KUBOTA DUCTILE IRON PIPE

Repair Manual

KUBOTA Corporation KUBOTA Membrane USA Corporation

Pipe Systems Global Marketing & Sales Dept. ERDIP Dept. / LA Office
1-3, Kyobashi 2-chome, Chuo-ku, Tokyo, 104-8307, JAPAN 3528 Torrance Boulevard, Suite 112, facebook

Tel : +81-3-3245-3228 Torrance,CA 90503, USA

Fax : +81-3-3245-3830 Tel : +1-424-358-5200
Website : https://www.kubota.com/products/ironpipe/ Website : https://www.kubota-membrane.com/page/erdip
E-mail : kbt_g.ironpipe@kubota.com E-mail : kbt_g.erdip-usa@kubota.com

The constructions and dimensions shown in this brochure are subject to change without prior notice. Cat.No.0500 Printed in Japan. '22.7. KES
CONTENTS

■ PREFACE 1

■ REPAIR FLOWCHART 2

■ CUTTING OF PIPE 3

■ CORRECTION OF DEFORMED SPIGOT 8

■ REPAIR OF INTERNAL LINING

(CEMENT MORTAR LINING) 11
□ Crack 13
□ Chip 16
□ Break 18

■ REPAIR OF INTERNAL LINING

(FUSION BONDED EPOXY COATING) 23

■ REPAIR OF EXTERNAL COATING 25

 PREFACE REPAIR FLOWCHART

Damage to ductile iron pipes, caused by improper handling during transportation, may be rectified by
applying certain repair procedures.
This manual has been compiled to offer some quick and effective methods of repairing damaged pipes.
Although these methods may change according site conditions, Kubota would advise the site supervisor
Inspection of Damaged Pipe and Fitting
to follow the repairs outlined in this manual.
The ultimate purpose of this manual is to ensure that the pipes provide lasting service and stand up to
the heavy usage regardless of the minor maintenance required.
Judgement

Minor Serious
Damage Repairable Damage Dispose

Cut Correct the Internal Lining Repair External

（P.3） Cement Mortar Lining Coating Repair
Deformed Spigot Fusion Bonded Epoxy Coating
（P.25）
（P.8） （P.11）

(Select any of the above methods to obtain reusable pipe)

Repaired Pipe Ready for Installation

1 2
 CUTTING OF PIPE

Inspection Procedure 1 Curvature gauge

(1)
Before cutting, carefully inspect the pipe: (1)Check the deformed portion and identify
(1) If the pipe is seriously damaged an undamaged portion with a curvature
reject the pipe. gauge.(Picture 1 )

(2) If there is a hole or crack in the pipe body (2)

reject or cut off the damaged portion. Check for
(3) If the socket is deformed or the spigot is damage
seriously damaged
cut off the damaged portion. (2) Measure the circumference with a
(3) 2
measuring tape.(Picture 2 )
●Dimension must be within the tolerance
in Table 1 of page 6. If it is not, find a
portion that satisfies the value.
Tools and Equipment 1

●Engine driven cutter (Picture 1 )

or Power operated metal saw (Picture 2 )
●Portable disc grinder (Picture 3 )
●Measuring tape (Picture 4 )
(3) Draw a line to indicate where to cut. 3
●Curvature gauge made of plywood, tin (Picture 3 )
plate, plastic, etc.(Picture 5 )
●This tool may be made on site using
2
available materials.
●Taper gauge made of plywood, tin plate,
plastic, etc.(Picture 6 )
●This tool may be made on site using
available materials.

(4) Cut the pipe along the line using an

4
engine driven cutter (Picture 4 ) or a
power operated metal saw. (Picture 5 )
3

4 5 6

3 4
 CUTTING OF PIPE

(5)Completion of cutting. (Picture 6 ) 6 (9)Draw white lines for jointing as per the 10
dimensions specified in Table 2 of page
7. (Picture 10 )
*Stenciled lines may be drawn also by
spray painting.

(10)Completion of cutting work.(Picture 11 )

11

(6)Measure the outside diameter in two 7

or more different directions. (Picture 7 )

