SPECIFICATION FOR GRP PIPES,

FITTINGS AND ACCESSORIES

0 02-02-2002 Approved Issue

rev. date Description/issued for prepared authorised
client: ADWEA
project: STANDARD SPECIFICATIONS FOR WATER WORKS
title: SPECIFICATION FOR GRP PIPES, FITTINGS AND ACCESSORIES

tender: project: document: W-P-SS-004 rev: 0 sheet: 1 of: 12

 Table of Contents page

1. SCOPE...................................................................................................3

2. APPLICABLE STANDARDS AND CODES ..........................................3

3. SITE CONDITIONS................................................................................4

4. DESIGN CONSIDERATIONS ................................................................4

5. TECHNICAL REQUIREMENTS.............................................................5
5.1 General........................................................................................5
5.2 Materials......................................................................................6
5.3 Raw Material................................................................................6
5.4 Wall Thickness ............................................................................7
5.5 Length .........................................................................................8
5.6 Diameter......................................................................................8
5.7 Stiffness.......................................................................................8
5.8 Longitudinal Strength...................................................................8
5.9 Hoop Tensile Strength.................................................................8
5.10 Joints ...........................................................................................8
5.11 Workmanship...............................................................................9
5.12 Fittings.......................................................................................10

6. INSPECTION & TESTING ...................................................................10

6.1 Inspection ..................................................................................10
6.2 Testing.......................................................................................10

7. PACKING AND SHIPMENT ................................................................11

7.1 Storage......................................................................................11
7.2 Marking......................................................................................12

8. VENDOR DOCUMENTATION .............................................................12

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR GRP PIPES, FITTINGS AND ACCESSORIES

tender: project: document: W-P-SS-004 rev: 0 sheet: 2 of: 12

 1. SCOPE

This specification covers the minimum requirements for the Glass Reinforced Plastic (GRP)
piping for water transmission and distribution pipelines using the filament wound
manufacturing process. The sizes covered are DN 100mm up to DN 2000mm.

The Manufacturer's design shall satisfy the minimum requirements set herein. This
specification includes the minimum requirements for design, manufacture, workmanship,
testing, inspection and installation of standard GRP pipe systems.

2. APPLICABLE STANDARDS AND CODES

The following internationally accepted standards are the minimum requirements for the
manufacturer of GRP Pipe Systems and are referenced through out the specification as
appropriate.

AWWA C 950 Glass Fiber Reinforced Thermosetting Resin Pressure Pipe.

AWWA M 45 Manual of water supply practised. Fibre glass pipe design.

ASTM D 3517 Standard specification for Fiberglass Pressure Pipe.

ASTM D 2412 Standard Test Method for Determination of External loading

characteristics of Plastic pipe by Parallel plate loading.

ASTM D 2290 Standard Test Method for Apparent Tensile Strength of ring or tubular
plastics and reinforced plastics by Split Disk Method.

ASTM D 2584 Standard Test Method for Ignition Loss of cured Reinforced Resins.

ASTM D 2583 Indentation hardness of rigid plastics by means of a Barcol Impressor.

ASTM D 638 Standard Test Method for tensile properties of Plastics.

BS 6920 Suitability of non-metallic products for use in contact with water for
human consumption with regard to their effect on the quality of the
water.

BS 7159 Code of Practice for Design and Construction of Glass Reinforced

Plastics (GRP) Piping systems for individual plants or sites.

BS 3396 Woven glass fibre fabrics for plastics reinforcement.

BS 3496 Specifications for E glass fibre chopped strand mat for reinforcement of
polyester and other liquid laminating systems.

BS 3532 Method of specifying unsaturated polyester resin systems.

BS 3691 Specification for E glass fibre roving for reinforcement of polyester and
epoxy resin systems.

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR GRP PIPES, FITTINGS AND ACCESSORIES

tender: project: document: W-P-SS-004 rev: 0 sheet: 3 of: 12

 BS 3749 Specification for E glass fibre woven roving fabrics for reinforcement of
polyester and epoxy resin systems.

3. SITE CONDITIONS

For site and climatic conditions refer "General Technical Requirements" document.

