Is.9523 (2000) LNT

A Presentation on
IS 9523 (2000) :
DUCTILE IRON FITTINGS FOR PRESSURE PIPES
FOR WATER, GAS AND SEWAGE
WATER & EFFLUENT TREATMENT IC – WSD EDRC

Sensitivity: LNT Construction Internal Use
PROJECT TITLE (IN SHORT) 1
CONTENT
Introduction & Scope
Manufacture and Repair
Thickness of fittings
Tests
Sizes
Joints
Dimensions and other
requirement
Tolerances
Coating
Quality Assurance
Marking
Special Casting

PROJECT TITLE (IN SHORT) 2
Introduction & Scope
 A fitting is used in pipe system that function as

connection, control, direction change, and support.
 This standard covers requirements for ductile iron

fittings (special castings) to be used with pressure pipes
for carrying water, gas and sewage for sizes from 80
to 2000 mm nominal diameter.
 This standard is applicable to fittings meant for

mechanical joints (bolted gland), push-on-joints and
flanged joints for jointing by means of various types
of gaskets.
Fig. 1. Socket and spigot Flexible Push-
 The fittings are suitable for fluid temperatures on Joint.
between 0°C and 50°C excluding frost.

Sensitivity: LNT Construction Internal Use PROJECT TITLE (IN SHORT) 3
Manufacture and Repair
 The metal used for the manufacture of casting shall conform to the appropriate grade as specified
in IS 1865. It shall be prepared at the discretion of the manufacturer in cupola, or an active mixer.
 The castings shall be stripped with all precautions necessary to avoid warping or shrinkage defect,
detrimental to their good quality. The castings shall be sound and free from surface or other
defects.
 Minor defects may be rectified with the approval of the purchaser. Repairing of defects by
welding, plugging off leaks by caulking or by application of epoxy putty, may not be done without
previously securing the approval of the purchaser.
 The castings shall be such that they could be cut, drilled or machined. In case of dispute the
castings may be accepted provided that the hardness measured on the external un-machined
surface does not exceed 250 HBS.
PN (Pressure Nominal): Maximum permissible gauge working pressure in MPa

4
Thickness of Fittings
The thickness ‘e’ of fittings is calculated as a function of the nominal diameter

'DN' by using the formula given below with the following values for K:
e = K (0.5 + 0.001 DN)
where K = 14
e = 7 + 0.014 DN
where K = 12
e = 6 + 0.012 DN
For ‘DN 80’ the thickness of the fitting has been limited to minimum of 7 mm, so
that, taking the tolerances into account, the thickness of the fittings is always at
least equal to that of the pipes of the same nominal diameter.

5
Tests
Mechanical Tests:
• Tensile test: One tensile test shall be made on bar cast from the same metal in accordance with the
methods specified in IS 1608. The result of the test shall conform to the mechanical properties
given in Table.
Nominal Type of castings Tensile Elongation at
Diameter(mm) strength(Min), break
(Mpa) percent(Min)
All sizes Fittings 420 5
• Hardness test: The hardness measured on the external un-machined surface does not exceed 250
HBS. Test should be carried out on tensile tested bar mentioned above.
• Heat Treatment: Fittings shall be supplied in either ‘as cast’ condition or ‘heat treated’ condition. In
either case, the fittings shall comply with the mechanical properties specified in above two points.
• Retest: If the piece representing the lot fails to pass tests specified in above mentioned tensile and
hardness test, two additional tests shall be made on test pieces made from the same metal used for
that lot. Should either of these additional test pieces fail to pass the test the lot shall be considered as
not complying with this standard.
6
Tests
Hydrostatic test
For hydrostatic test, the fittings shall be kept under pressure for 10 seconds. They shall withstand
the pressure test without showing any sign of leakage, sweating or other defect of any kind. The
test shall be conducted before the application of surface coating.
Nominal Diameter DN(mm) Hydrostatics test pressure at works,

(Mpa)
Upto and including 300 2.5
Over 300 and upto and including 600 1.6
Over 600 and upto and including 2000 1

7
Sizes
The standard nominal sizes ‘DN” of the fittings covered in this
standard are as follows:
80, 100, 125, 150, 200, 250, 300, 350, 400, 450, 500, 600,700,750,
800,900, 1000, 1100, 1200, 1400, 1600, 1800 and 2000 mm.

