Utilizing 70% post-consumer

recycled paper pulp

KUBOTA
DUCTILE IRON PIPE

KUBOTA Corporation KUBOTA Membrane USA Corporation

Pipe Systems Global Marketing & Sales Dept. ERDIP Dept. / LA Office
1-3, Kyobashi 2-chome, Chuo-ku, Tokyo, 3528 Torrance Boulevard, Suite 112,
104-8307, JAPAN Torrance, CA 90503, USA Facebook
Tel : +81-3-3245-3228 Tel : +1-424-358-5200
Fax : +81-3-3245-3830 Website : https://www.kubota-membrane.com/page/erdip
Website : https://www.kubota.com/products/ironpipe/ E-mail : [email protected]
E-mail : [email protected]

The constructions and dimensions shown in this brochure are subject to change without prior notice. Cat.No.0100 Printed in Japan. '22.7. KES
 COMPANY PROFILE CONTENTS
Corporate Name 03 Kubota Pipeline System

CONNECT
KUBOTA Corporation 05 Kubota's History with Ductile Iron Pipe
Established 06 Plant Information
1890
07 Advantages of Ductile Iron Pipe
Capital
11 Line Up
￥84.1 billion（as of April 25,2017）

TO THE FUTURE
15 Manufacturing Process and Quality Control
Revenues (Consolidated)
￥1,596.1 billion 17 Supply Record
（Fiscal Year ended December 31,2016）
Number of employees(Consolidated)
38,291 （as of December 31, 2016）
*The number of full-time employees.
01 02
 Drainage Pump Ductile Iron Ductile Iron Pipe Double Disc Wedge

KUBOTA
with Vehicle Water Well Casing Pipe (Earthquake Resistant Joint) FCC Slide Valve Gate Valve

PIPELINE SYSTEM

Dam

Refinery Plant
Petrochemical Plant

Water Treatment Plant

Sewage
Water System System Seawater
Desalination Plant

Sewage Treatment Plant

Lifting Pumping
Station

Double Suction Volute Resilient Seated Vertical Shaft Volute Type Ductile Iron Pipe
Vertical Mixed Flow Pump Butterfly Valve Ductile Iron Pipe High Pressure Pump
Pump Gate Valve Mixed Flow Pump (Jacking Pipe)

03 04
 Kubota Pipeline System

KUBOTA’S HISTORY PLANT

Kubota's History with Ductile Iron Pipe
Plant Information
Advantages of Ductile Iron Pipe
Line Up

WITH DUCTILE IRON PIPE INFORMATION

Manufacturing Process and Quality Control
Supply Record

Where the world's largest DN2600 Ductile Iron pipe is manufactured.

Hanshin Plant
Site area
Main Plant
141,000m2
Marushima Factory
159,000m2
Amagasaki Plant
54,000m2

Employees
850

Production capacity
Pipe 20,000 ton / month
Fitting 550 ton / month

Main products
Pipe DN75 to DN2600
Fitting DN900 to DN2600

(as of January 1, 2016)

Where the world's longest 9-meter length Ductile Iron pipe is manufactured.
KUBOTA 48 inch pipes & valves, Osaka city, Japan. (1914)
Keiyo Plant
Site area
Main Plant
History 300,300m2
Logistics center
1890 Established as a foundry. Started production of castings for weighting equipment and daily commodities. 142,000m2

1893 Started production of cast iron pipe for water supply.

Employees
1897 Changed the corporate name from Oide Chuzo-jo (Oide Foundry) to Kubota Tekko-jo (Kubota Iron Works). 439
Started production of waterworks equipments such as fire hydrant and gate valve.
Production capacity
1917 Supplied cast iron pipes and valves to Indonesia, our first experience of export. Pipe 17,000 ton / month
1930 Developed high-grade cast iron.
Main products
1941 Started production of centrifugal cast iron pipe. Pipe DN75 to DN1500
9-meter length pipe DN600 to DN1600
1954 Started production of Ductile Iron pipe.

