Technical Submission for supply of Ductile Iron Pipes

Project No 10P104 – Ref No 10P104-P0041-301

Polgahawela, Pothuhera and Alawwa Integrated Water Supply Project
…………………………………………………………………………………………………………………………………...........
Ductile Iron Pipes
Jindal SAW Limited (JSAW) manufacturer’s diameter Ductile Iron Pipes in its India
plant (Samaghogha, Gujarat, India) with diameter range - DN 80 to DN 1000

1.0 Socket and Spigot Ductile Iron Pipes

Ductile Iron Socket and Spigot pipes will be centrifugally cast Ductile Iron pipes in
accordance with the International Standard ISO 2531:2009.

1.1 Technical Specifications of Ductile Iron Pipes Pipe as per ISO2531:2009

Product Name Ductile Iron Pipe with Socket & Spigot ends suitable for
Push-on-Jointing
Class of Pipe C- Class as per ISO 2531:2009

Size Range DN 80 to DN 1000

Standard Length 5.5 mtr

Ordinary Portland Cement confirming to EN197 as per ISO

Internal Lining
4179 and ISO2531:2009

Metallic Zinc 200 gm/m² with finishing layer of Bitumen

External Coating
(70µm) as per ISO2531:2009 as per ISO 8179-1

Coating of Joint Area Bitumen as per ISO2531:2009

DI Pipes Conforming
ISO2531 :2009
Specifications

Quality Certifications Issued by Bureau Veritas / ISO 9001:2008.

Product Compliance
Issued by Bureau Veritas / Conformance to ISO2531:2009
Certifications

Jindal Centre, 12 Bhikaiji Cama Place, New Delhi – 110066. Phone.: +91 (11) 26181360-74. Fax.: +91 (11) 26170691
Page 1|7
 Technical Submission for supply of Ductile Iron Pipes
Project No 10P104 – Ref No 10P104-P0041-301
Polgahawela, Pothuhera and Alawwa Integrated Water Supply Project
…………………………………………………………………………………………………………………………………...........

1.2 Details of Push-on-Joint Ductile Iron Pipes Pipe as per BSEN 545: 2010

L ØDE

Sectional View of Ductile Iron Pipe

Push –on-Joint Gasket (EPDM)

Dimensional details of Push-on-Joint Ductile Iron Pipe as per ISO 2531:2009

Standard Pipe Minimum Nominal
Class Allowable Pressure
Length of (Ø Tolerance Wall Wall
DN Pipe (L) of (Bar)
DE) Thickness Thickness
Pipe
Mtrs mm Mm mm Mm PFA PMA PEA
150 5.5 170 +1 / -2.9 3.0 4.5 C40 40 48 53
200 5.5 222 +1 / -3.0 3.1 4.7 C40 40 48 53
250 5.5 274 +1 / -3.1 3.9 5.5 C40 40 48 53
300 5.5 326 +1 / -3.3 4.6 6.2 C40 40 48 53
350 5.5 378 +1 / -3.4 4.7 6.3 C30 30 36 41
400 5.5 429 +1 / -3.5 4.8 6.5 C30 30 36 41
600 5.5 635 +1 / -4.0 6.7 8.7 C30 30 36 41
700 5.5 738 +1 / -4.3 6.8 8.8 C25 25 30 35

Jindal Centre, 12 Bhikaiji Cama Place, New Delhi – 110066. Phone.: +91 (11) 26181360-74. Fax.: +91 (11) 26170691
Page 2|7
 Technical Submission for supply of Ductile Iron Pipes
Project No 10P104 – Ref No 10P104-P0041-301
Polgahawela, Pothuhera and Alawwa Integrated Water Supply Project
…………………………………………………………………………………………………………………………………...........

