Gloss Reinforced Plastics (GRP) Report.indd 1 20-08-2018 ...

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Gloss Reinforced Plastics (GRP) Report.indd 1 20-08-2018 16:47:02

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APPROACH PAPER

Usage of GRP Pipes in Potable Water, Irrigation and Sewerage Systems


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Copyright © (2018) Confederation of Indian Industry (CII). All rights reserved.

Without limiting the rights under the copyright reserved, this publication or any part of it may not be translated, reproduced, stored, transmitted in any form (electronic, mechanical, photocopying, audio recording or otherwise) or circulated in any binding or cover other than the cover in which it is currently published, without the prior written permission of CII.

All information, ideas, views, opinions, estimates, advice, suggestions, recommendations (hereinafter ‘content’) in this publication should not be understood as professional advice in any manner or interpreted as policies, objectives, opinions or suggestions of CII. Readers are advised to use their discretion and seek professional advice before taking any action or decision, based on the contents of this publication. The content in this publication has been obtained or derived from sources believed by CII to be reliable but CII does not represent this information to be accurate or complete. CII does not assume any responsibility and disclaims any liability for any loss, damages, caused due to any reason whatsoever, towards any person (natural or legal) who uses this publication.

This publication shall be submitted by CII to the Government Authorities and End Users for their kind consideration and cannot be sold for consideration, within or outside India, without express written permission of CII. Violation of this condition of sale will lead to criminal and civil prosecution.

Published by Confederation of Indian Industry (CII), The Mantosh Sondhi Centre; 23, Institutional Area, Lodi Road, New Delhi 110003, India, Tel: +91-11-24629994-7, Fax: +91-11-24626149; Email: [email protected]; Web: www.cii.in

Acknowledgements

We would like to express our sincere thanks to the members of the Task force for their valuable contribution, inputs and insights for making this approach paper possible.

CII Contact

Suvendu Mahapatra T: 011 2468 2230 [email protected]


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FOREWORD

The global Glass Fibre Reinforced Plastic (GRP) pipe market size in terms of value is projected to grow at a CAGR of 3.5% to reach $4 billion by 2020. Major growth in Asia-Pacific GRP pipe market is due to the growth opportunities, considering significant demands from end application in water/waste water, sewage and in industrial use for chemicals, oil and gas. The GRP pipe market in the emerging countries in Asia-Pacific region is growing at higher rate following faster industrial growth.

With the scope for wider application of GRP pipes, the Confederation of Indian Industry (CII) has prepared this Approach Paper on the Usage of Glass Fibre Reinforced Plastic (GRP) Pipe for Potable water, Irrigation and Sewerage Systems. This paper intends to make critical parameters and practices available at one place for manufacturing and installation of Quality GRP pipes. It also suggests end to end guideline for use of GRP pipe in Potable water, Irrigation and Sewage application, including qualification criteria for manufacturer, raw material specification, pipe manufacturing process, design, engineering, testing & inspection criteria, installation guideline, etc.

This paper directs our synergetic efforts to upgrade the existing practices and include the latest advances in the field of GRP piping, thereby enhance its reference value and scope in potable water, Irrigation and Sewage applications.

The suggested approaches are intended for suitable use by all involved in the procurement, manufacture, installation, commissioning and operation of GRP pipe systems. Every effort has been taken to ensure that the Approach Paper is based on the best knowledge available from the key stakeholders and the suggestive manufacturing guidelines for GRP pipes comply with the latest Indian and international standards.

I am hopeful that this document highlights the recommended practices required for the successful execution of GRP Pipe system projects with high quality standards.

Chandrajit Banerjee Director General, CII


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Contents

1 Introduction .......................................................................................................................1

2 Codes and Standards .......................................................................................................3

3 Manufacturer Qualification Criteria ...................................................................................5

4 Submittals for Manufacturer/ Contractor Qualification Criteria ........................................6

5 Raw Material Requirements ..............................................................................................7

6 Manufacturing Process ...................................................................................................10

7 Design Requirement .......................................................................................................11

8 Inspection and Test Plan (ITP) for Pipe and Fittings .......................................................13

9 GRP Fittings and Specials ..............................................................................................15

10 Joints ..............................................................................................................................16

11 Type Test .........................................................................................................................17

12 Marking ...........................................................................................................................18

13 Transportation and Delivery of Pipe ................................................................................19

14 Lowering, Laying & Bedding of GRP Pipe .....................................................................20

15 Checking the Installed Pipe ...........................................................................................22

16 Qualification Criteria for Contactor .................................................................................24

17 Field Hydrostatic Test .....................................................................................................25

18 Annual Maintenance Contract (AMC) – Terms & Conditions ..........................................26

Annexure - I .............................................................................................................................27

Annexure II ..............................................................................................................................28


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This approach paper provides end to end technical specification for use of Glass Fibre Reinforced Plastics (GRP) pipe in Potable water, Irrigation and Sewage application, which includes qualification criteria for manufacturer, raw material specification, pipe manufacturing process, design & engineering, testing & inspection criteria and installation procedure. This paper is also intended to make critical parameters available at one place for manufacturing and installation of high quality GRP pipe.

A task force led by Confederation of Indian Industry (CII), which includes major manufacturers of GRP Pipe, Resin and Glass Fiber in India is involved in creating this approach paper to ensure that quality GRP pipe is produced and installed. This paper will also help to fulfill the aspirations of the Indian Government’s Make in India initiative, where all major raw materials including Resin, Glass Fiber and GRP pipe will be sourced and made in India for domestic consumption.

1 Introduction


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Code & Standards

The design, manufacturing, inspection and testing of GRP pipes shall comply with the latest Indian Standard, IS 14402 (GRP Pipes, Joints and Fittings for use for sewerage Industrial waste and water (other than potable), IS 12709 (GRP Pipes, Joints and Fittings for use for potable water supply – specification, ) or ASTM 3517 (Standard Specification for Fiberglass (Glass Fiber Reinforced Thermosetting Resin) Pressure Pipe in the case of pressure pipes) or AWWA C 950 (Standard for fiber glass pressure pipe) & AWWA M 45 (Fiberglass Pipe design) unless otherwise specified elsewhere in this Technical Specification.