1957 Started production of centrifugal Ductile Iron pipe.

1971 Started production of the world's largest DN2600 pipe.

1982 Started production of the world's longest 9-meter length pipe. (as of January 1, 2016)

1985 Produced the world's largest DN2900 pipe.

1990 Celebrated our 100th year in business. Changed the corporate name to KUBOTA Corporation.
Certificates
2009 Started production of restrained joint pipe (TLH-type).
Both Hanshin Plant and Keiyo Plant are
2012 Supplied Earthquake Resistant Ductile Iron Pipe (ERDIP) to the United States. ISO 9001 and ISO 14001 certificated.
2014 Supplied a huge number of Ductile Iron pipe to Mega Reservoir Project in Qatar,
Founder of KUBOTA Group
one of the Middle East's largest water supply project.
Gonshiro Kubota (1870-1959)

05 06
 Kubota Pipeline System

ADVANTAGES OF
Kubota's History with Ductile Iron Pipe
Plant Information
Advantages of Ductile Iron Pipe
Line Up

DUCTILE IRON PIPE

Manufacturing Process and Quality Control
Supply Record

Ductile Iron 2. Long-term Durability Chemical composition (%)

Ductile Iron Pipe Cast Iron Pipe Steel Pipe
Ductile iron is a family of cast iron. The Corrosion Resistance Carbon 3.2-3.8 3.2-3.8 0.1-0.2
difference between ductile iron
Ductile iron is well known as a highly Silicon 1.7-2.7 1.4-2.2 0.15-0.4
and cast iron is in the graphite
resistant material to corrosion all over Manganese max. 0.4 0.4-0.6 0.3-0.6
formation in the metal. Cast iron is
the world. This is because ductile iron Phosphorus max. 0.1 max. 0.5 0.02-0.03
characterized by a random flake
contains a certain amount of carbon Sulfur max. 0.02 max. 0.1 0.02-0.03
graphite pattern. In ductile iron, the
and silicon. Magnesium min. 0.02 - -
graphite form is small spheroids rather Microstructure
For example, we found pipe body and
than flakes. This creates fewer of ductile cast iron (left)
cement mortar lining remained usable
discontinuities in the structure of the and cast iron (right).
condition. There was no leakage after
metal and produces a stronger ductile
hydraulic pressure test. This proves that
iron.
Ductile Iron pipe has corrosion
resistance and long life service.
In addition, Ductile Iron pipeline is
1. Tough and Strong Mechanical properties Hydraulic Pressure Test
insusceptible to electric corrosion.
The pipes after 53 years in service The pipes are tested by hydraulic pressure.
Ductile iron Pipe Cast Iron Pipe Steel Pipe This is because the rubber gasket set in
Ductile Iron pipe has excellent strength
Tensile Strength(N/mm ) 2 min.420 150-260 min.400 every joint works as an insulator. Electric resistance of ductile iron and steel
and ductility. It is flexible Electric Resistance(μ Ω・cm)
Bending Strength(N/mm ) 2 min.590 200-360 min.400
and will not crack even if passably Ductile Iron 50∼70
Elongation(%) min.10 Negligible min.18
deformed. It is suitable for high Steel 10∼20
Modulus of Elasticity(N/mm ) 2 15-17x10 4 10-12x10 4 approx.20x10 4
pressure or under main road pipeline.
Hardness(HBW) max.230 max.230 approx.140 Internal Lining and
External Coating
Internal cement mortar lining or epoxy
(kN) Deformation and Load Diagram coating, and external zinc and bitumen
25
Ring action strength synthetic resin coating work as
(mm) corrosion protection systems of Ductile
No. Pipe Material Wall Thickness Iron pipe and fitting. Polyethylen sleeve
20
1 Ductile Iron Pipe 18 also can be applied to ductile iron pipes
2 Ductile Iron Pipe 14 to improve corrosion resistance.
3 Cast Iron Pipe 23.5
15 We continue developing new types of Cement mortar lining Epoxy coating
4 Steel Pipe 10 coating for higher corrosion resistance.
Load

