6 85 300 9.6 55
350 10.2 95 350 10.2 60
400 10.8 110 400 10.8 65
450 11.4 120 450 11.4 70
500 12.0 130 500 12.0 75
600 13.2 150 600 13.2 85
700 14.4 175 700 14.4 95
750 15.0 185 750 15.0 100
800 15.6 195 800 15.6 110
900 16.8 220 900 16.8 120
1000 18.0 240 1000 18.0 130
1100 19.2 260 1100 19.2 140
1200 20.4 285 1200 20.4 150
1400 22.8 260 1400 22.8 130
1600 25.2 280 1600 25.2 140
1800 27.6 305 1800 27.6 155
2000 30.0 330 2000 30.0 165

NOTE : The figure is schematic. All dimensions are in mm.

39
 Table-19
90° DUCKFOOT DOUBLE SOCKET BEND

FIGURE TO BE DEVELOPED

NOTE : The figure is schematic

Nominal e L c d
size
mm mm mm mm mm
80 7.0 100 110 180
100 7.2 120 125 200
125 7.5 145 140 225
150 7.8 170 160 250
200 8.4 220 190 300
250 9.0 270 225 350
300 9.6 320 255 400
350 10.2 370 290 450
400 10.8 420 320 500
450 11.4 470 355 550
500 12.0 520 385 600
600 13.2 620 450 700
700 14.4 720 515 800
750 15.0 770 545 850
800 15.6 820 580 900
900 16.8 920 645 1000
1000 18.0 1020 710 1100
1100 19.2 1130 775 1200
1200 20.4 1230 840 1300
1400 22.8 1430 970 1500
1600 25.2 1630 1100 1700

90 degree duckfoot bends are up to DN 300 are to be used with pipes of C40. In the range DN 350 to DN
1600 they can be used with C 20 pipes. 90 degree bends are not to be used over 1600mm

40
 Table-20
DOUBLE SOCKET CONCENTRIC TAPERS

DN ( Body ) dn ( Branch ) e1 e2 L
mm mm mm Mm mm
100 80 7.2 7.0 90
125 80 7.5 7.0 140

150 80 7.8 7.0 190

150 100 7.8 7.2 150

200 100 8.4 7.2 250

200 150 8.4 7.8 150

250 150 9.0 7.8 250

250 200 9.0 8.4 150

300 150 9.6 7.8 350

300 200 9.6 8.4 250
300 250 9.6 9.0 150

350 200 10.2 8.4 360

350 250 10.2 9.0 260
350 300 10.2 9.6 160

400 250 10.8 9.0 360

400 300 10.8 9.6 260
400 350 10.8 10.2 160

450 350 11.4 10.2 260

450 400 11.4 10.8 160

500 350 12.0 10.2 360

500 400 12.0 10.8 260

600 400 13.2 10.8 460

600 500 13.2 12.0 260

700 500 14.4 12.0 480

700 600 14.4 13.2 280

750 500 15.0 12.0 480

750 600 15.0 13.2 280

800 600 15.6 13.2 480

800 700 15.6 14.4 280

900 700 16.8 14.4 480

900 800 16.8 15.6 280
1000 800 18.0 15.6 480
1000 900 18.0 16.8 280

1100 1000 19.2 18.0 280

1200 1000 20.4 18.0 480
1400 1200 22.8 20.4 360

1600 1400 25.2 22.8 360

1800 1600 27.6 25.2 360
2000 1800 30.0 27.6 360

Note: The larger end is designated DN and the smaller end is designated dn.

41
 Table-21
ALL SOCKET, FLANGED ON DOUBLE SOCKET TEES

Nominal dia. e e1 L H
DN dn Flange on All Flange on All
Body Branch double socket Socket double socket Socket
mm mm mm mm mm mm mm mm
80 80 7 7 170 170 165 85
100 80 7.2 7 170 170 175 95
100 100 7.2 7.2 190 190 180 95

125 80 7.5 7 170 170 190 105

125 100 7.5 7.2 195 195 195 100
125 125 7.5 7.5 225 225 200 110

150 80 7.8 7 170 170 205 120

150 100 7.8 7.2 195 195 210 120
150 150 7.8 7.8 255 255 220 125

200 80 8.4 7 175 175 235 145

200 100 8.4 7.2 200 200 240 145
200 150 8.4 7.8 255 255 250 150
200 200 8.4 8.4 315 315 260 155

250 80 9 7 180 180 265 170

250 100 9 7.2 200 200 270 170
250 150 9 7.8 260 260 280 175
250 200 9 8.4 315 315 290 180
250 250 9 9 375 375 300 190

300 100 9.6 7.2 205 205 300 195

300 200 9.6 8.4 320 320 320 205
300 300 9.6 9.6 435 435 340 220

350 100 10.2 7.2 205 - 330 -

350 200 10.2 8.4 325 - 350 -
350 350 10.2 10.2 495 - 380 -

400 80 10.8 7.0 185 - 355 -

400 100 10.8 7.2 210 - 360 -
400 150 10.8 7.8 270 - 370 -
400 200 10.8 8.4 325 - 380 -
400 300 10.8 9.6 440 - 400 -
400 400 10.8 10.8 560 - 420 -

42
Nominal dia. e e1 L H
DN dn Branch All Flange on All Socket
Body Branch Flange on Sock double
double socket et socket
mm mm mm mm mm mm mm Mm
450 100 11.4 7.2 215 - 390 -
450 250 11.4 9.0 390 - 420 -
450 450 11.4 11.4 620 - 460 -

500 100 12.0 7.2 215 - 420 -

500 200 12.0 8.4 330 - 440 -
500 400 12.0 10.8 565 - 480 -
500 500 12.0 12.0 680 - 500 -

600 200 13.2 8.4 340 - 500 -

600 400 13.2 10.8 570 - 540 -
600 600 13.2 13.2 800 - 580 -

700 200 14.4 8.4 345 - 525 -

700 400 14.4 10.8 575 - 555 -
700 700 14.4 14.4 925 - 600 -

750 400 15.0 10.8 575 - 585 -

750 750 15.0 15.0 985 - 635 -

800 200 15.6 8.4 350 - 585 -

800 400 15.6 10.8 580 - 615 -
800 600 15.6 13.2 1045 - 645 -
800 800 15.6 15.6 1045 - 675 -

900 200 16.8 8.4 355 - 645 -

900 400 16.8 10.8 590 - 675 -
900 600 16.8 13.2 1170 - 705 -
900 900 16.8 16.8 1170 - 750 -

1000 200 18.0 8.4 360 - 705 -

1000 400 18.0 10.8 595 - 735 -
1000 600 18.0 13.2 1290 - 765 -
1000 1000 18.0 18.0 1290 - 825 -

