Dossier Guanghua Casting Pipe

SHANXI NEW GUANGHUA CASTING PIPE CO., LTD.

TECHNICAL DOSSIER / GUANGHUA PIPES
TECHNICAL DOSSIER
GUANGHUA PIPES
Your first choice for water project
01 COMPANY PROFILE 02 TYPE OF JOINT
EXTERNAL ANTI-CORROSION INTERNAL ANTI-CORROSION

03 COATING 04 COATING
05 MANUFACTURING PROCESS AND

COATING REPAIRS 06 QUALITY CONTROL SYSTEM
REQUIREMENTS FOR STORAGE

07
AND TRANSPORTATION
1
COMPANY PROFILE
PART 01
PART 01
2
FACTORY GATE OFFICE BUILDING
GARDEN LIKE FACTORY FOUNDRIES
DN2600 CENTRIFUGAL CASTING ZINC SPRYING
3
COMPANY PROFILE
Shanxi New Guanghua Casting Pipe Co., Ltd. (formerly Shanxi Guanghua Casting Pipe Co., Ltd.)
established from the year of 2002 with more than 1500 employees, a group company gathering Coking plant,
Metallurgical plant, power plant, and Ductile Iron Pipes & fittings manufacturing plant...
GUANGHUA Pipes an over 15 years leading large scale manufacturer which specialized in the production of
Centrifugal casting Ductile Iron Pipes & fittings products, foundries located at Shanxi Province, China, which
is rich resource of coal & iron.
Now the company owns five production lines to produce the Ductile Iron Pipes size ranging from DN80 to
DN2600, and it's annual production capacity is 450,000 tons.
With global vision, GUANGHUA Pipes steps into rapid development, our products are widely used in
municipal engineering, water supply and drainage projects and large-scale water diversion projects and
export to over 40 countries around the world.
The company passed ISO9001 / ISO14001 / OHSAS18001 Management system certifications, and
obtained ISO2531/ISO7186/EN545/ EN598/ ISO4179/ ISO8179 Product conformity certifications, and
WRAS/ACS non-toxic certifications.
Guanghua Pipes had been awarded the "National Trustworthy Enterprise" Entitled " China Foundry Pioneer
Enterprise“, “AAA Credit Enterprise of China Foundry Association , "GUANGHUA" brand Ductile Iron Pipes
are the China Well Known Brand, Shanxi Province Famous trademark, and Shanxi Province Noted Brand.
Guanghua Pipes is not only a pipe supplier, but a team of engineers and technicians committed to provide
solutions from the start to the successful completion of the project.
Water is important for life, it's our mission to deliver safe, healthy and pure water to the world.
GUANGHUA Pipes, reliable partner you can rely on.
4
TYPE OF JOINT
PART 02
5
Ductile iron material features similar mechanical properties with carbon steel, such as high mechanical
strength and good ductility, and the same anti-corrosion performance as cast iron. Therefore, ductile iron
pipe has gradually become one of the most secure and reliable pipes in the water supply and drainage area
throughout the world.
Shanxi New Guanghua Casting Pipe Co., Ltd.

provides ductile iron pipe products ranging
from DN80 ~ DN2600 in accordance with ISO
2531/ISO 7186 or EN 545/EN 598.
Meanwhile, it can provide the most
appropriate joints and internal and external
anti-corrosion solutions according to the
pipeline laying and using conditions.
For details, see the table below:
Table: Ductile Iron Pipes Joint and Anti-corrosion Solutions

Anti-corrosion coating
Joint type Specification range
Internal lining External coating
T-type joint DN80~2000

Flexible joint XT2-type joint DN80~2600 Cement mortar lining Zinc + high chlorinated
TF joint DN80~1200 Cement mortar lining + polyethylene finishing
Self-anchored Xanchor joint DN1400~2600 epoxy seal coat layer
joint
Rigid Welded flange DN80~2000 Polyurethane lining Zinc+epoxy coating
joint
XTJ jacking pipe DN250~2000 Ceramic epoxy linning Polyurethane coating
6
Relevant standards:
ISO2531: 2009, specifies the requirements and test methods applicable to ductile iron pipes, fittings,
accessories and their joints for the construction of pipelines
ISO2531: 1998, Ductile iron pipes, fittings, accessories and their joints for water or gas applications
ISO 4016, Hexagon head bolts — Product grade C
ISO 4034, Hexagon nuts — Product grade C
ISO 4633, Rubber seals — Joint rings for water supply, drainage and sewerage pipelines — Specification
for materials
ISO 6506-1, Metallic materials — Brinell hardness test -– Part 1: Test method
ISO 7005-2, Metallic flanges — Part 2: Cast iron flanges
ISO 7091, Plain washers — Normal series — Product grade C
ISO 10803, Design method for ductile iron pipes
ISO 10804, Restrained joint systems for ductile iron pipelines — Design rules and type testing
EN545: 2010, Ductile iron pipes, fittings, accessories and their joints for water pipelines —Requirements
and test
methods
BS EN545: 2006, Ductile iron pipes, fittings, accessories and their joints for water pipelines - Requirements
and test methods
ISO8179-1: 2004 Ductile Iron Pipes——The external zinc coating Part 1：Metallic zinc with finishing layer
ISO8179-2: 1995 Ductile Iron Pipes—— The external zinc layer coated Part 2:Zinc rich paint with finishing
layer
EN 1092-2, Flanges and their joints — Circular flanges for pipes, valves, fittings and accessories, PN
designated — Part 2: Cast iron flanges
EN 196-1, Methods of testing cement — Part 1: Determination of strength
EN 197-1, Cement – Part 1: Composition, specifications and conformity criteria for common cements
EN 681-1, Elastomeric seals — Material requirements for pipe joint seals used in water and drainage
applications — Part 1: Vulcanized rubber
EN 805:2000, Water supply — Requirements for systems and components outside buildings
EN 1092-2, Flanges and their joints — Circular flanges for pipes, valves, fittings and accessories, PN
designated — Part 2: Cast iron flanges
EN 1333:2006, Flanges and their joints Pipework components — Definition and selection of PN
EN 14901, Ductile iron pipes, fittings and accessories — Epoxy coating (heavy duty) of ductile iron fittings
and accessories — Requirements and test methods
EN ISO 4016, Hexagon head bolts — Product grade C (ISO 4016:1999)
EN ISO 4034, Hexagon nuts — Product grade C (ISO 4034:1999)
EN ISO 6506-1, Metallic materials — Brinell hardness test — Part 1: Test method (ISO 6506-1:2005)
EN ISO 6892-1, Metallic materials – Tensile testing – Part 1: Method of test at room temperature (ISO
6892-1:2009)
EN ISO 7091, Plain washers — Normal series — Product grade C (ISO 7091:2000)
EN ISO 9001:2000, Quality management systems — Requirements (ISO 9001:2000)
BS 3416:1991. Specification for bitumen-based coatings for cold application
7
Ductile iron pipe wall thickness

Guanghua ductile iron pipes can be graded by the wall thickness class coefficient K or pressure class C.
Standards are as following:
ISO 2531/ISO 7186
GB/T 13295, GB/T 26081
EN 545/EN 598 and other related standards for ductile iron pipes
Note: The wall thickness class coefficient K (or pressure class C) shall be specified in the agreement
between the supplier and the purchaser.
—— Graded by wall thickness class coefficient K

The nominal wall thickness of ductile iron pipe is calculated as a function of nominal diameter DN, and the
calculation formula is as following:
enom = K (0.5 + 0.001DN )

Where: enom—— Nominal wall thickness(mm)
DN —— nominal diameter (mm)
K —— Wall thickness class coefficient, selected from a series of whole numbers ... 9,10,11,12 ...
The minimum nominal wall thickness of centrifugal casting ductile iron pipe is 6mm, and the minimum wall
thickness of non-centrifugal casting ductile iron pipe and fittings is 7 mm; the tolerance on thickness for pipes
and fittings is shown in the table below.
Table 2 Limit Deviation on Nominal Wall Thickness for Pipes and Fittings
Dimensions in millimeters
Type of casting e Limit Deviation