8
Joints
Push-on-Joint:
• The push on joint consists of a special bell, plain-end rubber gasket. The bell is provided with an
internal groove in which the appropriate gasket is seated. The joint is assembled by pushing the
plain end into the bell which compresses the gasket and forms a watertight seal. The push-on joint
has been tested to more than 1,000 psi internal pressure, 430 psi external pressure and 14 psi
negative air pressure with no leakage or infiltration.

9
Joints
Mechanical Joints:
It has four parts, a flange cast with the bell, a rubber gasket that fits in the bell recess, and tee bolts
and nuts. It is a very simple assembly and required only one tool ˗ an ordinary ratchet wrench. The
pressure rating is similar to push on joints.

10
Joints
Flanged-Joints:
These are very few times used for underground water mains. These joints are most commonly
used for inside piping in pump room, filter plants, sewage treatment plant. Because of its rigidity
this type of joints are not recommended where heavy vibrations is likely to occur. These joint can
be work up-to 350 psi depending upon the nominal diameter.

11
Dimensions and other Requirement
Dimensions of Fittings for Push-on-Joint

and Mechanical Joint
All Dimensions are in mm

12
Dimensions of Standard Flange Drilling for Flange Fittings PN 10

13
Dimensions of Standard Flange Drilling for Flange Fittings PN 25

14
Tolerances
Table 1 Tolerances on the External Diameter D and E
DN→ 80, 100, 150, 200, 350, 400, 700, 750,

125 250, 300 450, 500, 800, 900,
600 1000
Tolerance ±4.5 +5.5, -2.5 +6.5, 3.5 +7.5, -4.0
on D→
Tolerance ±4.0 ±4.5 ±5.0 ±5.5
on E→
DN→ 1100, 1200 1400 1600, 1800 2000
Table 2 Tolerances on Thickness of Flange Tolerance +8.5, -4.0 +10.0, -5.0 +12.0, -6.0 +12.0, -6.0
on D→
Type of Flange Tolerance
Integrally Cast Flanges ±(3+0.05b) Tolerance ±5.5 ±6.0 ±6.0 ±6.0
on E→
Welded and Screwed on ±(2+0.05b)
Flanges

15
Tolerances
Table 3 Tolerances on Raised Face Height (f) Table 4 Tolerances on Flange Drilling
Dimension Día 19 to dia Dia 31 to Dia Above dia 62
Height of raised face(f) Tolerance 28 56
3 +1.5, -2.0
Bolt hole +2, -0 +3, -0 +4, -0
4 +2, -3.0 diameter,(d)
5 +2.5, 4.0 Pitch circle ±2 ±2.8 ±4.8
diameter,(C)
Centre-to- ±2 ±2.8 ±4.8
Centre of
adjacent bolt
holes

16
Tolerances
Tolerance on ovality
• Fittings shall be as far as possible circular internally and externally. The tolerance for out of
roundness of the socket and spigot ends in the jointing zone for push-on-joint as given in Table 1
and for mechanical joint as given in Table 2.
Table 2 Allowable Ovality for Mechanical
Table 1 Allowable Ovality for Joint Fittings
Push-on-Joint Fittings
Nominal Maximum
Nominal Allowable Diameter Ovality of
Diameter Difference DN(mm) Spigot of
DN(mm) between Minor External
Axis and DE, Diameter
Min(mm) DE(mm)
80-300 1.0 80-150 5

350-600 1.75 200-350 10
700 2.0 400-500 20
750-800 2.4 600-800 30
900-1000 3.5 900-1000 40
1100-1200 4.0 1100-1400 50
1400-1600 4.5 1600-2000 60