4. DESIGN CONSIDERATIONS

GRP pipe and fittings shall be manufactured by an established pipe Manufacturer in a

purpose - built facility for the production of such materials. The Manufacturer shall have
experience in the production of the similar pipe sizes and lengths. Evidence of previous
experience shall be presented to the main Project CONTRACTOR during the bidding stage.
The Manufacturer shall have an approved Quality Management System complying with ISO
9002 or 9001 which shall cover all activities being undertaken during the manufacturing, of
the subject pipe systems.

The GRP pipe system Manufacturer will be responsible for the following:

a) Manufacturer and supply of the GRP pipe, fittings, flanges, saddles and pipe closing
(make -up) pieces. Manufacturer to also supply the gaskets for use in flange
connections and provide general recommendations on installation of associated
equipment such as valves, expansion bellows, nuts and bolts and other accessories.

b) Design of any above ground (or in chambers) GRP pipe system including Stress
Analysis (Surge and Flexibility), Support Location / Function Analysis and the
Conceptual Support Design where necessary for the given design and routing.

c) Inspection and testing at the Manufacture's works in accordance with specified

requirements herein.

d) Marking of pipe for identification as per Section 7.2.

e) Provision of a Site Supervisor (s) to assist the CONTRACTOR during erection.

f) All lamination work of GRP pipe joints and fittings shall be executed by the Manufacturer
or by the CONTRACTOR under the direct supervision of the Manufacturer. In any case,
the Manufacturer shall be responsible for all lamination work.

The pipes and fittings shall be resistant to ultra violet rays and the joints shall be capable of
withstanding axial tensile strength.

Pipe shall meet the following minimum design requirements.

Operating Pressure (Pw) Min 1000 Kpa unless otherwise specified.

Surge Pressure (Ps) 40% of 'Pw' unless otherwise specified.

Vacuum (Pv) Full (-1 bar) (-0.8 bar test)

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR GRP PIPES, FITTINGS AND ACCESSORIES

tender: project: document: W-P-SS-004 rev: 0 sheet: 4 of: 12

 Earth Cover Minimum 1.0 m or as shown on drawings for buried pipe.
Maximum 8 meters.

Initial Installed Deflection 2.0% Max.

for buried pipe
Safety Factors

Pressure rating >= 1.8

Ring bending strain(stress) >= 1.5

Combined strain(stress) >= 1.5

Buckling >= 2.5

The CONTRACTOR shall be responsible for implementing / installing the correct design for
each GRP Pipe system.

The GRP pipe design shall be established in accordance with AWWA M45. Support
requirements for complex above ground piping systems shall be based on computer flexibility
analysis (static and dynamic) of the piping systems.

Design Calculations shall be submitted to the ADWEA/ENGINEER for review and approval.

All the materials used for the pipes, fittings etc. shall be non-toxic quality and suitable for
drinking water service

5. TECHNICAL REQUIREMENTS

5.1 General

GRP pipe shall be machine-made consisting of a corrosion resistant liner, one or more
structural walls and a resin rich exterior layer.

a) Liner

Pipe and Fittings shall have a resin rich internal liner of a minimum 1.0mm thickness.
The liner surface will be reinforced with "C" glass and impregnated with Isophthalic resin.

b) Structural Walls

The pipe structural walls shall be as specified in AWWA C 950. Consisting of Isophthalic
polyester resin and glass reinforcements.

c) The pipe also includes a stiffness wall section (core) consisting of resin, glass
reinforcement and aggregate.

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR GRP PIPES, FITTINGS AND ACCESSORIES

tender: project: document: W-P-SS-004 rev: 0 sheet: 5 of: 12

 d) External Layer

Pipe shall have a 0.01" (0.25 mm) thick resin rich exterior surface impregnated with
resin.

5.2 Materials

Glass Reinforcements shall have a finish compatible with the impregnating resin used.

Resins used shall be a commercial high grade thermosetting resin of the Isophthalic type. No
resin fillers shall be used.

No dark pigments shall be used in the GRP pipe or joints. No additives shall be used except
when required for viscosity or degassing control.

High purity silica sand may be included in the pipe wall section for stiffness control.

5.3 Raw Material

All incoming raw material shall be subjected to a receiving inspection and shall be checked for
compliance with the manufacturers specification suited only material that conforming to the
manufacturers specification sheets shall be used in the process.

a) Resins:

The resins shall comply with BS 3532 and ASTM D 1763.