1100 400 19.2 10.8 600 - 795 -

1100 600 19.2 13.2 830 - 825 -

1200 600 20.4 13.2 840 - 885 -

1200 800 20.4 15.6 1070 - 915 -
1200 1000 20.4 18.0 1300 - 945 -

1400 600 22.8 13.2 1030 - 980 -

1400 800 22.8 15.6 1260 - 1010 -
1400 1000 22.8 18.0 1495 - 1040 -

1600 600 25.2 13.2 1040 - 1090 -

1600 800 25.2 15.6 1275 - 1120 -
1600 1000 25.2 18.0 1505 - 1150 -
1600 1200 25.2 20.4 1740 - 1180 -

43
 Nominal dia. e e1 L H
DN dn Branch All Flange on All Socket
Body Branch Flange on Sock double
double socket et socket
mm mm mm mm mm mm mm mm
1800 600 27-6 13.2 1055 - 1200 -

1800 800 27.6 15.6 1285 - 1230 -

1800 1000 27.6 18.0 1520 - 1260 -

1800 1200 27.6 20.4 1750 - 1290 -

2000 600 30.0 13.2 1065 - 1310 -

2000 1000 30.0 18.0 1530 - 1370 -

2000 1400 30.0 22.8 1995 - 1430 -

NOTE: PN 16 is the preferred flange PN10, PN 25 and PN 40 flanges are supplied when specified.
All socket Tees, which are used in distribution network are used up to diameter DN 300.The Flange on Double
Socket Tees is provided at the branch to fix the Valve to control the flow in the branch.

44
 Table-22
COLLARS,

Nominal dia E L d
DN
mm Mm mm mm
80 7.0 160 109
100 7.2 160 130
125 7.5 165 156
150 7.8 165 183
200 8.4 170 235
250 9.0 175 288
300 9.6 180 340
350 10.2 185 393
400 10.8 190 445
450 11.4 195 498
500 12.0 200 550
600 13.2 210 655
700 14.4 220 760
750 15.0 225 810
800 15.6 230 865
900 16.8 240 970
1000 18.0 250 1075
1100 19.2 260 1180
1200 20.4 270 1285
1400 22.8 340 1477
1600 25.2 360 1683
1800 27.6 380 1889
2000 30.0 400 2095

Note : For operational convenience collars are with mechanical joints only.

45
 Table-23
FLANGED SOCKET

Nominal dia E L d
DN
mm Mm mm mm
80 7.0 130 109
100 7.2 130 130
125 7.5 135 156
150 7.8 135 183
200 8.4 140 235
250 9.0 145 288
300 9.6 150 340
350 10.2 155 393
400 10.8 160 445
450 11.4 165 498
500 12.0 170 550
600 13.2 180 655
700 14.4 190 760
750 15.0 195 810
800 15.6 200 865
900 16.8 210 970
1000 18.0 220 1075
1100 19.2 230 1180
1200 20.4 240 1285
1400 22.8 310 1477
1600 25.2 330 1683
1800 27.6 350 1889
2000 30.0 370 2095

Note : PN10 and PN16 are the preferred flange . PN 25 and PN 40 flanges are supplied when specified.

46
 Table-24
FLANGED SPIGOT

Nominal dia DE e L
DN
mm mm mm mm
80 98 7.0 350
100 118 7.2 360
125 144 7.5 370
150 170 7.8 380
200 222 8.4 400
250 274 9.0 420
300 326 9.6 440
350 378 10.2 460
400 429 10.8 480
450 480 11.4 500
500 532 12.0 520
600 635 13.2 560
700 738 14.4 600
750 790 15.0 600
800 842 15.6 600
900 945 16.8 600
1000 1048 18.0 600
1100 1152 19.2 600
1200 1255 20.4 600
1400 1462 22.8 710
1600 1668 25.2 780
1800 1875 27.6 850
2000 2082 30.0 920

Note : PN10 and PN16 are the preferred flange . PN 25 and PN 40 flanges are supplied when specified.

47
 Table-25

BLANK FLANGES, TYPE PN 16

Nominal dia a b c D
DN
mm mm mm mm
80 19.0 16.0 200
100 19.0 16.0 220
125 19.0 16.0 250
150 19.0 16.0 285
200 20.0 17.0 340
250 22.0 19.0 400
300 24.5 20.5 455
350 26.5 22.5 520
400 28.0 24.0 580
450 30.0 26.0 640
500 31.5 27.5 715
600 36.0 31.0 840
700 39.5 34.5 910
750 41.0 36.0 970
800 43.0 38.0 1025
900 46.5 41.5 1125
1000 50.0 45.0 1255
1100 53.5 48.5 1355
1200 57.0 52.0 1485
1400 60.0 55.0 1685
1600 65.0 60.0 1930
1800 70.0 65.0 2130
2000 75.0 70.0 2345

Note : PN10 and PN16 are the preferred flange . PN 25 and PN 40 flanges are supplied when specified.

For blank flanges of nominal diameter greater than or equal to 300 Disc type blank flanges may be used.

48
 Table-26

90° DOUBLE FLANGED BEND

NOTE : The figure is schematic

Nominal e L
size
mm mm mm
80 7.0 165
100 7.2 180
125 7.5 200
150 7.8 220
200 8.4 260
250 9.0 350
300 9.6 400
350 10.2 450
400 10.8 500
450 11.4 550
500 12.0 600
600 13.2 700
700 14.4 800
750 15.0 850
800 15.6 900
900 16.8 1000
1000 18.0 1100
1100 19.2 1235
1200 20.4 1340
1400 22.8 1550
1600 25.2 1765

Note : PN10 and PN16 are the preferred flange . PN 25 and PN 40 flanges are supplied when specified.
Double Flanged 90 degree bends are not used beyond DN 300 international. For low pressure up to C 20
they may be used up to DN 1600.

49
 Table-27

45° DOUBLE FLANGED BEND

NOTE : The figure is schematic

Nominal e L
size
mm mm mm
80 7.0 130
100 7.2 140
125 7.5 150
150 7.8 160
200 8.4 180
250 9.0 350
300 9.6 400
350 10.2 298
400 10.8 324
450 11.4 350
500 12.0 375
600 13.2 426
700 14.4 478
750 15.0 504
800 15.6 529
900 16.8 581
1000 18.0 632
1100 19.2 694
1200 20.4 750
1400 22.8 775
1600 25.2 845
1800 27.6 910
2000 30.0 980

Note : PN10 and PN16 are the preferred flange . PN 25 and PN 40 flanges are supplied when specified.