1.3 Mechanical Properties of Ductile Iron Pipes as per ISO2531:2009

Mechanical Properties Values

Tensile strength : Min. 4,200 Kg/cm2

Yield Strength : 3,000 Kg/cm2

Min 10% for DN 80 to DN 1000 and 7% for diameter

Elongation :
> DN 1000

Hardness : Max. 230 BHN

1.4 Allowable Pressure for Ductile Iron Pipe as per ISO2531:2009

Size/ Allowable operating Maximum Allowable Allowable site test pressure,

Class pressure, PFA operating pressure, PMA PEA

C Class Bar bar Bar

C40 40 48 53

C30 30 36 41

C25 25 30 35

NOTE: The actual site test pressure will depend on the field working pressure

1. Maximum Operating Pressure (PMA) = 1.2 x PFA (Including Surge)

2. Allowable Test Pressure (PEA) = PMA + 5 bar

Jindal Centre, 12 Bhikaiji Cama Place, New Delhi – 110066. Phone.: +91 (11) 26181360-74. Fax.: +91 (11) 26170691
Page 3|7
 Technical Submission for supply of Ductile Iron Pipes
Project No 10P104 – Ref No 10P104-P0041-301
Polgahawela, Pothuhera and Alawwa Integrated Water Supply Project
…………………………………………………………………………………………………………………………………...........

1.5 Internal Lining of Ductile Iron Pipes

Internal lining of cement mortar

The internal cement mortar lining of ductile iron pipes constitute a dense, homogeneous layer covering
the total internal surface of the pipe barrel. The cement mortar mix shall comprise cement, sand and
water. The cement shall be Ordinary Portland Cement as per BS EN197-1 as per the technical
specification confirming to ISO 4179.

The water used in the mortar mix complies with standard set for the drinking water.

Strength of the lining

When measured, the compressive strength of the cement mortar after 28 days of curing shall be not
less than 50 MPa. The compressive strength of the lining is directly related to other functional
properties such as high density, good bond and low porosity.

Thickness and surface condition

The surface of the cement mortar lining shall be uniform and smooth. Trowel marks, protrusion of
sand grains and surface texture inherent to the method of manufacture are acceptable. However, there
shall be no recesses or local defects which reduce the thickness to below the minimum value. The
nominal thickness of the cement mortar lining and its tolerance shall be as given in Table below.

DN Thickness, mm
Nominal value Limit deviation
80 to 250 4 - 1.0
300 to 600 6 - 1.0
700 to 900 8 - 2.0

Co-efficient for pipes Cement mortar lining shall be C140

Jindal Centre, 12 Bhikaiji Cama Place, New Delhi – 110066. Phone.: +91 (11) 26181360-74. Fax.: +91 (11) 26170691
Page 4|7
 Technical Submission for supply of Ductile Iron Pipes
Project No 10P104 – Ref No 10P104-P0041-301
Polgahawela, Pothuhera and Alawwa Integrated Water Supply Project
…………………………………………………………………………………………………………………………………...........

1.6 External Coating of Ductile Iron Pipes

All Ductile Iron Pipes are supplied with an external coating. The basic coating specification of pipes is
with an external metallic zinc coating with finishing layer of bitumen.
External Coating of zinc with finishing layer of Bitumen

The external coating of ductile iron pipes and fittings comprise a layer of metallic zinc 200 gm/m2
covered by a finishing layer of a Bitumen coating as per ISO 8179-1 and ISO 2531:2009. The metallic
zinc is normally applied on oxide surface pipes after annealing or it may also be applied on blast-
cleaned fittings. Prior to application of the zinc, the pipe surface shall be dry and free from rust or non-
adhering particles or foreign matter such as oil or grease.

Coatings characteristics
The metallic zinc coating covers the external surface of the pipe and provides a dense, continuous,
uniform layer. The purity of the metallic zinc used shall be at least 99.99%. The Ductile Iron pipes and
fittings are manufactured with the mean mass of zinc per unit area is 200g/m2on the basis of zinc
mass applied to the pipe surface as per ISO 8179-1.

The finishing layer of Bitumen is uniformly covering the whole surface of the zinc layer. The
uniformity of the finishing layer is checked and when measured, the mean thickness of the finishing
layer shall be not less than 70 µm and the local minimum thickness not less than 50 µm.

