w-p-ss-004

SPECIFICATION FOR GRP PIPES, FITTINGS AND ACCESSORIES

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02-0 02-022-20 2002 02 Appr Approv oved ed Issu Issue e

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Description/issued for De client: project: title:

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ADWEA STANDARD SPECIFICATIONS SPECIFICATIONS FOR W ATER WORKS SPECIFICATION FOR GRP PIPES, FITTINGS AND ACCESSORIES

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Table of Contents 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 Project: Title:

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ADWEA STANDARD SPECIFICATIONS FOR W ATER WORKS SPECIFICATION FOR GRP PIPES, FITTINGS AND ACCESSORIES

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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 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.


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BS 3749

3.

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

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)


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Earth Cover

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

Initial Installed Deflection for buried pipe Safety Factors

2.0% Max.

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.


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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

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


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b)

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

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.

c)

Moisture Content (Rovings & Mats)

-

Max. 0.15%

Size Content (Rovings & Mats)

-

Max. 1.7%

Tex. (gms/1000 mt.) (Roving)

-

600 ± 5% 1200 ± 5% 2400 ± 5%

Chop Mat (gm/sq.mt.) (Woven Mat)

-

450 ± 5% 280 ± 5% 360 ± 5% 580 ± 5%

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 Project: Title:

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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


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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:

5.11

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

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 Project: Title:

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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.


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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.


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7.2

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

8.

•

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

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.


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