Ductile Pipe Fitting
Ductile pipe fittings is the abbreviation of ductile iron pipe fittings , they are components used in piping systems to connect, divert, or otherwise manage the flow of fluids (usually water or sewage) through ductile iron pipes. These fittings are made from ductile iron, a type of cast iron known for its improved strength, flexibility, and impact resistance compared to traditional cast iron
Judberd is a chinese manufacturer for ductile pipe fittings, our ductile iron fittings are classified as EN545/ISO2531 ductile iron fittings (fittings for water supply and fittings for irrigation), EN598 ductile iron fittings (fittings for sewage) and AS/NZS 2280 ductile iron fittings (fittings for Australia, new Zealand and Fiji ), EN12842 ductile iron fittings for PVC pipe and EN545/ISO2531 loose flange ductile iron fittings. Judberd is specially competitive for MJ fittings, also called mechanical joint fittings. Details as below
Ductile Iron Fittings for PVC Pipe Catalog
EN12842 Ductile Iron Fitting For PVC Pipe
EN545/ISO2531 Loose Flange Ductile Iron Fitting
Except the above pipe fittings in our drawing, we can also design special pipe fittings according client requirement.Below our special ductile iron pipe fittings are for your reference.
SURFACE COATING
Cement Inside,Zinc And Bitumen Outside
For Potable Water
High Alumina Cement Lining Inside, Red Epoxy Paint Outside
For Sewage
Fusion Bonded Epoxy Inside And Outside
For Potable Water
Epoxy Paint Inside,Zinc And Bitumen Outside
For Potable Water
EPDM lining inside , anti-rust paint outside
For Sea Water
PTFE lining inside , Red epoxy paint outside
For Chemical Fluid
How to guarantee the material of ductile iron fittings?
1,Check the chemical composition of the iron with a pre-furnace analyser
2,Adjust metal content in iron water by adding metal until the metal content is quanlified
3,Machine test bars to standard sizes for tensile strength and elongation testing
4,Use instrument to tensile test bars to test tensile strength and elongation
5，Polishing samples for spectroscopy with a spectroscopy grinder
6，Chemical Composition Testing By Spectrometer, 2 Tests Are Required To Ensure Accuracy
7，Polishing Of Samples For Metallographic Testing Using A Metallographic Specimen Grinding And Polishing Machine
8，Metallographic testing to compare test results with standards to determine compliance
INSPECTION
Judberd is a competitive manufacturer of ductile pipe fittings. We have strict inspection procedures for product quality inspection as follows for reference
Chemical Composition Inspection
Hydrostatic Pressure Testing
Paint Thickness Inspection
Dimension Inspection
MATERIAL
For Ductile Iron Pipe Fitting ,The Material Is Ductile Cast Iron,The Most Popular Used Are Ductile Iron EN GJS400-18,EN GJS450-10,EN GJS500-7 And ASTM A536 65-45-12.They Are Difference In Tensile Strength, Yield Strength, Elongation And Hardness, But They All Work Well For Normal Working Conditions. For Some Special Working Conditions, Such As Extremely Low Temperatures, The Content Of Trace Elements In The Ductile Iron Needs To Be Adjusted To Achieve This.
Take EN GJS400-18 as an example, ‘400’ refers to the tensile strength, and ’18’ refers to the elongation. The higher the tensile strength, the better the material’s resistance to tension, making it more capable of withstanding greater stretching stress, thus ensuring safer and more reliable use. Elongation affects the material’s toughness; the higher the elongation, the better the material’s toughness, making it less prone to breaking. Materials with high tensile strength are suitable for applications with heavier loads, while those with low tensile strength are suitable for applications requiring higher toughness. High elongation is suitable for situations involving impact or vibration, whereas low elongation is suitable for applications requiring higher hardness.
Ductile iron nodularity is classified into five grades:
1st grade: Graphite is mostly spherical, with a few nodular and very few chunky, with a nodularity rate not less than 95%.
2nd grade: Most of the graphite is spherical, with the rest being nodular and very few chunky, with a nodularity rate from 90% to less than 95%.
3rd grade: Most of the graphite is nodular and spherical, with some being chunky, and a few worm-like shapes are allowed, with a nodularity rate from 80% to less than 90%.
4th grade: Most of the graphite is chunky and nodular, with some being spherical and a small amount worm-like, with a nodularity rate from 70% to less than 80%.
5th grade: Graphite is dispersed in worm-like, spherical, chunky, and nodular forms, with a nodularity rate from 60% to less than 70%.
