SPECIFICATION FOR PRESSURISED & RESTRAINED, LAMINATED

JOINT GLASS REINFORCED PLASTIC PIPING SYSTEMS

(I) INTRODUCTION:

(i) Design of piping system shall conform to the requirements of ISO 14692, and additionally
to AWWA M45 for underground applications, as appropriate.

(ii) All GRP components (including bends and fittings) shall be designed and fabricated by
one manufacturer.

(iii) Pipe size shall be as shown on the drawings, unless noted otherwise. Nominal sizes
indicated refer to internal diameters .

(iv) Installation of underground pipes shall be in accordance with these additional OP

requirements , vendor's recommendations and the approved Project Method Statement.

(v) The following is the logical sequence of events to be adhered to during the contract.

• 1000 hr tests shall not be permitted to commence until pipe design calculations are
approved by OP.

• Stress Analysis can not be finalized until 1000 hour tests are completed successfully .

• Fittings shall not be installed until Stress Analysis recommendations are approved by
OP, unless otherwise agreed with OP on a project-by-project basis. However, long
straight pipe runs may be installed after pipeline design calculations (pipe and joint)
have been approved.

• Sectional Hydrotesting on site can not commence until recommendations of approved

Stress Analysis have been implemented for the section under test.

(II) QP'S ADDITIONAL REQUIREMENTS:

(A) DESIGN:

(i) General : Minimum wall thickness shall be 5 mm for both above-ground and under­
ground piping for diameters up to and including 150 mm. For diameters above 150 mm,
minimum wall thickness shall be 10 mm. Operating and design conditions are indicated
in Enquiry Sheet, Annex . I. All pipes and joints shall be capable of withstanding an
external pressure of 100 KPa (i.e. full vacuum) without infiltration in both the straight and
misaligned positions. All pipes and joints shall be designed for a service life of 30 years,
with up to 5% deflection in their installed condition .

(ii) Stiffness : Minimum stiffness of pipes and fittings, both above ground and underground
shall be 10,000 N/m 2 • For pipes 1000 mm diameter and above, manufacturer shall
recommend stiffness for OP review and approval, but it shall not be less than 5,000 N/m2

(iii) 1000 hr Test Pressure and Qualified Stress: The 1000-hour test pressure for pipes
and fittings shall be based on pressure only, and shall be established in accordance with
ISO 14692 . Any additional thickening of pipes due to requirements of AWWA M45 and

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 default thickness specified herein by QP, shall not be taken into account when
determining the 1000 hr test pressures. However, the qualified stress shall be validated
based on the 1000 hr Test Pressure over the overall thickness (excludinq the top
coating) of the pipe supplied / tested.

(iv) Project Specific 1000-hour tests: Project specific 1OOOhr tests shall be carried out on
the following items for each product sector representative for range of diameters as
specified in Table A.1 of ISO 14692-2 Annex A to be used on the project, unless
otherwise agreed with QP.

a) Pipe and Joint (2 No. samples)

b) Elbow (2 No. samples)

c) Tees (2 No. samples)

Note: The joint length for the specimen used for qualification of pipe + joint shall be
based on the calculated bond length as per ISOrrS24817. Bond lengths shall be
measured exclusive of a 1 in 6 taper.

(v) Lamination Thickness of Joints and Mitered Fittings and Qualified Stresses: The
lamination thickness for all joints and mitered fittings shall be in accordance with
ISOrrS24817, but shall as a minimum be made equivalent to the thickness of the
structural wall (i.e. including inner liner thickness) of the main pipe.

Qualified stresses of fittings used in stress analysis shall be those actual stresses
qualified by 1000 hr tests (i.e. before additional thickening). Any additional thickening
identified from the stress analysis shall be in addition to the minimum requirement of
equaling the main pipe structural wall thickness.

(vi) Lamination Joints: Lamination bond lengths shall be calculated in accordance with
ISOrrS24817 and shall be measured exclusive of a 1 in 6 taper.

(vii) Thickness of Reducing Tees: Thickness of lamination for both run and branch shall be
the thickness of the main run pipe structural wall, as a minimum , for main pipe runs of
diameters up to 1000 mm.

(viii) Thickness of Reducer: Thickness of lamination shall be the thickness of the higher size
main pipe structural wall, as a minimum .

(ix) Stress Analysis: Stress analysis shall be based on the manufacturer's qualified stress,
as validated by the relevant 1000 Hour tests . Requirement for thrust blocks shall be
determined by stress analysis. Surge forces generated at all components shall be used
as an input file for stress analysis purposes.

(x) On-Site Hydrostatic Testing : Sectional Hydrotesting shall be undertaken at 1.5 x

Design Pressure for a minimum duration of 30 minutes , but actual duration shall be
based on length of section under test, after consultation with the manufacturer.

The final System Hydrotest shall be undertaken at 1.5 x Design Pressure for a minimum
of 1 hour and then reduced gradually to 1.1 x Design Pressure for a period of 24 hours.

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(xi) Hydrostatic Factory Tests: Hydrostatic Factory Tests at 1.5 x Design Pressure shall be
carried out on 100% of all pipes and 5% of all fittings.

(B) MATERIAL:

1. Raw Materials:

(i) General: Generally, epoxy, polyester and vinyl esters are acceptable for most mediums.
However, manufacturer shall recommend / select the most suitable resin based on the
medium and design temperature, unless otherwise specified by OP. Isophthalic
resins shall comply with the relevant provisions of BS 3532 Type B.

(ii) Glass: Glass shall comply with the relevant provisions of the following standards :

BS 3691 for ravings

BS 3496 for chopped strand mat.

BS 3396 or BS3749 for woven fabric.