The various standards used in the design, manufacture and testing of GRP pipes are as follows:

Table 1

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S. No. Standard No. Standard Title

1 IS 14402 GRP Pipes, joints and Fittings for use for sewerage, Industrial waste and water (other than potable) – specification

2 IS 12709 GRP Pipes, Joints and Fittings for use for potable water supply – specification

3 IS 5382 Specification for Rubber sealing rings for gas mains, water mains and sewers

4 IS 13916 Installation of GRP Piping system - code of practice

5 IS 6746: 1994 Unsaturated polyester resin systems - specification

6 IS 11273 Woven roving fabrics of ‘E’ glass fiber

7 IS 11320 Fiber rovings for the reinforcement of polyester and of epoxide resin systems.

8 IS 11551 Glass fiber chopped strand mat for the reinforcement of epoxyand polyester resin systems

9 AWWA C950 Standard for fiber glass pressure pipe

10 AWWA M 45 Fiberglass Pipe design

11 ASTM C 33 Standard specification for Concrete aggregates

12 ASTM D 638 Standard Test Method for Tensile Properties of Plastics

13 ASTM D 2105 Standard Test Method for Longitudinal Tensile Properties of Fiberglass (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe and Tube

14 ASTM D 2290 Standard Test Method for Apparent Hoop Tensile Strength of Plastic or Reinforced Plastic Pipe by Split Disk Method


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S. No. Standard No. Standard Title

15 ASTM D 2412 Standard Test Method for Determination of External Loading Characteristics of Plastic Pipe by Parallel-Plate Loading

16 ASTM D 2563 Standard practice clarifying visual defects in glass reinforced plastic laminated parts

17 ASTM D 2583 Standard Test Method for Indentation Hardness of Rigid Plastics by means of a Barcol impressor

18 ASTM D 2992 Standard practice for obtaining hydrostatic or pressure design basis for Fiberglass Pipe and Fittings

19 ASTM D 2996 Standard specification for Filament-Wound Fiberglass (Glass-Fiber-Reinforced- Thermosetting-Resin) Pipe

20 ASTM D 3262 Standard Specification for Fiberglass (Glass-Fiber Reinforced Thermosetting Resin) Sewer Pipe, in the case of gravity sewer pipes.

21 ASTM D 3517 Standard Specification for Fiberglass (Glass Fiber Reinforced Thermosetting Resin) Pressure Pipe

22 ASTM D 3567 Standard practice for determining dimensions of Fiberglass (Glass Fiber Reinforced Thermosetting Resin) Pipe and Fittings

23 ASTM D 3681 Standard Test Method for Chemical Resistance of Fiberglass (Glass-Fiber-Reinforced Thermosetting -Resin) Pipe in a Deflected Condition

24 ASTM D 3839 Standard guide for underground installation of Fiberglass Pipes.

25 ASTM D 4161 Standard Specification for Fiberglass (Glass Fiber Reinforced Thermosetting Resin) Pipe Joints Using Flexible Elastomeric Seals

26 ASTM D 5365 Standard Test Method for Long-Term Ring- Bending Strain of Fiberglass (Glass-Fiber- Reinforced Thermosetting-Resin) Pipe

27 ASTM D 5421 Standard specification for contact molded “Fiber glass” flanges.

28 ASTM F 477 Standard Specification for Elastomeric Seals (Gaskets) for Joining Plastic Pipe

29 ISO 2078/ASTM D 578/ DIN 1259-01

The nomenclature ECR Boron free glass for use in corrosive environments

30 ISO 3672 Part 1 and Part 2

Plastics - Unsaturated Polyester Resins (UP-R) - Part 1: Designation System; Part 2: Preparation of Test specimens and determination of properties


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Manufacturer Qualification Criteria

Bidder or its sub–vender should have manufactured in India and supplied Glass Fiber Reinforced Plastic (GRP) pipes either with continuous Filament winding or Helical Filament winding process, following below qualification criteria.

Table 2

Also at least 10 km of GRP pipes supplied by Bidder or its sub-vendor, according to above condition, should be in successful operation for not less than one year in cross – country, municipal, irrigation or industrial piping systems prior to the date of Techno-Commercial bid opening.

In case of not meeting any of above requirements, manufacturing facility shall be pre-inspected by Third party and/or end user for evaluation of capability to manufacture, test and supply of GRP pipe. Manufacturer will request to end user for inspection before bidding. Check list as per Annexure I shall be followed for pre-qualification inspection.

Manufacturer must have fully equipped in-house test facility for conducting required tests for raw material & pipe, as per approved Inspection and Test Plan (ITP).

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Condition / Project requirement Criteria

For pipe diameters (DN) ≤ 1000 mm • History of manufacturing & supply of minimum 10 Km GRP pipe length of ≤ DN 1000 mm within 5 years prior to the date of Techno-commercial bid opening.

For pipe diameters (DN) > 1000 mm • History of manufacturing & supply of minimum 10 Km GRP pipe length of ≥ DN 1000 mm within 5 years prior to the date of Techno-commercial bid opening.

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• Self-certification for machine capability to manufacture & availability of all test facilities for project required diameter

New Manufacturer/Not meeting above criteria

• Pre-inspection by Third party and/or end user (As per Annexure I) for evaluation of capability to manufacture, test and supply of GRP pipe of project requirement diameter


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Submittals for Manufacturer/Contractor Qualification Criteria

The end user shall ask for following necessary information from pipe manufacturer or contractors in the tender submission documents for GRP Pipes.

1. Capability determination: Manufacturing Capacity of bidder, or associate manufacturer/s like Diameter range, Essential testing facility (as per IS 12709/14402), Turn Key Installation Capability, Financial strength for Guarantee Obligations (Letter of credit, etc.)

2. Testimonials of Pipe supplied/projects executed of any pipe size of minimum 10 km in last 5 years and proof of its successful operation from end user or contractor.

3. Design methodology & calculations for confirming the adequacy of specified thickness of GRP pipe to meet the project requirement as specified in tender, shall be submitted to end user/contractor after award of project.

4. Previous third-party Inspection Reports for the final product supplied by manufacturing plant for at least 1 project.

5. Authorization to use relevant IS marking (IS 12709/IS 14402) and certification of Quality Management System as per requirements of latest ISO 9001 standard.

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Raw Material Requirements

5.1 Resin

Selection of Resin for manufacturing of GRP Pipe shall be according to Raw material selection table of this guideline specification document, (Refer Table 5, Page 9). Resin used in GRP pipe shall satisfy the requirement of Annexure II of this document and shall be certified by neutral third-party laboratory. Refer Annexure II for detailed quality parameter of resin.

