Recessed Covers Information for Drains with BIC

Posted on September 4, 2022February 9, 2024 by admin

In some surfaced areas, sunken drain covers or recessed tray covers are used to conceal the presence of inspection chambers, manholes, and access fittings.

As per BIC, Recessed drain covers are essential when it comes to the field of artistic, natural, or colored stone paving, especially as compared to the utilitarian covers typically used in modern construction, find out the brief from us here.

They consist of two parts: the tray that sits inside the frame that is installed above the manhole. To blend in with the surroundings, this is covered in paving.

There are different sizes available, usually on order, but 450x600x90mm is the standard size used on patios and domestic driveways. To manageable maintain the bulk of the paved tray, the larger covers typically use two or more separate trays inside one frame.

In general, the ones used in commercial projects or public spaces are made of a galvanized steel frame and a galvanized steel tray. The plastic frame can be used for those with light use, such as driveways in homes. Due to the increased usage of plastic trays for footways and driveways.

For foot traffic, only grade “A” covers are necessary. For driveways, however, an “AA” cover and a safe operating load of at least 1.5 tons are needed. When parking vans or large 4x4s in driveways, think about utilizing class B cover. In public spaces, heavier applications must have Class B, C, or D coverings.

Many of the sunken manhole covers and recessed covers for drains used in residential areas today are constructed of plastic, as has been noticed. This has various benefits, such as lighter weight and lower manufacturing costs. Additionally, there are now fewer reports of jammed trays. On the other hand, the existence of trays and frames that are prone to deformation irks certain contractors. This in turn has an impact on the installation’s final aesthetic appeal, with a Ductile Iron Manhole Cover.

The development of “Square to Round” recess tray covers has been made possible by the transition to plastic frames. These are designed to fit over a circular or round Access Chamber (AC) or Inspection Chamber and give a rectangular or square cover (IC).

Access covers and manholes are intended to blend in with the paving’s design by using recessed tray covers or recessed drain covers. They are hardly noticeable when professionally and correctly fitted. However, if they get into the wrong hands, they can be turned into harmful weapons.

After the final fastening, it is advised to generously coat the internal sides of the frame and the tray’s outer borders with a thick, non-setting lubricant, such as petroleum jelly, to prevent jamming. By doing this, the sand particles are kept out of the space between the tray and frame. Additionally, the jelly makes it simpler to remove the tray.

So, get your drain cover fitted with our best manufacturing firm and keep safe your life along with others.

Smart Plumbing: Measurement of Noise in Cast Iron Pipes

Posted on August 8, 2020 by admin

In residential as well as commercial buildings noise is generated in piping systems. An important consideration for architects and engineers when designing these buildings is the noise levels contributed by sanitary drainage pipes. These considerations influence the materials of pipes used, their orientations, and even the type of false ceiling. As a premier supplier of cast iron pipes and fittings, we at BIC detail in this blog a concise version of the available literature.[i] It entails the process of how noise level tests were conducted and the consequent results obtained for cast iron pipes in comparison with other materials.

Methodology Used

The measurements were carried out in the acoustical laboratory of Peutz bv in Mook in the Netherlands.

The variables of interest examined in this study are as follows:

Material of drainage pipe
Construction orientation

The experiment was carried out at a flow rate of 3.0 l/s.

Materials and constructions

The following table lists the types of pipes used for the experiment.

Drainage Pipe

1. Type: Cast Iron
Mass: 8.5 kg/m
Inside Diameter: 103 mm
Outside Diameter: 110 mm

2. Type: U-PVC
Mass: 1.3 kg/m
Inside Diameter: 103 mm
Outside Diameter: 110 mm

3. Type: Polyethylene (PE)
Mass: 1.23 kg/m
Inside Diameter: 103 mm
Outside Diameter: 110 mm

Standard clamps and rubber inlays were used. The pipes were installed in three variations as shown in the diagram below:

An offset with two 45º bends.
Straight vertical
Straight horizontal

Calculations

To quantify the measured noise levels in the given room, a standard sound pressure level Ln in dB(A) is calculated as follows:

Where:

Ln = sound pressure level (dB)

L0 = measured sound pressure level caused by water flow in the pipe (dB)