6 -1.3
Pipes centrifugally cast
＞6 -(1.3+0.001DN)
Pipes non-centrifugally cast and 7 -2.3
fittings ＞7 -(2.3+0.001DN)
—— Graded by pressure class C

When the ductile iron pipes are classified by pressure class C, its allowable operating pressure is expressed
by Arabic numerals prefixed by the letter C, and its unit is bar. Minimum wall thickness of the pipe is
calculated by the allowable operating pressure. The formula is as following:
PFAxFxDE
emin =
20  Rm + PFAxSF
Where: emin ——Minimum wall thickness of pipe (mm)
PFA——Allowable operating pressure (bar)
SF —— Safety factor of PFA (SF = 3)
DE —— External diameter of pipe, (mm)
8
Rm —— Minimum tensile strength of ductile iron pipe, (MPa Rm=420 MPa)
For pipes centrifugally cast, the minimum wall thickness shall not be less than 3mm;
for pipes non-centrifugally cast, the minimum wall thickness shall not be less than 4.7 mm; the tolerance on
thickness for pipes is shown in table 3.
Specification range for preferred pressure class of C-class pipes are shown in Table 4.
Table 3 Tolerance on Wall Thickness For

C-class Pipes and Fittings
Type of casting Tolerance

Pipes centrifugally cast +(1.3+0.001DN)
Pipes non-centrifugally cast and fittings +(2.3+0.001DN)
Table 4 Specification Range for Preferred Pressure Class

of C-class Pipes
Preferred pressure
Specification range
class
DN80 - DN300 C40
DN350 - DN600 C30
DN700 - DN2600 C25
9
T-type joint ductile iron pipe

Joint description
Joint structure
—— Sealing principle
Structure of T-type joint is shown in Figure 1. During joint installation, the external spigot is extruded on the
rubber ring inside the socket. The compression deformation can generate a certain degree of contact
pressure. And it is the so-called self-sealing action of the rubber ring that keeps the joint tight. The selfsealing
effect means, when the rubber ring is under the fluid pressure, the actual contact pressure on the rubber ring
is the sum of the contact pressure of the pre-compressed rubber ring and the new contact pressure on the
rubber ring brought by the fluid pressure. Since the contact pressure is higher than the fluid pressure, so that
the joint is well tightened.
—— Joint features
The joint features simple structure, easy installation and sound
sealing performance. The positioning of sealing ring and
deflection of joint are taken into consideration during socket
structure design. By controlling the insertion depth of the
spigot, the joint can have certain axial flexibility. Therefore this
type of joint is able to adapt to certain foundation settlement,
while long-distance deflection of pipeline can be achieved
through its deflection angle θ. Joint deflection installation is Joint deflection
shown in Figure 2.
The rubber ring consists of two parts, i.e. the hard rubber and soft rubber. The hard rubber can support and
align the pipe joints, and greater thrust is needed during installation. T-type Joint is unable to prevent pipe
slippage, therefore the concrete blocks to resist the axial forces should be set at the bend of pipeline, or
certain length of self-anchored joint ductile iron pipe should be laid.
—— Application field
Pressure/non-pressure water supply (potable water, sewage, etc.) pipeline;
belowground/aboveground laying, and the pipe laying slope does not exceed 20% (aboveground) or 25%
(belowground).
10
Technical parameters
The main technical parameters of T-type joint ductile iron pipe
T Type joint Ductile Iron Pipes
K9 C-class1
Lu
DN DE D P θ enom PFA enom PFA
mm
mm bar mm bar
80
mm
98
mm
140
mm
85
° 6 64 4.4
100 118 163 88 6 64 4.4
125 144 190 91 6 64 4.5
150 170 217 94 6 64 4.5
200 222 278 100 6.3 62 4.7
250 274 336 105 6.8 54 5.5
4 40
300 326 393 110 7.2 49 6.2
350 378 448 110 7.7 45 6.3
400 429 500 110 8.1 42 6.5
450 480 540 120 8.6 40 6.9
500 532 604 120 9 38 7.5
3 30
600 635 713 120 9.9 36 8.7
700 738 824 150 10.8 34 8.8
6000
800 842 943 160 11.7 32 9.6
900 945 1052 175 12.6 31 10.
1000 1048 1158 185 13.5 30 6
11.
1100 1152 1270 202 14.4 29 6
12.
1200 1255 1378 217 15.3 28 6
13.
1400 1462 1600 242 17.1 28 6
15.
1500 1565 1710 253 18 27 7
16.
1600 1668 1821 266 18.9 27 7
17.
2 25
1800 1875 2043 297 20.7 26 7
19.
6000/81
2000 2082 2262 319 22.5 26 7
21.
50
1 C-Class pipe of preferred pressure class complying with ISO 2531-2009 8
11
TF Self-anchored joint ductile iron pipe
Joint description
TF self-anchored joint structure
—— Joint structure
As shown in Figure 6, TF self-anchored joint adopts the T-type joint sealing structure. Compared with T-type
joint, it adds a welded bead on spigot, an open-end locking ring, a special gland and connecting bolts to
provide
the joint with good anti-slippage performance. The locking ring and the gland can slide between each other,
so that the joint has certain axial stretching and deflection capability.
—— Working principle
The axial thrust forces generated at the bending places and tees of the pressure pipeline will cause the
socket and spigot components to have relative displacement. Axial stress generated at spigot is passed on
to the socket through welded bead, locking ring, gland and connecting bolts, enabling the transmission of
axial stress to equip the joint with good anti-slippage performance. When the friction between the restrained
pipeline and its surrounding soil is greater than the axial stress generated inside the pipe, safe operation of
the pipeline can be guaranteed, thus avoiding the set-up of concrete block.
In the following conditions, certain length of pipeline with TF-joints could be applied in order to prevent
pipeline slippage:
1. Places such as bends, tees, reducers and plugs, etc;
2. When the pipeline laying slope exceeds 20% (aboveground) or 25% (belowground);
3. When it is uneconomical (such as large-diameter high-pressure pipelines, etc.) or unable to set concrete
buttress, for example:
A. The construction site is too narrow; there is no space to set up specified concrete block;
B. Construction schedule is tight.
12
The technical parameters of TF self-anchored joint ductile iron pipe are shown as below:
P Lu
TF Self anchored joint Ductile Iron Pipes
Technical Parameters of TF Self-anchored Joint Ductile Iron Pipe

K9
DN DE DGland P θ Lu enom PFA1
mm mm mm ° mm mm bar
80 98 243 85 6
100 118 264 88 6
150 170 321 94 6
200 222 375 100 6.3
250 274 433 105 6.8
2 30
300 326 509 110 7.2
350 378 567 110 7.7
400 429 591.6 110 8.1
450 480 675 120 8.6
500 532 700 120 9
1.5
600 635 811 120 9.9
700 738 935 150 10.8
25
800 842 1048 160 6000 11.7
900 945 1158 175 12.6 23
100 1048 1308 185 13.5 22
0
110 1152 1420 200 14.4 21
1
0
120 1255 1539 215 6000/8150 15.3 20
0
1 By adjusting the wall thickness class of the pipe and material of connecting bolts, etc., PFA of TF joint
can reach 25bar. Please consult us for detailed technical parameters.
13
1.5 Xanchor self-anchored joint ductile iron pipe
1.5.1 Joint description
Xanchor self-anchored joint Ductile Iron Pipes
—— Joint structure
Xanchor self-anchored joint, as shown in Figure8, adopts the sealing structure of XT2-type joint. Its socket is
designed to have two annular chambers, i.e. sealed chamber and anchoring chanber. The sealed chamber
is where the sealing ring is set, and the stopper chamber is used to house the self-anchored components
which are comprised of the front blocks, the rear blocks, the supporting ring and welded bead.
—— Working principle
Working principle of Xanchor joint is quite different from that of the traditional self-anchored joint. The
essential mechnism is to effectively prevent slippage through the two rows of rigid blocks. Meanwhile,
the circular sliding of the front and rear rows of blocks along the stopper chamber provides the joint with
greater flexibility. Compared with other self-anchored joint, Xanchor joint features simpler structure, easier
installation, better anti-axial-splippage performance and flexibility.
The same with TF joint, please refer to Joint description – Application Field.
14
1.5.2 Technical parameters:
K9
DE D P θ Lu
DN mm mm mm ° mm enom PFA1
mm bar
1400 146 160 328 1. 17.1 19