50
 Table-28
90° DUCKFOOT DOUBLE FLANGED BEND

NOTE : The figure is schematic

Nominal e L c d
size
mm mm mm mm mm
80 7.0 165 110 180
100 7.2 180 125 200
125 7.5 200 140 225
150 7.8 220 160 250
200 8.4 260 190 300
250 9.0 350 225 350
300 9.6 400 255 400
350 10.2 450 290 450
400 10.8 500 320 500
450 11.4 550 355 550
500 12.0 600 385 600
600 13.2 700 450 700
700 14.4 800 515 800
750 15.0 850 550 850
800 15.6 900 580 900
900 16.8 1000 645 1000
1000 18.0 1100 710 1100
1100 19.2 1235 775 1200
1200 20.4 1340 840 1300
1400 22.8 1550 970 1500
1600 25.2 1765 1100 1700

Note : PN10 and PN16 are the preferred flange . PN 25 and PN 40 flanges are supplied when specified.
Double Flanged duck foot bends are never used beyond DN 1600.

51
 Table-29

ALL FLANGED TEES

NOTE 1 : The figure is schematic.

NOTE 2 : No value is specified for radius R but internal and external radius are equal.

Nominal dia. e e1 L H
DN dn
Body Branch
Mm mm mm mm mm mm
80 80 7.0 7.0 330 165
100 80 7.2 7.0 360 175
100 100 7.2 7.2 360 180

125 80 7.5 7.0 400 190

125 100 7.5 7.2 400 195
125 125 7.5 7.5 400 200

150 80 7.8 7.0 440 205

150 100 7.8 7.2 440 210
150 125 7.8 7.5 440 215
150 150 7.8 7.8 440 220

200 80 8.4 7.0 520 235

200 100 8.4 7.2 520 240
200 150 8.4 7.8 520 250
200 200 8.4 8.4 520 260

250 100 9.0 7.2 700 275

250 200 9.0 8.4 700 325
250 250 9.0 9.0 700 350

300 100 9.6 7.2 800 300

300 200 9.6 8.4 800 350
300 300 9.6 9.6 800 400

350 100 10.2 7.2 850 325

350 200 10.2 8.4 850 325
350 350 10.2 10.2 850 425

400 100 10.8 7.2 900 350

400 200 10.8 8.4 900 350
400 400 10.8 10.8 900 450

52
 Nominal dia. e e1 L H

DN dn
Body Branch
Mm mm mm mm mm mm
450 100 11.4 7.2 950 375
450 200 11.4 8.4 950 375
450 450 11.4 11.4 950 475
500 100 12.0 7.2 1000 400
500 200 12.0 8.4 1000 400
500 400 12.0 10.8 1000 500
500 500 12.0 12.0 1000 500
600 200 13.2 8.4 1100 450
600 400 13.2 10.8 1100 550
600 600 13.2 13.2 1100 550
700 200 14.4 8.4 650 525
700 400 14.4 10.4 870 555
700 700 14.4 14.4 1200 600
750 200 15 8.4 670 555
750 400 15 10.8 890 585
750 750 15 15.0 1275 640
800 200 15.6 8.4 690 585
800 400 15.6 10.8 910 615
800 600 15.6 13.2 1350 645
800 800 15.6 15.6 1350 675
900 200 16.8 8.4 730 645
900 400 16.8 10.8 950 675
900 600 16.8 13.2 1500 705
900 900 16.8 16.8 1500 750
1000 200 18.0 8.4 770 705
1000 400 18.0 10.8 990 735
1000 600 18.0 13.2 1650 765
1000 1000 18.0 18.0 1650 825
1100 400 19.2 10.8 980 795
1100 600 19.2 13.2 1210 825
1200 600 20.4 13.2 1240 885
1200 800 20.4 15.6 1470 915
1200 1000 20.4 18.0 1700 945

1400 600 22.8 13.2 1550 980

1400 800 22.8 15.6 1760 1010
1400 1000 22.8 18.0 2015 1040
1600 600 25.2 13.2 1600 1090
1600 800 25.2 15.6 1835 1120
1600 1000 25.2 18.0 2065 1150
1600 1200 25.2 20.4 2300 1180
1800 600 27.6 13.21 1655 1200
1800 800 27.6 15.6 1885 1230
1800 1000 27.6 18.0 2120 1260
1800 1200 27.6 20.4 2350 1290
2000 600 30.0 13.2 1705 1310
2000 1000 30.0 18.0 2170 1370
2000 1400 30.0 22.8 2635 1430

Note : PN10 and PN16 are the preferred flange . PN 25 and PN 40 flanges are supplied when specified.

53
 Table-30

DOUBLE FLANGED CONCENTRIC TAPERS

DN dn e1 e2 L
Body Branch
mm mm mm mm mm
100 80 7.2 7.0 200
125 100 7.5 7.2 200

150 125 7.8 7.5 200

200 150 8.4 7.8 300

250 200 9.0 8.4 300

300 250 9.6 9.0 300

350 300 10.2 9.6 300

400 350 10.8 10.2 300

450 400 11.4 10.8 300

500 400 12.0 10.8 600

600 500 13.2 12.0 600

700 600 14.4 13.2 600

750 600 15.0 13.2 600

800 700 15.6 14.4 600

900 800 16.8 15.6 600

1000 900 18.0 16.8 600

1100 1000 19.2 18.0 600

1200 1000 20.4 18.0 790

1400 1200 22.8 20.4 850

1600 1400 25.2 22.8 910

1800 1600 27.6 25.2 970

2000 1800 30.0 27.6 1030

Note : PN10 and PN16 are the preferred flange . PN 25 and PN 40 flanges are supplied when specified.

54
 Table-31
REDUCING FLANGE PN 16

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

Larger diameter Smaller diameter

Nomina D b c1 Nominal c2 a
l dia dia.
(DN) DN
200 340 17 3 80 3 40
200 340 17 3 100 3 40
200 340 17 3 125 3 40

350 520 22.5 4 250 3 54

400 580 24 4 250 3 54

400 580 24 4 300 4 55

700 910 34.5 5 500 4 67

900 1125 41.5 5 700 5 73

1000 1255 45 5 700 5 73

1000 1255 45 5 800 5 77

Note : PN10 and PN16 are the preferred flange . PN 25 and PN 40 flanges are supplied when specified.

55
For Sewerage :

8.2 Fittings for Gravity Sewers

8.2.1 Collars

Figure 7

The standardized DN are all those from DN 80 to DN 2000

8.2.2 Manhole connectors

Figure 8

The standardized DN are all those from DN 150 to DN 2000

8.2.4 Angle Branches

The standardized DN are all those from DN 100 to DN 500 for the body and from dn 80 to dn 250 for the
branch. The various combinations DN x dn, the types of ends (socket or spigot) and the angle a of the
branch shall be given in the manufacturer's catalogues.

