25/12/2018

DUCTILE IRON PIPE

SPECIFICATIONS

6.24 DUCTILE IRON(DI) PIPELINE 6.24.1 GENERAL

AGENCY 202 EXECUTIVE ENGINEER

This specification covers the specific requirement of design, material, manufacture / fabrication, constructional
features, inspection & testing, transportation, handling, laying and site testing of Ductile Iron (DI) Pipes, Joints,
fittings and specials.

6.24.2 CODE AND STANDARDS

The material, design, manufacture, dimensions, tolerances, mechanical properties, internal cement mortar lining,
external zinc coating along with bituminous finished layer, inspection and testing of DI water pipes shall comply
with the latest Indian Standard, “IS 8329 (Centrifugally cast (spun) ductile iron pressure pipes for water, gas and
sewage – specification)” or equivalent international standard unless otherwise specified elsewhere in this
Technical Specification. The various referred National and International codes generally used in the design,
manufacture and testing of DI pipes are as mentioned below:

Sl. Code
Code Title
No. No.
1. IS 8329 Centrifugally cast(spun) ductile iron pressure pipes for water, gas and sewage – specification
2. IS 9523 Ductile iron fittings for pressure pipes for water, gas and sewage – specification
3. IS 5382 Rubber sealing rings for gas mains, water mains and sewers
4. IS 638 Specification for Sheet Rubber Jointing and Rubber Insertion Jointing
5. IS 12288 Code of practice for use and laying of Ductile Iron pipes
6. IS 11606 Methods for sampling of Cast Iron pipes and fittings
7. IS 455 Portland slag cement
8. IS 12330 Sulphate resisting Portland cement
9. IS 6452 Specification for high alumina cement for structural use

Western Irrigation System Pvt Ltd ⏐ info@westernispl.com ⏐ +91 99099 78440

10. IS 6909 Specification for super - sulphated cement
11. IS 8112 43 grade ordinary Portland cement
12. IS 1387 General requirements for supply of metallurgical materials
13. IS 1500 Methods for Brinell hardness test for metallic materials
14. IS 1608 Mechanical testing of metals - tensile testing
15. ISO 2531 Ductile iron pipes, fittings, accessories and their joints for water applications
16. ISO 4179 Ductile iron pipes and fittings for pressure and non pressure Pipelines -- Cement mortar lining
Rubber seals -- Joint rings for Irrigation, drainage and sewerage pipelines - Specification for
17. ISO 4633
materials
18. ISO 8179 Ductile iron pipes -- External zinc based coating -- Part 1: Metallic zinc with finishing layer

AGENCY 203 EXECUTIVE ENGINEER

Sl.
Code No. Code Title
No.
19. ISO 8179 Ductile iron pipes -- External zinc coating -- Part 2: Zinc rich paint with finishing layer
20. ISO 8180 Ductile iron pipelines - - Polyethylene sleeving for site application
21. ISO 10802 Ductile iron pipelines - - Hydrostatic testing after installation
22. ISO 10803 Design method for ductile iron pipes
23. ISO 16132 Ductile iron pipes and fittings - - Seal coats for cement mortar linings
AWWA M Ductile - Iron pipe and fittings (guideline code for design, manufacturing, testing, jointing,
24.
41 laying &installation etc.)
Ductile iron pipes, fittings, accessories and their joints for water pipelines - Requirements and
25. BSEN 545
test methods

6.24.3 DUCTILE IRON (DI) PRESSURE PIPES FOR RISING MAINS & DISTRIBUTARY MAINS 6.24.4 Design
Requirements
Classification

The class of DI pipes to be provided shall be as specified in the data sheet attached with this sub section. The
external diameter and wall thickness of socket and spigot pipes for the specified Class shall be as per IS 8329 or
equivalent international standard.

Pressure class and thickness class of pipe flanges shall be as specified in the data sheet attached with this sub
section and shall conform to the requirements of IS 8329 or equivalent international standard.

Length

Socket and Spigot pipes shall be supplied in standard working lengths of 5.5m or 6m and flanged pipes in lengths
of 4m / 5m / 5.5m as per requirements.

