Mehrab Industrial Valves — Company Profile
Founded in 1999 (1378 SH) with a small gray-iron furnace in Pakdasht, Mehrab began by producing 2–6″ gate valves. Early on, the team realized Iran’s market needed products aligned with global standards. After three years, ductile-iron casting (spheroidal graphite) went online, enabling pressure parts up to PN16.
The 2000s were a technology leap: investment in fully automated CNC lines, a 250,000-cycle fatigue tester for stainless-steel stems, and Fusion-Bonded Epoxy (FBE) coating. These upgrades helped Mehrab gate and check valves replace imports in the municipal networks of four major cities (2010–2012 / 1389–1391). Export sales started in 2015 (1394) and ISO 9001:2015 quality management was implemented, placing Mehrab among reputable regional brands.
Today, the foundry and machining lines operate on 40,000 m² with an annual capacity of 18,000 t of cast components.
Timeline of Key Actions and Outcomes
| Year (SH) | Key action | Technical / market outcome |
|---|---|---|
| 1381 (2002) | Installed 1.5-ton induction furnace | Achieved ductile iron GGG50 |
| 1386 (2007) | Hydrostatic test system up to 25 bar | 100% product testing before delivery |
| 1390 (2011) | Mass production of PE chamber valve | Eliminated corrosion in buried locations |
| 1394 (2015) | WRAS certification (UK) | Enabled exports to Iraq and Oman |
| 1403 (2024) | Fully automated packaging line | End-to-end serial traceability for each valve |
Technical Backbone & Quality Control Cycle
Mehrab produces ductile iron using automatic sand-mold casting with magnesium treatment to form uniform nodular graphite, delivering tensile strength up to 500 MPa. After precision machining, parts are shot-blasted and immediately enter the FBE tunnel; a 250–300 µm epoxy layer is cured at 220 °C, improving corrosion resistance at least fivefold vs. conventional liquid paint.
Each valve then undergoes hydrostatic testing at 1.5× its PN rating. Test results are encoded as a QR mark on the body so customers can access records anytime. Final sealing uses dual NBR O-rings formulated for ozone and chlorides. This rigorous QA cycle has kept product returns below 0.7% over the past five years.
Product Portfolio & Specialized Uses
1) Gate Valves
- Resilient-seated (DN 50–300): Zero leakage; the go-to solution for potable-water networks and municipal pump stations thanks to minimal headloss.
- Metal-seated (DN 80–400): Suited for fluids up to 80 °C or with abrasives (e.g., lime) in treatment plants.
- Long-stem series: Stem extended up to 120 cm above body for deep chambers on buried lines.
2) Swing Check Valves
Ductile-iron monoblock body with stainless-steel levered shaft and external counterweight. Hinge geometry limits closing angle to <15° to mitigate water hammer on pump shutdown. Sizes DN 50–300, PN10 and PN16.
3) Chamber & End-of-Line Valves
- 45° nozzle: Controlled discharge for mains flushing or rapid draw-off in farms.
- Automatic Hydrofix: Simultaneous air/water release for high-pressure PE lines; stable performance under pressure fluctuations.
- High-pedestal handwheel: Above-ground actuation without opening a manhole.
4) Flanged Fittings
90° elbows, T-tees, crosses, and blind flanges in DN 50–600; drilling per EN 1092-2 with double-sided epoxy. A dedicated adapter ring for PE-to-ductile-iron transitions is in continuous production.
5) Sealing Accessories
NBR gaskets reinforced with fabric insertion, 2–48″ diameters, vulcanized in a 160 °C steam press to a uniform 65 Shore A—driving flange leakage toward zero for years.
Competitive Advantages vs. Domestic & Foreign Brands
- EU-grade raw materials: Every melt is checked by a 32-channel spectrometer; DIN EN 1563 chemistry ensures strength and nodularity.
- Thermal cycling: 50 cycles between 5–60 °C validate sealing under expansion–contraction.
- Digital traceability: Each product carries a unique code and pressure-test certificate, streamlining after-sales support.
- Field technical support: Mobile teams cover 18 provinces for on-site training and troubleshooting.
- Spare-parts access: Discs, O-rings, and handwheels available from the central warehouse for 10 years after purchase.
Benchmark Snapshot
| Metric | Mehrab | Competitors’ average |
|---|---|---|
| Epoxy thickness (µm) | 250–300 | 150 |
| Pressure testing | 100% of products | Random sampling |
| Minimum service life (est.) | 30 years | 20 years |
| After-sales support | 10-year parts & repair | 3–5 years |
Application Domains
- Urban water networks: High water-hammer resistance and zero-leakage resilient gate valves suit transmission and distribution lines.
- Pressurized & drip irrigation: Chamber valves with high pedestals and automatic Hydrofix ensure continuous farm operation.
- Mineral processing: Ductile-iron metal-seated gates withstand abrasive slurries.
- Water & wastewater treatment: 300-µm epoxy shields against corrosive environments.
- Oil & petrochemical fire-water (PN16): Certified pressure and hydrostatic leak tests qualify special gate valves for fire-water lines.
Innovation & R&D
In partnership with Iran University of Science & Technology on SGI metallurgy, Mehrab started (2023/1402) a smart gate-valve project with an open/close position sensor and Bluetooth telemetry. The prototype completed 10,000 lab cycles with no headloss. Phase two will adopt NB-IoT so valve status and consumption data are stored in the cloud and visible in water-network SCADA.
Growth Outlook to 2031 (1410 SH)
Targets include 25,000 t annual capacity and ISO 29001 certification for oil & gas. A continuous casting line for ductile-iron parts up to 800 mm is under study. Mehrab also aims to expand exports into Central Asia and East Africa, where durable valves are in high demand.
Distribution
As one of Mehrab’s distribution channels, Tamam Baha maintains broad inventory at its central Tehran warehouse, enabling fast supply across sizes for municipal, agricultural, and industrial contractors. Buyers receive the same three-year replacement warranty and ten-year after-sales service from Mehrab, while other procurement options are also available nationwide.
