Cast iron single faced thimble mounted sluice gates

IS 13349: Scope and Key Specifications for Sluice Gates

1. Scope (Clause 5.1)

• Covers nominal sizes of sluice gates (square/round and rectangular).
• Sizes are based on clear opening of gate frame.
• Rectangular gates specified as Width × Height (Width is first dimension).
• Preferred sizes are given; other sizes allowed by agreement.

2. Nominal Sizes (Tables 1 & 2)

| Rectangular Sizes (mm) (Width × Height) | Examples: 1000×750, 1000×1200, 1100×1500, 1200×900, 1200×1500, 1400×1800, 1500×1200, 1800×1500, 2000×2500, 2250×2500, 2500×2000 |

3. Design Notes (Clause 4.2.4)

• Operating headstock can be platform-mounted or yoke-mounted.
• Self-contained sluice gates have headstock mounted on yoke.

4. Materials Reference (Annex B)

• Grey iron castings (IS 210)
• Structural steel (IS 226)
• Bronze and brass specifications (IS 291, IS 318)
• Stainless steel (IS 6603, IS 6911)

Summary Table: Nominal Rectangular Gate Sizes (mm)

IS 13349 - Types of Bottom Closure for Sluice Gates (Clause 4.2.2 & Annex D)

1. Conventional (Flush) Bottom Closure - D-I Conventional

• Design: Two corrosion-resistant seating faces mate when gate fully closes.
• Seating: One face on bottom of slide, other on horizontal bottom of frame.
• Travel: Bottom edge of slide travels beyond gate invert for closure.
• Application: Requires ample vertical clearance between gate invert and chamber/channel invert.
• Limitation: If gate invert = chamber invert, a recess/cut-out forms, causing debris accumulation and closure issues.

2. Flush Bottom Closure

• Design: No corrosion-resistant seating faces on slide or frame bottom.
• Seating: Resilient rubber seating face replaces metal seating.
• Rubber Seal Placement:
  • On bottom of slide, closing against a machined cast iron bar on frame (flush with gate invert).
  • Or on bottom of frame, with rubber seal top flush with gate invert, slide closes against rubber.
• Application: Recommended where gate invert and chamber/channel floor are at same elevation to avoid debris traps.

Summary Table

flowchart LR
    A[Gate Closure Types] --> B[Conventional Bottom Closure]
    A --> C[Flush Bottom Closure]
    B --> B1[Metal seating faces on slide & frame]
    B --> B2[Slide travels beyond gate invert]
    C --> C1[Rubber seal on slide or frame]
    C --> C2[Slide closes flush with gate invert]
    C --> C3[Prevents debris accumulation]

This design choice ensures proper sealing and operational reliability based on site elevation and clearance conditions.

IS 13349 - Key Materials Specifications (Clause 6.1, Table 3):

IS 13349 - Materials Used in Manufacture (Clause 6.1)

IS 13349: General Design & Construction Requirements Summary

1. Nominal Sizes of Rectangular Sluice Gates (Clause 5.1, Table 2)

• Width and Height vary from 300 mm to 2500 mm.
• Common sizes include:
  • 1000×750 mm
  • 1200×900 mm
  • 1400×1800 mm
  • 1800×2500 mm
  • 2500×2000 mm
• Select sizes based on hydraulic & structural requirements.

2. Materials Specifications (Clause 6.1, Table 3)

Notes:

• Avoid brass where dezincification risk exists.
• Stainless steel seating faces may gall under high pressure; use phosphor or silicon bronze if possible.
• Minimum cast iron grade: FG 200.

3. Design & Construction Considerations (Clause 7.10.2)

• Wall thimble length and shape as per design.
• Stem type: Rising or Non-rising (Annex C).
• Closure type: Conventional or Flush Bottom (Annex B).

IS 13349 - Frame Construction: Key Points & Specifications

1. Frame Construction (Clause 7.1.2)

• Frame must surround the waterway opening periphery.
• Must be unit construction, cast in one piece without joints.
• Rear face of frame is machined for direct bolting to the wall.

