IS 210 : 2009Grey Iron Castings

IS 210 (2009) provides Specifications for Grey Iron Castings — the IS code for grey cast iron components used in industrial machinery, plumbing fittings, manhole covers, drainage gratings + general engineering applications.

Use when: specifying grey iron castings for engineering components; pipes + plumbing fittings (per IS 1538); manhole covers + frames (per IS 5961); industrial machinery; municipal infrastructure.

Grey iron grades (per IS 210): - FG 150: Tensile strength ≥ 150 MPa — general purpose - FG 200: ≥ 200 MPa — engineering components - FG 220: ≥ 220 MPa — medium-duty - FG 260: ≥ 260 MPa — high-strength - FG 300: ≥ 300 MPa — heavy-duty / premium

Common applications: - Manhole covers (heavy-duty): FG 220-300 - Drainage gratings: FG 200-260 - Pipe fittings: FG 200-220 - Pump components: FG 200-260 - Engine blocks (light): FG 220-260 - Brake drums: FG 260+ (heat resistance + strength) - Machine bases: FG 200-260

Chemical composition (typical): - Carbon (C): 2.5-4.0 % - Silicon (Si): 1.0-3.0 % - Manganese (Mn): 0.3-1.0 % - Phosphorus (P): ≤ 0.2 % - Sulphur (S): ≤ 0.15 % - Iron (Fe): balance

Properties: - Density: ~7.2 g/cm³ - Tensile strength: 150-300+ MPa (per grade) - Compression strength: 600-1000+ MPa (~3× tensile) - Hardness: 150-260 HB - Modulus: 100-145 GPa - Vibration damping: excellent (advantage over steel) - Wear resistance: moderate to high

Casting quality: - Surface finish: per IS 210 specification (machined / unmachined) - Dimensional tolerance: ± 1-3 % typical (machined surfaces tighter) - No defects: cracks, blowholes, slag inclusions - Cleanliness: per IS 210

Testing per IS 210: - Tensile test on test bars - Hardness (Brinell) - Chemical analysis - Dimensional inspection - Non-destructive (visual, dye penetrant for critical)

Acceptance criteria: - Tensile strength per grade - Hardness within specified range - Composition within tolerance - Visual: no major defects - Dimensions per drawing - NABL-accredited testing for certification

Manhole cover specific (per IS 5961): - Grade: FG 220-300 (heavy-duty) - Surface: anti-slip pattern - Hinged or self-locking for safety - Load class: per location (A 15 to F 900 tonnes) - Frame: separate or integral

Service life: - Buried application: 30-50+ years - Indoor / dry: 50-100 years - Outdoor + salt environment: shorter, may need coating - Coating (paint / polymer) extends life

Modern alternatives: - Ductile iron: higher strength (per IS 12288:1987 reference) - Steel castings: for high stress - Composite materials: lightweight alternatives - Stainless steel: marine + chemical exposure

• IS 210 (other parts) — Cast iron specifications.
• IS 5961 — Cast Iron Manhole Covers + Frames.
• IS 12592 — Concrete Manhole Covers.
• IS 1538 — Cast Iron Pipe Fittings.
• IS 1729 — Centrifugally Cast Iron Pipes.
• IS 12288:1987 — Ductile Iron Pipes.
• IS 1726 — Cast Iron Manhole Covers (older).
• IS 8329 — Ductile Iron Pressure Pipes.
• IS 6411 — Centrifugally Cast Iron Pipes (Class A).
• ASTM A 48 — Standard Specification for Grey Iron Castings.
• EN 1561 — Grey Cast Iron.
• ISO 185 — Grey Cast Iron.
• AWWA C151 — Ductile Iron Pipes.
• CPHEEO Manual on Sewerage.

1. Wrong grade for load → casting cracks under stress. 2. Casting defects (porosity, blowholes) → premature failure. 3. Surface corrosion in outdoor → strength reduction. 4. No quality testing per batch → variable performance. 5. Manhole covers not load-rated for vehicle traffic → failure. 6. Mixed cast iron + steel without compensation → galvanic corrosion. 7. Brittle behavior under impact → crack propagation. 8. Inadequate machining surface finish → poor mating. 9. No coating in aggressive environment → premature failure. 10. Storage damage → surface defects.

1. Specification per application + grade per IS 210. 2. Manufacturer qualification. 3. Quality testing per batch. 4. Installation per relevant code (IS 5961 manholes, IS 12288 pipes). 5. Periodic inspection (visual). 6. Service life 30-100+ years depending on environment. 7. Replacement when degraded.

IS 210 is the grey iron casting reference for India's industrial + municipal infrastructure — applied on machinery, plumbing, drainage + municipal infrastructure.