The resins shall be cured to a hardness of not less than 90 percent of the Barcol
Hardness recommended by the resin manufacturers when measured in accordance to
ASTM D 2583.

The temperature of deflection of the resin shall not be less than 20°C higher than the
maximum service temperature at which the pipe work is to be used, if known, and
otherwise not less than 50°C.

The resins shall have the following characteristics:

Property Unit Liquid Resin Cured Resin

Appearance Visual Yellowish -
Colour Gardner Max. 5 -
Specific Gravity g/cc 1.1 to 1.2 1.2 - 1.3
Viscosity @ 25°C cps 450 ± 50 -
Styrene Content % Max. 45 -
Acid Number mg/KOH/g Max. 15 -
Flash Point °C Min. 34 -
Shelf Life @ 25°C Months 6 months -
Barcol Hardness (934-1) Units - Min. 40
Tensile Strength mpa - Min. 70

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR GRP PIPES, FITTINGS AND ACCESSORIES

tender: project: document: W-P-SS-004 rev: 0 sheet: 6 of: 12

 Tensile Modulus mpa - Min. 3500
Tensile Elongation % - Min. 3.0
Flexural Strength mpa - Min. 120
Flexural Modulus (Bend) mpa - Min. 3500
Heat Distortion Temperature °C - Min. 80

b) Glass Reinforcement:

Fibrous Glass Reinforcement shall be of E-glass type complying with BS 3496, BS 3691
or BS 3749.

The glass reinforcement can be of different forms viz. Continuous Roving, Chopped
Roving, Chopped Strand Mat or Woven Roving Mat.

In all cases, the following carrier shall be applicable to the reinforcement.

Moisture Content - Max. 0.15%

(Rovings & Mats)

Size Content - Max. 1.7%

(Rovings & Mats)

Tex. (gms/1000 mt.) - 600 ± 5%

(Roving) 1200 ± 5%
2400 ± 5%

Chop Mat (gm/sq.mt.) - 450 ± 5%

(Woven Mat) 280 ± 5%
360 ± 5%
580 ± 5%

c) Additional Material:

c.1 Aggregate:

Aggregate (Inert Granular material of a size between 0.05 to 1.0 mm, such as
graded Silica Sand (min. Silica Content in the form of Si02 shall be 95%). The
moisture content shall not exceed 0.2%.

c.2 Fillers:

No Fillers shall be used in the resin.

5.4 Wall Thickness

The wall thickness required for each size/pressure class shall be established by the
manufacturer to meet the design pressure and stiffness requirements. The pipe working
pressure class shall be based on the long term (60 years) Hydrostatic Design Stress (HDS) of
the pipe with design factor 1.8.

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR GRP PIPES, FITTINGS AND ACCESSORIES

tender: project: document: W-P-SS-004 rev: 0 sheet: 7 of: 12

 5.5 Length

GRP pipe shall be manufactured in standard lengths of 10 or 12 Meters Random short

lengths, if supplied, shall not exceed 10% of the quantity supplied of each size. The tolerance
on the Manufacturer's declared laying length shall not exceed ± 25 mm.

5.6 Diameter

Pipe shall be manufactured in standard metric sizes based on the pipe nominal inside
diameter. The actual inside diameter shall not vary from the nominal inside diameter by more
than 1% or 4mm whichever is greater.

5.7 Stiffness

The pipe stiffness shall be determined by the Manufacturer to meet the design requirement
with particular regards to installation method, burial depths, deflection limits, buckling and
vacuum requirements.

The manufacturer shall perform stiffness tests at a frequency of one test for each 100 lengths
of pipe produced from each manufacturing run, which ever provides the most frequency
sampling of each class and size. The minimum pipe stiffness shall be determined at 5 percent
deflection using the approvals and procedure of ASTM D2412. The acceptance levels shall
be as per AWWA C950 standard.

5.8 Longitudinal Strength

The GRP pipe shall meet the minimum longitudinal tensile strength requirements in AWWA C
950 for the appropriate pressure class specified when tested in accordance with ASTM D
638.

The above requirements are intended to provide adequate strength for normal handling and
under ground conditions. Pipe intended to withstand the end load resulting from internal
pressure at changes of direction or the beam load resulting from above ground installation
shall require higher longitudinal strengths and have a suitably designed, fully restrained,
jointing system.