5.2 Curing Additives for Resins

Major curing additives which can be used with polyester or vinyl ester resin are mentioned below. Concentration and ratio of additives and resin shall be maintained based on recommendation from resin manufacturer/curing/storage or holding time required for particular manufacturing method and atmospheric conditions. Manufacturer can use any additive, according to their process requirement.

5.3 Glass Fiber Reinforcement

Major type of glass fiber used for manufacturing of GRP pipe is Surface Nonwoven Veil/Tissue, Chopped Strand Mat (CSM), Woven Roving, Single end Roving & Multi end roving. Only ECR glass roving shall be used for manufacturing of GRP pipe. Selection of glass shall be done based on its resin system compatibility. Physical properties of all required glass fiber are mentioned in Table 4, Page 8.

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S. No. Curing Additives Additives

1 Initiators Methyl ethyl ketone peroxide (MEKP), Cumene hydroperoxide (CuHP), Dibenzoyl peroxide (BPO), acetyl acetone peroxide (AAP), Cyclohexanone peroxide (CHP) etc.

2 Accelerators Cobalt naphthenate, Cobalt octoate

3 Promoters Dimethylaniline(DMA), Diethylaniline (DEA), dimethyl acetoacetamide (DMAA)

4 Inhibitors Tertiary butyl catechol (TBC)

Table 3


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Reinforcement Type GSM (gm/m2)/ Tex (gm/km)

LOI (%) Moisture Content (%)

Tensile Breaking Load (N)

Surface Veil/Tissue (gsm) 20 – 50 ± 3 10.5 ± 1.5 --- ---

Chopped Strand Mat (gsm) 225 – 600 ± 7% 4.5 ± 1.5 0.2 Max ---

Woven Roving (gsm) 360 – 850 ± 7% Nom. ± 0.3 0.3 Max ---

Multi End Roving (Tex) 2400 ± 5%

4800 ± 5%

Nom. ± 0.2 0.2 Max ---

Single End Roving (Tex) 600 ± 7.5% 1200 ± 7.5% 2400 ± 5% 4800 ± 5%

Nom. ± 0.3 0.3 Max 600 > 118 1200 > 225 2400 > 470 4800 > 940

Table 4: Glass Fiber Types and Key Physical Properties

5.4 Other Additives

5.4.1 Thixotropic agents

Thixotropic agents such as fumed silica may be added to the resin up to 5% by mass, using a high shear stirrer, for viscosity control, provided it does not interfere with visual inspection.

5.4.2 Paraffin wax

The final layer may contain paraffin wax in order to meet requirements for surface cure. Paraffin wax shall be resin compatible.

5.4.3 Ultraviolet absorbers (UV Stabilizers)

When required, ultra-violet absorbers may be incorporated into the laminate or outer layers, in accordance with the supplier’s recommendations (usually at a level of less than 0.5% by mass).

5.4.4 Pigments

As per project requirement, pigments are permissible only in the external layer resin surface and shall be applied after visual inspection has been carried out or as per agreement between manufacturer and buyer.

5.4.5 Surface active agents

Surface active agents may be added to the resin to improve its processability. Examples of this type of additive are air release agents, wetting agents, activators for thixotropic agents and monomer emission suppressants.


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ApplicationLiner /Corrosion Barrier Structural Layer External Layer

Glass Fiber Resin Glass Fiber Resin Glass Fiber Resin

Potable/Irrigation Water

ECR Orthophthalate UP



Sewer Water

ECR Vinyl Ester ECR Orthophthalate UP


Table 5: Resin and Glass Fiber for Liner/Corrosion Barrier, Structural Layer and External Layer

5.5 Major Raw Material Selection Guideline

Based on the end application mentioned below, resin and glass fiber type shall be selected as given in Table 5. For any specific project conditions or application requirements which are not covered below, selection of resin and glass shall be done based on confirmation from raw material manufacturer for that specific condition.

• For saline soil, external layer shall be with Isophthalic resin.


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Manufacturing Process

6.1 Liner

Minimum Liner/Corrosion barrier thickness shall be 1.0 mm for irrigation & potable water application. For other application, it should be 1.5 mm or as per the agreement between manufacturer and end user, whichever is greater.

Liner must be made following below mentioned sequence for making GRP pipe

1. Layer of Surface Veil (25 – 50 gsm) with 5 - 10 mm overlap and approximate 90% resin rich.

2. Remaining thickness shall be achieved using CSM or multi end roving, based on manufacturing process and must be 60 – 70 % resin rich.

3. Any kind of Filler or Silica sand is not allowed in liner.

Resin and glass fiber type used for liner shall be according to Table 5. Special care shall be taken while making liner to achieve required workmanship. For Liner, workmanship should be according to level I of ASTM D 2563/IS 12709/IS 14402.

6.2 Reinforcement/Structural Layer

Structural layer shall be made using processes covered under AWWA M 45 cl. 3.1 using resin & glass roving. Raw material selection must be according to Table 5.

Silica sand can be used only in core zone of the structural layer, to be protected by glass fiber rich layer on both sides, in order to achieve the desired stiffness properties.Sand used shall be river sand and shall have rounded particles free from moisture (less than 0.1%) and organic material (less than 0.5%). Sand shall have particle size limitation as specified in IS 12709 and 14402

Special care shall be taken while making structural layer to achieve required workmanship. Refer ASTM 2563 level II/IS 12709/IS 14402 for workmanship criteria.

6.3 External LayerThe exterior surface shall be relatively smooth with no exposed fiber or sharp projection by using resin rich surface veil. External layer resin may contain UV Stabilizers for protection from UV rays if pipe is intended for over the ground application or is likely to be stored in open for long durations (more than 1 year). Pigmentation may be done as per project requirement and agreement.

6.4 Pipe Composition

Pipe composition shall be according to manufacturer’s internal data sheet.

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Design Requirement

Project wise, pipe and fittings drawing and Inspection & test plan (ITP) must be submitted by the manufacturer and to be approved by contractor or end user before the start of pipe manufacturing.

7.1 Nominal Diameters

Pipes shall be supplied with the nominal diameters in accordance with AWWA C 950/IS 12709/IS 14402.