A = determined absorption area (m2 area of opening)

A0 = reference absorption area (10 m2 area of opening)

The result obtained is detailed in the following table:

Table: Sound pressure level L_n in dB(A) for three variants and pipe materials, flow 3.0 l/s

Pipe material	Offset vertical (A)	Straight Vertical (B)	Horizontal pipe (C)
PE	67.5	61.0	64.5
PVC	64.5	57.5	61.0
Cast Iron	Not Measured	51.0	50.5

It can be seen that the sound pressure level for the offset vertical with two 45° bends is higher than the straight vertical and horizontal pipe. BIC cast iron pipe has the lowest noise production with similar sound pressure levels for the straight vertical pipe and the horizontal pipe.

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[i] Measurement of the noise production in drainage pipes. W.G. van der Schee. https://www.irbnet.de/daten/iconda/CIB_DC25341.pdf

Defects in castings – Ductile & Grey Cast Iron

Posted on May 10, 2019 by admin

Defects during the casting process are not uncommon. Under practical conditions, all casting products contain voids, inclusions and other imperfections which contribute to a normal quality variation. Such imperfections begin to be regarded as true defects or flaws only when the satisfactory function or appearance of the product is in question: consideration must then be given to the possibility of salvage or, in more serious cases, to rejection and replacement.

Classification

The general origins of defects lie in three sectors:
1. the casting design,
2. the technique of manufacture–the method,
3. the application of the technique–‘workmanship’.

Standardization and optimisation of all aspects of the production technique offers the best way-out against such troubles. More specific precautions can be taken in those cases where there is a known susceptibility to a particular defect, whilst the radical approach of design modification may need to be considered in the extreme cases which do not respond to changes in foundry technique. It should be clear that any approach to the elimination of casting defects must be on an economic basis.

1. Shaping faults arising in pouring.
2. Inclusions and sand defects.
3. Gas defects.
4. Shrinkage defects due to volume contraction in the liquid state and during solidification.
5. Contraction defects occurring mainly or wholly after solidification.
6. Dimensional errors.
7. Compositional errors and segregation.

Significance of analysis of defects

Casting defects, whatever their cause, cannot be considered in isolation; their significance can only be established in relation to the function of the casting. Behaviour under service stresses and environment is in most cases the important reason behind the appearance.

What are the reasons of their occurrence? The first one is the
quality and the parameters of moulding and core mixtures. Number of the
defects was affected by temperature and humidity of ambient air, both in
store yards and in moulding mixture preparation shop. Consequently, it is
reflected in moisture content of silica sand and moulding mixture. This fact
can affect the quality of moulding and core mixtures and their prone to
disintegration by molten metal flow.
The second one is the presence of complicated design of the cavity in the mould,
containing thin walls, profiles, runners. From this fact follows the necessity
to design parameters of moulding mixtures from the mould complexity
point of view.
The third one is chemistry and pouring temperature of molten metal.
Viscosity of poured metal is extremely important.

Cast Iron Products: Quality Control and Management

Posted on January 29, 2019 by admin

Quality control methodology has undergone a long period of change, involving a broadening of the subject to enhance many more aspects of the production process and product than were traditionally considered. These changes have had major effects in the field of internal management organization, as well as in the commercial relationships involved in the procurement of castings.

Casting defects can negatively impact the profit margin of the company. There are instances such as rework costs or casting scrap costs that not only affect financial state of the company but also affect customer services. However, in many cases, the casting defects may appear at the machining stage, at the assembly stage or during use of the component. The resultant value added costs and warranty costs may sometimes be passed on to the foundry by their customers.

Let’s take a look at the kind of defects and how they can be identified.

Tests for defects in the surface zone

Cracks and other flaws communicating directly with the surface of the casting can be detected using techniques including penetrant methods, chemical etching and oil and chalk testing. The penetrant methods are based on the use of fluids to permeate and highlight defects by increasing their contrast and are helpful in establishing the soundness and integrity of thin walled castings in cases where pressure testing is difficult to execute. If there is any seepage, then it can be easily observed.

Dye penetrant testing

The surface of the casting is treated with a dye solution based on a low viscosity solvent which is applied by brush or aerosol spray or the casting can be entirely immersed in a tank of solution; the casting is then thoroughly rinsed and dried. After a time, seepage of residual fluid occurs from cracks and other narrow surface defects to produce a visible stain.