Tolerances

Tolerances on External diameter, ovality, thickness and length of pipes etc. shall conform to the provisions of IS:
8329 or equivalent international standard.

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Material Requirements

The metal used for manufacturing the pipes shall be of good quality, commensurate with the mechanical
requirements laid down in IS 8329 or equivalent international standard.

Manufacturing Requirements

Pipes supplied shall be centrifugally cast (spun) Ductile Iron pipes conforming to IS 8329 or equivalent
international standard. The pipes shall be stripped with all precautions to avoid

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warping or shrinkage defects, detrimental to their good quality. The pipes shall be sound and free from surface or
other defects.

External layer

The DI pipes supplied shall be provided with external protection of metallic zinc coating with finishing layer of
bituminous paint as per IS 8329 or equivalent international standard.

Internal lining

The pipes shall be provided with suitable cement mortar internal lining as per IS 8329 or equivalent international
standard.

Joints

Push on flexible joints shall be provided for pipe to pipe connection as per IS 8329 or equivalent. Wherever, flange
joints are required e.g. at terminal points, valves, over ground and underground pipe connection etc., Welded on
flanges shall be used.

Rubber gaskets

Rubber gasket used with push on flexible joints shall conform to the requirements of IS: 5382 or equivalent.
Rubber gaskets for use with flanged joints shall conform to IS 638 or approved equivalent.

6.24.5 DI FITTINGS & SPECIALS General

DI Fittings should preferably be manufactured by the manufacturer of the pipes. In case they are not, it will be the
responsibility of the manufacturer of the pipes to have them manufactured through a suitable manufacturer
under its own supervision and have it tested at his/sub contractor’s premises as per the contract. The pipe
manufacturer will ensure the compatibility of the pipes and fittings by prescribed type test with its own pipe and
the outsourced fittings. Therefore Ductile Iron fittings should be sourced from the manufacturer of the pipes.

The manufacturing unit should have ISO 9001 certification.

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The company should have fully equipped laboratory with in-house microscope to check nodularity and to check
chemical composition along with tensile, hardness & elongation by universal testing machine. The laboratory of
the manufacturer should be accredited by NABL.

Since the socket design is not given in the standard the min. socket thickness of fittings at any point must not be
lesser than minimum body thickness given in the standard.

6.24.6 Design Requirements Classification

The class of DI fittings to be provided shall be as specified in the data sheet attached with this sub section. The
external diameter and wall thickness of fittings for Push on joints for the specified Class shall be as per IS 9523 or
equivalent.

The Pressure class of flanged fittings shall be as specified in the data sheet attached with this sub section and shall
conform to the requirements of IS 9523 or equivalent.

Permissible deviations on length of fittings

The permissible deviations on the length of fittings shall be as per IS: 9523 or equivalent. AGENCY 205 EXECUTIVE
ENGINEER

Tolerances

Tolerances on external diameter, Raised face height, thickness and Flange drilling of fittings etc. shall conform to
the provisions of IS: 9523 or to the provisions of international equivalent standard to which they are supplied.

6.24.7 Material Requirements

The metal used for manufacturing the fittings shall conform to the appropriate grade as specified in IS 1865, in
commensurate with the requirements of IS 9523 or equivalent.

6.24.8 Manufacturing Requirements

The fittings shall be stripped with all precautions to avoid warping or shrinkage defects, detrimental to their good
quality. The fittings shall be sound and free from surface or other defects.

Linings and Coatings for Ductile Iron Fittings

The DI Fittings are to be lined with Cement Mortar Linings with a sand cement mixture and the lining thickness
should be as per Table 33 ( Annex B) of IS 9523. The Coatings to DI fittings shall be similar in line with the
provisions of DI pipes. All fittings must be painted with Zinc rich paint as per Annexure A of IS 9523. Bitumen being
used for External coating should be approved By WRAS or similar approval authority. However, in soil conditions
where soil resistivity is less than 1000 ohm-cm with or without water table, fusion bonded epoxy lined and coated
DI fittings to be used in place of other type of lined and coated fittings.