7.2 Lengths

The pipe standard effective length can be 3, 6, 9 & 12 meters with a tolerance of ± 25 mm. A maximum of 10% of the pipe sections may be supplied in random lengths according to the provisions of IS standards or as agreed between manufacturer & contractor/end user.

7.3 Wall Thickness

Wall thickness of pipe shall be specified by pipe manufacturer based on their design calculation. Details calculation sheet along with the thickness value shall be submitted to end user before start of pipe manufacturing for approval. The minimum wall thickness at any point shall not be less than the wall thickness specified by the pipe manufacturer.

7.4 Pressure Class & Stiffness Class

Pressure and stiffness class shall be defined by the end user or proposed by the manufacturer, as per project requirement. It should be in line with IS 12709/IS 14402. Selection of stiffness shall be based on depth of burial from the top of pipe and shall be done based on below table.

Table 6: Guideline for Selection of Stiffness Class

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S. No.Depth of Burial (from top of pipe)

Recommended Stiffness ClassMin. Max.

1 1 mtr. Or 1D, whichever is more 4 mtr. 248 KPa (5000 N/mtr.2)

2 1 mtr. Or 1D, whichever is more 8 mtr. 496 KPa (10000 N/mtr.2)

• For depth of burial of more than 8 mtr. Pipe manufacturer shall be contacted for selection of stiffness.


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7.5 End Squareness

All around periphery of each end of the pipe unit shall fall within ± 6.5 mm or + 0.5 % of the nominal diameter of pipe whichever is the greater to a plane perpendicular to the longitudinal axis of the pipe, when measured as per IS 12709 or IS 14402.

7.6 Hydrostatic Testing

100% of the pipe up to DN 1400 mm, shall be hydro tested by pipe manufacturer at 2x design pressure, maintaining for minimum 1 minute. For the pipe of above DN 1400 mm, the frequency of the hydro test shall be as agreed between the manufacturer and purchaser.

7.7 Hoop and Longitudinal Tensile Strength

Longitudinal Tensile Strength and Hoop Tensile Strength for each size and class should meet or exceed the requirement as mentioned in table 5 & 6 of IS 12709 and in table 6 & 7 of IS 14402.

7.8 Barcol Hardness of Pipe

Average Barcol hardness of pipe shall not be less than 80% of the resin hardness specified by resin manufacturer, when checked at 10 different places.

7.9 Workmanship

All the pipes must be made with proper care for any visual or laminate defects. Visual inspection shall be done according to ASTM D 2563/IS 12709/IS 14402.


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Inspection and Test Plan (ITP) for Pipe and Fittings

All the pipes & fittings shall be inspected by third party inspection (TPI) agency or end user, before dispatch from manufacturer premises, as per agreed frequency. Below inspection & test plan shall be followed for pipe & fittings manufacturing and inspection.

Table 7: Inspection & Test Plan for GRP Pipe & Fittings Manufacturing

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S. No. Test Reference DocumentFrequency of Sample

Manufacturer TPI/End UserRaw Material

1 Resin

I Viscosity Resin specification 1 Per Batch R

II Gel Time Resin specification 1 Per Batch R

III Gel to Peak Time Resin specification 1 Per Batch R

IV Peak Exotherm Resin specification 1 Per Batch R

V FTIR Resin specification 1 Per Batch R

2 Glass Fiber

I Tex/GSM Glass fiber spec. 1 Per Batch R

II Moisture Glass fiber spec. 1 Per Batch R

Pipe and Fittings

3 Dimension Approved drawing 100% 1 Sample/Lot

4 Visual ASTM 2563 100% 1 Sample/Lot

5 Longitudinal Tensile Strength*

IS 12709/1S 14404 1 Sample/Lot 1 Sample/Lot

6 Hoop Tensile Strength*

IS 12709/1S 14404 1 Sample/Lot 1 Sample/Lot

7 Stiffness* IS 12709/1S 14404 1 Sample/Lot 1 Sample/Lot

8 Hydrostatic Test* GRP Pipe spec. 100% 1 Pipe/Lot

• 1 Lot consists of maximum 100 numbers of pipes of each size & specification• *For Pipe only• R – Review


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8.1 List of Testing Laboratory

Samples collected from site will be sent to any one of below mentioned laboratories. Third party inspector or end user will send the sample with proper marking and identification to the laboratory based on testing facility and location.

Other labs can also be used for testing of pipe, based on available facility

8.2 List of Third-Party Inspection Agency

Selection of third-party inspection agency shall be done from below mentioned list. Appointment of same will be done by end user for inspection at manufacturing unit as well as for site.

S. No. Name of Laboratory Location Availability of Testing Facility

1 CIPET Hyderabad LT, HT, Stiffness

2 CIPET Ahmedabad LT, HT, Stiffness

3 ATIRA Ahmedabad LT,HT

S. No. Name of Agency Location

1 SGS All India

2 Rites All India

3 BVQI All India

4 TUV All India

5 Lloyds All India

6 UL All India

7 IRS All India

Table 8

Table 9

• Alignment with laboratory to be done before sending any sample.


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GRP Fittings & Specials

9.1 General

All GRP fittings, such as Bend/Elbows, End Caps, Tees, Flanges and Reducers etc. shall be equal to or superior in performance to pipe of the same classifications and shall have smooth internal finish.

All GRP fittings shall be manufactured at pipe manufacturer premises. Internal diameter of the fittings shall be same as pipe, other dimensions of the fittings shall be as per project requirement and approved drawings.

Specific required fittings may be permitted (End user or contractor approval) to be fabricated / laminated at site. However, the technicians doing the job should be approved by manufacturer.

9.2 Fittings made from Pipe (Mitered Fittings)

Fittings shall be fabricated from complete pipes or portions of straight pipe complying with IS 14402 / IS 12709 standards, as applicable for the pipe classifications. The fitting shall comply with the declared design requirement and be suitably mitered. The cut section of pipe shall be joined by butt wrap lamination using woven roving and/or chopped strand mat. Lamination should be such that it will ensure meeting the requirement of longitudinal and circumferential tensile strength equal to main pipe. All mitered fitting shall have calibrated ends for coupling fixing or plain ends for butt joint with pipe.

Open area at the ends after cutting shall be properly sealed with same resin as used in liner. Lamination at liner shall be done with same resin as used for liner of the pipe and should be resin rich and smooth finish.