2. Materials (Clause 6.1, Table 3)

3. Guide Construction (Clause 7.5.2)

• Guides can be integrally cast or bolted guide strips/bars.
• Must prevent lateral movement.
• Wedges attached securely to guides for full contact in closed position.

4. Nominal Sizes (Clause 5.1, Table 2)

• Rectangular sluice gates sizes range from 300 mm to 2500 mm in width and height.
• Example sizes:
  • 1000 × 750 mm
  • 1200 × 900 mm
  • 1500 × 1200 mm
  • 2500 × 1600 mm

Summary Diagram: Frame & Guide Assembly

graph TD
    A[Waterway Opening] --> B[Frame (Unit Cast)]
    B --> C[Machined Rear Face]
    C --> D[Wall Bolting]
    B --> E[Guides]
    E --> F[Integral Cast or Bolted Guide Bars]
    F --> G[Wedges for Wedging Surfaces]

Note: Avoid brass where dezincification is possible; prefer phosphor or silicon bronze for seating faces. Stainless steel

Key Specifications & Construction Details for Slide (IS 13349)

1. Slide Construction (Clause 7.2.2):

• Tongues: Full-length tongues on each side, machined accurately on contact surfaces.
• Machining: Surfaces contacting seat facings and wedges must be precisely machined.
• Clearance: Max clearance between slide and slide guides = 1.5 mm.

2. Guide Construction (Clause 7.5.2):

• Guides can be:
  • Integrally cast with the frame, or
  • Bolted guide strips/bars with grooves.
• Must prevent lateral movement of bolted guides.
• Wedges/wedge facings securely attached to guides for full contact in closed position.

3. Rubber Seal (Clause 7.4.3):

• Mounted on slide or frame.
• Held by retainer bar bolted to frame/slide.
• Must leave unobstructed flush invert.

Nominal Sizes of Rectangular Sluice Gates (Table 2, Clause 5.1)

Summary Diagram: Slide & Guide Interaction

flowchart LR
    Slide[Slide with Tongues]
    Guide[Guide (Cast or Bolted)]
    Wedge[Wedge/Wedge Facing]
    Seal[Rubber Seal]

    Slide -->|Machined Contact Surfaces| Guide
    Guide -->|Secure Attachment| Wedge
    Slide -->|Seal Mounted| Seal
    Guide -->|Prevents Lateral Movement| Slide

Remember: Accurate machining and tight tolerances (1.5 mm clearance) are critical for smooth slide operation and sealing integrity.

IS 13349: Seating Faces Key Points

• Seating Face Clearance (Clause 7.3.2):
  Maximum clearance between seating surfaces in closed position = 0.10 mm
  Ensures tight fit to minimize leakage.

• Surface Finish (Clause 10.1.2):
  Seating faces must have smooth machined or hand-scraped finish.
  All mating surfaces (guides-to-frame, frame-to-wall thimble) must be machined flat for proper sealing.

• Leakage Limit (Clause 13.3.1):
  Under maximum specified seating head, leakage ≤ 1.25 lpm per meter of seating perimeter.

Summary Table

Seating Face Concept Diagram

flowchart LR
    A[Seating Face] -- Clearance ≤ 0.10 mm --> B[Slide in Closed Position]
    B -- Leakage ≤ 1.25 lpm/m --> C[Seating Perimeter]
    A -- Smooth Machined Surface --> D[Proper Seal]

This ensures a reliable, leak-tight seating in valve or sliding components per IS 13349.

Seals for Flush Bottom Gates (IS 13349 - Clause 7.4)

• Seal Types:

  • Machined flat surface seals
  • Machined groove seals (for Class 1 duty gates)

• Material Considerations:

  • Avoid materials prone to dezincification or dealuminization unless proven safe.
  • Common acceptable materials include brass, bronze, stainless steel, cast iron (for wedges).
  • Wedges may be lined with brass/bronze/stainless steel on tapered faces or have cast iron contact faces.

• Design & Installation:

  • Installation drawings must specify clearances, wall thickness, wall pipe & thimble details, lift mechanism location (yoke/platform), and gate operation direction (up/down).
  • Length and shape of wall thimble per Clause 7.10.2.
  • Leakage tests may be required depending on purchaser specifications.