1500 2
156 2
171 342 2
1. 18 18
1600 5
166 4
182 361 1
1. 18.9 17
1800 8
187 4
204 408 1
1. 20.7 16
8000
2000 5
208 5
227 425 0
0. 22.5 15
1 By increasing 2 the wall thickness
6 8
class of the pipe and material of connecting bolts, etc., PFA of TF
joint can reach 25bar. Please consult us for detailed technical parameters.
15
Flange welded joint ductile iron pipe
Joint description
Figure Flange welded joint structure
—— Sealing principle
Structure of Flange-joint is shown in above Figure, Its sealing is realized through the flange’s compressing
the sealing ring, which is achieved by fastening the bolts.
—— Joint features and application field

Flange joint is rigid joint with sound sealing performance. It is usually used in the following places, such as
the connection with pumps, valves, fire hydrant as well as crossing foundation, walls and so on.
Guanghua can provide flange (welded) components ranging from DN80 ~ DN2000. Length of flanged pipe
and the number and position of puddle flange would be customized according to customer requirements. For
detailed product information, please refer to Table 9.
Standards for Flange: ISO 7005-2 or EN 1092-2
Table 9 Flange welded Pipe Catalogue
Name Symbol Name Symbol
Double-spigot pipe with

Double flanged pipe
puddle flange
Double flanged pipe with puddle Socket-spigot pipe with

flange puddle flange
Flanged spigot pipe Flanged socket pipe
16
Flange spigot pipe with puddle Flanged socket Pipe with

flange Puddle Flange
Allowable operating pressure for welded flanged pipes of K9:

DN80~DN1200 PN10/PN16/PN25
DN1400~DN1600 PN10/PN16
DN1800~DN2000 PN10
17
XTJ ductile iron jacking pipe
Product description
Figure: Ductile Iron Jacking pipe structure
—— Pipe structure
XTJ jacking pipe, as shown in above Figure, is to make a tubular reinforced concrete protective jacket on the
external wall of T-type joint pipe. There’s a jacking flange welded on the spigot of the pipe. During the pipe
jacking, the pushing force is evenly passed from the flange with ribbed plate welded at the spigot to the
socket, thus ensuring the pushing operation will not cause deformation of the spigot and will not damage the
outer protective sleeve;
XTJ jacking pipes are applied when the pipeline need to cross obstructions such as roads, railways, rivers
and buildings, while trench excavation is not allowed or difficult to prepare on the construction site.
XTJ jacking pipe adopts T-type flexible joint. It features sound sealing performance, faster installation, more
reliable internal and external anti-corrosion coating, and is adaptive to various soil environments and different
transmitted media.
Technical parameters of XTJ jacking pipes are shown as below:
18
Lu
Figure: XTJ Ductile Iron Jacking pipe

Dimensions Allowable jacking force
Wall thickness DE D A Total weight

Lu mm kN
DN class mm mm mm kg Tonf
4000 518
250 274 344 100 920 94
6000 773
4000 639
300 326 399 105 1240 127
6000 953
4000 767
350 378 450 105 1270 129
6000 1145
4000 907
400 429 504 105 1350 138
6000 1353
4000 1046
450 480 553 115 1560 159
6000 1556
4000 1268
500 532 618 115 1910 195
6000 1890
4000 1626
600 635 728 115 2720 278
6000 2423
4000 2281
700 738 853 145 2720 277
6000 3385
4000 2661
800 842 959 155 3300 337
6000 3992
4000 3171
900 945 1067 170 4140 422
6000 4706
4000 3685
1000 1048 1173 180 5080 518
6000 5376
4000 5046
1200 1255 1400 210 7240 739
K9 6000 7349
4000 6154
1400 1462 1604 237 9020 920
6000 8963
4000 7749
1600 1668 1825 261 12360 1261
6000 11255
4000 9523
1800 1875 2047 292 12360 1261
6000 13826
4000 11352
2000 2082 2266 314 16970 1731
6000 16459
The jacking pipe with grouting hole can be provided according to customer requirements;
We could also supply jacking pipe with other wall thickness class. Please contact us for detailed technical parameters.
19
EXTERNAL ANTI-CORROSION
COATING
PART 04
20
External anti-corrosion coating
Soil aggressivity
Soil aggressivity evaluation

Pipelines buried will be exposed to various corrosive elements, including the aggressive soil and backfilled
soil, and soil polarity caused by local topographical and backfilling. Therefore, technicians should familiarize
themselves with the topographical and geography of the targeted area through topographical map, based
on which initial analysis shall be formed on the corrosivity of the soil. Then, through on-site examination,
further analysis shall be made. Finally, through lab-test of the sample soil, precise judgement will be made.
⚫ Data collection
—— Collect the topographical information for the area of pipeline burrial, such as the distribution and
altitudes of level ground, hills, swamp lands, paddy fields, rivers and beaches, soil types of various regions,
transitional areas of two different soils and the terrains with great changes. For example, in the dry area in
high altitude, the soil tends to be less aggressive; while in damp areas in low altitude such as ponds, lakes,
marshes and peat beds, the soil tends to be more aggressive due to rich humic acid and anaerobes. In the
river mouths, lowland, marshes, saline and alkaline lands and other regions along the sea, the aggressivity
of soil is probably high.
—— Collect potential corrosive elements for the embedded ductile iron pipes along the pipeline, including
corrosive sewage discharged from livestock farms, wineries, paper mills and other factories, or from local
residence.
—— Collect potential disturbing power sources near the pipelines that probably corrode ductile iron pipes,
such as power plants, substations, HV transmission lines, and other forms of DC and AC interfering power
sources.
—— Gather local meteorological data, including maximum and minimum temperature, average temperature
per year, soil temperature at the burial depth of ductile iron pipes, soil freezing depth, underground water
level, rainfall volume and sunlight intensity, etc.
—— A report shall be issued with information mentioned above for the reference of designers.
⚫ Site surveys
—— The selection of site surveys shall be based on following principles:
a. At least 2 test points shall be chosen for every soil type;
b. For the same type of soil, one test point shall be chosen every 400~500m;
c. Test points shall be typical for the topographical features of the area along the pipeline;
d. Mark test points on the general pipeline layout plan to make a soil survey test point distribution
—— Identify soil texture, color and appearance
—— Investigate the status of underground water and backfill soil
—— Soil resistivity test: soil resistivity, as an important index of evaluating soil aggressivity, is a
comprehensive factor of soil water content and salt content, and reflects soil conductivity. In general, the
smaller the soil resistivity is, the stronger the soil aggressivity is. AC quadrupole test method is adopted on
the site.
21
—— ORP test (Eh7): oxidation reduction potential is an index that can reflect comprehensively oxidation
reduction degree, which has a lot to do with the activity of bacteria in the soil. To certain extent, the lower
Eh7 is, the greater corrosive action of sulphate reducing bacteria on metals is. Therefore, oxidation
reduction potential can become an index of soil microbiological corrosion under the condition of strong
reducibility.
⚫ Laboratory analysis
Laboratory analysis is supplementary to the analysis mentioned above. Chemical analysis conducted in the
laboratory mainly includes the following items:
pH value, total soluble salt, moisture content, soil bulk density, air content, Cl-, SO4 2-, S2-, microorganisms,
etc.
Selection of external coating