5.9 Hoop Tensile Strength

GRP pipe systems shall meet the minimum hoop tensile strength requirements specified in
AWWA C950 for the appropriate pipe operating pressure class, when tested in accordance
with ASTM D 2290.

5.10 Joints

a) Flexible Joints

aa) Standard buried pipe with unrestrained joints shall be filament wound GRP
coupling, with confined EDPM Rubber gaskets. Bell and spigot joints with rubber
rings may only be used subject to approval by ADWEA/ENGINEER. EDPM Rubber

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR GRP PIPES, FITTINGS AND ACCESSORIES

tender: project: document: W-P-SS-004 rev: 0 sheet: 8 of: 12

 shall conform to BS 2494 or ASTM F477. Joints shall allow for at least 1 degree
deviation while remaining water tight at 1.5 times the pipe operating pressure.
EDPM Rubber shall be the sole element depended upon for water tightness. These
joints shall be used where no unbalanced forces exits. At the change of directions
and where unbalanced forces occurs (inside the restrained length) restrained joints
as described below shall be used. No thrust block will be necessary.

bb) EDPM Rubber Seal Locked Joints may also be used. This system is considered to
be fully restrained and requires no thrust blocks at changes in direction.

b) Rigid Joints

Flanges

GRP flanges where used shall be machine filament wound. Contact molded flanges
may be used for sizes 2000 mm and larger. Flanges shall be manufactured with Epoxy
or vinylester Resin. Flanges shall be flat faced with full or 'O' ring type gaskets. Gasket
material and design shall be per the Manufacturer's recommendations. The pipe
Manufacturer shall provide the torque sequence and maximum tightening torque as
appropriate for each flange size and design. Washers shall be used under all nuts and
bolts heads with special spacers to be used at connections with raised faced flanges as
required.

Flange drilling and rating shall be as specified on the drawings.

c) Reinforced Overlay Joints ( butt & wrap)

Butt and Wrap joints where used shall consist of layers of Glass fiber reinforcement
impregnated with vinylester or epoxy resin. The wall thickness, tensile and axial strength
of the reinforced overlay shall meet or exceed the design strength of the adjoining pipe
sections. Butt & Wrap joints on site shall be performed only by or under the supervision
of the pipe Manufacturer. The joints shall be tensile resistance and suitable for use
above or under ground with no thrust blocks.

Note: Only vegetable based lubricant shall be used while connecting the joints. The
lubricant may be supplied by the pipe manufacturer.

5.11 Workmanship

GRP pipe, fittings and joints shall be commercially free from delaminations, cracks, bubbles,
pinholes, pits, blisters, foreign inclusions and resin-starved areas that due to their nature,
degree or extent can detrimentally affect the strength and serviceability of the pipe. No glass
fiber reinforcements shall penetrate the interior surface of the pipe wall.

Joint sealing surfaces shall be free of dents, gouges, de-laminations, or other surface
irregularities that will affect the integrity of the joints.

GRP pipe, fittings and joints shall be as uniform as commercially practicable in color,
capacity, density and other physical properties.

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR GRP PIPES, FITTINGS AND ACCESSORIES

tender: project: document: W-P-SS-004 rev: 0 sheet: 9 of: 12

 5.12 Fittings

GRP fittings such as bends, tees, junctions and reducers shall be equal or superior in
performance to the GRP pipe of the same diameter and pressure. All fittings shall have a
smooth internal surface with similar wall construction.

Standard fittings shall be filament wound on a collapsible mold (25-300 mm Diameter) or

mitered (350-1200mm Diameter).

All GRP flanges and blind flanges up to 2000 mm diameter shall be machine filament wound.

For GRP fittings, the deviation from the state value of the angle of change of direction of a
bend, tee, junction etc. shall not exceed ± 1 degree.

The tolerance on the Manufacturer's declared length of fitting shall be ± 10 mm taken from the
point of intersection to the end of the fitting or ± 10mm on a straight fittings.

All GRP fittings shall be fabricated in the factory to ensure Quality Control. Complex fittings
arrangements may be pre-assembled by the pipe Manufacturer in the factory such that field
joints are kept to a minimum.

All pipes used for conveyance of potable water shall be certified by an independent agency
confirming their suitability for use with potable water under BS 6920.