• Fluid Type:

  • Fresh water, raw water, sewage, etc., influence seal material selection.

Key Table: Stem Pitch for Various Diameters (Clause 7.11.1)

Design Notes:

• Stem diameters and slenderness ratio (max 200) are per Euler's Column formula (see Clause 7.11.1).
• Seal fitment must ensure leakage control and ease of operation.

flowchart TD
    A[Flush Bottom Gate] --> B[Seal Types]
    B --> B1[Machined Flat Surface]
    B --> B2[Machined Groove]
    A --> C[Material Selection]
    C --> C1[Brass/Bronze/Stainless Steel]
    C --> C2[Cast Iron Wedges]
    A --> D[Installation Details]
    D --> D1[Wall Thimble (Clause 7.10.2)]
    D --> D2[Lift Mechanism Location]
    D --> D3[Gate Opening Direction]

For detailed sizing, refer to Table 2 for nominal gate sizes and Clause 5.1 materials.

IS 13349: Guide Extensions — Key Specifications & Formulas

1. Design & Construction (Clauses 7.5.2.1, 7.5.2.2)

• Guide extensions extend vertically above the frame; can be:
  • Integral with frame casting or guide bars.
  • Split construction bolted to frame or guide bars.
• Split extensions must be aligned using dowel pins or slot & tenon joints for groove alignment.

2. Machining & Clearances (Clause 7.5.2.3)

• All bearing/contact faces of guides and extensions must be machined.
• Seating faces of guide extensions contacting the slide must be of same material as the slide.
• Maximum clearance between slide and guide: 1.5 mm.

3. Structural Design (Clause 3.1)

• Guides (cast iron) designed for max head with safety factor = 5 for shear, compression, tension.
• Must withstand entire thrust from water pressure + wedging action.
• Length of guide extension above waterway opening:

[ \text{Guide extension length} \geq (0.5 \times H + 250) \text{ mm} ]

where H = height of waterway opening (mm).

Summary Table

flowchart TD
    A[Guide Extension] --> B{Type}
    B --> C[Integral with Frame]
    B --> D[Integral with Guide Bars]
    B --> E[Split Construction]
    E --> F[Bolted to Frame or Guide Bars]
    E --> G[Aligned with Dowel Pins / Slot-Tenon]
    A --> H[Machined Bearing Faces]
    H --> I[Seating Faces same material as Slide]
    A --> J[Length ≥ (0.5 × H + 250) mm]

Force Required to Activate Sluice Gate (IS 13349: Clause 7.11.1.3, Annex E)

Key Formulas:

1. Maximum Force to Open (including friction and wedges):

[ F = 10,000 \times f \times A \times H + 15 \times P_1 + P_2 ]

• (F) = Total max force to open slide (Newtons)
• (f) = Friction factor (typically 0.35)
• (A) = Gate opening area (m²)
• (H) = Head of water at gate center line (m)
• (P_1) = Weight of slide (Newtons)
• (P_2) = Weight of stem (Newtons)

2. Sustained Effort Force (after unseating):

[ F = 10,000 \times f \times A \times H + P_1 + P_2 ]

Additional Specifications:

• Friction factor (f): 0.35 (slide-seat friction)
• Weight of slide and stem: Obtain from manufacturer; buoyancy effects usually neglected.
• Wedge friction: accounted by adding half the slide weight (15 × (P_1)) in Eq (1).
• Stem Diameters and Pitch (Clause 7.11.1):

• Stem diameters are designed per Euler's column formula with slenderness ratio ≤ 200.

Nominal Sizes of Rectangular Sluice Gates (Clause 5.1, Table 2)

IS 13349 - Lift Mechanism Key Points and Specifications

1. Pedestal Requirements (Clause 9.3):

• Pedestal must be machined and drilled for gear housing and bolting to operating floor.
• Height to position handwheel or crank axis at ~500 mm above pedestal base or operating floor for ergonomic operation.
• Include a covered window for easy cleaning and greasing of stem threads.

2. Operating Effort Limit (Clause 9.3.2):

• Effort on the lifting device must not exceed 70 Nm after the gate is unseated from wedges.