DN1100×1,000mm long Pipe Ring

10 As a new type of superior corrosion
protection method, “Zinc Alloy Coating”
Beam action strength was developed. It is applied on the
5 external surface of a pipe body, which
Wall Maximum Maximum Span
DN Pipe Material Thickness Load Deflection Remarks brings excellent self-healing
(m)
(mm) (kgf) (mm) performance against scratches caused
Ductile Iron PIpe 6.0 >4,000 >400 3.6 No Collapse by transportation and handling. Zinc
0 50 100 150 200 250 300 (mm) 100
Cast Iron Pipe 7.5 3,500 135 3.6 Collapsed External zinc and bitumen coating Polyethylen Sleeve
Deformation ions gradually dissolve out from the zinc
Ductile Iron PIpe 6.0 >7,000 >450 4.8 No Collapse
150 alloy layer, and zinc compounds are
Cast Iron Pipe 8.0 6,600 150 4.8 Collapsed Synthetic resin coating Zinc compounds
Ductile Iron PIpe 8.0 >14,000 >450 4.8 No Collapse
formed on the scratched area. Thus, it
Zn alloy coating
200 prevents corrosion from proceeding.
Cast Iron Pipe 8.8 12,700 125 4.8 Collapsed Ductile iron
Synthetic resin coating
Ductile Iron PIpe 6.0 >24,000 >400 4.8 No Collapse Duration of this sacrificial protection Zn alloy coating
250 Scratch
Cast Iron Pipe 9.5 21,000 100 4.8 Collapsed effect is much longer than that of Current
Ductile iron
Ductile Iron PIpe 5.5 >32,000 >450 5.8 No Collapse normal zinc coating.
300
Cast Iron Pipe 10.0 23,200 130 5.8 Collapsed
Ductile Iron PIpe 7.0 >50,000 >130 5.8 No Collapse Upon request,other types of coating or Specification (Conceptual diagram) Self-healing mechanism (Conceptual diagram)
400
Cast Iron Pipe 11.5 46,900 100 5.8 Collapsed lining may be applied. Zinc Alloy Coating

07 08
 Kubota Pipeline System

ADVANTAGES OF
Kubota's History with Ductile Iron Pipe
Plant Information
Advantages of Ductile Iron Pipe
Line Up

DUCTILE IRON PIPE

Manufacturing Process and Quality Control
Supply Record

3. Adaptability against Various Situations

Flexible Joint (See page 11) Joint performance of ERDIP

A joint of Ductile Iron pipe is composed of a spigot and socket with Property Perforamce ISO 16134
a rubber gasket for sealing. It is flexible since it allows a certain
Amount of
amount of deflection, expansion and contraction. Because of its expansion/contraction
1% of L*1 Class S-1

flexibility, small curves in a pipeline can be easily accommodated

Slip-out resistance 3D kN*2 Class A
without use of bends. Furthermore, some ground movement can
be also absorbed.
Joint deflection angle 6-8°
*3

*1:L is the nominal length, in millimetres (mm).

*2:D is the nominal dlameter of pipe, in millimetres (mm).
*3:The joint deflection angle differs depending on a pipe diameter.

Restrained Joint (See page 11 and 12) Hanging test of earthquake resistant joint

Restrained joints can be used to protect bends, tees or tapers Jacking Method (See page 12)
from the thrust force caused by the internal pressure of a pipeline
For road, railway and river crossing, Kubota
instead of using thrust concreate blocks.
offers special pipes for jacking method. This
method enable to jack the pipe directly into
Kubota has several types of Restrained Joint. The appropriate
the ground without sleeve pipes. As the
type is selected depending on the pipe diameter and operating
result, the installation cost and time period
pressure of a pipeline.
can be reduced, and the installation work
can be also carried out safely without Jacking Method Usage example
disturbing traffic.

Earthquake Resistant Joint (See page 13 and 14) 4. Easy and Quick Installation
Ground movement due to earthquake or soft ground could
cause expansion and contraction forces and the bending There is no need of skilled operators/special
moment to a pipeline. Kubota offers Earthquake Resistant pipe tools for assembling ductile iron pipes.
to withstand such ground undulations. Ductile iron pipes can be also installed in the
Chain Structure pipeline can adjust ground rain. Furthermore, ductile iron pipes can be
Pipeline with earthquake resistant joints is called Chain Structure deformation with joint deflection performance.
immediately backfilled after its assembling.
pipeline. Even when large ground displacement occurs and one
joint fully expands/contracts, the joint can pull/push the adjacent
In case of Push-on Joint (T-type), simply install
pipes one after another like a buried chain. a rubber gasket in the socket and apply
lubricant paste both on the rubber gasket and
Kubota's Earthquake Resistant Ductile Iron Pipes (ERDIP) has the pipe spigot end. After alignment of the
had no documented damages or leaks in the past major pipe, just insert the spigot end to the socket
earthquakes whose magnitude is larger than 6, including the with lever hoists or a simple tool.
2011 Great East Japan magnitute 9.0 earthquake. The excellent
performance of ERDIP is highly appreciated in many Japanese
water agencies. General assembling time
DN T-type (min) NS-type (min)
Besides the earthquake resistant purpose, Kubota ERDIP NS-type DN150（6”）after landslide
effectively performs against ground deformation and subsidence DN500 10 16
as “Pullout Prevention Pipe”.
DN1000 20 24
Ground deformation occurs in such cases of landslide and
uneven settlement/movement by underground structures and *Source : Technical reference of Japan Ductile Iron Pipe Association Jointing work of push-on joint (GX-type)

faults.Ground subsidence may occur in a tunnel construction for

“subway”, mass transportation system.