9.3 Fittings made by Moulding

Moulded GRP fittings shall be made by hand lay-up, contact moulding, or tape winding process, ensuring equal or superior properties than pipe. Silica sand is not allowed for making moulded fittings. Same resin sequence which has been used for pipe shall be used for making fittings.

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Joints

The pipeline shall have a jointing system that shall provide for fluid tightness for the intended service condition.

All GRP pipes and fittings shall be joined with unrestrained sleeve couplings (Double REKA joint) or un-restrained double `O’ ring bell-Spigot joints or by butt wrap.

10.1 Flanged Joint

Flanged joints shall be used for connecting GRP pipes with valves, pumps and other material piping etc. Flanged joints are recommended to be used with EPDM gasket and hot dip galvanized bolts. The flanged joint is made from the same material as pipe.

10.2 Gaskets

All gaskets used in GRP pipe jointing must be of EPDM rubber. EPDM gasket used with push-on flexible joints shall conform to the requirements of IS 5382 / ASTM F 477/IS 638.

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Type Test

The Manufacturer or its Technology provider should have already carried out Long Term Type Test duly approved by TPI

The following long-term test reports to be submitted by Manufacturer or its Technical provider

1. Long term Hydrostatic Design Basis (HDB) as per IS 12709

2. Chemical resistance test as per IS 14402

3. Elastomeric gasket coupling joints shall be qualified in accordance with section 7 of ASTM D 4161

4. For potable water, potability tests to establish potability of water according to IS 12709

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Marking

Marking shall be done on inside and outside surface at least on one end of pipe for, including below mentioned requirements.

1. The nominal pipe diameter in mm.

2. Pressure class & stiffness class of pipe

3. Batch no. or date of manufacturing

Additionally, the pipe should have marking for following at least at one place on outer surface

1. Name/Number of standard, followed for manufacturing of GRP pipe i.e. IS 12709/IS14402/AWWAM 45 /ASTM etc.

2. The manufacturer’s name or trademark

3. Any other project specific requirement

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Transportation and Delivery of Pipe

Preparation of shipping should protect the pipe wall and joining ends from damage and should be acceptable to the carrier, manufacturer and purchaser. Refer IS 13916, clause 4.0 for transportation, loading and unloading of GRP pipe.

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Lowering, Laying & Bedding of GRP Pipe

IS 13916/AWWA M 45 shall be followed for installation of GRP pipe following below mentioned parameters.

Standard Trench profile for underground installation of GRP Pipe

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14.1 Trench Bottom

Excavate trench upto a minimum of 6 in. (150 mm) below the bottom of the pipe. When ledge, rock, hardpan or other unyielding material, or cobbles, rubbles, debris, boulders or stone larger than 1.5 in. (40 mm) are encountered in the trench bottom, excavate a minimum depth of 12 in. (300 mm) below the pipe bottom. Based on the condition, if foundation is required, trench depth can be further increased.


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14.2 Pipe Bedding

The bedding should be placed over a firm, stable trench bottom to provide proper support. Provide 150 – 300 mm for bedding below the pipe. For soft or unstable trench, an additional foundation may be needed to achieve firm support for bedding.

14.3 Backfilling

Selection of backfilling material should be made based on local, regional and economic aspects. Each material used, has to meet the requirement of maximum allowable particle size mentioned below. Soil selection category should be considered from clause 6.5.1 of AWWA M 45.

Immediate backfilling after joining is recommended to prevent floating of pipe due to heavy rain and thermal movement due to large temperature fluctuation.

14.4 Compaction

As per the requirement, compaction should be done for Minimum 85% of Standard Proctor Density (SPD).

DN Max. Sieve Size (mm)

≤ 1000 13

>1000 19

Table 10


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Checking the Installed Pipe

Initial diametrical deflection shall not exceed 3% of diameter or as per manufacturer’s recommendations. Bulges, flat areas, or other abrupt changes of pipe wall curvature are not permitted. Deflection checks shall be done when the first installed pipes have been backfilled and continued periodically throughout the entire project. Laying shall not get too far ahead before verifying the installation quality & backfilling.

Pipes over 5% deflection shall be rectified completely. No attempt to jack or wedge the installed over deflected pipe into a round condition shall be made to avoid damage to the pipe.

15.1 Correcting over Deflected Pipe

Pipe installed with initial diametrical deflections exceeding the approved values shall be corrected by re-exposing the pipe, re-compacting the pipe zone backfill and if required bedding also to ensure long term performance of the pipe. Damaged pipe shall be repaired or replaced as decided by manufacturer. Recompact / backfill to the grade & re-check the pipe deflections to verify they have not exceeded the values to the satisfaction of employer.

15.2 Misalignment of the Joint

When for reasons of the lay-out of the line, the joint has to be misaligned (but such degree of misalignment must remain within the limits provided by the supplier of the pipes) within flexible joint, such misalignment at the predetermined angle should be applied only after having inserted the pipe and then joint is thoroughly checked for its proper installation to ensure water tightness.

15.3 Thrust Block

RCC thrust block shall be provided at all bends, Tees, reducers & Blinds and at places of reduction in cross section to take care of thrust.

GRP pipes shall cross minor road / nallah through hume pipes (casing pipes). When buried GRP pipes are crossing roads & nallah sand / sand bags shall be put around GRP pipes within Hume pipe. For railway crossing and / or high way crossings of underground GRP pipes, culverts or casing pipe with pushing technology shall be adopted. However, manufacturer’s installation manual/ guideline shall be followed in all such cases.

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At the end of each working day and whenever work is interrupted for any period of time, the open ends of laid pipes shall be protected against the entry of dirt, water or other foreign matter by means of proper plugs or end caps. Butt wrap lapping joint of last joint during erection shall be done at a de-humidified condition by certified skilled worker to ensure correct workmanship and curing.

15.4 Inspection and Test Plan (ITP) for installation

Contractor shall offer installation test plan (ITP) for inspection of installed pipe to end user. Inspection shall be done for, following parameters as per below typical ITP.

Inspection & Test Plan for GRP Pipe & Fittings Installation

S. No. Test Reference Document Frequency

Contractor TPI/End User

1 Bedding thickness GRP Pipe spec. 100% Every 500 mtr.

2 Overall Trench Width GRP Pipe spec. 100% Every 500 mtr.

3 Overall Trench Depth GRP Pipe spec. 100% Every 500 mtr.

4 Deflection of Installed Pipe

GRP Pipe spec. 100% Every 500 mtr.