The higher the nodularity grade, the better the performance of ductile iron. Typically, we use nodularity grades 2-3.
Common nodularization methods include the shot sleeve method or the wire feeding nodularization method. We use the wire feeding nodularization method, which has the advantages of minimal temperature drop, good absorption, and high nodularity level.
Many factors affect the performance of ductile iron, with chemical composition and nodularity rate being key factors. For each batch of raw materials, we conduct spectral analysis to measure the content of over 20 chemical elements, and we never use materials with excessive harmful elements. After each batch of molten iron is smelted, we test the content of each element and accurately add the required elements. Once the temperature is reached, we proceed with wire feeding nodularization. After nodularization is complete, it must be poured within 10 minutes. If pouring is not completed, the remaining molten iron is returned for remelting. At the end of each molten iron pouring, we take samples and use a metallographic microscope to observe the nodularity level. If the nodularity level doesn’t meet the standard, it is remelted. Additionally, each batch of products undergoes tensile strength and elongation testing using test bars, ensuring the quality of our products.
DESIGN STANDARD
The design standards for ductile iron fittings are different in different regions and are mainly divided into
American & Canadian ductile iron fittings standards ANSI/AWWA C110 ANSI/AWWA C153
Austrilia , new zealand , Fiji ductile iron fittings standard AS/NZS 2280
The rest of the region EN545/ISO2531
PRODUCTION PROCESS
The common production processes for ductile pipe fittings are Lost Foam and sand casting, and their production processes are as follows.
1, Vaccum Lost Foam Casting Production Process
1,Pre-expanded Bead 2,Model Shaping 3, Bond&Model Form 4,Coat Paint 5,Model lay box 6,Molten iron melting 7,Nodular Treatment 8,Pouring 9, Polish&Clean 10,Zinc Paint Spray 11,Mechanical Machining 12,Hydraulic Press Test 13,Cement Lining 14,Bituminous Paint Externally 15,Finished Products Packing
2, Sand Casting
1, Moldling 2,Iron Melting 3,Ductile Iron Treatment 4,Ductile Iron Fittings Casting 5,Turning Over The Box 6,Shot Blasting Cleaning 7,Mechanical Processing 8,Painting Or Coating According To Client Requirement 9,Ductile Iron Fittings Are Packed In The Warehouse.
Wall Thickness
Dimensional requirement for EN545/ISO2531 and EN598 ductile iron pipe fitting
Wall thickness
The nominal iron wall thickness of pipe fittings shall be calculated according to the nominal size DN :
e=K(0.5+0.001DN)
but should be no less than 7mm
where K is a coefficient used for determination of thickness class. It is selected from a series of whole
numbers:…12,14…
The tolerances on nominal wall thickness of pipe fittings shall be given as below table
| e,mm | Tolerance,mm |
| 7 | -2.3 |
| >7 | -(2.3+0.001DN) |
SURFACE QUALITY REQUIREMENT
Surface Quality
The surface of ductile iron fittings must be bright and clean, no cracks, cold compartments, wrong boxes and other obvious defects that hinder the use, where local defects that reduce the wall thickness are allowed, but their maximum depth is (2 + 0.05t) mm (t is the pipe body wall thickness)
Ductile iron pipe fitting flange outline is clear, no casting defects affecting the use are allowed.
With the consent of the demand side, local defects that do not affect the use can be repaired, but the repaired pipe fittings must be re-hydraulic or gas tightness test.
Coating
Ductile iron pipe fittings can be coated with cement inside ,zinc &bitumen outside , FBE coating inside or outside or other anti-corrosion materials on the inside and outside surfaces, and if there are special requirements, they will be determined through consultation with the supply and demand sides.
When the ductile iron fittings are used for water supply, the sanitary conditions should be in accordance with the local regulations of the relevant standards for drinking water.
Before coating, the inside and outside of the fittings should be cleaned up, and after coating, the inside and outside surfaces should be bright and clean, and the coating should be uniform, firm and not abnormal due to the change of climate.