17
Deviation on lengths of Fittings
Type of fittings Nominal Diameter DN(mm) Deviation in L and H(mm)
Flanged Sockets, Flanged 80 to 1200 ±25

Spigots, collars, Tapers
1400 to 2000 ±35
Tees 80 to 1200 +50/-25
1400 to 2000 +75/-35
Bends 90°(1/4) 80 to 2000 ±(15 + 0.03DN)
Bends 45°(1/8) 80 to 2000 ±(10 + 0.025DN)
Bends 22°30’ and 11°15’ 80 to1200 ±(10 + 0.02DN)
1400 to 2000 ±(10 + 0.025DN)

18
Coating
External Coatings
• The following coatings may be applied depending upon the external condition of use:
a) Metallic zinc
b) Zinc rich paint
c) Bituminous Paint
d) External Sleeving

19
Coating
• Zinc coating on ductile iron pipe is the most effective and dependable way to eliminate corrosion
in iron pipe for more than 50 years.
• The metallic zinc coating shall be applied by a spraying process in which metallic zinc material is
heated to a molten state and projected in small droplets by spray guns onto surface. The zinc rich
paint coating shall be applied by a spraying or a brush process onto the fittings surface.
• Damaged areas of zinc coating or zinc rich paint coating caused by handling are acceptable
providing the damage is less than 5 cm² per square meter of coated surface and the minor
dimensions of the damaged area does not exceed 5 mm.
• The mean mass of zinc coating measured shall be not less than 130 g/m² with a local minimum of
110 g/m². In case of zinc rich paint the mean mass is 150 g/m² and the local minimum value is 130
g/m².

20
Coating
• The mean mass of zinc coating M expressed in Grams per square meter, is calculated as,
• Where, M₁,M₂= masses in grams before and after zinc coating.

A= area of token provided with the fittings.
a) 250mm*100mm
b) 500mm*50mm
C= Correction factor depends upon the difference between surface roughness of
fittings and token.
• After metallic zinc coating or zinc rich paint coating the fittings shall be given a finishing layer of
bituminous paint or synthetic resin compatible with the zinc coating.
• The mean dry film thickness of the finishing layer shall be less than 70 μm with a less minimum
thickness of 50 μm.

21
Coating
Internal Linings
• The following lining may be applied depending on the internal conditions of use:
a) Portland cement (with or without additives) mortar
b) Blast furnace slag cement mortar
c) High alumina (calcium aluminate) cement mortar
d) Cement mortar with seal-coat
e) Bituminous paint
• Portland cement (as per IS 269 or IS 455) mortar lining perform rather well and have an expected
life of approximately 50 years in soft water with moderate amount of aggressive CO ₂ and when
pH is within 6 to 9. Longer service life can be obtained by increasing the mortar lining thickness.
• Where cement mortar lining may be exposed to sulphate attack, ordinary Portland cement should
be replaced by sulphate resisting Portland cement (as per IS 12330 or IS 6909). The sulphate
concentration limit for sulphate resisting Portland cement is approximately 3000 mg/l, for sea
water transmission blast furnace slag cement which has, C₃A content below 3 percent can be used.

22
Coating
Recommended Types of Cements
Used for Lining
Water Portland Cement Sulphate resisting High Alumina

Characteristics Cement Cement
Maximum Value of 6 5.5 4
pH
Max. Aggressive 7 15 no-limit
CO₂(in mg/l)
Max. Sulphates 400 3000 no-limit
SO₄¯(in mg/l)
Max. Magnesium 100 500 no-limit
Mg˖˖(in mg/l)
Max. Ammonium 30 30 no-limit
NH₄˖(in mg/l)

23
Coating
Thickness of the Lining
DN(Nominal Nominal Value of Tolerance in Maximum Crack
Diameter)mm Thickness(mm) Thickness(mm) width and radial
displacement(mm)
80 to 300 3 -1.5 0.8
350 to 600 5 -2.0 1.0
700 to 1200 6 -2.5 1.2
1400 to 2000 9 -3.0 1.5
• Determination of lining thickness

The thickness of the lining is checked on the freshly centrifuged mortar by the insertion of a steel
pin, or on the hardened mortar by means of a non-destructive method of measurement. The
thickness of the lining shall be measured at both ends of the fittings in at least one section
perpendicular to the fittings axis.

