Material Insights · Understanding the Material World

Metal products: Follow one offering through the chain

Fabricators making castings, forgings, tubes, fasteners and cans from steel and metals

Follow one offering through the chain

1 Example story · 6 steps · India

A ductile iron water pipe from Electrosteel

Follow molten iron from a blast furnace into a spun, zinc-coated pipe laid for Jal Jeevan Mission.

1 / 6 · Metal supply

Iron from the company's own furnace

164.9 MtIndia's crude steel output, 2025

A ductile iron pipe starts as molten iron. Electrosteel Castings runs an integrated chain with its own coke ovens, sinter plant and furnaces producing liquid iron, so iron ore and coking coal become hot metal on site rather than bought-in scrap. It works inside the world's second-largest steel economy: India made 164.9 Mt of crude steel in 2025.1,3,6

Constraint Coking coal: coke ovens tie pipe costs to coking coal, and about 95% of the steel sector's requirement is imported (Ministry of Coal, 2026). Fe Iron oreKc Coking coalCaO LimeMn ManganeseTransport and logistics
2 / 6 · Metal supply

A pinch of magnesium lets it bend

86%China's share of primary magnesium (calculated)

What turns brittle grey iron into ductile iron is a small dose of magnesium, usually added as magnesium ferrosilicon, which makes the graphite form round nodules instead of flakes. Electrosteel makes its own ferrosilicon, but magnesium is close to a Chinese monopoly: China smelted about 950,000 of the world's 1.1 million tonnes of primary magnesium in 2025 (estimate).4,3

Constraint Concentration: about 86% of 2025 primary magnesium came from China (calculated), so Chinese export curbs would hit every ductile iron foundry. Mg MagnesiumSi SiliconHVAC AC transmission
3 / 6 · Casting and forging

Spun into a pipe

9 lakh tElectrosteel DI pipe capacity a year

The treated iron is poured into a water-cooled steel mould spinning at high speed, and centrifugal force spreads it into a pipe wall of even thickness. Electrosteel has about 9 lakh tonnes a year of ductile iron pipe capacity across plants in West Bengal, Andhra Pradesh and Tamil Nadu, within an Indian castings industry of about 12 Mt a year.2,3

Constraint Fragmentation: about 85% of India's foundries are small, so few can match the scale and export quality of integrated pipe makers. Fe Iron oreMg MagnesiumSi SiliconEH Electric heatingMachinery and equipment
4 / 6 · Casting and forging

Bends, tees and valves to match

60%fittings revenue earned from exports

A pipeline also needs bends, tees, flanges and valves, which are sand-cast separately. About 60% of Electrosteel's fittings revenue comes from exports, and in 2025-26 it bought TIS, an Italian valve maker with €41 million of 2025 revenue, for €11.5 million, to sell whole systems into an Indian valve market it sizes at about ₹2,000 crore.3

Constraint Export markets demand tight certification and consistent quality, which favours scaled, automated foundries over India's many small units. Fe Iron oreMg MagnesiumQz Silica sandKao Kaolin & claysMachinery and equipment
5 / 6 · Finishing and treatment

Annealed, zinc-sprayed and cement-lined

200 g/m2minimum zinc coating, ISO 8179-1:2017

Fresh from the mould, each pipe is annealed in a furnace to relieve stress and toughen the iron. It is then sprayed outside with metallic zinc under a finishing coat, and lined inside with cement mortar so water never touches bare metal. The 2017 edition of the international coating standard raised the minimum zinc layer from 130 to 200 grams per square metre.5

Constraint Zinc: the 200 g/m2 minimum is about 54% more than the old 130 g/m2 rule (calculated), so coating cost tracks zinc prices. Zn ZincCem CementQz Silica sandGas Natural gasBuilding materials
6 / 6 · Distribution to users

Sold into Jal Jeevan Mission trenches

-25%Electrosteel volumes, FY26 on FY25 (calculated)

Most pipe goes by tender to contractors laying village and town water schemes, while dealers and stockists supply fittings, gaskets and smaller lots. Demand therefore follows government water spending: Electrosteel's sales of pipes and fittings fell from 7.81 lakh tonnes in FY25 to 5.84 lakh tonnes in FY26, which the company put down to slower domestic demand.3,7

Constraint Budget-driven demand: in March 2026 the Cabinet extended Jal Jeevan Mission to 2028 with an ₹8.69 lakh crore outlay, but orders follow actual state spending. St SteelEPDM EPDMTransport and logisticsFinance: banking, insurance, markets

What the chain shows

India has the iron, the foundries and the demand for water pipe; the chokepoints are imported coking coal, Chinese magnesium and the pace of state water spending.

Sources
  1. December 2025 crude steel production and 2025 global crude steel production totals World Steel Association, 2026
  2. India's foundry industry to reach USD 42.5 bn by 2029: Bharat Foundry 360 Insight 2025-2047 report The Machine Maker (report launched at the Indian Foundry Congress), 2026
  3. Q4 and FY26 investors presentation Electrosteel Castings Ltd, 2026
  4. Mineral Commodity Summaries 2026: Magnesium metal US Geological Survey, 2026
  5. ISO 8179-1:2017 Ductile iron pipes, fittings, accessories and their joints: external zinc-based coating (preview, foreword) International Organization for Standardization, via ANSI Webstore, 2017
  6. Government notifies coking coal as a critical and strategic mineral under the MMDR Act, 1957 (press release, 29 January 2026) Ministry of Coal, Government of India, 2026
  7. Cabinet approves extension of Jal Jeevan Mission period up to December 2028 with enhanced outlay Prime Minister's Office, Government of India, 2026

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