09 10
 Kubota Pipeline System

LINE UP
Kubota's History with Ductile Iron Pipe
Plant Information
Advantages of Ductile Iron Pipe
Line Up
Manufacturing Process and Quality Control
Supply Record

Nominal Diameter 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000 1100 1200 1400 1500 1600 1800 2000 2100 2200 2400 2600 mm

T-type
Flexible Joint K-type (Pipe)
(Fitting)
TLH type
Restrained Joint Kubolock-T
Kubolock-K

Flanged Joint RF-type

Jacking Pipe T-type

Nominal Diameter 80 100 150 200 250 300 350 400 450 500 600 700 800 900 1000 1100 1200 1400 1500 1600 1800 2000 2100 2200 2400 2600 mm

Flexible Joint Restrained Joint

Pipe:DN2100-DN2600
T-type DN80-DN2000
K-type Fitting:DN80-DN2600 Kubolock-T DN80-DN1200
Kubolock-K DN80-DN1200

Lock bolt Lock bolt

Push-on Joint Rubber gasket Mechanical Joint Bolt & nut
Set bolt Wedge
Body
Rubber gasket Wedge Body

T-head bolt & nut

T-type joint is push-on joint. It has flexibility and excellent water K-type joint is mechanical joint. It has flexibility and Kubolock-T is restrained coupling. It can be simply assembled Kubolock-K is retainer gland. It can be simply assembled with
tightness. excellent water tightness. with T-type joint for restrained mechanism. K-type joint for restrained mechanism.

Restrained Joint Flanged Joint Jacking Pipe

TLH-type DN400-DN1600
Spigot ring RF-type DN80-DN2600
T-type (For Jacking Method) DN250-DN1600

T-type ductile iron pipe

Tie-bolt
Rubber gasket Bolt & nut Reinforced concrete
Flange
Socket ring

Lock ring B

Weld bead
Set bolt B
Lock ring A
TLH-type is restrained joint. It is converted from T-type joint by providing Jacking method is used to install a pipeline without trench excavation.
the spigot with projection and assembling the special joint accessories. RF type is rigid joint. Pipe is covered with reinforced concrete, which allows the pipe
It can be used under high pressure and can be used with deflection. Generally, it is used to joint valves and other parts. to be jacked directly into the ground without a pipe casing.

11 12
 Kubota Pipeline System

LINE UP
Kubota's History with Ductile Iron Pipe
Plant Information
Advantages of Ductile Iron Pipe
Line Up
Manufacturing Process and Quality Control
Supply Record

Earthquake Resistant Joint Nominal Diameter 75 100 150 200 250 300 400 500 600 700 800 900 1000 1100 1200 1350 1500 1600 1650 1800 2000 2100 2200 2400 2600 mm

GX - type
The Earthquake Resistant Ductile Iron Pipe
NS - type
(ERDIP) absorbs the large ground displacement
S - type
such as ground subsidence and crack by joints
US - type
expansion/contraction, deflection, and anti-pull
UF - type
out structure.
Pipe Size 3 4 6 8 10 12 16 20 24 28 32 36 40 44 48 54 60 64 66 72 80 84 88 96 104 inch

Pipes Pipes Pipes

GX-type DN75-DN400
3"-16"
NS-type DN500-DN1000
20"-40"
S-type DN1100-DN2600
44"-104"
US-type DN800-DN2600
32"-104"
Push-on Joint Lock ring* Mechanical Joint Rubber gasket Mechanical Joint Mechanical Joint
Rubber gasket Gland ring
Projection of spigot Lock ring Rubber gasket Lock ring Fixing bolt
Gland
Rubber gasket Gland
Projection of spigot Gland Projection of spigot
Bolt & nut Lock ring

Bolt & nut

Mortar
Bolt ＆ nut

*External coating: C-protect *Lock ring is preset.