5 Particle size of backfilling material

GRP Pipe spec. 100% R

6 Availability of Thrust Block

GRP Pipe spec. 100% 100%

7 Field Hydrostatic Test GRP Pipe spec. 100%** 100%**

Sample Collection from Site. (To be collected in presence of manufacturer’s representative & tested within 15 days of receipt of lot at site)

8 Longitudinal Tensile Strength*

IS 12709/1S 14404 NA 1 Sample/supply lot

9 Hoop Tensile Strength*

IS 12709/1S 14404 NA 1 Sample/supply lot

10 Stiffness* IS 12709/1S 14404 NA 1 Sample/supply lot

11 FTIR Spectroscopic Analysis

GRP Pipe spec. NA 1 Sample/supply lot

• 1 Lot consists of maximum 1 km of installed pipes.• *only for pipe• **Except Non-testable joints and ends• R – Review

Table 11


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Qualification Criteria for Contractor

Apart from criteria about financial strength, experience of civil work and experience of installation of pipe line network (depending upon the size of the work) will be required for qualification of contractor. Also, contractor, who is going to do the installation of GRP pipe, must undergo installation training either from pipe manufacturer or approved third party agency. This training should be done for all the supervisory manpower who are going to handle/ install the pipe, for the organization. Training can be done after allocation of project, so that certificate can be presented to end user before start of the installation.

16


25

Field Hydrostatic Tests

The pipeline shall be hydro tested in stretches of about 1 km at 1.5 x design pressure. Pressurized pipe shall be maintained for minimum 1 hour and pressure should be checked at lowest level end of pipe. Frequency of testing shall be according to above testing and inspection plan.

Hydro test at site shall be conducted in presence of third party inspector, end user and contractor. Water and other facilities as required for such hydro testing shall be arranged as per contract by the contractor.

17


26

Annual Maintenance Contract (AMC) Terms & Conditions

The Contractor to provide Annual Maintenance Contract (AMC) for 5 years after completion of the defect liability period. The following services shall be included under AMC:

A) Round the clock monitoring of GRP pipe installation for any leakage / rupture / damage of the pipeline.

B) Arranging all manpower (including skilled & unskilled labour), machineries, testing equipment, fixtures, maintenance tools &tackles consumables etc. for repair, maintenance, re-erection/ re-commissioning of any or whole portion of GRP piping system.

C) Repairing the damaged pipes/joints, replacing the damaged part of piping/ joints including fittings with new pipes / fittings, wherever necessary, making damaged or excavated bed & trench of GRP pipe and restoring the trench bed to the original specified bed conditions.

D) Recharging the entire GRP pipe installation to the satisfaction of the Employer.

Additional Information to Contractors by Supplier

Additional information needs to be provided by pipe manufacturer to contractor, based on the project requirement

1. Guidelines for pipe unloading, storage and handling at site

2. Guide lines for trench preparation, bed preparation, pipe zone backfilling compaction method/ procedure and compaction testing,

3. Pipe lowering, laying, jointing and installation checking.

4. Joint preparations and joining method

5. Sectional hydro testing procedure and equipments required for it.

6. Guidelines for jointing two hydrotested sections

7. Precommissioning checks and commissioning procedure

8. Jointing material storage, handling and preparation guideline

9. The use of short pipe section and rigid end detail to provide pipe flexibility

18


27

Annexure - ICheck List for Pre - Inspection of GRP Pipe Manufacturer Qualification

Sr. No Description Pipe Manufacturer Comments

1 Name of Company

2 Address, Phone No. & E-mail

3 Year of Establishment

4 Single company or joint venture

5 If joint venture then, Name and address of Joint venture

6 Organization chart

7 Total No. of Staff

8 No. of QC/QA Staff

9 BIS Certification

10 ISO certified?

11 No. of Winding Machine and size capacity i. Continuous Filament Winding ii. Helical Filament Winding

12 Details of Available Mould

13 Raw Material Storage capacity

14 Annual GRP Pipe manufacturing capacity

15 Details of Ongoing Projects

16 Details of projects executed in last three years

17 Capacity of Longitudinal Tensile Testing machine

18 Capacity of Hoop Tensile Testing Machine

19 Capacity of Stiffness Testing Machine

20 Long Term Design Testing Facility

21 Capacity of Hydro Testing Facility

22 Raw Material Testing Facility i. Resin ii. Glass Fiber iii. Additives

23 Calibration status

24 List of Machine


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Annexure IIGuideline for: (A) Pre-Qualification of Manufacturer and Suppliers of Resins for Pipe Manufacturing (B) Approval of Resin Grade and its Registration / Certification for Pipe Manufacturing

1. Introduction

Considering the need for quality consistency and quality monitoring at the source of material of construction, this Annexure provides guidelines for the Pre-qualification of Manufacturer / Suppliers of Resin and also Approval and Registration / Certification of different grades of Resins suitable for the manufacturing of Pipes, which would ensure the desired performance in the field.

1.1 Pre-Qualification of Manufacturer / Suppliers of Resins:

For the approval of Manufacturer / Supplier of Resins the organization must have the prevailing ISO 9001 certification. Further, a Third Party Inspection of works, must be carried out for Qualification based on the Quality Assurance Plan. The Quality Assurance Plan of the organization must be able to demonstrate in-house capabilities of testing the resin materials during production and also before the dispatch to manufacturer of pipes for the Liquid Resin, Cast Resin and Laminate properties as per the Table A1, Table A2 and Table A3 respectively in Section 2.2.2.

Detailed requirements / guidelines for the Works Approval Program are described in Section 2.1.

1.2 Approval and Registration / Certification of Different Grades of Resins

After the approval of Manufacturer / Supplier works, a further program for the approval of Individual Product grades needs to be carried out by Third Party Inspection (TPI).

The approval and certification of each Product would be Site Specific. Hence, a Manufacturer / Supplier with Multiple Site operations would need to get their Products approved and certified at every site individually and independently.

TPI would be responsible for the Quality and Performance Test of individual product grades to grant the Approval and certify the product grades to be used in the manufacturing of Pipes.

2. Pre-Qualification of Manufacturer / Supplier of Resins:

2.1 Works Approval Programme

• The manufacturing unit shall be compliant and certified as per the prevailing ISO 9001 standard.

• In-house testing facility must be available for testing basic properties of liquid resin like Density, Viscosity, Non-volatile matter, Acid Number, cure behaviour (Gel time, Reactivity Testings) as per ISO or relevant standards.