3. Mounting (Clause 9.3.1):

• Manual lifting mechanisms can be mounted directly on the yoke of self-contained gates, with or without pedestal.

4. Design Guidance:

• Refer to IS 11228:1985 for detailed design of lift mechanisms.

Important Formula for Torque (Effort) on Lifting Device:

[ T = F \times r ]

• T = Torque (Nm) ≤ 70 Nm (as per clause 9.3.2)
• F = Force applied by operator (N)
• r = Radius of handwheel or crank arm (m)

Summary Table

flowchart LR
    A[Pedestal] --> B[Gear Housing Mounting]
    B --> C[Handwheel/Crank at 500 mm Height]
    C --> D[Operator Applies Torque ≤ 70 Nm]
    D --> E[Gate Unseated & Lifted]
    E --> F[Gate Operation]

This ensures ergonomic, efficient, and maintainable lift mechanism design per IS 13349.

IS 13349: Fabrication and Workmanship - Key Points

1. Surface Preparation (Clause 9.8)

• All exposed surfaces of the headstock mechanism must have protective coatings as per Clause 8.
• Surfaces must be clean, smooth, and free from rust or scale before coating.

2. Fabrication & Workmanship (Clause 10.1.2)

• Seating faces: smooth machined or hand-scraped finish.
• Guides-to-frame and frame-to-wall thimbles: machined flat surfaces for proper fit and function.

3. Materials (Clause 6.1, Table 3)

4. Important Notes on Materials

• Avoid brass in acidic/alkaline water due to dezincification.
• Use phosphor or silicon bronze with low zinc content for seating faces where dezincification risk exists.
• Avoid stainless steel for seating faces and wedges to prevent galling under high pressure.

Summary Diagram: Fabrication Workflow

flowchart TD
    A[Surface Preparation] --> B[Machining of Seating Faces]

IS 13349 - Testing: Key Points & Specifications

Surface Finish (Clause 10.1.2)

• Seating faces: Must have smooth machined or hand-scraped surface finish.
• All mating surfaces (guides-to-frame, frame-to-wall thimble): Must be machined flat to ensure proper fit and performance.

Shop Testing (Clause 11)

• No detailed clause, but testing should ensure:
  • Dimensional accuracy
  • Surface finish compliance
  • Functional performance under simulated loads

Reference Standards (Annex B, Clause 2.1)

Testing and material specifications refer to these IS codes for materials used in components:

Testing Method Note (Clause 7.8.2)

• Clamps may replace top and bottom wedges during testing for convenience and safety.

Summary Table: Testing Requirements

If you need formulas or load test procedures, typically:

• Load test formula: ( P = A \times f_y )
  • ( P ) = test load
  • ( A ) = cross-sectional area
  • ( f_y ) = yield strength of material

flowchart TD
    A[Start Testing] --> B[Check Surface Finish]
    B --> C{Is surface smooth & flat?}

IS 13349: Installation Key Points & Specifications

1. Installation Guidelines (Clause 12.2)

• Follow manufacturer's guidelines for minimum clearance during installation, storage, and handling.
• Handle & install wall thimble, gate, operating mechanism, stem, guides, and accessories per manufacturer's drawings.
• Avoid warping gate frame; maintain tolerances between seating faces.
• Ensure all gates, thimbles, stems, and operators are plumbed, shimmed, and aligned accurately.
• Tapped holes in thimbles must be plugged during concrete pouring to protect threads.

2. Material Specifications (Clause 6.1, Table 3)

3. Nominal Sizes of Rectangular Sluice Gates (Clause 5.1, Table 2)

• Width & Height range typically from 300 mm to 2500 mm.
• Common sizes include:
  • 1000 × 750 mm
  • 1200 × 900 mm
  • 1500 × 1200 mm
  • 1800 × 1500 mm
  • 2250 × 1500 mm

4. Testing (Clause 5.2)

• Apply water pressure of 1.5 times the max operating head for 5 minutes.
• No leakage or permanent deformation allowed.

Summary Diagram: Installation Flow

flowchart TD
    A[Receive gate & accessories] --> B[Check manufacturer's guidelines]
    B --> C[Handle & store carefully]