Fittings with Flexible Push-on joint

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Flexible joints shall be of spigot and socket “push-on” type suitable for angular deflection in any direction and
capable of axial movement to compensate for thermal expansion or contraction and ground movement.

Fittings with Flanged joint

Fittings with Flanged joints will be with raised face and they shall be supplied complete with approved gaskets,
hot dipped galvanized or cadmium plated bolts, nuts.

Fittings with Mechanical joint

Where Fittings with mechanical type joints are specified, proposed and approved they shall be supplied complete
with approved gaskets, glands, hot dipped galvanized or cadmium plated bolts, nuts and all other necessary
accessories.

Fittings with Restrained Joints

DI fittings with restrained joints shall be utilized in underground application where pipelines have to cross roads
through existing ducts or in areas with restricted accessibility where the use of concrete anchor blocks is
prohibited, or as directed by the Engineer-in-Charge. The CONTRACTOR shall submit with his bid with full details
of the type of restrained joint he proposes to use.

Whenever in the course of work the CONTRACTOR intends to utilize restrained joints he shall obtain prior
approval from the Engineer-in-Charge.

Calculation of the number of pipe lengths with restrained joints required on both sides of the fitting shall follow
the manufacturer’s recommendation and shall be subject to the Engineer- in-Charge approval.

Restrained joints shall be designed in accordance with ISO 10804-1. The permissible angular deflection will be as
declared by the manufacturer. The performance Type test of this Joint in

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line with ISO 10804-1/EN545 has to be established by the manufacturer by getting it witnessed by a NABCB
(National Accreditation Board for Certification Bodies) or IAF (International Accreditation Forum) or EA (European
Cooperation for Accreditation) accredited institution / certification agency. The certificate must be produced with
the technical bid.

Rubber ring for joints shall be of a type that will not deteriorate when stored under manufacturer’s guidelines or
during operation. The rubber gasket shall be of EPDM elastomer in accordance with IS:5382 suitable for Irrigation.

Joints between pipe and fittings

Push on flexible joints shall be provided for pipe to fitting connection as per IS 9523 or equivalent. Flange joints,
wherever required, shall conform to the requirements of IS 9523 or equivalent.

Rubber gaskets

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Rubber gasket used shall conform to IS: 5382:1985 or amended up to date. Other requirements of gaskets are as
per clause-7 of IS 9523:2000. Rubber Gaskets to be ISI marked EPDM quality.

6.25 TYPE TESTS

The contractor / manufacturer shall carry out the type tests as listed in this specification on the pipes to be
supplied under this contract. The bidder shall indicate the charges for each of these type tests separately in the
relevant schedule of Section VII (Forms & Procedures) and the same shall be considered for the evaluation of the
bids. The type tests charges shall be paid only for the test(s) actually conducted successfully under this contract
and upon certification by the Employer.

The type tests shall be carried out in presence of the Employer’s representative, for which minimum 15 days
notice shall be given by the contractor. The contractor shall obtain the Employer’s approval for the type test
procedure before conducting the type test. The type test procedure shall clearly specify the test set–up,
instruments to be used, procedure, acceptance norms, recording of different parameters, interval of recording,
precautions to be taken etc. for the type test(s) to be carried out.

In case the contractor / manufacturer has already conducted such specified type test(s), he may submit the type
test reports to the Employer during detailed engineering for consideration of waiver of conductance of such type
test(s) or otherwise as deemed fit by Employer. Such test(s) should have been either conducted at an
independent laboratory or duly approved by accredited third party agency. The Employer reserves the right to
waive conducting of any or all the specified type test(s) under this contract. In case type tests are waived, the type
test charges shall not be payable to the contractor.

The type test shall be performed whenever a significant change is made in the design, material or process of
manufacture or a new size or size range of the product is being supplied by the manufacturer.

The following type tests shall be carried out:

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Joint Leak Tightness Test

a)

b)

Tests for joints (push on flexible joints) shall be conducted as per the guidelines of ISO 2531 to establish adequate
joint performance with respect to internal pressure, external pressure and vacuum pressure under both normal
alignment of joints and deflected alignment of joints as dictated in ISO 2531. prior to commission of project

Tests for Leak tightness and mechanical resistance of flanged joints shall be conducted as per ISO 2531.