Fittings Fittings Fittings

GX-type DN75-DN400
3"-16" NS-type DN500-DN1000
20"-40" UF-type DN800-DN2600
32"-104"
Mechanical Joint Rubber gasket Mechanical Joint Rubber gasket Mechanical Joint Fixing bolt Rubber gasket
Metal touch
Lock ring* Lock ring
Gland Lock ring Gland
Gland Projection of spigot
Bolt & nut Projection of spigot
Bolt & nut

Mortar

Bolt ＆ nut

*External coating: C-protect *Lock ring is preset.

13 14
 Kubota Pipeline System

MANUFACTURING PROCESS
Kubota's History with Ductile Iron Pipe
Plant Information
Advantages of Ductile Iron Pipe
Line Up

AND QUALITY CONTROL

Manufacturing Process and Quality Control
Supply Record

Pipe Casting

Selection of Material Centrifugal Casting Annealing Inside Cement Mortar Lining, Steam Curing
-Best raw materials (pig iron, steel scrap, coke, limestone, etc.) -Pipes are casted by -Annealing is a heat treatment process undertaken to -Cement Mortar
are selected for casting ductile iron pipes. centrifugal casting method. improve the mechanical properties of the pipes. lining is applied
In annealing, cementite of the as-cast pipes is decomposed inside the pipe
to obtain high toughness ferrite. for corrosion
Melting in Hot Blast Cupola Desulfurization protection.

-Calcium carbide (CaC2) is

added to molten iron in order to
remove Sulfur.

Outside Coating
Magnesium small diameter pipes middle and large diameter pipes
(Hanshin Plant)
Treatment -Zinc and bitumen/
synthetic resin
-Magnesium, in a small small diameter pipes Treatment and Machining coatings are applied
quantity, is added to the outside of the pipe for
molten iron in order to -Pipes which passed the strict inspections
corrosion protection.
promote the formation of are surface-treated and machined to
spheroidal graphite specified shape and dimension.
Composition
microstructure.
Adjustment The addition of magnesium
is done by pressure Shipping
-If the composition of plunging method. This
molten iron is outside the -Pipes are shipped
method was developed by
standards, it will be all over the world.
Kubota.
adjusted by adding alloy
and other elements.

middle and large diameter pipes

1 2 3 4 5 6 7 8 9 10 11

Inspection of Insepection of Heat TreatmentEffect Hydrostatic Final Inspection

Spheroidal Graphite Pressure Test
-Tensile test -Pipes are inspected carefully before
Spectrographic Analysis -Hardness test -All pipes are subjected to shipping.
Fitting Casting -Spheroidal graphite
hydrostatic test to check
microstructure is examined
-Composition is analyzed by water-tightness.
-Fittings are casted by sand mold. by microscopic test.
using spectrographic analyzer.

Inspection of Appearance and Dimensions

15 16
 Kubota Pipeline System

SUPPLY RECORD
Kubota's History with Ductile Iron Pipe
Plant Information
Advantages of Ductile Iron Pipe
Line Up
Manufacturing Process and Quality Control
Supply Record

Kuwait United States of America

Project Name MEW/19 Project Name Seismic Improvement Project at Northridge Hospital
Year 2012-2013 Year 2014-2015
End User Ministry of Electricity and Water Los Angeles Department of Water and Power
End User
Size DN2200-DN2400 （LADWP）
Size DN100-DN300
Length 1.8km
Length 4.3km

Africa Middle East Asia Oceania North America Central America South America
Qatar Congo Sierra Leone Bahrain Afghanistan Myanmar Australia Canada Guatemala Bolivia Bangladesh
Egypt South Africa Iran Bangladesh Nepal Marshall Islands USA Haiti Chile
Ethiopia South Sudan Iraq Brunei Pakistan Palau Honduras Ecuador
Guinea Sudan Jordan Cambodia Philippines Papua New Guinea Jamaica Peru
Kenya Tanzania Kuwait China Singapore Tonga Nicaragua
Libya Zambia Oman East Timor Sri Lanka
Malawi Zimbabwe Palestine Hong Kong Taiwan
Mali Qatar India Thailand
Mauritius Saudi Arabia Indonesia Vietnam
Nigeria Syria Korea
Seychelles UAE Laos
Yemen Malaysia

Pipelines for Mega Reservoirs Corridor Main 2 Project Name Karnaphuli Water Supply Project C-2
Project Name
（GTC599/2013 Package B） Year 2011-2014
Year 2014-2016 Chittagong Water Supply and Sewerage Authority
End User
Qatar General Electricity and （CWASA）
End User
Water Corporation (KAHRAMAA) Size DN300-DN1200
Size DN600-DN1600 Length 70km
Length 88km

17 18