56
8.2.5 Connection Branches

The standardized dn are all those from dn 100 to dn 250 for connection to pipes from DN 200 to DN 2000.
The type of end (socket or spigot) for connection with different pipe materials shall be given in the
manufacturer’s catalogues, as well as the angle of the branch and the shape of the hole to be cut in the
pipe (circular, square or rectangular).

8.2.6 Inspection Tees

Figure 12

The standardized DN are all those from DN 100 to ON 800. The types of ends (socket or spigot) shall be
given the manufacturer's catalogues as well as the shape and dimensions of the access branch

8.2.7 Access Traps

Figure 13

The standardized DN are all those from DN 150 to DN 1400. The shape and dimensions of the hole to be
cut the pipe shall be given in the manufacturer's catalogues, as well as the method of connection to the
pipe.

57
 Annex A
(informative)

External Protection

A.1 Factors characterizing aggressivity of external operating environments

Resistivity

pH

water table level

stray currents

corrosion cells

contamination

A.2 Centrifugally cast pipe coatings for protection against aggressive external operating
environments

metallic zinc with finishing layer, in accordance with ISO 8179-1;

zinc rich paint with finishing layer, in accordance with ISO 8179-2;

polyethylene sleeving, in accordance with ISO 8180;

For other types of pipe coatings, refer to national standards or pipe manufacturers.

A.3 Fittings and accessory coatings for protection against aggressive external operating
environments

polyethylene sleeving, in accordance with ISO 8180;

metallic zinc with finishing layer, in accordance with ISO 8179-1;

zinc rich paint with finishing layer, in accordance with ISO 8179-2;

For other types of fittings and accessory coatings, refer to national standards or pipe
manufacturers.
FIELD OF USE, CHARACTERISTICS OF SOILS

Ductile iron pipelines supplied with external coatings complying with 16.2 may be buried in contact with
the majority of soils, except those.

- with a low resistively, less than 1500 .cm above the water table or less than 2500 .cm below the
water table;
- with a low pH, below 6;
- with contamination by certain wastes or organic or industrial effluents.

58
In such soils, and also in the occurrence of stray currents or of corrosion cells due to external metallic
structures, it is recommended that an additional protection is used (polyethylene Sleeving or other types of
external coatings as appropriate (see Clause ).

Annex -B

ZINC OR ZINC ALLOY COATING

B.1 Fittings Surface Condition

The fitting surface shall be dry and free from rust or any non-adhering particles or foreign matter such as
oil or grease. Metallic zinc or Alloy of Zinc shall be applied on to the oxide external surface of the fitting.

Note : The zinc or alloy of Zinc is normally applied on the fitting with oxide skin but, at the
manufacturer’s option, it may applied on a blast cleaned fitting surface.

B.2 Materials

The coating materials are metallic zinc with content of at least 99% by mass. When Zinc alloy is used
manufacturer should fix the ratio of Zinc and alloying element.

B.3 Method of Application

The metallic zinc or Zinc alloy shall be applied by a spraying process in which, the metallic zinc or zinc
alloy material is heated to a molten state and projected in small droplets by spray guns onto surface. Zinc
rich paint shall be applied by spraying or a brush process onto the pipe surface in case of repair only.

B.4 Coating Characteristics

B.4.1 The metallic zinc or zinc alloy coating shall cover the outside diameter of the pipe and shall be free
from such defects as bare patches or lack of adhesion.

B.4.2 Damaged areas of zinc or zinc alloy coating caused by handling are acceptable providing that the
damage is less than 5cm² per square meter of coated surface and providing that the minor dimensions of
the damaged area does not exceed 5mm.

B.5 Zinc or Zinc Alloy Coating Mass

The average mass of zinc or zinc alloy coating shall be not less than 130g/m² with a
local minimum of 110g/m².
B.6 Determination Quantity of zinc or Zinc Alloy in the Coating

Manufacturing Process Control system shall specify the frequency of this test. A rectangular token is
attached along the pipe axis before passing it through the zinc coating equipment. After coating and
trimming the minimum token sizes shall be either.

a) 250 mm x 100 mm or
b) 500 mm x 50 mm

The average mass of zinc or zinc alloy coating M expressed in Grams per square metre, is calculated by
mass difference of the token before and after zinc or zinc alloy coating from the following formula :-

C( M 2 M 1 )
M
A
M1 and M2 are masses in Grams before and after zinc coating measured to an accuracy of 0.1g.

A is the area of the coating on the token in square meter :

C is a correction factor depending on the material of the token taking into account difference in surface
roughness between the token and the pipe surface.
The value of C shall be determined by the manufacturer and specified when required in test documents.

59
B.7 Repairs of The Zinc or Zinc Alloy Coating

Areas left uncoated e.g. under the test token and coating damaged in excess of 5cm² per sq. Meter of
coating shall be repaired by either.

1) A metallic zinc or zinc alloy spray.

2) By application of zinc rich paint containing more than 90% zinc by mass in the dried film: mean mass
of the applied paint shall not be less than 150 g/m².
3) Flanges of Welded Flanged fittin and welded parts of the flanges shall be coated with Zinc rich paints.
(90%)

B.8 Finishing Layer

After metallic zinc or zinc alloy coating or zinc rich paint coating the fitting shall be given a finishing layer
of bituminous paint or synthetic resin compatible with the zinc coating.

Any proven process, at the manufacturer’s choice, such as spraying or brush coating, may do application
of this finishing layer. It shall uniformly cover the zinc coating and be free from bare patches or lack of
adhesion.

The mean dry film thickness of the finishing layer shall not be less than 70 m with nowhere less than
50 m.

Annex-C

BITUMINOUS OR EPOXY PAINT COATING

C.1 BITUMINOUS PAINT COATING : GENERAL

Unless otherwise agreed between the purchaser and manufacturer, all Fittings shall be coated externally
with Bituminous coatings either hot applied or cold applied.

C.2 Bituminous Paint Coating : General Characteristics

C.2.1 Coating shall not be applied to any fitting unless its surfaces are clean, dry and free from rust.

C.2.2 Unless otherwise agreed between the purchaser and the manufacturer all fittings shall be coated
externally with the same material. The method of coating shall be as per usual practice of the
manufactures. The coating material shall set rapidly with good adherence and shall not scale off.

The mean thickness of the coating shall be not less than 70 m and the local minimum thickness shall be
not less than 50 m.

C.2.3 Where the coating material has a Bitumen base, it shall be smooth and tenacious and hard.

C.2.4 Fittings with or without sockets and flanges which are imperfectly coated or where the coating does
not set or conform to the required quality, the coating shall be removed and the fittings/flanges re-coated.

C.3 EPOXY PAINT COATING: GENERAL

The epoxy paint coating is to be provided if the customer specifies it.

C 3.1 Coating Thickness

Unless otherwise specified by the purchaser, the minimum dry film thickness (DFT) provided shall be
average 150 micron with minimum at one point of 130 micron. After curing but prior to lying of the
fittings, the coating shall be a continuous film, free of thin spots and other imperfections.

