Electrosteel D.I. Pipes and Fittings are available with following types of jointing systems:
- Socket & Spigot Flexible Push-on Joints
- Restrained Joint Push-on Type
- Mechanical Flexible Joints (only fittings)
- Flanged Joint
Socket & Spigot Flexible Push-on Joints
Socket and Spigot Flexible Joints are assembled with synthetic (Ethylene Propylene Diene Monomer / Styrene-Butadiene-Rubber) rubber gaskets of special shape. The gasket has a hard ‘Heel’ and a soft ‘Bulb’. In Push-on joint the soft bulb of the rubber gasket is compressed when the spigot is inserted into the socket. The ‘Heel’ locks the position of the gasket and does not allow the gasket to get displaced when the spigot is pushed in. The joint becomes tighter with the increase in internal pressure of water. The rubber is confined in a place and cannot blow out.
Permissible Deflection at Socket and Spigot Joints
Where it is necessary to deflect the pipeline from a straight line, either in the vertical or horizontal plane, to avoid obstructions etc., deflection at joint should not exceed the following:
|Push on Joint
||Maximum Deflection Angle
Electrosteel ductile iron pipe Joints are type tested
Electrosteel's design of the socket and the rubber gasket ensures guaranteed leak-tight joint through Type Test as per BSEN:545/ EN598 and ISO:2531. Type Test is testing the pipe and pipe joint at extreme working conditions (the product and use) to ensure satisfactory performance for a long time.
Jointing of Pipes
||Step 1: Clean the socket grooves and outside spigot end.
||Step 2: Hold the gasket as shown and place inside the socket
||Step 3: Apply lubricant on the gasket. Do not use petroleum based lubricant.
||Step 4: Apply lubricant on the spigot also. Please check that the spigot end is properly champhered.
||Step 5: Properly align both the pipes.
||Step 6: Gently push the spigot into the socket with suitable mechanical means.
The absence of sunlight and oxygen, presence of moisture/water, relatively lower and uniform surrounding temperature in buried conditions help in preservation of rubber gaskets. Thus this type of joint is expected to last for more than 100 years.
- Good quality Synthetic rubber gaskets made either of SBR (Styrene Butadyne Rubber) or EPDM (Ethylene Propylene Diene Monomer) conforming to IS:5382 are used with Ductile Iron push-on joint pipes.
- Gasket should be stored in a cool & dry place. Direct exposure to sunlight should be avoided.
- It is advised that the users should obtain gaskets through Electrosteel only.
- The sockets should face uphill while pipeline is laid on a slope.
- The direction of flow has nothing to do with direction of the socket.
- Never use petroleum based lubricant during jointing. It damages the gasket.
- All Fittings should be suitably anchored against displacement as recommended in the laying specification.
- Spigots should be inserted into the socket up to the white insertion mark to ensure proper jointing.
- The joint deflection should not be more than the recommended deflection.
Restrained Joint Push-on Type for Buried Pipes
Restrained Joints are special jointing system, which can take care of axial movement in case of thrust. Hydraulic thrust forces occur in pressurized mains, when there is any change in direction (bends, tees) or any change of diameter (tapers, valves) or any pipeline end (blank flanges or caps). These special joints are necessary on fittings and a few pipes adjacent to the fittings. Restrained Joints eliminate use of concrete anchor blocks, which are costly and delay the progress of laying operation.
Mechanical Flexible Joints
In mechanical joint, sealing is achieved by applying pressure on the gasket by a separate gland. When bolted with the pipe, the gland exerts pressure on the sealing rubber gasket and makes the joint leak proof.
Mechanical Joints are popular due to the following advantages:
- Easier to assemble and dismantle without any special tool.
- Needs only a spanner.
- The leaking joint can be repaired very easily.
- Offers high flexibility and wider dimensional tolerance of the socket and spigot.
Jointing Procedure of Mechanical Joint Pipe & Fittings
- Clean the jointing socket and spigot of the pipe thoroughly.
- Insert the follower gland and the gasket on the spigot.
- Put the spigot into the M/J socket and align the pipes. Next slide the gland and gasket in position.
- Insert the nut-bolts and tighten diametrically opposite bolts.
- Ensure that the follower gland presses the rubber gasket properly.
- In case of any leakage the bolts may be tightened further.
- Joints to be assembled completely and then give required deflection.
Jointing of Flanged Pipes
Over ground and specialized applications require restrained joints where Flanged pipes are used. Flanged Pipes have the following advantages:
- Acts as self-restrained Joint reducing the requirement of thrust blocks.
- Ideal for over-ground and Exposed Installations
- Flanged Pipes are ideal for Vertical pipelines.
- Used for Temporary Installations (over pillars) where pipelines need to be disengaged or displaced.
- Widely used for interconnection in Pump House and Treatment Plant.
|Flanged Pipe type
||Diameter Range and lengths
||Available PN Ratings
|Welded Flanged Pipes
|Flanges are welded on either side of a Class K9 barrel
||From 80DN to 1000DN lengths up to 5.0 m.
||PN 10, PN 16, PN 25, PN 40
|Screwed Flanged Pipes
|Flanged are screwed-fit on either side of a Class K9
||From 80DN to 300DN diameter, in lengths up to 5.0 m.
||PN 10, PN 16
|Cast Flanged Pipes
|Flanged Pipe is cast as a single unit using advanced Lost Foam method.
||From 80DN to 200DN up to 700mm length and 250DN to 700DN up to 1.2 m length
||PN 10, PN 16, PN 25, PN 40
Jointing of Flanged Joints
- Properly align the pipes
- Clean flange faces and remove rust and dirt
- Position the gasket. Use 3 mm. thick moulded rubber gaskets with quality conforming to IS 5382.
- Lubricate bolt threads, all mating surface and flanges
- Use automotive grade oil / grease
- Insert the nut-bolts one by one. Tighten diametrically opposite bolts to the recommended torque
- If necessary, re-tighten bolts before pressure testing
Electrosteel manufactures Flanged Pipes using all the three methods, that is, Welded Flanged Pipes, Screwed Flanged Pipes and integrally Cast Flanged Pipes (short lengths). Other types of coating and lining to the Flanged Pipes are also available. All flanged pipes are normally lined with Cement Mortar and has outside Zinc and Bitumen Coating.
- Buried installation of flanged pipe is not recommended.
- Flanged joint being a rigid joint, perfect alignment of the flange faces during jointing and bolt tightening is absolutely vital.
- Use of duck foot bend at bottom of vertical flange pipe line is necessary.
- For high pressure application, flanged pipeline needs thrust block / support at bends / tees.