24
Coating
Bituminous Coating
• Unless otherwise agreed between the purchaser and the manufacturer, fittings shall be coated
externally and internally with the same material. (Bituminous coatings are either hot applied or
cold applied).
• Where the coating material has a tar or similar base, it shall be smooth and tenacious and hard
enough not to flow when exposed to a temperature of 65°C but not so brittle at a temperature of
0°C as to chip off when scribed with a penknife.
• When the pipes are to be used for conveying potable water the inside coating shall not contain any
constituent soluble in such water or any ingredient which could impart any taste or whatsoever to
the potable water after sterilization and suitable washing of the mains.
• When specified the cement lining shall be given a seal coat of bituminous material or any other
epoxy based material compatible with Cement Mortar Lining. The purpose of seal coat is to
minimize lime leaching of the cement mortar as well as to restrict the unwanted rise in pH value of
the transmitted water.

25
Coating
Polyethylene Sleeving
• The material used for making the film is polyethylene or a mixture of polyethylene's and/or
ethylene and olefin copolymers.
• The nominal thickness of the sleeving shall be not less than 200 μm and not more than 250μm
unless otherwise agreed.
• Tensile strength of the film in the longitudinal and transverse direction shall be not less than 8.3
MPa.
• The elongation at fracture of the film in the longitudinal and transverse directions shall be not less
than 300 percent.
• The Dielectric Strength of the film should be 31.5V/μm minimum.

26
Quality Assurance
 The manufacturer shall be able to demonstrate the conformity of the product to the requirements
contained in this standard by controlling the manufacturing process and carrying out the various
tests as specified in this standard.
 The manufacturer shall control the quality of the product during manufacturing process by a
system of process control in order to comply with the technical requirements contained in this
standard wherever possible statistical sampling techniques should be used to control the process so
that the product is produced within the specified limits.

27
Marking
Each fittings shall have as cast, stamped or indelibly painted on it, the following appropriate marks.
a) Indication of the source of manufacture,
b) The nominal diameter,
c) The last two digits of the year of manufacture,
d) PN rating of flanges when applicable, and
e) Any other mark required by the purchaser.
BIS Certification Marking

The use of the Standard Mark is governed by the provisions of the Bureau of Indian Standards Act,
1986 and the Rules and Regulations made thereunder. The details of conditions under which the
license for the use of the Standard Mark may be granted to manufacturers or producers may be
obtained from the Bureau of Indian Standards.

28
Special Casting
Special castings of the following types with their ends either socketed (for mechanical joints or push-on-joints)
or flanged.
• Double Socket 90° Bend
• Double Socket 45° Bend
• Double Socket 22½° Bend
• Double Socket 11¼° Bend
• Double Socket 90° Duck-foot Bend
• Double Socket Tapers
• All Socket, Flanged on Double socket Tees
• Collars
• Flanged Socket
• Flanged Spigot
• Blank Flanges
• 90° Double Flanged Bend
• 45° Double Flanged Bend
• 90° Duck-foot Double Flanged Bend
• All Flange Tee
• Double Flanged Tapers
• Reducing Flange

29
Double Socket 90° Bend
Normal application: Change in direction of pipeline by 90°

30
Double Socket 45° Bend
Normal application: Change in direction of pipeline by 45°

31
Double Socket 22½° Bend

32
Double Socket 11¼° Bend

33
Duck-foot Double Socket 90° Bend
Normal application:
Location of vertical bend where high vertical load or thrust is present.

34
Double Socket Concentric Taper
Normal application: Change in nominal size of pipeline.

35
All Socket, Flange on Double Socket Tees

36
All Socket, Flange on Double Socket Tees

37
Flanged Socket

38
Flanged Spigot

39
Blank Flanges
Normal Application :These flanges are used for capping off or terminating

another flange.