*The dimensions must be within the

■Tolerances on Diameter and Circumference (ISO 2531/BS EN 545 & 598)
tolerance in Table 1 of page 6. If it is Table 1 （Dimensions in mm）
not,correct the pipe according to the Allowable
Outside diameter
procedure “Corrections of Deformed DN circumferential
Spigot”. (See page 8-10) Nominal Tolerance length
80 98 +1 -2 301.6 ~ 311.0
100 118 +1 -2 364.4 ~ 373.8
(7)Taper the edge of the spigot with 8 150 170 +1 -2 527.8 ~ 537.2
a portable disc grinder as per the 200 222 +1 -2 691.2 ~ 700.6
dimensions specified in Table 2 of page 7. 250 274 +1 -2 854.5 ~ 863.9
(Picture 8 )
300 326 +1 -2 1017.9 ~ 1027.3
*Taper gauge can be Taper gauge 350 378 +1 -2.3 1180.3 ~ 1190.7
used to easily check 400 429 +1 -2.3 1340.5 ~ 1350.9
the angle of the 450 480 +1 -2.3 1500.7 ~ 1511.1
tapered end. 500 532 +1 -2.3 1664.1 ~ 1674.5
600 635 +1 -2.3 1987.7 ~ 1998.1
700 738 +1 -3.5 2307.5 ~ 2321.6
800 842 +1 -3.5 2634.2 ~ 2648.4
(8)A p p l y the zinc rich paint to the 9
exposed iron surface. And then, apply 900 945 +1 -3.5 2957.8 ~ 2971.9
the bituminous paint to the dried zinc 1000 1048 +1 -3.5 3281.4 ~ 3295.5
rich coating. (Picture 9 ) 1100 1152 +1 -3.5 3608.1 ~ 3622.3
1200 1255 +1 -3.5 3931.7 ~ 3945.8
1400 1462 +1 -3.5 4582.0 ~ 4596.2
1500 1565 +1 -3.5 4905.6 ~ 4919.7
1600 1668 +1 -3.5 5229.2 ~ 5243.3
1800 1875 +1 -5 5874.8 ~ 5893.6
2000 2082 +1 -5 6525.1 ~ 6543.9
Note : Minus tolerance on outside diameter can be increased additionally 0.5 mm for DN≦600 and 1 mm for DN>600
when the measured circumference of the pipe is within the allowable value.
5 6
 CUTTING OF PIPE CORRECTION OF DEFORMED SPIGOT

■ Dimensions of Tapered Spigot for Push-on Joint Inspection 1

L Although ductile iron pipes are tough and

strong, they may be accidentally deformed
X by improper handling. However minor
a b a
deformations can be repaired by the 2 3
following method.
Y
Generally only ellipse on the spigot end can
be corrected. (Picture 1 ) However, if the
spigot is severely deformed and concave
(Picture 2 )or extensively flat (Picture 3 ),
White line generally it can not be corrected. In such a
case, the deformed portion need to be cut.
Table 2 （Dimensions in mm）
Taper White lines Tools and Equipment 1
DN
Y X L a b
●Hammer (Large) (Picture 1 )
80 3 9 82 10 13
●Hydraulic jack (Picture 2 )
100 3 9 86 10 13
●Iron plate with curvature that conforms
150 3 9 95 10 13
to the inner wall of the repairing pipe.
200 3 9 110 10 13
(Picture 3 )
250 3 9 115 10 13
*This can be made on site by cutting
300 3 9 120 10 13 2
out pieces from rejected pipe or cut
350 5 14 135 10 13
pipe, etc.
400 5 14 135 10 13
●Measuring tape (Picture 4 )
450 5 14 135 10 13
500 5 14 140 10 13 ●Wood block (Picture 5 )
600 5 14 145 10 13 ●Curvature gauge (Picture 6 ) made of
700 6 15 160 15 20 plywood, tin plate, plastic,etc.
800 6 15 165 15 20 *This can be made on site using
900 6 15 180 15 20 available materials.
1000 7.5 19 190 15 20
1100 7.5 19 205 15 20 3 4
1200 7.5 19 220 15 20
1400 8.5 23 250 15 20
1500 8.5 23 265 15 20
1600 8.5 23 280 15 20
1800 9.5 26 310 15 20
2000 9.5 26 340 15 20

5 6

7 8
 CORRECTION OF DEFORMED SPIGOT

(4)Release pressure of the hydraulic jack

Procedure 1
and measure the diameters in two or
4

(1)Position the pipe so that the minimum more directions and see if they are within
diameter point is located vertically. the tolerance specified in Table 1 of page
(Picture 1 ) 6.(Picture 4 ) If they are not, repeat (3)
and (4).
*This procedure may be repeated several
times until a correct circle is obtained.

(2) Set the hydraulic jack, a wood block 2

and iron plates in the pipe. (Picture 2 )

Curved iron plate

Wood block

Hydraulic jack

Curved iron plate

In case there is a deformation on the 5

pipe, correct the deformation with a
(3) Gradually expand the diameter until hammer while expanding the
the diameter slightly exceeds the diameter. (Picture 5 )
required dimensions. (Picture 3 ) 3
*Excessive expansion of the pipe
diameter will cause the damage to the
mortar lining.