60
C 3.2 Coating Application: General

The fitting lining shall be applied in accordance with the manufacturer’s recommendations. Application by
airless spray equipment is preferred.

C.3.3 Fittings Preparation

The fitting exterior is to be thoroughly cleaned of all loose foreign matter with the help of clean, dry, oil free
compressed air in a manner that does not adversely affect the cleaned surface. Alternatively, vacuum
cleaning or other methods may be used in place of compressed air. Shot blasting can be used also.

C.3.4 Application of Epoxy Coating System

If more than one coat is applied, the second coat shall be applied within the time limits, surface conditions
and temperature recommended by the manufacturer. If the period between coats is exceeded, then a
repair procedure shall be obtained from the coating manufacturer and its recommendations followed.

C.4 Coating Repair

Accessible areas of fitting requiring coating repairs shall be cleaned to remove debris and damaged coating
using grinders or other means acceptable to the purchaser. The adjacent coating shall be feathered by
sanding, grinding, or other methods approved by the purchaser. Accumulated debris shall be removed by
vacuum blowing or wiping with clean rags.

Annex - D

POLYETHYLENE SLEEVING
D.1 Material

D.1.1 Characteristics

The material used for making the film is polyethylene or a mixture of polyethylene and/or ethylene and
olefin copolymers. Its density shall be between 910 and 930 kg/m³.

D.2 Dimension

D.2.1 Width : The nominal flat width of the tube or flat or flat sheet is specified in Table-D given below.

D.2.2 Thickness : The nominal thickness of the sleeving shall be not less than 200 m and not more
than 250 m unless otherwise agreed. The negative tolerance on the nominal thickness shall not exceed
10%. If necessary, it is permitted to use thicker sleeving or double sleeving.

D.3 Mechanical Properties

Tensile strength of the film in the longitudinal and transverse direction shall be not less than 8.3 MPa.

D.4 Elongation

The elongation at fracture of the film in the longitudinal and transverse directions shall be not less than
300%

D. 5 Dielectric Strength -

The Dielectric Strength of the film should be 31.5V/ m minimum.

61
 Annex - E
(informative)

Internal Protection

E 1.Factors characterizing aggressivity of raw and potable waters

pH

sulphates

magnesium

ammonium

aggressive CO2

E.2 Centrifugally cast pipe linings for protection against aggressive raw and potable waters

Portland cement mortar, in accordance with ISO 4179;

blast furnace slag cement mortar, in accordance with ISO 4179;

cement mortar with seal coat, in accordance with ISO 16132.

For other types of pipe linings, refer to national standards or the pipe
manufacturers.

E3.Fittings and accessory linings for protection against aggressive raw and potable waters

Portland cement mortar, in accordance with ISO 4179;

blast furnace slag cement mortar, in accordance with ISO 4179;

cement mortar with seal coat, in accordance with ISO 16132.

For other types of fittings and accessory linings, refer to national standards or the
pipe manufacturers.

62
 Annex - F
CEMENT MORTAR LINING

F.1 MATERIALS

F.1.1 Cement

The cement used for the lining shall conform to the existing standards on cement. The type of cement to
be used is to be mutually decided between the purchaser and manufacturer. Normal recommendation are:

I. Portland and Portland Slag cement (as per or IS:455) mortar lining perform rather well and have an
expected life of approximately 50 years in soft water with moderate amount of aggressive CO2 and
when pH is within 6 to 9. Longer service life can be obtained by increasing the mortar lining
thickness.

II. Where cement mortar lining may be exposed to sulphate attack, ordinary Portland cement should be
replaced by sulphate resisting Portland cement (as per IS:12330 or IS:6909)and or Blast Furnace Slag
Cement which has blast furnace slag more than 50 %. The sulphate concentration limit in water
which needs sulphate resisting Portland cement is approximately 3000 mg/litre, in similar
concentration blast furnace slag cements can also be used because they possess an equally good
resistance to sulphate attack in addition to other better properties.

III. The recommended type of cement used for lining are as given below:

Table F.1
Water Characteristics Portland Blast-furnace Slag Cement/ Sulfate
cement resisting Portland cements)
Minimum value of pH 6 5.5
Maximum content (mg/1) of:
Aggressive CO2 7 15
Sulfates (SO4-) 400 3000
magnesium (Mg++) 100 500
ammonium (NH4+) 30 30

F.1.2 Sand

The sand used shall have a controlled granulometric distribution from fine to coarser elements; it shall be
clean and shall be composed of inert, hard, strong and stable granular particles.

The fine fraction comprising particles passing through a sieve of aperture size 0, 125 mm shall not be
more than 10 % by mass;

The fraction comprising grains up to a maximum diameter equal to one-third of the normal thickness of
the mortar lining shall not be less than 50 % by mass.

The coarsest fraction (comprising particles which do not pass through a sieve of the aperture size closest
to half the normal thickness of the mortar lining) shall not exceed 5% by mass.

F.1.3 Water

The water used for the preparation of the mortar shall be drinking water or water of comparable quality.

F.1.4 Mortar

The mortar of the lining shall be composed of cement, sand and water.

Additives, which shall be specified, may be used, provided that they do not prejudice the quality of the
coating and that of the transported water. The mortar shall be thoroughly mixed and shall have a
consistency, which results in a dense and homogeneous lining.

The mortar shall contain by mass at least one part of cement to 3.5 parts of sand.
63
Compressive strength of mortar shall be conducted with the actual sand, cement, water ratio available in
the freshly applied lining and tested and records of each supply is maintained.

F.2 Condition of the Interior Surface of the Fitting before Application of the Lining

All foreign bodies, loose scale or any other material, which could be detrimental to good contract between
the metal and the lining, shall be removed from the surface to which the lining is to be applied.

The inner surface of fitting shall also be free of any metal projections likely to protrude beyond 50% the
thickness of the lining.

F.3 Application of the Lining

A Centrifugal spinning process or a centrifuged sprinkler or a combination of both methods applies the
cement mortar lining at works.

Apart from the inner surface of the joint, the parts of the pipe coming into contact with the transported
water shall be entirely covered with mortar.

Once centrifuging is finished, the lining shall be cured at temperatures greater than 4 C. Any loss of water
from the mortar by evaporation shall be sufficiently slow so that hardening is not impeded.

After lining, the pipe shall be transferred to a curing area in such a manner as to prevent damage to the
lining, and shall remain undisturbed for a minimum period of 24 h.

F.4 Repair of Lining

Repairs to damaged or defective areas are allowable. The damaged mortar shall first be removed from
these areas. Then using, for example, a trowel with fresh mortar so that a continuous lining having a
constant thickness is again obtained shall repair the defective part.