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2.1.1 Documentation required for Works Approval

A) General Information:

• Brief Introduction on the firm

• Manufacturing Activities, as permitted by the licensing authority

• Type of products approved for manufacturing, with flow charts detailing procedure and process flow

• Number of employees engaged in the production, quality control, storage and distribution

B) Personnel:

• Organizational Chart showing the arrangements for quality assurance, including production and quality control

• Qualification, experience, and responsibilities of key personnel

C) Premises:

• Simple plan or description of manufacturing areas drawn to scale

• Nature of construction and fixtures/fittings

D) Equipment:

• Brief description of major equipment used in production and in the quality control laboratories (a list of equipment used)

E) Production:

• Brief Description of production operations, using wherever possible, flow sheets and charts specifying important parameters

• Arrangements for the handling of starting materials, packaging materials, and bulk and finished products; this includes the arrangements for sampling, release, and storage.

• Arrangements for the handling of rejected materials and products.

• Brief description of the general policy for process validation

F) Quality Control:

• Description of the quality control system and of the activities of the quality control department.

• Procedures for the release of the finished product

2.2 Resin Qualification and Approval Plan

2.2.1 Material Approval Tests for Registration and Certification


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2.2.1.1 Sampling of Liquid Resin at Manufacturer’s facility:

• About 5 to 10 kg of Liquid Resin Sample is to be drawn from the stores in a suitable Tin Container, in the presence of TPI and Sealed off for conducting all the tests related to Liquid Resin, Cast Resin and Laminate Tests.

The tests are to be carried out by one of the following

• An independent third party test house that has been accredited, by a nationally recognised body, for the tests undertaken with testing witnessed by TPI.

• The manufacturer’s own, in-house test facility with testing witnessed by TPI.

2.2.1.2 Sample preparation and Testing of Liquid Resin

• Before testing is undertaken by a TPI, the Liquid Resin Sample should be conditioned preferably at 25°C for at least 24 hours.

• The Liquid Resin Testing is to be carried out as per the standards mentioned in Section 2.2.2, Table A1.

• The limits on the nominal values shall be as per Table A4, Table A7 & Table A10 in Section 2.2.3.

2.2.1.3 Sample preparation and Testing of Cast Resin

Preparation of the cast to be tested for Resin Approval needs to be done as per the following

• Cast the resin to be tested in the form of an unfilled casting using the catalyst/accelerator system and curing schedule specified by the resin manufacturer.

• A suitable mould for casting is made from two pieces of plate and a suitable gasket 25 mm wide. Clamp the pieces of plate-glass and gasket after covering with a suitable release film in a vertical position with the gasket in between to form an open ended cell.

• A gasket can be made out of a suitable material like Rubber, Teflon, Polypropylene, Polyethylene, etc.

• The Unfilled Casting is to be cured at Room Temperature (25-30°C) for 24 hours followed by Post Curing at 60°C for 16 hours.

• The preparation of Samples for Approval Tests needs to be done by cutting, machining and shaping of the prepared Unfilled Casting into different sizes and shapes as per the standards mentioned in Section 2.2.3, Table A2.

• Cast Resin samples prepared as the part of Resin Approval Process, need to be tested as per ISO / ASTM Standards as mentioned in Section 2.2.2, Table A2.

• The limits on the nominal values shall be as per Table A5, Table A8 and Table A11 in Section 2.2.3.

2.2.1.4 Sample preparation and Testing of Laminate

Preparation of the laminates to be tested for Resin Approval needs to be done as per the following:

• The resin for approval is to be used to prepare a laminate containing a nominal 1800 g/m2 of chopped strand mat reinforcement with 30 – 35 % glass content.

• The laminate prepared is to be cured at Room Temperature (25-30°C) for 24 hours followed by Post Curing at 60°C for 16 hours or as suggested by the Resin Manufacturer.


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• The preparation of Samples for Approval Tests needs to be done by cutting, machining and shaping of the prepared Laminate into different sizes and shapes as per the standards mentioned in Section 2.2.3, Table A3.

• Laminate samples prepared as the part of Resin Approval Process, need to be tested as per ISO / ASTM Standards as mentioned in Section 2.2.2, Table A3.

• The limits on the nominal values shall be as per Table A6, Table A9 & Table A12 in Section 2.2.3.

2.2.1.5 Benchmark FTIR Fingerprinting

• After the different grades of resins have been tested and approved, having met the required minimum values of properties for liquid resin, cast resin and laminates, FTIR Fingerprinting of the approved resin in all the three forms, Liquid, Cast and Laminate needs to be carried out.

• These FTIR Fingerprints of approved resins would be used as benchmark reference for comparing the FTIR Fingerprints of resin being supplied to pipe manufacturers, thus ensuring quality and consistency of basic input raw material.

2.2.2 Test Method Standards for Characterization

Table A1: Test Methods for Determination of Uncured Resin Properties

Table A2: Test Methods for Determination of Cured Resin Properties

Sr. No. Properties Test Method

1 Density ISO 1675

2 Colour ISO 2211

3 Refractive Index* ISO 5661

4 FTIR Spectroscopic Analysis ASTM E168

5 Acid Number ISO 2114

6 Viscosity ISO 2555

7 Non-Volatile Matter ISO 3251

8 Flash Point ISO 2592

9 Gel Time ISO 2535

* optional


1. Barcol Hardness EN 59 / ASTM D2583

2. Density ISO 1183

3. FTIR Spectroscopic Analysis ASTM E168

4. Tensile Properties1 ISO 527-2 Test speed = 2 mm / min

5. Flexural Properties ISO 178 Test Speed = (Thickness * 0.5) mm / min

6. Heat deflection temperature ISO 75-2 Method A

7. Glass Transition Temperature2 ISO 6721-2 / ASTM D3418

8. Water Absorption ISO 62

• ISO 527-2 – Tensile properties are to be measured using extensometer• Optional Test