Surface tissues shall comply with one of the above Standards.

(iii) Sand Aggregate: Sand aggregate shall not be utilized.

(iv) Additives: Use of additives such as fire retardant, UV inhibitors, coloured pigments or
dyes is permissible, and shall be subject to the approval of OP.

2. Product:

(i) Pipes shall be suitable for the operating temperatures stated in the Enquiry Sheet. Pipes
shall be suitable for immersion in corrosive ground water.

(ii) All pipes shall have a resin-rich internal liner. Minimum thickness shall be 1.5mm for
vinyl ester and polyester pipe and 0.5 mm minimum for epoxy pipes. The resin-rich liner
shall be reinforced with "C" glass surface tissue . Resins shall be cured to achieve 90%
of the manufacturer's recommended Barcol hardness value.

(iii) Fillers, as defined in BS 5480, shall not be used.

(iv) All exposed pipework and chambers shall be painted in accordance with requirements of
Regulation for Colour Code Identification for Pipework in RLC (Doc No
RLC/GLl002/2004) on-site.

(v) All pipes shall be solid wall construction . Additional exterior stiffeners shall be provided
to maintain circularity on large diameter pipes, as required.

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3. Mechanical Properties:

(i) Pipe stiffness shall be a minimum of 10,000 N/m 2 , for diameters of less than 1000 mm.
For pipes 1000 mm diameter and above , manufacturer shall recommend stiffness for OP
review and approval, but it shall not be less than 5,000 N/m 2

(i) Pipes shall sustain the following short term deflections when subjected to parallel plate
loading.

a) No visible liner cracks at 9% deflection.

b) No visible structural cracks at 15% deflection.

4. Flanges:

(i) Flanges shall be filament wound with epoxy or vinyl ester resins.

(ii) Drilled flanges shall conform to ASME B 16.5 flat face, and to the rating specified in the
Enquiry Sheet. All bolts shall be galvanized.

(iii) Flanges manufactured by hand-lay-up methods are not accepted for diameters up to and
including 1800 mm.

5. Gaskets:

(i) Gasket material shall be EPDM rubber, conforming to BS 2494 Type "W" requirements
or as per manufacturer's recommendations and approved by OP.

(ii) Gasket lubricant shall be as recommended by the gasket manufacturer.

(iii) Gaskets for flanged fittings shall conform to ASME B16.21 & BS 6920 (for potable water
applications only)

(C) INSPECTION:

(i) Manufacturer shall provide sufficient "type" test results to prove the proposed pipe
design will meet the desired service life and the service conditions . Also refer to items 8
& 9 of table below.

(ii) Manufacturer as a minimum should have a long term regression line (HDB) for the
offered pipe.

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(iii) Routine Quality Control shall be done according to the following:

ROUTINE QUALITY CONTROL TESTING

Frequenc Evaluation
I No Test Description Method
y Criteria

1. Dimensional ASTM 100% As per standards

control D3567
BS 5480
2. Curing (Barcol ASTM 100% As per
hardness) D2583 specifications

3. Stiffness BS 5480 1 in 50 As per

ASTM specifications
D2412
4. Longitudinal BS 5480 1 in 50 As per standard
tensile strength

5. Loss on ignition ASTM 1 in 50 As per

D2584 specifications
6. Hoop tens ile ASTM 1 in 50 As per
strength D2290 specifications

7. Hydrostatic BS 5480 100% of No visible leak or

pressure test pipes and weeping
5% of all
flanged
and non
flanged
fittings.

8. Assembled joint IS014692 Type As per standard .

tightness test, AWWA Test
internal C950
pressure,
external
pressure and
shear load ing.

9. Cycl ic Load ing IS08533 Type As per standard .

(if applicable) Test
(D) INSTALLATION:

1. In the case of underground piping, the GRP pipe shall be buried in dune sand /
granular fill surround as per manufacturer's recommendations and approved by
OP.

2. All buried joints shall be restrained, laminated joints unless otherwise specified.

3. All joints for exposed piping shall be flanged, laminated or mechanical couplers,
as specified.

4. All test water shall be disposed of in accordance with RLC Environmental

Guidelines

(E) CERTIFICATION and DOCUMENTATION:

1. Material certificates shall conform to EN 10204 3.1.

2. 1OOO-hour test shall be witnessed by a TPIA, approved by OP.

3. Manufacturers Serial Number shall provide a cross-reference on all required

Documentation in accordance with EN 10204 3.1.

4. Manufacturer shall be ISO 9001 and ISO 14001 accredited.

5. Manufacturer shall hold Water Regulations Advisory Scheme 0NRAS)

certification for compliance of GRP pipe in compliance with BS 6920 for potable
water applications.

6. Manufacturer shall provide the production data for all the GRP components as
per clauses 11.6.1 to 11.6.3 of ISO 14692-2.
 Annex I

Enquiry Sheet

1. Project

Project name

Location

Type of system

Fluid composition

Special operations

2. Service conditions

Design pressure (MPa)

Service cyclicity and transient loads

Above-ground or buried system?

Design external pressure (MPa) Full vacuum (QP default requirement)

Maximum fluid temperature CC)

Minimum fluid temperature (OC)

Maximum ambient temperature CC)

Minimum ambient temperature (OC)

Flow velocity and particulate content Not to exceed 3 m/s (QP default requirement)

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3. Additional items

Is manufacturer's supervision of installation required? Yes (OP default requirement)

Is potable water health certification required?

If "Yes" above, specify applicable health authorities

Restrictions on resin/curing agent Yes-as per Design Temp (OP default)

Are resin-rich internal liners required? Yes (OP default requirement)

Electrical conductivity requirements

Fire performance requirements?

Chemical resistance requirements