40
Double Flanged 90°Bend

41

42

43
Double Flanged Concentric Tapers

44
Reducing Flange
Normal Application : Reducing flanges are a
specialty flange that are most often used on projects that
require the fitting together of different sized pipes.
A reducing flange consists of a flange with one specified
diameter having a bore of a different and smaller, diameter.

45
Thank You

46

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A Presentation on

WATER & EFFLUENT TREATMENT IC – WSD EDRC

WATER & EFFLUENT TREATMENT IC – WSD EDRC

 A fitting is used in pipe system that function as

 This standard covers requirements for ductile iron

 This standard is applicable to fittings meant for

WATER & EFFLUENT TREATMENT IC – WSD EDRC

PN (Pressure Nominal): Maximum permissible gauge working pressure in MPa

WATER & EFFLUENT TREATMENT IC – WSD EDRC

The thickness ‘e’ of fittings is calculated as a function of the nominal diameter

WATER & EFFLUENT TREATMENT IC – WSD EDRC

Nominal Diameter DN(mm) Hydrostatics test pressure at works,

WATER & EFFLUENT TREATMENT IC – WSD EDRC

WATER & EFFLUENT TREATMENT IC – WSD EDRC

WATER & EFFLUENT TREATMENT IC – WSD EDRC

WATER & EFFLUENT TREATMENT IC – WSD EDRC

WATER & EFFLUENT TREATMENT IC – WSD EDRC

Dimensions of Fittings for Push-on-Joint

All Dimensions are in mm

WATER & EFFLUENT TREATMENT IC – WSD EDRC

All Dimensions are in mm

WATER & EFFLUENT TREATMENT IC – WSD EDRC

All Dimensions are in mm

WATER & EFFLUENT TREATMENT IC – WSD EDRC

DN→ 80, 100, 150, 200, 350, 400, 700, 750,

WATER & EFFLUENT TREATMENT IC – WSD EDRC

All Dimensions are in mm

WATER & EFFLUENT TREATMENT IC – WSD EDRC

80-300 1.0 80-150 5

WATER & EFFLUENT TREATMENT IC – WSD EDRC

Flanged Sockets, Flanged 80 to 1200 ±25

1400 to 2000 ±35

Tees 80 to 1200 +50/-25

1400 to 2000 +75/-35

Bends 90°(1/4) 80 to 2000 ±(15 + 0.03DN)

Bends 45°(1/8) 80 to 2000 ±(10 + 0.025DN)

Bends 22°30’ and 11°15’ 80 to1200 ±(10 + 0.02DN)

1400 to 2000 ±(10 + 0.025DN)

WATER & EFFLUENT TREATMENT IC – WSD EDRC

WATER & EFFLUENT TREATMENT IC – WSD EDRC

WATER & EFFLUENT TREATMENT IC – WSD EDRC

• Where, M₁,M₂= masses in grams before and after zinc coating.

WATER & EFFLUENT TREATMENT IC – WSD EDRC

WATER & EFFLUENT TREATMENT IC – WSD EDRC

Water Portland Cement Sulphate resisting High Alumina

WATER & EFFLUENT TREATMENT IC – WSD EDRC

• Determination of lining thickness

WATER & EFFLUENT TREATMENT IC – WSD EDRC

WATER & EFFLUENT TREATMENT IC – WSD EDRC

WATER & EFFLUENT TREATMENT IC – WSD EDRC

WATER & EFFLUENT TREATMENT IC – WSD EDRC

BIS Certification Marking

WATER & EFFLUENT TREATMENT IC – WSD EDRC

WATER & EFFLUENT TREATMENT IC – WSD EDRC

All Dimensions are in mm

WATER & EFFLUENT TREATMENT IC – WSD EDRC

Normal application: Change in direction of pipeline by 45°

All Dimensions are in mm

WATER & EFFLUENT TREATMENT IC – WSD EDRC