9 10
 REPAIR OF INTERNAL LINING
CEMENT MORTAR LINING

Repair Material
Select Epoxy Resin or Cement Mortar Table 3 Selection of Repair Material
depending on the degree of damage of
Cement Mortar
Condition
Repair material
cement mortar lining as per Table 3. of damage It is recommended to select cement of the 1 Cement Sand
Crack Epoxy Resin (page 13-15) same quality as that used for the cement
Chip Epoxy Resin (page 16-17) mortar lining.（e.g. Portland cement,
Epoxy Resin (page 18-19) sulphate resisting cement, etc.）
Break
Cement Mortar (page 20-22) (1)Prepare cement and sand in the ratio
of 1：1 by weight. (Picture 1 )

Epoxy Resin 1 Base Resin Hardener

The two different clay-like materials are (2)Mix them well in a container. (Picture 2 )
mixed together and used as putty. The 2
mixing procedure is as follows：
(1)Prepare Epoxy Resin compound. And
take out appropriate ratio of "Base
Resin" and "Hardener" with different
spoons. (Picture 1 )

(3) Add water in small amounts to the

3
mixture and continue to mix them.
(Picture 3 )
( 2 ) Mix t h e m w e l l u n t i l t h e y b e c o m e 2
uniform in color (Picture 2 and 3 ).
*The pot life and condition of the
materials vary according to the materials
and temperature.

(4)Keep mixing until the mixture* becomes 4

such that it can be formed into a lump
3 when grasped firmly in one hand.
(Picture 4 )
*Use the mixture within one hour.

11 12
 REPAIR OF INTERNAL LINING
CEMENT MORTAR LINING

Repair Method

Crack

Inspection Procedure 1

1. Inspect the cement mortar lining. When the cement (1)Cut back the lining about 10-20 mm in
mortar lining has large cracks, deformation of pipe body w i d t h w i t h a c h i s e l a n d h a m m e r.
is expected. In this case, correction of the pipe is (Picture 1 ) A portable disc grinder may
necessay prior to the repair of the lining. be used instead of a chisel and hammer.
(Picture 2 )
2. After the concern of deformation is cleared, check the
crack width and radical displacement. If the pipe has
cracks and radical displacement less than the width
given in Table 4, it is not necessary to repair the surface
crazing and the small cracks. Crack width Radical
Displacement 2
3. If the cement mortar lining has cracks and radical
displacement exceeding the width given in Table 4,
Kubota would recommend repairing them. However,
there is an exception mentioned in BS EN 545 2010.
10∼20mm

Abstract from BS EN 545 2010

Table 4
Storage of pipes and fittings in a hot, dry environment can Maximum crack width and radical displacment
cause metal expansion and mortar shrinkage cracks DN mm
exceeding the width given in Table 4. When the lining is 40 to 300 0.4
reexposed to water, it will swell by absorption of moisture
350 to 600 0.5
and the cracks will close to conform to Table 4 and will
eventually heal by an autogenous process. 700 to 1200 0.6
1400 to 2000 0.8
(2) Clean the surface of the cut-back 3
portion with a brush etc. (Picture 3 )
Tools and Equipment *Remove moisture from the surface.
● Hammer (Picture 1 ) ● Spatula (Picture 2 ) ● Brush (Picture 3 )
● Portable disc grinder (Picture 4 ) ● Chisel (Picture 5 )

1 2 3

4 5

13 14
 REPAIR OF INTERNAL LINING
CEMENT MORTAR LINING

Repair Method

Crack Chip
(3)Fill the cut-back portion with Epoxy Resin
4 Inspection 1
and smooth the surface with a spatula.
(Picture 4 ) Inspect the damaged area carefully and
confirm that there is no deformation or
crack on the pipe body. (Picture 1 )

Tools and Equipment 1

(4)Inspect the finished surface (Picture 5 ) 5 ●Brush (Picture 1 )

●Spatula (Picture 2 )

Procedure 1

(1) Clean the surface of the damaged

portion with a brush, etc. (Picture 1 )
*Remove moisture from the surface.

15 16
 REPAIR OF INTERNAL LINING
CEMENT MORTAR LINING

Repair Method

Chip Break
(2)Fill the chip with Epoxy Resin (See page
1 1 ) and smooth the surface with a 2 Inspection 1
spatula. (Picture 2 ) Inspect the damaged area well. If the
cement mortar lining is broken off in a large
area, cut the pipe to remove the damaged
portion. (Picture 1 )

Tools and Equipment 1

●Hammer (Picture 1 )
●Chisel (Picture 2 )
●Brush (Picture 3 )
●Spatula (Picture 4 )
(3)Inspect the finished surface. (Picture 3 ) 3

