Fabricated Unbalanced Head Penstock Gate
Precision-Engineered for Four-Side Sealing Under High Differential Pressures
Overview
The Fabricated Unbalanced Head Penstock Gate from Fundametal Technologies is purpose-built to provide reliable isolation under seating and unseating head pressures up to 25 meters. These gates are engineered for precision, long-term performance, and full traceability, with customization across dimensions, load ratings, and materials to suit both municipal and industrial water control systems.
Compliance & Standards
These gates are designed and fabricated in full compliance with:
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AWWA C561 – The international benchmark for fabricated sluice gates, covering structural strength, leakage performance, reinforcement requirements, and dimensional tolerances.
With selected design elements referenced from:
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IS 13349 – Though originally applicable to cast iron gates, this standard provides useful guidelines for spindle sizing, leakage rates, and sealing arrangement. Only applicable design elements are considered; material-related clauses are excluded.
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DIN 19569-4 – Referenced for frame geometry, sealing strip design, and installation tolerances where beneficial.
Design & Construction
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Tailored Engineering
Each gate is fully customized in height, width, and pressure rating, making it suitable for both retrofit and new installations. -
Four-Side Sealing
Designed to seal on all four sides, enabling full resistance to both seating and unseating heads. Applicable only for wall-mounted installations (flush or thimble).
Not suitable for open-channel applications due to lack of top or bottom sealing surface. -
FEA-Based Structural Validation
Each gate design is evaluated using Finite Element Analysis (FEA) to ensure stress and deflection are well within safe operating limits. -
Reinforcement Geometry
CAD-optimized flat bar and folded reinforcement patterns provide structural rigidity while keeping fabrication efficient.
Material Options
Our gates are manufactured using certified grades based on process conditions and corrosion exposure.
Standard Offerings
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Stainless Steel 304 – For general water and effluent handling.
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Stainless Steel 316 – For saline and mildly aggressive environments.
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Duplex Stainless Steel (2205) – For high chloride, high-strength applications.
Special Offerings (On Request)
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Titanium Grade 2 – For critical service in highly corrosive environments.
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Copper-Nickel 70/30 (C71500) – For marine and biofouling resistance.
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Copper-Nickel 90/10 (C70600) – For brackish water and coastal applications.
Special material options are offered only upon request at the time of order placement and may involve longer lead times.
Manufacturing Standards & Material Control
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Certified Raw Materials
All incoming materials are sourced from traceable, certified mills, supported with Mill Test Certificates (MTCs). -
Welding Standards
Welding is performed under qualified procedures in compliance with AWS D1.1 / D1.6, depending on material. Full WPS, PQR, and WQR documentation is maintained. -
Seats and Guides
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UHMWPE – Ideal for low-friction, submerged conditions.
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Phosphor Bronze – Preferred for high-duty, long-life service with superior wear resistance.
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Seals, Spindles & Operational Components
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Seals
High-quality EPDM or Nitrile rubber with low compression set for leak-tight operation across the gate’s lifecycle.
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Spindles
Rolled-thread stainless steel spindles, sized per IS 13349 guidelines, offering high strength and smooth actuation.
Flexible Operation Modes
The gates can be operated using:
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Direct Handwheel
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Manual Gearbox
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Electromechanical Actuators (SCADA compatible)
This provides full flexibility across manual and automated control systems.
Material Traceability & Testing
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Positive Material Identification (PMI)
Core structural elements are tested using handheld XRF analyzers, at both:-
Pre-manufacturing stage – to validate incoming raw material
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Post-manufacturing stage – to confirm final material compliance
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XRF Test Logs
All PMI results are logged and mapped to the gate’s serial number for traceability. -
Third-Party NABL-Accredited Testing
Independent testing for chemical and mechanical properties is carried out where applicable to verify material performance.
Factory Testing & QA Documentation
Documentation Supplied with Every Gate
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Structural FEA Report
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Weld Procedure Specification (WPS)
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Procedure Qualification Record (PQR)
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Welder Qualification Record (WQR)
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Material Test Certificates (MTC)
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NABL Lab Test Reports
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PMI Reports – pre and post
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Dimensional Inspection Report
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Internal XRF Log
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Functional Dry-Run Test Report
Optional (Available on Request at Order Stage)
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Hydrostatic Leakage Testing
Simulates site head conditions to verify sealing performance.
Performed only if explicitly requested at the time of order confirmation.
Application
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STP & ETP Isolation Chambers
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Pumping Station Wet Wells
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Interception and Diversion Chambers
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Sludge Handling Units
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Raw/Treated Water Structures
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Flood Control Installations
Conclusion
The Fabricated Unbalanced Head Penstock Gate by Fundametal Technologies is a high-integrity solution engineered for the toughest flow isolation conditions in water and wastewater systems. With its four-side sealing capability, FEA-verified structure, material traceability, and documentation-backed QA processes, this gate is built to outperform in both seating and unseating head scenarios — where ordinary gates fall short.
Offered in a wide range of material options — including Duplex, Titanium, and Copper-Nickel alloys — and designed in strict accordance with AWWA C561 and supplemented by IS 13349 and DIN 19569-4, our gates meet both consultant expectations and field realities.
Whether you are retrofitting into an existing chamber or engineering a new system from scratch, Fundametal Technologies ensures your isolation gate is purpose-built, pressure-rated, and project-ready.