For the repair operation, the mortar shall have a suitable consistency, if necessary, additives may be
included to obtain good adhesion against the side of the existing undamaged mortar.

F.5 Thickness of the Lining

The normal thickness of the lining and the minimum permissible mean and local values are given in the
table-F 2. Where the fluid being conveyed is aggressive to a cement mortar, the purchaser may specify a
thicker cement mortar lining.

At the pipe ends, the lining may be reduced to values below the minimum thickness. The length of the
chamfer shall be as small as possible but, in any case, shall be less than 50 mm.

F.6 Determination of Lining Thickness

During manufacture the thickness of the lining shall be measured, about 200mm away from the end face,
on the freshly applied lining by a spear having a diameter of 1.5mm or less and controlled on the finished
hardened lining by means of a suitable gauge e.g. magnetic.

F.7 Surface Condition of the Hardened Lining

The surface of the cement mortar lining shall be uniformly smooth. Only isolated grains of sand are
allowed to appear on the surface of the lining. The lining shall be such that it cannot be dislodged with
pressure of hand and shall be free from corrugations or ridges that could reduce the thickness of the
lining to less than the minimum value at one point, as specified in the table-F2.

64
 Table-F2

All dimensions in mm
DN Thickness Maximum crack width and
Nominal Value Tolerance radial displacement
80 to 300 3.0 -1.5 0.8
350 to 600 5.0 -2 1.0
700 to 1200 6.0 -2.5 1.2
1400 to 2000 9.0 -3 1.5

NOTE :- Cement Mortar linings at pipe ends may have a chamfer of maximum length of 50mm.

On contraction of the lining, the formation of cracks cannot be avoided. These cracks, together with other
isolated cracks which may result from manufacture or may develop during transportation, are acceptable
up to a width given in the above.

Fine crazing and hairline cracks associated with cement rich surface may appear in dry linings. When
shrinkage cracks inherent to cement-bound materials have developed in the dry linings, the crack width
and the corresponding radial displacement shall not exceed the values given in Table F 2.

Storage of pipes in a hot, dry environment can cause metal expansion and mortar shrinkage, which may
result in the dry lining developing areas of disbondment, and shrinkage cracks exceeding the width given
in Table F2. When the lining is re-exposed to water, it will swell by absorption of moisture and the cracks
will close to conform to Table F 2 and will eventually heal by an autogenously process.

F.8 Seal Coat

F.8.1 General

When specified the cement lining shall be given a seal coat of approved ISI marked bituminous material or
any other epoxy based material compatible with Cement Mortar Lining. Other seal - coat materials may be
used, but they shall be agreed on at the time of purchase and shall be specified on the purchase order.

65
 Annex – G
(informative)

CALCULATION METHOD FOR EXTERNAL LOAD & HEIGHTS OF COVER FOR BURIED PIPELINES

G.1 Calculations Method

G.1.1 Calculation Formula

The method is based on an ovalization calculation according to the formula below:

100 K ( Pe Pt )
=
8S ( fxE ' )
where:

is the pipe ovalization (%);

K is the bedding factor;
Pe is the pressure from earth loading, in kilonewtons per square metre;
Pt is the pressure form traffic loading, in kilonewtons per square metre;
S is the pipe diametral stiffness in kilonewtons per square meter, see table G.1;
f is the factor of lateral pressure (f = 0.061);
E is the modulus of soil reaction, in kilonewtons per square metre.

The ovalization calculated by means of this formula should not exceed the allowable ovalization shown in the
table G.1. The allowable ovalization shown in the table G.1. The allowable ovalization increases with DN while
remaining well below the value that the internal cement mortar lining can withstand without damage; in
addition, it provides a safety factor of 1.5 with respect to the elastic limit of ductile iron in bending (500 MPa
minimum) by limiting the stress in the pipe wall at 330 MPa; finally, it is limited to 4% for DN 800.

G 1 .1.2 Pressure from Earth Loading

The pressure Pe, uniformly distributed at the top of the pipe over a distance equal to the external diameter, is
calculated according to the earth prism method by the formula below:

Pe = H
Where
Pe is the pressure from earth loading, in Kilo Newton per square meter;
is the unit weight of backfill, in Kilo Newton per cubic meter;
H is the height of cover, in meters, that is the distance from the top of the pipe to be ground surface.

In the absence of other data, the unit weight of the soil is taken as being equal to 20 kN/m3 in order to cover
the vast majority of cases. If a preliminary geotechnical survey confirms that the actual unit weight of the
backfill will be less than 20 kN/m3, the actual value may be used for determining Pe. If, however, it
appears that the actual value will be more than 20 kN/m3, the actual value should be used.

G I.1.3 Pressure from Traffic Loading

The pressure Pt, uniformly distributed at the top of the pipe over a distance equal to the external diameter,
is calculated by means of the formula below:

Pt = 40 /H (1 – 2 x 10-4 DN)
Where;
Pt is the pressure from traffic loading in Kilo Newton per square meter;
is the traffic load factor.

This formula is not valid for H < 0.3 m.

There types of traffic loading are to be considered:
- traffic areas with main roads, = 1.5: this is the general case of all roads, except access roads;
- traffic areas with access roads, = 0.75: roads where lorry traffic is prohibited;
- rural areas, = 0.5: all other cases.
66
It should be noticed that all pipelines should be designed for at least = 2 should be adopted.

G I.1.4 Bedding Factor, K

The bedding factor depends upon the soil pressure distribution at the top of the fitting (over a distance
equal to the external diameter) and at the invert of the fitting (over a distance corresponding to the
theoretical bedding angle 2 ).Probable values of K are suggested in Table – I.

G I.1.5 Factor of Lateral Pressure, f

The factor of lateral pressure , is equal to 0.061; this corresponds to a parabolic distribution of the lateral
soil pressure over an angle of 100°, according to the IOWA-Spangler model.

G I.1.6 Modulus of Soil Reaction, E

The modulus of soil reaction E, depends upon the nature of soil used in the fitting zone and upon the
laying conditions. Table I given below recommends the value of K and E depending on various trench
condition.

TableG.1 – Modulus of soil reaction

Trench type 1 2 3 4 5
Placement of embedment Dumped Very light Light Medium High
compaction compaction compaction compaction
Standard Proctor density of a >75 >80 >85 >90
sidefill
Bedding reaction angle (2) 30° 45° 60° 90° 150°
Kx 0.108 0.105 0.102 0.096 0.085
E (MPa)
Soil Group A 4 4 5 7 10
Soil Group B 2.5 2.5 3.5 5 7
Soil Group C 1 1.5 2 3 5
Soil Group D 0.5 1 1.5 2.5 3.5
Soil Group E b b b b b
Soil Group F b b b b b
a. Depending on the type of soil and its moisture content, a standard proctor density of 70% to 80%
will normally be achieved by simply dumping the soil in the trench.

b. Use and E value of 0 unless it can be ensured that a higher value will be achieved consistently.