Cement Lining Smoothness Type Test

The contractor / manufacturer should have carried out Cement Lining Smoothness test to establish C value (Hazen
& William’s constant) of the offered DI pipe as 140. Necessary certificate for the same shall be furnished to the
employer.

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In case the contractor / manufacturer has not carried out the test, the same shall be carried out by the contractor
/ manufacturer within the scope of this contract.

Ring bend test

Ring bend test for 3% deflection with respect to external diameter of DI pipe offered shall be conducted by
contractor / manufacturer to prove that internal cement mortar lining does not come off the substrate surface of
Ductile Iron on random basis for each manufacturing lot.

If the contractor / manufacturer of pipes do not have the facility for this type test at his own works, the same can
be arranged by him to conduct and demonstrate the test.

6.26 TRANSPORTATION AND DELIVERY OF PIPES

Bidder shall have to submit a QAP for safe handling and stacking of pipes during transportation and at site. It shall
conform to the requirements stated in IS: 12288 or equivalent.

All pipes fabricated in the factory and temporarily stacked in the Contractor's yard or factory shall be transported
to site after shop testing & cleaning them internally. The loading in the factory shall be carried out by means of
either a crane, gantry or with shear legs, so as not to cause any damage to the finished material. Similarly, while
unloading and stacking, great care shall be taken to ensure that the material or lining inside is not damaged or
dented.

The material being delivered at site shall be jointly inspected by the Employer and the Contractor. Defective or
damaged pipe shall be rejected by Employer or in case of minor damage, the Employer may allow repair of the
pipe by the Contractor to the satisfaction of the Employer as per guideline of IS 8329.

Props of proven designs shall be fixed to the pipes during transit to avoid undue sagging and consequent
distortion. After the pipes are carefully stacked, props may be removed and re used for subsequent operations.

In case of transport by ship, packing shall be sea worthy so as to ensure safe delivery till site.

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All the Dl fittings shall be properly packed with jute cloth. Rubber rings shall be packed in polyethylene bags.
Rubber rings in PE bags and nuts, bolts etc. shall be supplied in separate jute bags.

At site, pipes shall be stacked in such a way that suitable gaps shall be left in the pipes at intervals to permit
access from one side to the other.

6.27 MARKING

Each Pipe shall have as cast or stamped or legibly and indelibly painted on it with the following marks:

a) The Manufacturer's name or trademark on each pipe

b) The nominal diameter of pipes and batch number.

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c) Class of Pipes and fittings

d) A white ring line showing length of insertion at spigot end

e) Standard ISI certification mark for the pipes conforming to IS or international standard mark to which they are
supplied.

f) The last two digits of the year of manufacture

g) Any important information that the manufacturer deems fit to be inscribed on pipe.

6.28 LAYING AND JOINTING OF DI PIPES

Laying, erection and jointing of DI pipelines at field / site shall be under the direct supervision of Manufacturer
(Supplier) from whom pipe is sourced / procured.

Laying Underground

Pipes shall be lowered into the trench with tackle suitable for the weight of pipes. For smaller sizes, up to 250 mm
nominal bore, the pipe may be lowered by the use of ropes but for heavier pipes suitable mechanical equipment
shall be used.

All construction debris shall be cleared from the inside of the pipe either before or just after a joint is made. All
persons shall vacate any section of trench into which the pipe is being lowered.

The assembly for the pipes shall be made as recommended by the pipe manufacturer and using the suitable tools.

The socket and spigot ends of the pipes shall be brushed and cleaned. The chamfered surface and the end of the
spigot end have to be coated with a suitable lubricant recommended by the manufacturer of the pipes. Oil,
petroleum bound oils, grease or other material, which may damage the rubber gasket, shall not be used as
lubricant. The rubber gasket shall be inserted into the cleaned groove of the socket. It shall be checked for correct
positioning.

