HYDRAULIC WORKING PRESSURE
Allowable Operating Allowable Maximum
DN (mm) Pressure (Excluding Surge) Operating Pressure (Including Surge)
in MPa in MPa
K7 K9 K7 K9
100 0.8 6.4 1.25 7.7
150 0.8 6.4 1.25 7.7
200 0.8 6.2 1.25 7.4
250 0.8 5.4 1.25 6.5
300 0.8 4.9 1.25 5.9
350 0.8 4.5 1.25 5.4
400 0.8 4.2 1.25 5.1
450 0.8 4.0 1.25 4.8
500 0.8 3.8 1.25 4.6
600 0.8 3.6 1.25 4.3
700 0.8 3.4 1.25 4.1
800 1.0 3.2 1.5 3.8
900 1.0 3.1 1.5 3.7
1000 1.0 3.0 1.5 3.6
JAI BALAJI INDUSTRIES LIMITED CM/L-5496181
Registered Office:
5, Bentinck Street, Kolkata - 700001, West Bengal, India
Phone : +91 33 2248 8173, 2248 9808, Fax : +91 33 2243 0021, 2242 6263 Product Catalogue
Marketing Office: New Delhi Office :
23, R.N. Mukherjee Road, Kolkata - 700001 Flat No. 1401 & 1402, Nirmal Tower
West Bengal, India 14th Floor, 26, Barakhamba Road
Phone : +91 33 2231 3660 - 63 New Delhi -110001, India
Phone : +91 11 4362 0220 - 21
Fax : +91 33 2231 3683
Fax : +91 11 4362 0219
E-mail : mkt.dip@jaibalajigroup.com
E-mail : delhi@jaibalajigroup.com
Works: Hydrabad Office:
Unit - III, (DI Pipe Plant) Durgapur 2nd Floor, D.K Road, Ameerpet
Village - Banskopa, PO - Rajbandh Hyderabad - 500016, Andhra Pradesh, India
Dist - Burdwan, West Bengal - 713212, India Phone : +91 90141 78075
Phone : +91 343 253 2651 - 52 E-mail : hydrabad@jaibalajigroup.com
Fax : +91 343 253 2653
Durg Office:
Borai Industries, Growth Centre, Ramsada
Mumbai Office:
Durg - 491001, Chhattisgarh, India
822, 8th Floor, Corporate Avenue
Phone : +91 788 261 7248, +91 93037 34435
Sonawala Road, Goregaon East
E-mail : purchase.durg@jaibalajigroup.com
Mumbai - 400063, Maharashtra, India
Phone : +91 98197 40916, +91 90211 34891 Ranchi Office :
E-mail : mumbai@jaibalajigroup.com NIPL, 1st Floor, Pustak Bhawan Complex
Court Road, Ranchi - 834001, Jharkhand, India
Phone : +91 651 220 3295
Website : www.jaibalajigroup.com E-mail : mkt.dip@jaibalajigroup.com
WHAT IS DUCTILE IRON?
Harnessing a combination of corporatization and entrepreneurship,
Jai Balaji Group has emerged as one of the tenth largest
Ductile Iron is an improvement to Cast Iron that has Mechanical Properties of Ductile Iron Pipe
manufacturer of Iron and steel in the country. served the water industry with distinction through
the centuries. The first Ductile Iron pipe was Tensile Strength 420 MPa Minimum
Our production facilities are spread over nine locations in the state produced experimentally in 1948. Minor but
of West Bengal, Chhatisgarh, Orissa and Jharkhand, manufacturing significant changes in chemistries and processing Elongation at Break 10% Minimum
a chain of value added products including. result in physical differences at the micro-structure
Modulus of Elasticity 1.7x1010 kg/m²
level that result in a vastly improved fracture
toughness and ductility making Ductile Iron
· DRI Hardness 230 BHN Maximum
substantially more resistant to damage from impact
· Foundry and Steel Grade Pig Iron
or concentrated loads. Density 7050 kg/m³
· Ferro Alloys
· Alloy, Carbon and Mild Steel Billets and Rounds Although both materials are classified as Cast Irons, Bending / Beam Strength Over 200 MPa
· Reinforcement Steel TMT Bars and Wire Rods in todays terminology, the older material is identified
· Ductile Iron Pipes as Gray Iron and the newer material as Ductile Iron. Crush Load and Impact Load Can take up Huge Impact
During the solidification stage of the casting process, Load (Charpy over 0.713)
the carbon, sometimes called graphite, comes out
of solution and collects in numerous small pools. Bursting Strength (Minimum) Factor of Safety against
The shape of these pools of carbon is a major factor Bursting is 8 to 10
in the mechanical properties of the material.
These photomicrographs compare the Advantages of Ductile Iron Pipe
microstructures of Gray Iron and Ductile Iron.
Strongest pipe - high tensile and beam strength
High ring stiffness - takes care of high soil and traffic load
Withstands severe crushing load and high impact load
Can endure high working pressure
Ductile Iron Cast (Grey) Iron DI Pipe is hydrotested at 50 kg/cm² at works. Provide complete
safety against surge (water hammer)
In the Gray Irons, these pools are form of flakes. That
is, they are generally in an elongated, flat form Speedy laying / installation due to push-on jointing system
We have a passion for achieving excellence in all our endeavors; ending in sharp points. The carbon content and
where it is adding more value to our existing products or diversifying Light weight and not brittle - easier to handle
flake graphite form give Gray Iron good machinability
into other areas of business. Having established our might in the and corrosion-resistant properties. The flakes, Welding is possible
Iron and Steel Industry, we have been generating Green Power however, break up the continuity of the metal, and
the sharp points are stress concentrators at the Centrifugally applied Cement Mortar Lining offers a smooth surface
in our plants and started work to diversify into Mining and Cement
microscopic level. Both of these characteristics limit and gives a higher Hazen Williams C value of 140
Industries. Our endeavor has always been to generate more direct
the ductility and tensile properties of the material.