Zinc coating is the basic external coating solution provided by Guanghua. It features satisfactory
anti-corrosion performance in most of the soil environments. However, in strong corrosive soil where zinc
coating would not be enough, PE sleeve will be used as additional anti-corrosive coating; or special coatings
and other strong anti-corrosion methods shall be taken to protect the pipelines. Guanghua can help
customers design cost-effective external anti-corrosion solutions for pipelines that can fulfill requirements of
the soil environment. Table below is a proposed anti-corrosion coating solution based on different corrosion
levels of the soil.
Table: External Coating Solution for Soils at Different Corrosion Levels
Corrosion level Pipelines

generality (most of the soil belongs to Zinc+HCPE finishing layer
this level)
Zn-Al rare earth alloy + blue epoxy
corrosive
coating Zinc + HCPE finishing layer
+ PE sleeve
highly corrosive special coating (PU coating)
22
1. Zinc+ bitumen finishing layer

—— Product description
Zinc coating used as external protection has proved to be one of the most effective anti-corrosion solutions
throughout the world. It can prolong the service life of pipelines. Standard anti-corrosion coating provided by
Guanghua is metallic zinc coating applied by electric arc (C-class pipe 200g/m2, K-class pipe 130g/m2). A
Bitumen finishing layer of at least 70um thickness will be sprayed outside the zinc coating.
Finishing layer
Metallic zinc
Cast iron pipe
—— Anti-corrosion mechanism
⚫ Active anti-corrosion : Sacrifice zinc anode to protect ductile iron cathode.
⚫ Stable protective layer: Zinc will corrode gradually to generate insoluble zinc salt in the process of
contacting with environmental soil, which will tightly adhere to the pipe walls so as to form a layer of
continuous, tight and insoluble protective film that is impermeable
Figure: Porous structure of the coating solution of Zinc+HCPE

finishing layer
The porous finishing layer sprayed on zinc coating also plays an important role. It is good for cathodic
protection and self-healing, and also for converted products of zinc to generate stable and tight insoluble
protective film.
⚫ Self-healing of damaged zinc coating: Some pipes may be locally damaged probably during
transportation
or installation. Zinc will transform into zinc ion rapidly under the action of primary cells. Zinc ion can migrate
through pores of finishing layer and cover the damaged portions, generating stable and insoluble protective
23
layer, as shown below:
In short, zinc coating plays an important role of anti-corrosion: on one hand, it will generate tight insoluble
protective film which will adhere to pipe walls, thereby reducing electrochemical corrosion to great extent;
on the other hand, the anti-corrosion performance of zinc coating and finishing layer also is reflected on
their mutual action. There is excellent adhesiveness between zinc and cast iron & zinc and finishing layer,
forming a complete protective screen between pipe and the external environment, and preventing
anticorrosion failure.
This kind of coating is applicable to most of the soil environments with slight aggressivity.
24
2. Zn-Al + blue epoxy coating

Zn-Al (85Zn15Al) alloy is sprayed on the surface of ductile iron pipes by electric arc with the coating mass of
400g/m2; epoxy coating (at least 100μm in thickness) is sprayed on the alloy coating so as to form active
anti-corrosion coating. Coating structure is shown in Figure below.
Epoxy coating
Zn-Al rare earth alloy
Cast iron pipe Cement mortar lining
⚫ Active anti-corrosion: Just like pure zinc, Zn-Al alloy is also a kind of active anti-corrosion coating.
⚫ Stable protective layer: Being similar with zinc coating, a layer of continuous, impermeable and insoluble
protective film that is hardly penetrated forms on ductile iron pipe walls. Aluminum in the alloy features
inactivation, and it can reduce the consumption rate of zinc even in the soil with high corrosivity;
Figure: Porous structure of the coating solution of Zn-Al rare earth alloy + blue epoxy coating
—— Advantages of Zn-Al rare earth alloy coating

Due to the addition of rare earth, Zn-Al rare earth alloy coating features the following advantages compared
with Zn-Al alloy coating:
⚫ Reinforcement effect
With strong chemical activity, rare earth element can react with many elements in Zn-Al alloy to generate
intermetallic compounds with strong hardness. Distributed in crystal boundary in a mesh pattern, these
compounds can hinder creep slip, thereby improving the hardness and wear-resistant property of alloy
25
coating to prolong the service life significantly.
⚫ Refining effect
During solidification of the coating, rare-earth element can reduce the surface tension of plating solution
to increase the crystal core so as to refine the crystalline grains. Such fine eutectic structures can prevent
the extension of cracks, even the structures and eliminate bare spots on the surface of coating. This is
the important mechanism of rare earth to improve the plasticity and flexibility of the coating, and it is also a
special feature of the rare-earth alloy coating.
⚫ Anti-corrosion performance
Re element can refine microstructure of the coating and reduce its porosity. Meanwhile, it can strengthen
Zn-Al alloy coating. Therefore, addition of a small amount of Re element can further improve the anti-
corrosion performance of Zn-Al alloy coating.
Zn-Al alloy coating is an enhanced anti-corrosion solution. It is applicable to the soil with strong aggressively
(i.e. soil with low resistivity, soil influenced by underground water or mixed soil), where PE sleeve is not
needed, except the following situations:
⚫ Acid peat soil;
⚫ Soil containing garbage, oxide skin and slag, or soil polluted by waste water and industrial effluent;
⚫ Soil below the sea level and with resistivity less than 500Ω•cm.
When applied to the soil types listed above, including the one with stray current, other type of external
coatings (such as PU coating) will be recommended.
26
3. Polyurethane coating
—— Product description:
PU coating of ductile iron pipe and fitting is formed by the PU material sprayed and cured on the surface of
pipe/fitting that is bi-component, solvent-free and 100% solid. This kind of coating has excellent anticorrosion
performance, high impact resistance and wearing resistance, which is applicable to the soil with very strong
aggressivity and all other types of the soil.
Epoxy coating PU coating

Ductile iron pipe wall
Coating thickness is as specified in Table 12

Location Adopted material Average thickness Minimum thickness
pipe body PU coating 900 700
socket and spigot epoxy coating 250 200
Requirements for material

PU coating: complying with EN 15189.
Epoxy coating: complying with EN 14901 and certified by WRAS for BS 6920.
—— Standards:
ISO 2531, GB /T 13295 and EN 545
Specification range
Products ranging from DN80 ~ DN2600.
27
4. Polyethylene sleeve
—— Product description:
PE sleeve is the Polyethylene or a mixture of polyethylene and/or ethylene and olefin copolymers sleeve
(film)
with thickness of 0.2mm that is wrapped on external walls of the pipe on the construction site. It can prevent
direct contact between cast iron pipes and the soil. Meanwhile, it also prevents underground moisture from
corroding the pipelines. It is used to supplement the basic pipe coating (metalic Znic + HCPE finishing layer)
in certain case of highly corrosive soils or in the presence of stray current.
⚫ Requirements for material