The two pipes shall be aligned properly in the pipe trench and the spigot end shall be pushed axially into the
socket either manually or with a suitable tool specially designed for the assembly of pipes and as recommended
by the manufacturer. The spigot has to be inserted up to the insertion mark on the pipe spigot. After insertion,
the correct position of the socket has to be tested with a feeler blade.

Deflection of the pipes, if any, shall be made only after they have fully been assembled. The deflection shall not
exceed 75% of the values indicated by manufacturer.

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On gradients of 1:15 or steeper, precautions shall be taken to ensure that the spigot of the pipe being laid does
not move into or out of the socket of the laid pipe during the jointing operations. As soon as the joint assembly
has been completed, the pipe shall be held firmly in position while the trench is back filled over the barrel of the
pipe. The backfill shall be well compacted.

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Special provisions in trench shall be made for accommodating socket (Bell) of each pipe, as applicable so that
barrel is uniformly rested on even trench bed surface, which is well compacted as recommended in codes /
standards.

At the end of each working day and whenever work is interrupted for any period of time, the free ends of laid
pipes shall be protected against the entry of dirt, water or other foreign matter by means of approved plugs or
end caps.

Laying above ground

The following is applicable only when no additional bending moments except that those due to self weight of pipe
and its content are present. If any additional moments are present, piping contractor has to suitably support the
pipe in consultation with manufacturer and Employer.

a) Socket and spigot pipes

Socket (Bell) and spigot pipes shall be provided with one support (usually pedestal or steel pipe support) per pipe.
The supports shall be positioned behind the socket of each pipe.

Pipes shall be fixed to the supports with mild steel straps so that axial movement due to expansion and
contraction resulting from temperature fluctuations is taken up at individual joints in the pipeline. Joints shall be
assembled with the spigot end withdrawn 5 to 10 mm from the bottom of the socket to accommodate thermal
movements.

The designed anchorage shall be provided to resist the thrusts developed by internal pressure at bends, tees, etc.

Where a pipeline crosses a watercourse, the design and method of construction shall take into account the
characteristics of the watercourse to ascertain the nature of bed, scour levels, maximum velocities, high flood
levels, seasonal variation, etc., which affect the design and laying of pipeline.

b) Flanged pipes

The maximum unsupported span for flanged pipes shall not be more than 8 m. The supports shall be located at
the centre of every second pipe.

The maximum unsupported span at water course shall also be not more than 8 m. The relative position of pipe
joints and pipe supports shall be as per IS 12288 or equivalent.

The supports of all flanged pipe work spans shall be stable and unyielding due to movements in the pipeline.

The straps shall prevent any lateral movement or lifting of the pipelines but not restrict expansions and
contractions caused by temperature fluctuations.

Cutting of pipes

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The cutting of pipe, if required, for inserting valves, fittings etc. shall be done in a neat and workman like manner
without damage to the pipe or lining so as to leave a smooth end at right angles to the axis of the pipe. Cutting of
pipes shall be reduced to a minimum required.

Cutting has to be made with suitable tools as per IS 12288 or equivalent and according to the recommendations
of the manufacturer. The spigot end has to be chamfered again at the same angle as the original chamfered end.
If there is no mark for the insertion depth on the spigot ends of the (cut) pipe it shall be marked again according
to the instructions of the manufacturer.

Pipeline anchorage

Pipeline shall be securely anchored at dead ends, tees, bends, tapers and valves to resist thrust arising from
internal pressure. Suitable thrust blocks made of concrete shall be designed and cast- in-situ.

All specials like bends, tees etc. and appurtenances like valves etc. shall be laid in synchronization with the pipes.
The Contractor has to ensure that the specials and accessories are available at site ready to be installed together
with the pipes.

6.29 EXTERNAL PROTECTION

The details of soil resistivity data shall be verified by the Contractor.

The contractor shall carry out soil resistivity survey along the ROW of the pipeline using Wenner’s 4 pin method in
the presence of Employer’s representatives.

On completion of all field work, a report incorporating resistivity (on semi log graph sheets) data shall be prepared
by the contractor and submitted to the Employer.