Oil and chalk testing

This long established technique uses paraffin oil as the medium. The casting is treated, usually by immersion, with heated paraffin; it is then rinsed in detergent solution and water and dried. Using a low pressure air dispenser the surface is coated with dry powdered chalk, which becomes marked after a time by seepage of paraffin from cracks or porous zones.

Chemical etching

Very fine surface cracks and similar defects may be masked by a thin layer of metal resulting from superficial plastic deformation. This can occur in shot blasting, in fettling or even in the machining of a casting. The masking layer may consist of oxide scale formed in heat treatment.

A simple analysis of casting defects

For the characteristic criterion of quality level measuring, it is assumed quantity of defects in one year. The first step of analysis is the assessment of process by means of Ishikawa’s diagram. Ishikawa’s diagram – diagram of cause and effect, or “fish bone” diagram – makes possible identification of sources of problems formation, helps quality a sequence of causes and makes easy problem solution (SIEKANSKI K. 2002).

Ishikawa Diagram_BIC

Fig. 10.1 Part of Ishikawa´s diagram for problem of non-conformances formations in process of casting products.

Source: https://tulip.co/blog/lean-manufacturing/fishbone-ishikawa-diagram-for-root-cause-analysis/

Extracting the Most from the Casting Project

Posted on September 6, 2018March 18, 2026 by admin

Partnering with the right supplier foundry is crucial to get the most from your casting project. Good planning and execution of the same, pave a path to castings compatible with your requirements. In fact, it needs a conjugated effort from a competent supplier foundry and the consumers to enjoy the benefits of a project. However, the challenge is to locate the top-notch supplier foundry as it demands acute research and an intense understanding of your component.

How to Start a Project with a New Foundry?

To start with a new project with a Ductile Iron Foundry India, it is crucial to understand whether it is proficient enough to produce the outcome as per the quality standards and listed specification. Once you locate the best foundry from the crowd and have the castings of ferrous and non-ferrous origins ready for the production, you may ask the shortlisted foundries to quote a price for your project. Not only this allows you to understand the capability and experience of the vendors but also enables you to take the decision as per your budget. Never close on a particular vendor before analyzing the prospects and quotations. This ensures you seal the deal with the best foundry for a cost-effective contract.

Is Budget the Exclusive Decision-Making Criterion?

Once you select the most favorable and affordable foundry, it is now time you analyze the other aspects of the quotation, which includes processing requirements, specifications, and exclusions of the drawings. Along with it, you must also analyze the other criteria like the tolerance, delivery, tooling requirement, delivery, and experience of the supplier foundry. This help complete the casting project with revised delivery routine, tolerance recommendations, reduced machine works, and enhanced reliability.

Primary Criteria to Get the Most from the Casting Project

Never approach a stereotypical path, to attain a fruitful outcome of the casting project. Rather, look for the core points to get the most from the same, which are as follows:

The volume of casting needed for the short and long-term demands.
Casting designs with proper drawings, models, samples, and images.
Specifications of the raw materials.
Inspection of the probable outcome and ensure a balance between requirements and specifications.
Details of the casting requirements that include weight, finish, and materials used.
Schedule of delivery according to the casting.
Details of the pattern.

Establishing a Coordinating Relationship with the Consumers for the Success of the Casting Project

If you believe the aforementioned criteria are enough to fetch the most desired casting project, you are under the wrong notion. Scrutinize the customer requirements with utmost importance through a proper communication to build a strong foundation for your project. Some of the best ways to establish a fruitful communication, while not relating to the standard inquiry are the back charge policy, expediting the procedure, casting return policy, as well as the sophisticated controls. Once you get your hands on the proper information, not only you succeed in creating an open relationship between the consumer and supplier foundry but also lead to a seamless accomplishment of the casting project. This will help you overcome all the hurdles associated with the casting projects so that you can enjoy the outcome without any exception.

Once you succeed in overcoming the challenges of quality, budget, and communication in the path of creating a standard casting project, the success is inevitable. Don’t restrict to explore the aforementioned criteria and delve into the niche to get the most from the project.