The Internal Section of the Sockets

The internal section of sockets of pipes shall be painted with Bitumen. The coating is suitable for use
in contact with potable water and is WRAS approved.
1.7 Joint Flexibility of Ductile Iron Pipes
Ductile Iron pipes shall be joined by push on joint and the minimum angular deflection allowed shall
be as per BSEN 545:2010
- 3030’ for DN 80 to DN 300
- 2030’ for DN 350 to DN 600
- 1030’ for DN 700 to DN 1000

1.8 Gaskets for Ductile Iron Pipes

Ductile Iron pipes and fittings shall be supplied with WRAS approved EPDM gaskets as per EN 681-1.

Jindal Centre, 12 Bhikaiji Cama Place, New Delhi – 110066. Phone.: +91 (11) 26181360-74. Fax.: +91 (11) 26170691
Page 5|7
 Technical Submission for supply of Ductile Iron Pipes
Project No 10P104 – Ref No 10P104-P0041-301
Polgahawela, Pothuhera and Alawwa Integrated Water Supply Project
…………………………………………………………………………………………………………………………………...........

1.9 Marking on Ductile Iron Pipes

Marking- Each pipe shall be legibly and durably marked with the following:
Marking Pipes
Name of the Employer as "NWSDB" Stencilled
Material of pipe indicated as "DI" Cast Embossed
Nominal Diameter or size Cast Embossed
Year of Manufacture Cast Embossed
Class designation Stencilled
Reference standard as ISO 2531 Stencilled
Manufacturer's identification mark - Brand Name Cast Embossed as well as Stencilled
Pressure rating of flanges Not Applicable
Angle of bends in degrees Not Applicable
Socket penetration lines of each pipe with push-in joints Stencilled
All markings shall be of a permanent nature Marking shall be as defined above
The manufacturer's name or identification marks shall be engraved
embossed/cast on the socket/flanges of all DI pipes OK - Cast Embossed

In addition to what specified in standards, all pipes shall be legibly and indelibly with details as
follows.
Item Diameter Details required Height of JSAW Remarks
(DN) Lettering (mm)
above 350 "NWSDB", 50 Only ‘NWSDB” will be in
Pipe standard (ISO 2531:2009), 50 mm height others as
Class type, Nominal dia. per JSAW standards.
150 to 350 "NWSDB", Only ‘NWSDB” will be in
(both Pipe standard (ISO 2531:2009), 50 mm height others as
inclusive) Class type, Nominal dia. 25 per JSAW standards.
Pipe Lengths
(as intervals 50 to 150 "NWSDB", Only ‘NWSDB” will be in
not more Pipe standard (ISO 2531:2009), 50 mm height others as
than 3m) Class type, Nominal dia. 10 per JSAW standards.

below 50 "NWSDB", 5(except

Pipe standard (ISO 2531:2009), "NWSDB")
Class 10(For Not Applicable
type, Nominal dia. "NWSDB")
Marking on pipes shall be either cast embossed, cold stamped and stenciled with indelible paint, JSL pipes
marking standard is as attached.

Jindal Centre, 12 Bhikaiji Cama Place, New Delhi – 110066. Phone.: +91 (11) 26181360-74. Fax.: +91 (11) 26170691
Page 6|7
 Technical Submission for supply of Ductile Iron Pipes
Project No 10P104 – Ref No 10P104-P0041-301
Polgahawela, Pothuhera and Alawwa Integrated Water Supply Project
…………………………………………………………………………………………………………………………………...........

2.0 Lubricant for Ductile Iron Pipes

Lubricant shall be supplied from Thomas Grozier and Son Pty Ltd, WRAS, Datasheet etc., shall be
submitted in attachments. Details of Lubrication quantity to be supplied (in Kg) for respective pipe
diameter size is as under:-
DN Quantity No of 1 Kg Lubricant supplied per lot of No of 1 Kg
pipes / joints for respective diameter lubricant to be
Mtrs No of Pipes
supplied
3003.0 546
150 108 5.25
1501.5 273
200 80 3.50
3503.5 637
300 42 15.25
11000.0 2000
350 30 66.75
3003.0 546
400 25 22.00
10010.0 1820
600 10 182.00
1501.5 273
700 8 34.25

Total No of 1 Kg lubricant to be supplied 329

Jindal Centre, 12 Bhikaiji Cama Place, New Delhi – 110066. Phone.: +91 (11) 26181360-74. Fax.: +91 (11) 26170691
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