The properties of polyethylene sleeve listed in table 14:
Table 14 Properties for PE Sleeve (film)
Test item Test result Test standard
Thickness(μm) ≥200 ISO 8180
Material density(kg/m3) 910~935 ISO 1183-1
Impact resistance(g) ≥900 ISO 7765-1 Method A
Tensile strength(MPa) ≥20 ISO 527-3 Type 2
Elongation(%) ≥500 ISO 527-3 Type 2
Propagation and tear resistance/(N) ≥20 ISO 6383-2
⚫ Specification range
This kind of anti-corrosion coating is applicable to ductile iron pipes of all sizes.
The anti-corrosion mechanisms for PE sleeve (film) wrapped outside zinc coating are as following:
⚫ First of all, PE sleeve can separate the pipelines from corrosive soil and inhibit the generation of
electrochemical cell. At the same time, it can also isolate stray current.
⚫ The PE sleeve is a kind of anti-corrosion method whose performance is achieved through the changing
of corrosive environment: it can change the corrosive environment from non-homogeneous soil with strong
aggressivity into one that is homogeneous with weak aggressivity.
—— Application fields
It is suggested to adopt this kind of protective layer for corrosive soil, for example:
⚫ Soil with low resistivity (with indicator of high aggressivity);
⚫ Regions with stray current;
⚫ Regions with high chlorine or sulphur content or active bacteria indicated by the analysis.
28
INTERNAL ANTI-CORROSION
COATING
PART 05
29
Internal lining
The internal lining of ductile iron pipes must be equipped with excellent hydraulic and anti-corrosion
performance. Factors such as corrosivity, flow speed and environment temperature of the conveyed fluid
have to be taken into consideration while choosing the pipe lining. Surface smoothness is also one of the
features that to be taken into consideration.
Adopted for the delivery of potable water, the anti-corrosion lining of ductile iron pipes should be nontoxic.
This is the most basic requirement for the choice of lining.
While adopted for sewerage delivery, the anti-corrosion performance that features microorganism resistance
and liquid erosion resistance becomes very important for the lining. And it is those linings with high abrasion
resistance and strong acid resistance (especially sulfuric acid resistance) that can provide long-term,
reliable protection for the pipes.
Evaluation on aggressivity of water for ductile iron pipes
Corrosivity of water
Water can be divided into corrosive water (propersity to attack exposed metal) and aggressive water
(propersity to attack cement mortar lining).
—— Corrosive water
Corrosive water refers to water that corrodes the metal of pipe without lining. Oxygen contained in most of
the water can react chemically with iron, which causes its oxidization, generating nodules and tuberculation
on internal pipe wall. It will reduce the pipe cross section and significantly cause water head losses
increasing over time. This phenomenon often happens in the old pipe without cement mortar lining.
—— Aggressive water
Aggressive water is the water that corrodes calcareous materials (such as cement). Based on chemical
analysis, three results will be caused by the changes in mineral content, pH value and temperature of the
water:
⚫ Under the given temperature, the water with calcium-carbon balance will neither cause attack nor
calciumcarbon deposition.
⚫ Scale deposition water tends to generate calcium salt deposition (e.g. calcium carbonate) on the internal
surface of pipe.
⚫ Aggressive water can attack the cement mortar containing calcium (e.g. lime, calcium carbonate, or
aluminum silicate, etc.).
According to the relevant international standards, potable water can be neither corrosive nor aggressive
Usually, various types of water are available to be supplied. Sometimes, it is water with low mineral content
(e.g. soft water), which may attack the materials just like corrosive or aggressive water.
Guanghua can provide ductile iron pipes with various internal linings, which are applicable for the conduction
of various types of water; based on the features of delivered water, proper lining materials (such as cement
30
mortar lining, cement mortar lining with epoxy seal coat, PU lining, or ceramic epoxy lining) shall be chosen
through calculation and analysis.
Materials in contact with potable water

The materials in contact with potable water shall not influence water quality.
All above materials adopted by Guanghua for ductile iron pipes have passed the WRC-NSF test of BS6920 of
the U.K. and WRAS certification, which proves that these materials can be used for the delivery of portable
water.
Lining materials for ductile iron pipes provided by Guanghua are listed in Table below.
Material Application Area
Cement mortar lining Linings of ductile iron pipe and fitting
Solvent-free PU Special linings for ductile iron pipe and fitting
Water borne epoxy coating Seal coat
Socket and spigot of pipes with special
Epoxy coating
coating
Rubber gasket Sealing rings for joints of pipes and fittings
Lining selection
As per the corrosivity of delivered water, anti-corrosion linings of the ductile iron pipes and fittings provided
by Guanghua can be divided into three categories:
—— Standard lining: Applicable for most raw water and portable water;
—— Reinforced anti-corrosion lining: Applicable for water which can attack ordinary cement (soft water,
slightly acidic water or highly abrosive water);
—— Special lining: Applicable for very special cases or corrosive water (e.g. industrial discharged water)
Guanghua will recommend proper internal linings based on water composition analysis. Table 16
summarizes
the types of anti-corrosion linings of Guanghua
Lining type Lining material
Standard lining Portland cement mortar lining
High-alumina cement mortar lining
Enhanced lining Sulphur resistant cement mortar lining
Cement mortar lining + seal coat
Special lining PU, ceramic epoxy lining
1. Cement mortar lining

31
Cement mortar lining of ductile iron pipes is applied through centrifugal application method:
When pipes are rotating on the lining machine, certain amount of cement mortar is poured into the pipes.
Through high-speed revolution under the centrifugal force, such cement mortar will fully cling to the
internal surface of pipe, forming a dense and smooth lining with uniform thickness, which can provide
good mechanical properties after curing for certain amount of time. Thickness of cement mortar lining shall
comply with specifications in Table 17.
Table 17 Thickness of Cement Mortar Lining

Thickness
DN Nominal thickness Minimum thickness at one point
mm mm
DN300 3 2
350 - 600 5 3
700 - 1200 6 3.5
1400 - 2000 9 6
2200 - 2600 12 7
—— Requirements for materials

Different types of cement can be chosen for the cement mortar lining of ductile iron pipe on the basis of
delivered water, such as ordinary cement (silicate, Portland), sulphur resistant cement (including slag
cement), and high-alumina cement.
As an active anti-corrosion coating, cement mortar lining possesses long-term anti-corrosion effect.
The anti-corrosion mechanism is that cement mortar lining can release alkaline substance upon
its contact with water. Such substance will gather on internal surface of ductile iron pipe, resulting in its
passivation, so as to provide electrochemical protection for base material, as shown in Figure 19. Therefore,
this kind of lining mainly relies upon its alkaline environment to passivate internal wall of ductile iron pipe, so
as to achieve corrosion
resistance.
—— Features of cement mortar lining

⚫ Self-healing
On contraction of the lining,the formation of cracks and radial displacements cannot be avoided,these
cracks and radial displacements together with other isolated cracks which may result from manufacture
or may develop during transportation,storage or laying,but these cracks shall not be detrimental to the
mechanical stability of the lining.
When the pipe with cement mortar lining contact water, these cracks and radial displacement will be closed
and healed along with expansion of the linings and continuous hydration of cement; therefore, the
anticorrosion effect won’t be influenced.
⚫ Good mechanical property
32
—— Expansion coefficient
The linear thermal expansion coefficient of cement mortar lining is 12 x 10-6/ ℃ , which is almost equal to
that of ductile iron (11 x 10-6/℃ ). Therefore, it can reduce the risk of crack generation due to difference of
thermal expansion coefficients.
⚫ Good adherence and anti-vacuum performance
⚫ Good resistance to longitudinal bending and to ovality
⚫ Good resistance to vibration and impact
⚫ With excellent abrasion resistance, cement mortar lining can be used to convey raw water with highly
abrasive particles
⚫ Excellent hydraulic performance
Guanghua adopts centrifugal processing technology for its production of ductile iron pipes with cement
mortar
linings, which contributes to the lining’s smoothness. According to the test of Testing Center of China
Institute of Water Resources and Hydropower Research, the equivalent roughness K of such lining is
0.030mm. Taking into consideration of the roughness caused by fittings, valves and other devices, as well as
the tolerance, it is suggested that the value of K selected as 0.10mm for the design purpose.
—— Application fields
Table below shows the substances that can be conveyed by various cement mortar linings.
⚫ Ductile iron pipe with common silicate cement mortar lining is applicable for water-supply project;
⚫ Ductile iron pipe with sulphate resistant cement mortar lining is applicable for water supply project and
water transmission project with water quality listed in Table below;
⚫ Ductile iron pipes with high-alumina cement mortar lining are applicable for the conduction of sewages
and industrial wastewater containing certain chemical substances. Nitrile butadiene rubber (NBR) gasket
will be used as accessories for sewage pipelines
Table: Various Cement Mortar linings