67
 Annex - H
(informative)

Fittings wall thicknesses, stiffness and diametral deflection

H. 1 General

Ductile iron fittings can undergo large diametral deflections in operation while keeping all their functional
characteristics. Allowable pipe diametral deflections, when the pipeline is in service, are given in
Tables D.1 through Table D.7, together with their minimum diametral stiffnesses, which allow the fittings
to withstand large heights of cover and/or heavy traffic loads in a wide range of installation conditions.

H. 2 Stiffness and diametral deflection

The diametral deflection, in percent, is one hundred times the vertical fitting deflection, in millimetres,
divided by the initial pipe external diameter DE, in millimetres. The values of allowable diametral
deflection given in Table D.1 through Table D.7 apply to cement lined C20, C25, C30, C40, C50, C64, and
C100 fittings; they provide joint integrity as well as safety against overstressing of the pipe wall and
excessive cracking of the lining. The maximum allowable deflection of cement mortar lined pipe is 4 %.
Manufacturers' catalogues may introduce more stringent limitations, such as 3 %.
The diametral stiffness S of a pipe is given by the formula:
E.I E 3
S 1 000 3 1 000 e stiff /D
D 12

where
S is the diametral stiffness, in kilonewtons per square metre;

E is the modulus of elasticity of the material, in megapascals (170 000 MPa);

I is the second moment of area of the fitting wall per unit length, in millimetres to the third power;

estiff is the minimum wall thickness of the fitting (emin) plus ½ the tolerance, in millimetres;

D is the mean diameter of the fitting (DE - estiff), in millimetres;

DE is the nominal fitting outer diameter, in millimetres.

H. 3 Method of Test for Diametral Stiffness of Fittings

The test shall be carried out on a fitting section 500 mm 20 mm long, cut from the fitting Barrel. The
fitting section shall be placed on a support approximately 200 mm wide and 600 mm long, having a V
shape with an angle between 170° and 180° (see Figure D1 ). The load shall be applied at the fitting crown
through a loading beam approximately 50 mm wide and 600 mm long. Both the V support and the loading
beam shall be covered with a sheet of elastomer with a thickness of 10 mm 5 mm and a hardness
greater than or equal to 50 IRHD. Before the test, the pipe section shall be immersed in water at ambient
temperature for approximately 24 h.

The load shall be increased steadily until it reaches the test load corresponding to the minimum diametral
stiffness given in Table 10 and kept constant for 1 min. The vertical deflection of the fitting section shall be
measured, recorded and the calculated ovalization shall not exceed the allowable value given in Table G1.
In addition, the fitting section shall be visually inspected in order to check that there is no damage to the
external and internal coatings, which can affect their function.

68
 Fig D1

The load shall then be increased until the vertical deflection reaches twice the value previously
measure. The load shall be kept constant for 1 min.

Table D.1 - Diametral stiffness and allowable deflection of Class C20 fiitings

Pressure Class C20

DN DE Minimum Nominal Minimum + Minimum Allowable
Thickness Thickness ½ Tolerance Stiffness Deflection
emin enom estiff S
mm mm mm mm mm kN/m² %
700 738 5.3 7.3 6.3 9 3.80
800 842 6.0 8.1 7.05 9 4.00
900 945 6.7 8.9 7.80 9 4.00
1000 1048 7.5 9.8 8.65 8 4.00
1100 1152 8.2 10.6 9.40 8 4.00
1200 1255 8.9 11.4 10.15 8 4.00
1400 1462 10.4 13.1 11.75 8 4.00
1500 1565 11.1 13.9 12.50 7 4.00
1600 1668 11.9 14.8 13.35 7 4.00
1800 1875 13.3 16.4 14.85 7 4.00
2000 2082 14.8 18.1 16.45 7 4.00
NOTE The values of S and deflection have been calculated assuming a pipe wall
thickness equal to the minimum thickness plus half of the tolerance, to take into
account that there are only a few points with a thickness equal or close to the minimum
thickness.

69
 Table D.2 – Diametral stiffness and allowable deflection of Class25 fittings
Pressure Class C25
DN DE Minimum Nominal Minimum + ½ Minimum Allowable
Thickness Thickness Tolerance Stiffness Deflection
emin enom estiff S
mm mm mm mm mm kN/m² %
1500 1565 13.9 16.7 15.30 14 4.00
1600 1668 14.8 17.7 16.25 13 4.00
1800 1875 16.6 19.7 18.15 13 4.00
2000 2082 18.5 21.8 20.15 13 4.00
NOTE The values of S and deflection have been calculated assuming a pipe wall thickness equal
to the minimum thickness plus half of the tolerance, to take into account that there are only a
few points with a thickness equal or close to the minimum thickness.

70
 Table D.3 – Diametral stiffness and allowable deflection of Class30 fittings
Pressure Class C30
DN DE Minimum Nominal Minimum + ½ Minimum Allowable
Thickness Thickness Tolerance Stiffness Deflection
emin enom estiff S
mm mm mm mm mm kN/m² %
700 738 7.9 9.9 8.90 26 3.80
800 842 9.0 11.1 10.05 25 4.00
900 945 10.1 12.3 11.20 24 4.00
1000 1048 11.1 13.4 12.25 23 4.00
1100 1152 12.3 14.7 13.50 24 4.00
1200 1255 13.3 15.8 14.55 23 4.00
1400 1462 15.5 18.2 16.85 22 4.00
a Allowable deflection is limited to a lower value than that described in ISO 10803 for consistency of design.
NOTE The values of S and deflection have been calculated assuming a pipe wall thickness equal to
the minimum thickness plus half of the tolerance, to take into account that there are only a few
points with a thickness equal or close to the minimum thickness.

71
 Table D.4 – Diametral stiffness and allowable deflection of Class40 fittings
Pressure Class C40
DN DE Minimum Nominal Minimum + ½ Minimum Allowable
Thickness Thickness Tolerance Stiffness Deflection
emin enom estiff S
mm mm mm mm mm kN/m² %
400 429 6.1 7.8 6.95 63 3.20
450 480 6.8 8.6 7.70 61 3.30
500 532 7.5 9.3 8.40 58 3.40
600 635 9.0 10.9 9.95 57 3.50
a Allowable deflection is limited to a lower value than that described in ISO 10803 for consistency of design.
NOTE The values of S and deflection have been calculated assuming a pipe wall thickness equal
to the minimum thickness plus half of the tolerance, to take into account that there are only a few
points with a thickness equal or close to the minimum thickness.