In case of highly corrosive soil (soil resistivity less than 1000 ohm cm), polyethylene sleeving shall be provided for
encasement of the pipes, fittings and joints against corrosion. This encasement shall be so designed to prevent
the contact of pipe, fittings and joints with the surrounding backfill and bedding material. It shall conform to the
requirements of IS 8329 & IS 12288 or equivalent international standards.

6.30 HYDRAULIC TESTING OF PIPELINES

After laying and jointing, the pipeline shall be tested for soundness and leak tightness of pipes, fittings and joints,
and soundness of any construction work. The pipeline may be tested in sections.

Water and other facilities as required for such hydro testing shall be arranged by the Contractor. Each section
shall be properly sealed off with special stop ends secured by adequate temporary anchors. The thrust on the stop
ends shall be calculated and the anchors designed to resist it. All permanent anchors shall be in position and, if of
concrete, shall have developed adequate strength before testing begins.

Hydraulic Testing of Sections

The section under test shall be filled with water, taking care that all the air is displaced either through vents at the
high points or by using a pig or a sphere.

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After filling, the pipeline shall be adequately pressurized for a period of time to achieve stable conditions.

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The pipeline is then pressurized up to the full test pressure as stipulated in the data sheet attached with this sub
section and the section under test completely shall be closed off. The test pressure shall be maintained for a
period of not less than 10 minutes to reveal any defects in the pipes, joints or anchorages. The test pressure shall
be measured such as to ensure that the required test pressure is not exceeded at any point in the entire pipeline.

If the test is not satisfactory, the fault shall be found and rectified. Methods employed for finding faults shall be as
per IS 12288.

Hydraulic Testing of Complete Pipeline

After all the sections have been joined together on completion of section testing, a test on the complete pipeline
shall be carried out. This test shall be carried out at a pressure as specified in the data sheet attached with this
subsection. During the test, the pressure at any point in the pipeline shall not exceed the pressure as specified in
the data sheet attached with this subsection.

6.31 QA REQUIREMENTS FOR DI PIPES, FITTINGS AND SPECIALS

Following tests / inspections to be carried out on the finished pipes, Joints, Gaskets, DI Fittings & specials as per
relevant IS/ISO standard:

1. Pipes produced are subject to following checks;

a. Visual Inspection for workmanship, marking, visual defect etc. b. Mechanical Properties as per relevant
governing Standard
c. Dimension



d. e.

f.

Inside Diameter Outside Diameter Wall Thickness Ovality of Pipes Length of Pipes Straightness

Hydrostatic Leak Tightness to be carried out as per relevant standard.

Zn coating & Bituminous painting on external layer DI pipes shall be carried out as per relevant standard /
Technical Specifications.

Identification – Manufacturer Logo, Nominal Diameter, Class, length indication for cutting of pipe at site, ISI
certification mark, pipe no.

2. Internal lining of suitable cement mortar shall be done as per relevant standard / Technical Specifications.

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3. Rubber gaskets shall confirm to the requirement of relevant standard / Technical Specifications.

4. Joints for pipe, DI Fittings & specials shall be as per relevant standard / Technical Specifications.

5. Type Tests: Please refer relevant sections of engineering portion of technical Specification.

AGENCY 212 EXECUTIVE ENGINEER

DATA SHEET FOR DI PIPES, FITTINGS & SPECIALS

Units
Sl.
Description Parameters
No.

Ductile Iron (DI) pipe internally cement mortar lined and externally
1. Pipe Material
coated with metallic zinc & finishing layer of bituminous paint

2. Applicable standards
IS / ISO / AWWA / BS as listed in technical specification
3. Hazen & William’s constant 140
4. Pipe Class K7/K9 based on approved design as per IS 8329 or equivalent
5. Pipe Joint type Push on flexible joints as per IS 8329
Pipe Joint type at valves,
6. Flange Joints as per IS8329 & IS 9523
pumps and other piping
Welded on Flange (as
applicable) Pressure
7. PN 16
Class
8. DI fittings class K12 as per IS 8329 or equivalent
DI fittings flange (as applicable)
9. PN 16 / as per approved design
class
Restrain mechanism atbends,
10. Thrust Blocks
specials etc.
11. Other Requirements As per technical specification

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