Ordinary Portland Sulphate resisting High-alumina cement
Water properties
cement mortar cement mortar mining mortar lining
PH ≥6 ≥5.5 ≥4
Corrosive CO2(mg/l) ≤7 ≤15 Unlimited
SO42-(mg/l) ≤400 ≤3000 Unlimited
Mg2+(mg/l) ≤100 ≤500 Unlimited
NH4+(mg/l) ≤30 ≤30 Unlimited
2. Polyurethane lining
33
Product description
PU lining of ductile iron pipe and fitting is formed by the PU material sprayed and cured on the surface of
pipe/fitting bodies that is bi-component, solvent-free system. This kind of lining has excellent anti-corrosion
performance and wearing resistance, as well as high impact resistance specific to various transmission
mediums (such as portable water, wastewater, softened water, municipal sewage, and industrial
wastewater), which is applicable to all water supply projects and municipal sewage drainage projects from
soft water to hard water.
Metallic zinc
Cast iron pipe
PU lining
Epoxy coating
Figure: Ductile iron pipe with PU lining
Lining thickness
The thickness of PU lining varies with water quality and pipe diameter. The thickness of the linings are
shown in Table 19 and Table 20:
Product features
—— As a passive anti-corrosion coating, the effectiveness of PU lining depends on its sustainability,
adhesion and stability over time.
—— Continuity and sealing performances of PU linings: Holiday test must be conducted for each ductile iron
pipe with PU lining produced by Xinxing under the testing voltage of 6kV, which is higher than 4kV as
specified in BS EN 15655, so as to guarantee the sustainability of PU linings.
—— PU lining can provide excellent adhesion, where Xinxing requires that it shall be no less than 11MPa at
23℃ ;
—— Stability of PU lining
PU lining of ductile iron pipe produced by Xinxing can provide excellent chemical stability and ageing
resistance: the increased weight of coating won’t exceed 4% after its immersion in 50℃ distilled water for
180 days; the adhesion of PU lining is greater than 8MPa after it is exposed outdoor for 6 months.
—— Good flexibility
PU lining also has good flexibility, which can withstand the impact and deformation from transportation,
34
installation or overload with deformation (ovalisation) in compliance with requirement of ISO 2531.
—— With smooth surface, it features small friction and excellent hydraulic performance. GUANGHUA has
entrusted authorized testing organization to test roughness coefficient of K of ductile iron pipes with PU
linings, and the test result is 0.010mm. Considering roughness arising from fittings, valves and other devices,
as well as tolerance, it is suggested that K value shall be 0.050mm for the design purpose.
Application field
Ductile iron pipes with PU linings can be used to deliver water
as follows:
—— all types of portable water, sewage water with pH 1~13
and industrial water shown in Table 22:
—— Soft water or pure water, such as water desalted from
seawater.
—— Maximum temperature of the substances transmitted by
such lining is 45℃ .
Standard
Applicable standards for ductile iron pipe and fitting: ISO
2531, ISO 7186, GB /T 13295, GB /T 26081, EN 545 and EN
598
Applicable standards for PU lining of ductile iron pipe: GB/T
24596 and EN 15655
35
COATING REPAIRS
PART 05
Coating repairs
36
1. Repairing Zinc coating + HCPE finishing layer/Zn-Al rare earth alloy + epoxy coating
Repair such coatings consists of two steps:
Step 1: Repairing zinc coating/Zn-Al rare earth alloy coating Step 2: Repairing blue epoxy coating or HCPE
finishing layer
⚫ Equipment required
brush
paint brushes roller
gas torch
⚫ Repairing paint:
Zinc-rich primer:10kg
⚫ Procedures
Brush to remove dirt
⚫ The temperature of surface to be repaired shall be 5 ℃ above the dew

point at least. In case that the surface is wet or the ambient temperature is very
low, the surface can be heated by gas torch so as to keep it dry and at least 5℃
above the dew point.
⚫ According to the requirements in Zinc-Rich Primer Product Specification

provided by the supplier, the paint shall be mixed in proportion evenly and
brushed on the surface to be repaired. The coating thickness shall reach at
least 200g/m2 (When the coating is Zn-Al rare earth alloy, the thickness shall
be equivalent to the weight of Zn-Al rare earth alloy coat). The coating
appearance shall be smooth without bubble, void or other defect.
2. Repairing blue epoxy coating /HCPE finishing layer
37
•Equipment required
brush
paint brushes roller
gas torch
•Repairing materials:
Blue epoxy paint - used to repair Zn-Al rare earth alloy + epoxy coating HCPE
anticorrosion paint - used to repair zinc coating + HCPE finishing layer
•Procedures
Brush to remove dirt
⚫ The temperature of surface to be repaired shall be 5 ℃ above the dew point at

least. In case that the surface is wet or the ambient temperature is very low, the
surface can be heated by gas torch so as to keep it dry and at least 5 ℃ above
the dew point.
⚫ According to the requirements in product specification provided by the paint

supplier, the paint shall be mixed in proportion evenly, and brushed on the
surface to be repaired. The thickness of black finishing layer is at least 70 um,
and the thickness of blue epoxy coating is at least 100um. The coating
appearance shall be smooth without bubble, void or other defect.
3. Repairing PU coating
38
⚫ Equipment required
wire brush paint brushes spatula chisel
rotary wire brush gas torch
⚫ Repairing materials
SPUA-R300 solvent-free PU paint
⚫ Procedures
Remove the damaged coating and its surrounding coat with
poor adherence by knife or other tools and remain the coat with
sound adhesion and no defect. Clean the surface of ductile iron
with a motor wire brush or other tool until its surface reaches
St3. Brush away debris and dust to keep the repair-to-be
surface clean.
➢ The temperature of surface to be repaired shall be 5℃ above

the dew point at least. In case that the surface is wet or the
ambient temperature is very low, the surface can be heated by
gas torch so as to keep it dry and at least 5℃ above the dew
point.
➢ According to the requirements in Product Specification provided

by the material supplier, the repairing material shall be mixed
evenly in proportion and brushed on the surface to be repaired.
The coating thickness shall be 700 um at least, and the coating
appearance shall be smooth without bubble, void or other
defect.
4. Repairing cement mortar lining
39
•Equipment required
wire brush
paint brushes
Trowel
Spatula
Chiselhammer
Palette knife
Repair products
⚫ Procedures
➢ Turn the area to be repaired to face upwards.
➢ Remove the damaged area and surrounding hollow lining with a
hammer or driver.
➢ The edges shall be vertical to the ductile iron pipe wall and ductile
iron surface shall be exposed.
⚫ Remove any loose debris with a wire brush

➢ Clean the surface to be repaired thoroughly, including part of the
rusted substrate.
➢ Wet the area to be repaired.
➢ Wet cement mortar lining around the area to be repaired a few
minutes before the repairing work.
Preparation of repairing material

Ratio of components
Material Weight ratio
Cement 100
Fine sand 200
Water 35-40
Firstly mix two kinds of powder materials, and then add certain
amount of water, mixing to obtain the continuous slurry. If necessary,
add small amount of water according to the viscosity.
➢ Fill the defective parts with new mortar, smear the mortaron it to a
uniform thickness with a trowel and make it dense. Operate
evenly to obtain flat and smooth surface. If required, regularly
water the trowel to facilitate troweling
➢ The repaired part shall be fully cured and not exposed in
sunshine. It shall be covered with plastic cloth to keep the
humidity
5. Repairing ceramic epoxy(PU)lining
40
•Tools required
wire brush paint
brush spatula
chisel
motor wire brush
gas torch
•Repairing materials
Solvent-free ceramic epoxy repair material for ceramic epoxy

•Procedures
lining; SPUA-R400 hand brush polyurethane for PU lining.
Remove the damaged coating and its surrounding coat with poor
adherence with knife or other tools and remain the coat with sound
adhesion and no defect.
Clean the substrate of ductile iron base with a motor wire brush or other tool
until its surface reaches St3.
Brush away debris and dust to keep the repair-to-be surface clean.
The temperature of the surface to be repaired shall be 5℃ above the dew
point at least. In case that the surface is wet or the ambient temperature is
very low, the surface can be heated by gas torch so as to keep it dry and at
least 5℃ above the dew point.
According to the requirements in Product Specification provided by the
material supplier, the repairmaterial shall be mixed evenly in proportion and
brushed on the surface to be repaired. The coating thickness shall be at
least 1000um, and the coating appearance shall be smooth without bubble,
void or other defect.
41
MANUFACTURING PROCESS
AND QUALITY CONTROL
SYETEM
PART 06
Manufacturing Process
42
Manufacturing process for ductile iron pipe
Preparation of molten iron