DIMENSION TOLERANCE
Ductile Iron pipe Fitting Length
| Type of fittings | DN(mm) | Tolerance(mm) |
|---|---|---|
| Fittings with socket ends | 80-2000 | ±20 |
| Pipe and fittings with flange ends | 80-2000 | ±10 |
| Flange sockets,Flange spigots,collars,Tapers | 80-1200 | ±25 |
| Flange sockets,Flange spigots,collars,Tapers | 1400-2000 | ±35 |
| Tees | 80-1200 | 25 |
| Tees | 1400-2000 | 40 |
| 90°(1/4) Bends | 80-2000 | ±(15+0.03DN) |
| 45°(1/8) Bends | 80-2000 | ±(10+0.025DN) |
| 22.5°(1/16) Bends | 80-1200 | ±(10+0.02DN) |
| 11.25(1/32)Bends | 1400-2000 | ±(10+0.025DN) |
Spigot external diameter of ductile iron pipe fitting
The ovality of spigot part should be :DN40-200 ,with tolerance of DE
DN250-600, not exceeding 1% of DE
>600, not exceed 2% of DE
Flange thickness and holes
Tolerance for flange thickness is ±(2+0.05*flange thickness)
Tolerance for diameter of bolt circle and diameter of bolt hole are given as below
| DN(mm) | Tolerance for diameter of bolt circle(mm) | Tolerance for diameter of bolt hole(mm) |
|---|---|---|
| 80-150 | ±1 | 1 |
| 200-1500 | ±1.5 | 1.5 |
| 1600-2000 | ±2 | 2 |
WEIGHT TOLERANCE
The total weight of fittings is the body weight plus socket(or flange) part calculated as per density of 7050kg/m3, the tolerance on weight of bends, fittings with branches and ununified fittings is -12%,other fittings are -8%,heavier is ok.
COATING REQUIREMENT
1,Cement Inside,Zinc And Bitumen Outside
Firstly be sure the casting surface be dry, free from rust or non adhering particles or foreign matter such as oil or grease.
the nominal thickness of the cement mortar lining and its tolerance as below.
| DN(mm) | Nominal lining thickness(mm) | Minimum thickness for one point(mm) |
|---|---|---|
| ≦300 | 3 | 2 |
| 350-600 | 5 | 3 |
| 700-1200 | 6 | 3.5 |
| 1400-2000 | 9 | 6 |
the zinc-rich coating and bitumen should be uniform and smooth. making sure the pipe fittings should be dry enough ,so it will not stick to others.
the mean mass of zinc rich painting should not be less than 150g/m2, with a local minimum at 110g/m2, the mean thickness of the bitumen coating should not less than 70um and the minimum thickness should not less than 50um
average thickness should no less than 250um, and minimum thickness for one point should no less than 200um according to en14901
the adhesion should be tested in accordance with en 14901.
3, Inspect the paint and coating quality according to client requirement details if there have any.
PACKAGE AND TRANSPORTATION
1,Ductile iron fittings should be prevented from bruising, deformation and damage when transported over short distances.
2, ductile iron fittings long-distance transport, prevent bruising for the socket and spigot ends of pipe fittings, so each pipe fitting should be packed separately with plastic paper to prevent each other’s bump. If necessary, add paper shells for isolation.
3, to ensure that each piece does not bump into each other, use fumigation-free plywood boxes or pallet for packaging.
4, the storage warehouse should be dry to prevent bolts and other accessories from rusting due to moisture.
5, the transport process should be as smooth as possible, when loading and unloading pipe fittings should be light, to prevent damage to the goods because of improper operation.
RFQ
Can ductile iron fittings be used to connect HDPE pipes?
Nowadays, it is very common to use ductile iron fittings to connect HDPE pipes, because HDPE pipes are connected by hot fusion, the construction is more difficult and the installation cost is about 40% higher than that of ductile iron pipes fittings, and the strength of HDPE pipe fittings is not as strong as ductile iron fittings, so many times we need to install ductile iron fittings to connect HDPE pipes. for example, saddle for water distribution, coupling for connecting two HDPE pipes, flange adaptor for connecting HDPE pipes and flanges, gate valve for connecting HDPE pipes, etc. compared to HDPE fittings, the advantages of ductile iron fittings are as below
1, No need for hot fusion, easier and faster installation, lower cost
2,the ductile iron material is stronger and more reliable than hdpe
3,no special tools or experience are required to install ductile iron fittings
What is Ductile Fitting and its advantage?
Ductile fitting also called ductile pipe fitting, ductile iron fitting, ductile iron pipe fitting, DI pipe fittings or DI fittings. It is ductile iron material pipe fittings which normally be used for water supply.
Compare to grey cast iron pipe fitting,Ductile iron pipe fittings have several advantages over grey cast iron pipe fittings, primarily due to their enhanced mechanical properties and performance characteristics. Here are the key advantages:
Dismantling Joint
Flange Adaptor
Pipe Coupling
Saddle Clamp
Repair Clamp