6. INSPECTION & TESTING

6.1 Inspection

The Manufacturer shall take adequate measures in the production of the products covered by
this specifications to assure compliance with the requirements herein. An Inspection and
Testing Plan (ITP) should be forwarded to ADWEA/ENGINEER for approval prior to start of
manufacture. Plant inspection by ADWEA's qualified personnel or the omission of such
inspection shall not relieve the Manufacturer of the responsibility to furnish products
complying with the requirements of these specifications. Reporting should be done in
accordance with DIN 50049 and 2.2 certificate should be issued accordingly.

Production and Testing Notice: When plant inspection is required by ADWEA/ENGINEER, the
Manufacturer shall provide adequate advance notice of when and where production and
testing of ordered products will commence.

ADWEA/ENGINEER shall have free access with reasonable advance notice to the
Manufacturer's plant areas that are necessary to assure that products comply with all
requirements herein.

6.2 Testing

As a minimum, the following tests shall be performed at the indicated intervals and shall form
part of the Manufacturers overall quality control program.

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR GRP PIPES, FITTINGS AND ACCESSORIES

tender: project: document: W-P-SS-004 rev: 0 sheet: 10 of: 12

 The following tests shall be conducted on every pipe:

• Visual Inspection

• Dimensional Measurements

• Resin cure (Barcol Hardness) ASTM D 2583

• Hydrostatic Pressure test for pipes at 2 x the pipe working pressure in accordance with
AWWA C950.

The following tests shall be conducted on pipe samples at a frequency of not less than one
per 50 pipes (one lot) of the same Diameter and Pressure.

• Stiffness ASTM D 2412

• Hoop Tensile Strength ASTM D 2290

• Longitudinal Tensile Strength ASTM D 638

• Loss on ignition ( composition ) ASTM D 2584

• Deflection to crack/damage ASTM D 3517

Test methods shall be in accordance with AWWA C950. Copies of all test reports shall be
submitted by the CONTRACTOR for each lot delivered to Site.

Pipe dimensions, test pressure requirements, minimum pipe stiffness shall be in accordance
with section V of AWWA C950 standard.

7. PACKING AND SHIPMENT

7.1 Storage

While storing the GRP pipes they shall be supported (at least four) by wooden beam. When
pipes are stored directly on the ground, it should be ensured that the surface is smooth and
rock free. Each row of pipes with wooden supports shall be firmly secured. Pipes shall not be
rolled along the ground. Pipes shall be lifted and lowered using fabric straps only.

The pipes and fittings shall be packed in a manner which shall ensure arrival at site in
satisfactory condition, acceptable to ADWEA/ENGINEER.

Pipe ends shall be protected with suitable protective covers securely attached. The bottom of
the crates shall be provided with skids to facilitate handling by forklift truck.

All pipes and fittings shall be permanently marked with the manufacturer's name, the pressure
class, the nominal diameter and identification code. Markings for identification shall be made
in such a manner as not to impair the integrity of pipes/fittings material.

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR GRP PIPES, FITTINGS AND ACCESSORIES

tender: project: document: W-P-SS-004 rev: 0 sheet: 11 of: 12

 7.2 Marking

Each pipe and fitting shall be indelibly marked with the following information.

• Manufacturers Name or trademark

• Manufacturing date

• Manufacturing number

• Nominal diameter in mm

• Rated Operating pressure in Kpa

• Pipe stiffness class

• Nominal laying length (for pipe only)

• Manufacturers Inspection mark

• Contract title and number

• Design Standard

8. VENDOR DOCUMENTATION

The CONTRACTOR shall furnish the following vendor data as a minimum, with the bid:

- Catalogues/Brochures.

- Dimensional details of pipes and fittings.

- Detailed material specifications.

- Manufacturer's drawings.

- Complete details of testing facilities available at manufacturer's works.

- Local (UAE) agent name and address.

Bids not accompanied by any of above mentioned information/data shall be considered

incomplete, and liable to be rejected.

Client ADWEA
Project: STANDARD SPECIFICATIONS FOR WATER WORKS
Title: SPECIFICATION FOR GRP PIPES, FITTINGS AND ACCESSORIES

tender: project: document: W-P-SS-004 rev: 0 sheet: 12 of: 12