Molten iron smelting
The Fe in the iron ore is reduced in the blast furnace, which will also keep suitable composition of Si, Mn, S,
P, and other trace elements in molten iron. With the storage function, the metal mixer can be utilized between
the blast furnace and electric furnace for the buffering and thermal insulation, so as to obtain the suitable
composition of molten iron. The composition and temperature of molten iron can be adjusted in the electric
furnace to achieve suitable values for spheroidisation.
Spheroidization and inoculation

After the molten iron’s spheroidization through the addition of magnesium, the precipitated graphite will
43
change its form from flake to spheroid during solidification, thus avoiding incision of flake graphite to the
continuity of iron matrix, so that enabling the ductile iron with excellent ductility, flexibility and impact
resistance.
Inoculation is an important procedure during production of ductileiron, through which graphite in the ductile
iron can become more rounded and refined, so that the spheroidizing level can be elevated, and the pipe wall
can become denser in structure; in addition, the product plasticity and toughness can be improved too
The metal-stream inoculation is performed along with the centrifugal casting simultaneously.
Pipe casting
Preparation of sand cores
The pipes with different joints are produced with pipe molds with different joint-sand-cores. The core sand
mixed with resin is added into the sand core mold, tamped and solidified for the centrifugal casting.
Centrifugal casting
The high-quality ductile iron pipe is produced by the centrifugal casting process: After spheroidization, the
44
qualified high-temperature molten iron flows through a launder into the metal mold rotating at high speed, and
then is distributed on the internal surface of metal mold under the centrifugal force, finally it is solidified into a
pipe. The impurities and gas in molten iron is sufficiently excluded due to the centrifugal force. The gradual
inward solidification makes the pipe wall extremely dense, so as to save materials to the most and improve
the mechanical properties of pipe.
Annealing
Annealing treatment is a necessary and important procedure during production of ductile iron pipe.
45
Generally, the elongation of ductile iron pipe by centrifugal casting is 2~5%, inferior to the requirement
specified by ISO 2531. In order to enhance elongation, the cast pipe shall be annealed, that is, the pipe is
heated to certain temperature in the annealing furnace, and then cooled to below certain temperature along
with the proper annealing curve, and continuously cooled in ambient temperature. After the annealing
treatment, the mechanical properties of ductile iron pipe can reach the indexes in below table and comply
with ISO 2531:
Mechanical Properties of Ductile Iron Pipes

Minimum tensile strength Minimum elongation
Type of casting Rm MPa A
DN80~2000 DN80~1000 %DN1100~2000
Centrifugal ductile iron pipe 420 10 7
Fittings, non-centrifugal ductile

iron pipe 420 5 5
Note: 1. The yield strength (RP 0.2) can be measured by agreement between the supplier and purchaser.
Where: RP 0.2 ≥ 270MPa, when A ≥ 12% for DN80 ~ 1000; or RP 0.2 ≥ 270MPa, whenA ≥ 10% for DN ＞
1000 and above.RP 0.2 ≥ 300MPa under other conditions.
2. For centrifugal ductile iron pipes between DN 80 ~ 1000,when the wall thickness class is above K12,
minimum elongation is 7%.
Finishing / coatings
Zinc spray on external wall
46
After the annealing treatment, the external surface of the pipe is sprayed with zinc coating complying with ISO
2531 by means of the electric arc spraying process: utilize low voltage and high current power to melt zinc
wire; atomize the molten zinc with high-speed compressed air stream, and then spray it on the external wall
of pipe in the form of micro droplet.
Hydrostatic test
Each ductile iron pipe and fitting manufactured by Guanghua shall be subject to hydrostatic test in
accordance with ISO 2531, qualified result of which is the prerequisite for the product’s entering into the next
procedure.
Cement mortar and other lining

Taking into consideration the sanitation requirements of urban water supply to prevent water pollution against
47
rust, it is necessary to conduct anti-corrosion protection for pipe from inside through application of internal
lining. Without special requirement, all ductile iron pipes produced by Guanghua shall be internally lined with
cement mortar complying with the portable water requirements.
According to the requirements of ISO 4179, Guanghua adopts the centrifugal lining process, through which
the cement mortar lining surface features smoothness, uniformity and flatness, as well as high bonding
strength with pipe wall, and is not easy to fall off.
Pipes with cement mortar lining centrifugally applied shall be placed in the environment with high temperature
and humidity, so as to accelerate the maturation of cement mortar lining.
Spray finishing layer, package and storage

After the spraying of finishing coating and marking, the cured pipe (DN ≤ 300) will be packed and put in
48
storage, and then shipped to the designated location as scheduled.
Quality control and inspection frequency
Dealing with
No. QC item Testing frequency Inspection equipment nonconforming products
Composition of molten iron

Each furnace Spectrometer Return
1 from the blast furnace
Composition of molten iron

Each furnace Spectrometer Readjust
2 from FM furnace
Temperature of molten iron

Each furnace Thermometer Readjust
3 from FM furnace
Composition of nodulized
Each pack Spectrometer
4 molten iron Return
5 Core appearance Full testing Visual inspection Repair or destroy

6 Core dimensions ≥5 Caliper Destroy
pcs/shift/specificatio
7 Pipe mold dimensions Each piece Micrometer, dial Rework
n indicator
Sampling test every
8 Casting temperature Thermometer Adjustment or return
3~10
9 Appearance pieces
Each piece Visual inspection Adjustment
10 Pipe weight Each piece Platform scale Adjustment
Test along
Furnace temperature Thermal instrumentation Adjustment
11 production, record
every half-hour
49
Test along
Chain speed Inverter
12 production, record Adjustment
13 Appearance every
Eachhalf-hour
piece Visual inspection Reject
14 Mechanical property 1 piece/batch Universal Testing Reject
15 Zinc coating weight 1 time/shift Electronic
Machine
balance Rework
16 Pipe weight Full testing Electronic scale Reject
Standard round and
17 Dimensions Full testing Reject
card board
18 Pressure test Full testing Pressure test machine Reject
19 Ratio of cement mortar Each bucket Electronic scales, water Adjustment
20 Lining appearance Each piece Visualmeter
inspection Reject or rework
21 Lining thickness ≥1 time/hour Steel needle, steel ruler Reject or rework
22 Curing time Each furnace Watch Adjustment
23 Curing temperature Each furnace Thermometer Adjustment
24 Appearance Full testing Visual inspection Reject or rework
25 Film thickness ≥3 Coating thickness tester Rework
26 Lining thickness ≥3
pcs/shift/specificatio Coating thickness tester Reject or rework
pcs/shift/specificatio
n
n
50
51
Production process and quality control of Ductile Iron Pipes
Unqualified Unqualified Unqualified

Reject
Blast Furnace Spectrum Qualified Component & Spectrum Qualified Spectrum Qualified
Molten Iron Inspection Mixer Furnace Temperature Inspection Spheroidization Inspection
Appearance and Unqualified Unqualified

Core Making Dimension Inspection Reject
Unqualified Unqualified
Qualified
Appearance and Spectrum Thickness Qualified Finishing Ring Cutting

Centrifugal Casting Weight Inspection Annealing Zinc Spray
Qualified Inspection Qualified Inspection Grinding Chamfering
Need
Qualified
Pipe Mould
Repairing Pipe Mould Inspection
Unqualified Unqualified Unqualified Unqualified