/ indirect employment and contribute more to the development Lesser friction-loss, offers impressive energy savings
of community in the area where we operate. In Ductile Iron, the majority of the pools of graphite
Inherently corrosion resistant - also given extra protection by
are in the form of spheroids. This distinctive shape
applying inside cement mortar lining and outside coating of zinc
significantly reduces the occurrence of points of
with finishing layer of bitumen / epoxy
stress concentration. Changing the carbon structure
from flake to spheroidal form and reducing the
ISO 9001:2008
phosphorus content results in an exceptionally strong
material with good machinability, high-impact and
corrosion resistance, and excellent beam strength.
For these reasons, Ductile Iron is an ideal material
for transporting water and wastewater etc.
ISO 14001:2004
CLASSIFICATION, DIMENSIONS AND OTHER KEY TECHNICAL INTERNAL LINING
All Ductile Iron Pipes are supplied with inside cement mortar lining. The lining is applied by using a high - speed
Wall Thickness
centrifugal process. By using this method, excellent quality control of the cement-mortar lining is maintained. The
Ductile Iron Pipes have been classified as K7, K8, K9, K10 etc depending on service conditions and wall thickness
cement linings produced are dense, smooth, uniform, well bonded to the pipe wall, and offer very little frictional
Nominal Diameter, External Diameter and Wall Thickness
resistance to the flow of water. The mortar of the lining is composed of cement, sand and water.
Scoket
Spigot
e
Advantage of Cement Mortar Lining (CML):
Provides higher Hazen Williams C value. DI Pipe has a C value of 140 in
DN
DE comparison to 100 for bare metallic pipes and 110 for projection method
cement mortar lined metallic pipes
Higher C value reduces pumping costs
L
Permanently increases water carrying capacity
Nominal Diameter External Diameter Barrel Wall Thickness (e) in mm Tolerance on
(DN) in mm (DE) in mm K7 K9 External Diameter Prevents pitting and tuberculation of metallic pipes and there by stops
chocking of pipe and the production of red water
100 118 5.0 6.0 +1/-2.8
150 170 5.0 6.0 +1/-2.9 Prevents abrasion of pipe wall and thus increases life of pipe
200 222 5.0 6.3 +1/-3.0
250 274 5.3 6.8 +1/-3.1
300 326 5.6 7.2 +1/-3.3
350 378 6.0 7.7 +1/-3.4
400 429 6.3 8.1 +1/-3.5
450 480 6.6 8.6 +1/-3.6 Thickness of Cement Mortar Lining :
500 532 7.0 9.0 +1/-3.8
600 635 7.7 9.9 +1/-4.0 DN in mm Thickness in mm
700 738 9.0 10.8 +1/-4.3
800 842 10.4 11.7 +1/-4.5 Nominal Value Tolerance
900 945 11.2 12.6 +1/-4.8 100 to 300 3.0 -1.5
1000 1048 12.0 13.5 +1/-5.0
350 to 600 5.0 -2.0
700 to 1200 6.0 -2.5
MANUFACTURING PROCESS MANUFACTURING PROCESS
Raw Material Blast Furnace Induction Furnace Magnesium Converter Core Making
Pipe Casting Annealing Zinc Coating Cement Mortar Lining Bitumen Coating Finishing Stacking Despatch
EXTERNAL COATING PE SLEEVING
Zinc Coating Polyethylene sleeving is a tubular film of low density polyethylene slipped over
The coating materials are metallic zinc with purity of at least 99% by mass. The and snugly fitted to a pipe at the time of laying. It is used to supplement to the
metallic zinc coating is applied by a spraying process in which metallic zinc material basic pipe coating (metallic zinc + bituminous paint / epoxy coating) in certain
is heated to molten state and projected in small droplets by spray gun onto the pipe cases of highly corrosive soils. Advantages of polyethylene encasement include:
surface. The average mass of zinc coating is 130gm/m² minimum. Relatively inexpensive
Advantage of Zinc Coating Easy to install
Zinc metallization is an active protection due to the galvanic effect of the zinc/iron
Does not require maintenance or monitoring
electrochemical couple. Its mechanism is two fold :
Easy to repair if damaged
Formation of a stable protective layer: Self-healing of damage:
In contact with the surrounding soil, the metallic zinc One of the particular features of the external zinc coating is
slowly transforms into a dense, adherent, impermeable its ability to restore the continuity of the protective layer
and continuous zinc salts. This acts as a protective barrier. where small areas of local damage exist. The Zn++ ions
The pore sealer, whilst permitting galvanic protection migrate through the pore sealer to plug the damage and
JOINTING SYSTEM PUSH ON JOINT
and self-healing, favours the formation of a stable and then convert into stable, insoluble zinc corrosion products.
insoluble layer of zinc conversion products.
Zinc corrosion
products
Zn**ions Current 1
Pore-sealer Metallic zinc Pipe wall
Iron
Damage Clean the socket Insert the gasket Apply lubricant onto the
and spigot into the socket inside surface of gasket
FINISHING LAYER
After metallic zinc coating the pipe is given a finishing layer of bituminous paint
or synthetic resin (epoxy) compatible with zinc coating.
The mean dry film thickness of the finishing layer is 70 µm.
Apply lubricant to Maintain straight Guide the spigot into the
the spigot end alignment socket & push
QUALITY MEASURES
Analysis of Raw Material Chemical Composition Micro Structure by Tensile Strength Test Hardness Testing by Hydro Testing in HPTM Dimensional Checking
Testing by Spectrometer Inverted Metallurgical by UTS Machine Brinell Hardness
Microscope Testing Machine