72
 Table D.5 – Diametral stiffness and allowable deflection of Class50 fittings
Pressure Class C50
DN DE Minimum Nominal Minimum + ½ Minimum Allowable
Thickness Thickness Tolerance Stiffness Deflection
emin enom estiff S
mm mm mm mm mm kN/m² %
250 274 4.8 6.4 5.60 129 2.65
300 326 5.8 7.4 6.60 125 2.70
350 378 6.7 8.4 7.55 120 2.70
NOTE The values of S and deflection have been calculated assuming a pipe wall thickness equal to
the minimum thickness plus half of the tolerance, to take into account that there are only a few
points with a thickness equal or close to the minimum thickness.

73
 Table D.6 – Diametral stiffness and allowable deflection of Class64 fittings
Pressure Class C64
DN DE Minimum Nominal Minimum + ½ Minimum Allowable
Thickness Thickness Tolerance Stiffness Deflection
emin enom estiff S
mm mm mm mm mm kN/m² %
80 98 3.0 4.4 3.70 856 1.40
100 118 3.0 4.4 3.70 481 1.70
125 144 3.3 4.8 4.05 343 1.90
150 170 3.8 5.3 4.55 295 2.00
200 222 5.0 6.5 5.75 266 2.10
NOTE The values of S and deflection have been calculated assuming a pipe wall thickness equal to
the minimum thickness plus half of the tolerance, to take into account that there are only a few
points with a thickness equal or close to the minimum thickness.

74
 Table D.7 – Diametral stiffness and allowable deflection of Class100 fittings
Pressure Class C100
DN DE Minimum Nominal Minimum + ½ Minimum Allowable
Thickness Thickness Tolerance Stiffness Deflection
emin enom estiff S
mm mm mm mm mm kN/m² %
80 98 3.4 4.8 4.10 1179 1.25
100 118 4.1 5.5 4.80 1080 1.30
125 144 5.0 6.5 5.75 1019 1.30
150 170 5.9 7.4 6.65 956 1.35
200 222 7.7 9.2 8.45 878 1.40
250 274 9.5 11.1 10.30 844 1.40
300 326 11.3 12.9 12.10 811 1.40
350 378 13.1 14.8 13.95 797 1.45
400 429 14.8 16.5 15.65 769 1.45
450 480 16.6 18.4 17.50 767 1.45
500 532 18.4 20.2 19.30 756 1.45
600 635 21.9 23.8 22.85 737 1.50
700 738 25.5 27.5 26.50 732 1.50
NOTE The values of S and deflection have been calculated assuming a pipe wall thickness equal to
the minimum thickness plus half of the tolerance, to take into account that there are only a few
points with a thickness equal or close to the minimum thickness.

75
 Annex - I
(normative)

Quality assurance

The manufacturer has the responsibility to demonstrate the conformity of his products with this standard
by:
Carrying out type tests (see E.1); and

Controlling the quality of the manufacturing process (see E.2).

I. 1 Type tests

The type tests specified in clauses 5 and 7 of this standard are carried out either by the manufacturer or,
at his request, by a competent testing institute in order to demonstrate compliance with the requirements
of this standard. Full reports of these type tests are retained by the supplier of fittings and gaskets as
evidence of compliance.
If fittings or gaskets are supplied separately from pipes, full reports of the type tests on these components,
and their compatibility with pipes, shall be made available to the client by the fittings or gaskets suppliers.

I.2 Quality control

The manufacturer controls the quality of his products during their manufacture by a system of process
control in order to comply with the technical requirements of this standard.
It is recommended that the manufacturer’s quality system conforms to ISO 9001.
If third party certification to ISO 9001 is involved, it is recommended that the certification body is
accredited to relevant international standard, as applicable.

76
 Annex - J
(informative)

Safety factors

The following safety factors are used in the design for minimum thicknesses for ductile iron pipes:

Table J.1 - Safety factors for ductile iron fittings

Design criteria Safety factor Mechanical property
PFA 3.0 Minimum ultimate tensile strength of 420
MPa
PMA 2.5 Minimum ultimate tensile strength of 420
MPa
External loads 1.5 Yield bending strength of 500 MPa.

77
 Annex – K
(informative)

In the absence of other data, the unit weight of the soil is taken as being equal to 20 kN/m3 in order to cover
the vast majority of cases. If a preliminary geotechnical survey confirms that the actual unit weight of the
backfill will be less than 20 kN/m3, the actual value may be used for determining Pe. If, however, it
appears that the actual value will be more than 20 kN/m3, the actual value should be used.

K I.1.3 Pressure from Traffic Loading

The pressure Pt, uniformly distributed at the top of the fitting over a distance equal to the external
diameter, is calculated by means of the formula below:

Pt = 40 /H (1 – 2 x 10-4 DN)
Where;
Pt is the pressure from traffic loading in Kilo Newton per square meter;
is the traffic load factor.

This formula is not valid for H < 0.3 m.

There types of traffic loading are to be considered:
- traffic areas with main roads, = 1.5: this is the general case of all roads, except access roads;
- traffic areas with access roads, = 0.75: roads where lorry traffic is prohibited;
- rural areas, = 0.5: all other cases.

It should be noticed that all pipelines should be designed for at least = 2 should be adopted.

K I.1.4 Bedding Factor, K

The bedding factor depends upon the soil pressure distribution at the top of the fitting (over a distance
equal to the external diameter) and at the invert of the fitting (over a distance corresponding to the
theoretical bedding angle 2 ).Probable values of K are suggested in Table – I.

K I.1.5 Factor of Lateral Pressure, f

The factor of lateral pressure , is equal to 0.061; this corresponds to a parabolic distribution of the lateral
soil pressure over an angle of 100°, according to the IOWA-Spangler model.

K I.1.6 Modulus of Soil Reaction, E

The modulus of soil reaction E, depends upon the nature of soil used in the fitting zone and upon the
laying conditions. Table I given below recommends the value of K and E depending on various trench
condition.

TableK.1 – Modulus of soil reaction

Trench type 1 2 3 4 5
Placement of embedment Dumped Very light Light Medium High
compaction compaction compaction compaction
Standard Proctor density of a >75 >80 >85 >90
sidefill
Bedding reaction angle (2) 30° 45° 60° 90° 150°
Kx 0.108 0.105 0.102 0.096 0.085
E (MPa)
Soil Group A 4 4 5 7 10
Soil Group B 2.5 2.5 3.5 5 7
Soil Group C 1 1.5 2 3 5
Soil Group D 0.5 1 1.5 2.5 3.5
Soil Group E b b b b b
Soil Group F b b b b b
c. Depending on the type of soil and its moisture content, a standard proctor density of 70% to 80%
will normally be achieved by simply dumping the soil in the trench.
d. Use and E value of 0 unless it can be ensured that a higher value will be achieved consistently.

78