Reject
Circle Dimension and Cement Thickness Qualified Lining

Checking Hydraulic Test Qualified Lining Inspection Curing Grinding
Qualified
Unqualified Unqualified
Reject
Qualified Qualified
Bitumen Spray Thickness Inspection Marking Appearance Inspection Packing Finish
Repairing
Unqualified
52
REQUIREMENTS FOR
STORAGE AND
TRANSPORTATION
PART 07
53
Lifting of ductile iron pipe
Precautions
Ductile iron pipe shall be lifted by straps or special tools and handled with care. The pipes shall be matted
steadily and firmly without collision with each other during shift-loading and transportation. The operation
shall strictly follow the requirements of protection and fastening, so as to avoid damage to the pipe and
protective coating.
Lifting tools
The crane or forklift is available for lifting, where
special hooks shall be applied, as shown in Figure
The special hooks include steel hook covered by
rubber, nylon strap or steel wire rope covered by
rubber , so as not to damage the internal cement
mortar lining and external protective coating,
thus protecting coating of both sides.
Figure 1. Special hooks
Lifting
For ductile iron pipes packed in bundles, strap and special lifting tools shall be used to lift them from the
bottom of whole bundle. It is prohibited to directly hook pipes or package strap so as to avoid packing
distortion, breakage of package straps or bundle-off during lifting. Generally, one hook is to lift one bundle.
If it is necessary to lift several bundles by a hook, the special lifting gear shall be used to prevent packing
deformation, so as to avoid the package damage, such as steel belt breakage and bundle deformation;
For ductile iron pipes packed in bulk, special hook or lifting strap can be used to lift one or several ductile
iron pipes each time, as shown in Figure 2;
Figure 2. Lifting operation
When forklift is applied, all its areas contacting with the pipes must be protected during lifting;
54
Transportation
⚫ If truck or train is adopted for transportation, the carriage must be cleaned without foreign matters. At
the same time, the loading scheme shall be prepared according to the acceptable capacity of vehicle;
⚫ If truck or train is adopted for transportation, planks formed by two or more pieces of wood shall be
placed on the carriage floor so as to avoid the direct contact between the socket end and carriage floor;
If a flat bed trailer is used for transportation, the casting pipes shall be placed on planks and then fixed
by wedges; the length of pipe extending out of the vehicle shall not exceed 1/4 of the pipe length; if iron
pipes are loaded in more than one layer, the pipe spigot and socket end of each layer shall be
staggered and finally fixed with steel wire rope firmly; the soft protective materials shall be used to
separate pipe and pipe, pipe and rigid vehicle body, as well as pipe and fastening steel ropes;
⚫ While unloading from the vehicle, it is necessary to avoid directly pulling or dropping the ductile iron
pipe, wrapped or not, over the ground, even over the sand ground,for dropping them.
55
Storage
Prepare the storage area
The selected site for ductile iron pipe storage shall be flat and solid, and the following places shall be
unacceptable:
- Unstable or sloped areas;
- Swampy areas;
- Seriously polluted land;
Two tracks of wooden planks shall be placed under the pipes to avoid their direct contact with the
ground, and the selected wooden planks shall be solid.
For the long-term storage, the pipes shall be covered with canvas or woven cloth, so as to protect
the pipes against dust or dirt.
Stacking patterns
⚫ Ductile iron pipes can be stacked in two patterns, i.e. the square and pyramidal form.
⚫ The square stack pattern is shown as Figure 3. The planks are placed under the bottom layer and fixed
with wooden wedges. In each layer of ductile iron pipe, the spigots and socket ends shall be arranged
alternately. For ductile iron pipes in adjacent layers, spigots and socket ends shall also be alternately,
and the upper layer shall be perpendicular to the lower layer. The width of each layer shall not exceed
5.5m.
⚫ Pyramid" stack pattern is shown as Figure 4. The bottom layer of ductile iron pipes is placed on two
rows of parallel planks with distance of about 1,000mm to each pipe ends; the planks are fixed with
wedges
Figure 3 Square stacking Figure 4 Pyramid stacking
The sockets and spigots of pipes of each layer are arranged alternately.
Taking into account the bearing capacity of the underlying pipes, the stacking height for K9 ductile iron pipe
is recommended as shown in Table 1, and the preferred height for C-class ductile iron pipes is shown in
56
Table 2.
Table 1. The Stacking Mode for K9 Ductile Iron Pipe

Recommended stacking Recommended stacking layers*
DN layers*
Pyram Squar DN Pyramid Square
80 id
32 e
20 700 7 4
100 26 18 800 6 3
125 24 16 900 5 3
150 20 16 1000 3 3
200 18 12 1100 3 2
250 17 9 1200 2 2
300 14 9 1400 2 1
350 12 9 1500 2 1
400 12 6 1600 2 1
450 10 6 1 1
500 9 5 1800 and 1 1
600 8 4 above 1 1
If increasing stacking layers of pipes ,it needs to add the planks placed under the bottom layer.Please
contact us for the specific
cases.
Table 2. The Stacking Mode for C-class Ductile Iron Pipe With Preferred Pressure Class
Recommended stacking Recommended stacking layers*
DN layers*
Pyram Squar DN Pyramid Square
80 id
26 e
18 700 5 3
100 24 16 800 4 3
125 21 14 900 3 2
150 18 14 1000 3 2
200 15 11 1100 2 2
250 14 9 1200 2 1
300 12 8 1400 1 1
350 10 7 1500 1 1
400 10 7 1600 1 1
450 8 6 1 1
500 7 5 1800 and 1 1
600 6 4 above 1 1
If increasing stacking layers of pipes ,it needs to add the planks placed under the bottom layer.Please
contact us for the specific cases.
57
58

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SHANXI NEW GUANGHUA CASTING PIPE CO., LTD.

SHANXI NEW GUANGHUA CASTING PIPE CO., LTD.

Your first choice for water project

01 COMPANY PROFILE 02 TYPE OF JOINT

EXTERNAL ANTI-CORROSION INTERNAL ANTI-CORROSION

05 MANUFACTURING PROCESS AND

REQUIREMENTS FOR STORAGE

FACTORY GATE OFFICE BUILDING

GARDEN LIKE FACTORY FOUNDRIES

DN2600 CENTRIFUGAL CASTING ZINC SPRYING

GUANGHUA Pipes, reliable partner you can rely on.

Shanxi New Guanghua Casting Pipe Co., Ltd.

For details, see the table below:

Table: Ductile Iron Pipes Joint and Anti-corrosion Solutions

T-type joint DN80~2000

Ductile iron pipe wall thickness

—— Graded by wall thickness class coefficient K

enom = K (0.5 + 0.001DN )

Type of casting e Limit Deviation

—— Graded by pressure class C

Rm —— Minimum tensile strength of ductile iron pipe, (MPa Rm=420 MPa)

Table 3 Tolerance on Wall Thickness For

Type of casting Tolerance

Table 4 Specification Range for Preferred Pressure Class

T-type joint ductile iron pipe

T Type joint Ductile Iron Pipes

TF Self-anchored joint ductile iron pipe

TF self-anchored joint structure

TF Self anchored joint Ductile Iron Pipes

Technical Parameters of TF Self-anchored Joint Ductile Iron Pipe

1.5 Xanchor self-anchored joint ductile iron pipe

1.5.1 Joint description

Xanchor self-anchored joint Ductile Iron Pipes

1.5.2 Technical parameters:

1400 146 160 328 1. 17.1 19

Flange welded joint ductile iron pipe

Figure Flange welded joint structure

—— Joint features and application field

Table 9 Flange welded Pipe Catalogue

Name Symbol Name Symbol

Double-spigot pipe with

Double flanged pipe with puddle Socket-spigot pipe with

Flanged spigot pipe Flanged socket pipe

Flange spigot pipe with puddle Flanged socket Pipe with

Allowable operating pressure for welded flanged pipes of K9:

XTJ ductile iron jacking pipe

Figure: Ductile Iron Jacking pipe structure

Figure: XTJ Ductile Iron Jacking pipe

Wall thickness DE D A Total weight

External anti-corrosion coating

Soil aggressivity evaluation

Selection of external coating

Corrosion level Pipelines

1. Zinc+ bitumen finishing layer

Figure: Porous structure of the coating solution of Zinc+HCPE

layer, as shown below:

2. Zn-Al + blue epoxy coating

Cast iron pipe Cement mortar lining

—— Advantages of Zn-Al rare earth alloy coating

coating to prolong the service life significantly.

Epoxy coating PU coating

Coating thickness is as specified in Table 12

pipe body PU coating 900 700