17 18
 REPAIR OF INTERNAL LINING
CEMENT MORTAR LINING

Repair Method

Break Break（Alternative Option - by means of Cement Mortar）

Procedure 1 Inspection 1

(1) Cut back the damaged lining so that Inspect the damaged area well. If the
the edge of the lining is at right angles to cement mortar lining is broken off in a large
the iron surface. (Picture 1 ) area, cut the pipe to remove the damaged
portion. (Picture 1 )

*If the cement lining is peeled off from the

iron surface, cut out the affected area.
Tools and Equipment 1

●Hammer (Picture 1 )
●Chisel (Picture 2 )
●Brush (Picture 3 )
Peeling of lining
●Spatula (Picture 4 )
(2) Clean the surface of the damaged 2 ●Adhesive tape (Picture 5 )
portion with a brush. (Picture 2 )
●Plastic sheet (Picture 6 )
2

(3) Fill the damaged portion with Epoxy 3

Resin and smooth the surface with a
spatula. (Picture 3 ) 3 4

(4)Inspect the finished surface. (Picture 4 ) 4

5 6

19 20
 REPAIR OF INTERNAL LINING
CEMENT MORTAR LINING

Repair Method

Break（Alternative Option - by means of Cement Mortar）

Procedure 1 (4)Fill the damaged portion with the cement 4

mortar mixture. (Picture 4 )
(1)Cut back the damaged lining so that
the edge of the lining is at right angles to
the iron surface. (Picture 1 )

*If the cement lining is peeled off from

the iron surface, cut out the affected
area. (5)Tap the filled cement mortar mixture gently 5
with a hammer until it is compacted.
(Picture 5 )

Peeling of
lining

(2) Clean the surface of the damaged

2
portion with a brush. (Picture 2 )
(6) Smooth the surface with a spatula. 6
(Picture 6 )

(3) Apply some water to the damaged 3

portion with a brush. (Picture 3 ) (7)Curing: 7
Cover the repaired portion with a wet
towel or wet paper, then seal up with
plastic film and adhesive tape. Keep it on
for more than 24 hours. (Picture 7 )
*Other curing methods may be applied
according to the condition on site and
the supervisor's decision.

21 22
 REPAIR OF INTERNAL LINING
FUSION BONDED EPOXY COATING

Repair Material Repair Method

2-pack epoxy paint 1 Base Resin Hardener Tools and Equipment 1

The two different materials are mixed

together and used as paint. The mixing ●Sandpaper (Picture 1 ) ●File (Picture 2 )
procedure is as follows: ●Portable disc grinder (Picture 3 ) ●Brush (Picture 4 )
(1)Prepare 2-pack epoxy paint. And take
out appropriate ratio of “Base Resin” and
2 3 4
“Hardener” with different spoons. (Picture 1 )
*Use our recommended repair material.

Procedure 1

(2)Mix them well in a container until they 2 (1) Roughen the sound coating around
become uniform in color. (Picture 2 the damaged area with a sandpaper, file
and 3 ) or portable disc grinder to the extent of
10mm to 20mm. (Picture 1 )
10-20mm 10-20mm
FBE coating

Ductile Iron

(2)Clean the surface of the damaged area 2

with a brush, etc. (Picture 2 )
3 *The area to be repaired shall be clean
and free from sand, dust, moisture, etc.

(3) Appy the 2-pack epoxy paint to the 3

damaged area and the roughened
surrounding coating with a brush.
(Picture 3 )
*Paint several times at intervals to obtain
Repair Method
the specified dry film thickness.

Inspection

Inspect the fusion bonded epoxy coating. (4)Inspect the finished surface.(Picture 4 ) 4
If the fusion bonded epoxy coating is
damaged, repair of the fusion bonded
epoxy coating is required.

23 24
 REPAIR OF EXTERNAL COATING

Inspection Precautions
Inspect the external coating. If the external (1)Do not apply coating when the pipe
coating is damaged, repair of the external surface is wet. The coated surface has
coating is required. to be completely dried before installation.

Tools and Equipment

●Wire brush ●Sandpaper ●Brush (2)Keep away from open flames because
the coating material is inflammable.

(3) Use the coating material only in well

ventilated areas.
Procedure 1

(1) Remove foreign materials and clean

the surface. (Picture 1 )
*If the surface is rusted, use wire brush or
sandpaper to remove the rust, then wipe
off with a cloth.

(2)Apply the zinc rich paint to the cleaned 2

iron surface with a brush. (Picture 2 )
*Zinc rich paint shall not be applied to the
wet or moist iron surface or over the
existing bitumen coating.

(4)Avoid contact with the skin and eyes. If

contact occurs, wash affected area
(3)Apply the bituminous paint to the dried 3 immediately with soap and water.
zinc rich coating with a brush. (Picture 3 )
*The bituminous paint can be thinned
with the specific thinner when the
viscosity of the bituminous paint is too
high to apply with a brush.

25 26
 MEMO

27