Ductile lron Features


What is Ductile Iron?

It is also named as Ductile Cast Iron, Nodular Cast Iron, Spheroidal Graphite Iron, Spherulitic Graphite Cast Iron, and SG Iron. It is more flexible and elastic than the variety of cast iron. It is not a single material but a part of the material’s group that produce a wide range of properties through control of microstructure as compared with the Grey Cast Iron. It is also claimed to be one of the most significant metallurgical developments and had increased the impact in many industries due to it is competitive properties with polymeric materials like the PVC, HDPE, LDPE and Polypropylene. Ductile Iron is produce by treating or adding molten low-sulfur base iron with magnesium under controlled conditions. The start of change in the metal is characterized by the free graphite in ductile iron which is being deposited in the spheroidal or nodular form instead of flakes form as in gray iron. With the nodular form the continuity of the metal matrix are on the maximum, the table below shows the formation of more superior metal properties than Gray Cast Iron.

Properties                                                                              

INDIPCO is manufacturer of ductile iron pipes with the additional features.

  •  High Strength/Impact
  •  High Safety factor
  •  Single Rated system
  •  Tolerates ground movement
  • Proven ease of jointing and installation
  •  Extensive size range
  •  Suitable for above and below the   ground
  •  Bend strength of 200 MPa
  •  Crossing bridges and rivers


Production Process Flow and Quality Control

INDIPCO's main goal ts to be always the world’s number one producer of high Quality Ductile Iron Pipe to satisfy client’s needs and conformed to its standard specification. “Doing the right from begin to end; means to produce a Quality products.”

Raw Material
  • Laboratory personnel are carefully analyzed the incoming raw materials to achieve best Quality product.
  • Metal compositions, purity, viscosity and etc.
            
Melting
  • At this stage the raw materials are increased its temperature to achieved the super-heat to obtain a molten metal.

            


Magnesium Treatment
  • introduce the Magnesium metal as nodulizing element at specific amount and at exact temperature condition for producing a quality ductile iron pipe that provides the maximum ductility and malleability of metal properties.
  • Quality checking is observed in this stage. Sample is analyzed in the laboratory for chemical composition and micro-structure of metal.
            
Iron Mold Centrifugal Casting Machine
  • The molten metal is injected into a centrifugal mold casting machine with quality made sand core.
  • Molten metal is rotated at certain rpm so it will evenly cover the long cylindrical mold.
  • Quality control’s tight visual inspection on the pipes like damage, cracks, and holes.

            


Annealing
  • The pipes are passed in this process tor micro-structure correction to give the best result for the ductility and malleability of the metal.
  • Tight sampling technique and inspection in this area is very challenging and dimensional inspection of pipes.
            
Zinc Coating
  • It is coated at the outer layer for the pipe to have corrosion resistance of all types of mineral or chemical in soil.
  • It is dimensional inspection implemented and base on the Acceptance Quality Level of thickness.

            


Internal Cement Lining
  •  This lining reduces the tuberculation inside the pipe network. And the lining provides an area of high pH near the pipe and provides a barrier between the liquid passing through and the pipe, reducing its susceptibility to corrosion.
  • Thickness inspections were monitored base on statistical method of standard specification and testing.
            
Bitumen Coating
  •  It is an organic liquids that are highly viscous, black, sticky and composes primarily of highly condensed Poly-cyclic Aromatic Hydrocarbons, Which used for protecting the pipe prior to installation.
  • Visual inspection for even coating and coating thickness are monitored.

            


Finished Product

Visual inspection and leak test is conducted in socket to spigot base on the SASO 1014 GS 766.