32


1. Glass Content -

2. Barcol Hardness EN 59 / ASTM D2583

3. FTIR Spectroscopic Analysis ASTM E168

3. Tensile Properties1 ISO 527-4 Test speed = 2 mm / min

4. Flexural Properties ISO 14125 Test Speed = (Thickness * 0.5) mm / min

5. Compressive Properties ISO 14126 Method A Test Speed = 1 mm / min

6. Inter-laminar Shear Strength ISO 14130

7. Water Absorption ISO 62

Properties Test Methods Unit Continuous Filament Winding

Helical Filament Winding

Centrifugal Casting

Appearance Visual - Clear Pale Yellow Viscous Liquid

Clear Pale Yellow Viscous Liquid

Clear Pale Yellow Liquid

Density EN ISO 1675 g/cc 1.12 – 1.14 1.12 – 1.14 1.12 – 1.14

Gel time *

EN ISO 2535

minutes 12 – 18 12 – 18 10 – 15

Reactivity, 25°C to 35°C * (a)

minutes 14 – 24 14 – 24

Reactivity, 35°C to Peak exotherm* (b)

minutes < 40 < 40

b/a < 2 < 2

Peak Exotherm Temperature*

°C > 140 > 140 60 – 100

Viscosity* Brookfield Viscometer

EN ISO 2555 cP 280 – 420 280 – 420 250 – 350

Non-Volatile Content

EN ISO 3251 % 59 – 65 59 – 65 62 – 68

Acid Value EN ISO 2114 mg KOH/g 16 – 24 16 – 24 17 – 23

* 100g Resin with 1% Cobalt Octoate Accelerator (Cobalt Metal Content of 1%) and 1.5% MEKP (9% Active Oxygen, Eg.: Butanox M-50 or equivalent) OR As suggested by the Resin Manufacturer

All tests carried out at 25°C

Table A3: Test Methods for Determination of Laminate Properties

2.2.3 Minimum Qualification Criteria for Approval/Certification of different types of Resins:

The nominal values for all the Liquid Resin, Cast Resin and Laminate Samples shall be as per the Table A4 to Table A12:

2.2.3.1 Orthophthalate Polyester Resin

Table A4: Orthophthalate Unsaturated Polyester Liquid Resin Properties

• ISO 527-4 – Tensile properties are to be measured using extensometer (extensometer which may be removed for strain to failure).


33



Centrifugal Casting

Barcol Hardness

EN 59 - > 35 > 35 > 35

Density ISO 1183 g/cc 1.19 – 1.21 1.19 – 1.21 1.19 – 1.21

Tensile Strength

EN ISO 527-2

MPa ≥ 60 ≥ 60 ≥ 65

Elongation at Break

% ≥ 2.0 ≥ 2.0 ≥ 3.0

Tensile Modulus

GPa ≥ 3.5 ≥ 3.5 ≥ 3.6

Flexural Strength

EN ISO 178

MPa ≥ 90 ≥ 90 ≥ 120

Flexural Modulus

GPa ≥ 3.5 ≥ 3.5 ≥ 3.6

Heat Deflection Temperature

EN ISO 75-2 Method A

°C ≥ 70 ≥ 70 ≥ 75

Water Absorption 24 hours

EN ISO 62 % w/w < 0.25 < 0.25 < 0.25

Properties Test Method Unit Dry Value Wet Value3

Barcol Hardness EN 59 - ≥ 34 ≥ 34

Glass Content - % 30 – 45 30 – 45

Tensile Strength ISO 527-4 MPa ≥ 90 ≥ 67

Tensile secant modulus

GPa ≥ 6.9 ≥ 5.2

Flexural Strength MPa ≥ 160 ≥ 120

Flexural Modulus ISO 14125 GPa ≥ 5.7 ≥ 4.28

Compressive Strength

MPa ≥ 117 NR4

Compressive modulus

ISO 14126 Method A GPa ≥ 6 NR4

Inter-laminar Shear Strength

ISO 14130 MPa 15 – 18 11.25 – 13.5

Water Absorption ISO 62 - 70 mg maximum NR4

Table A5: Orthophthalate Unsaturated Polyester Cast Resin Properties

Table A6: Orthophthalate Unsaturated Polyester Laminate Properties1,2

• Laminates with Chopped Strand Mat Only.• Minimum Values for Properties of Laminate & valid for a maximum Glass Content of 45%. Laminates for testing of Dry and Wet

value tests should be same.• Test specimens immersed in distilled water at 35±2°C for 28 days, cooled to room temperature in distilled water for 30

minutes, dried with a cloth and tested within one hour.• NR: Not Required


34



Centrifugal Casting

Appearance Visual - Clear Pale Yellow Viscous Liquid




Gel time*

EN ISO 2535

minutes 12 – 18 12 – 18 10 – 15

Reactivity, 25°C to 35°C* (a)

minutes 14 – 24 14 – 24

Reactivity, 35°C to Peak exotherm* (b)

minutes < 40 < 40

b/a < 2 < 2


°C > 140 > 140 60 – 100

Viscosity Brookfield Viscometer

EN ISO 2555 cP 280 – 420 280 – 420 400 – 500

Non-Volatile Content

EN ISO 3251 % 59 – 65 59 – 65 40 – 45

Acid Value EN ISO 2114 mg KOH/g 7 – 15 7 – 15 7 – 15

* 100g Resin with 1% Cobalt Octoate Accelerator (Cobalt Metal Content of 1%) and 1.5% MEKP (9% Active Oxygen, Eg.: Butanox M-50 or equivalent) OR As suggested by the Resin Manufacturer




Centrifugal Casting

Barcol Hardness EN 59 - > 35 > 35 30 – 40

Density ISO 1183 g/cc 1.19 – 1.21 1.19 – 1.21 1.19 – 1.21

Tensile Strength

EN ISO 527-2

MPa ≥ 60 ≥ 60 40 – 50

Elongation at Break

% ≥ 2.0 ≥ 2.0 > 35

Tensile Modulus GPa ≥ 3.5 ≥ 3.5 1.5 – 2.5

Flexural StrengthEN ISO 178

MPa ≥ 90 ≥ 90 60 - 80

Flexural Modulus GPa ≥ 3.5 ≥ 3.5 1.5 – 2.5



°C ≥ 80 ≥ 80 > 50


EN ISO 62 % w/w < 0.2 < 0.2 < 0.2

2.2.3.2 Isophthalate Polyester Resin

Table A7: Isophthalate Unsaturated Polyester Liquid Resin Properties

Table A8: Isophthalate Unsaturated Polyester Cast Resin Properties


35

Properties Test Methods Unit Dry Value Wet Value3


Glass Content - % 30 – 45 30 – 45



ISO 527-4 GPa ≥ 6.9 ≥ 5.2

Flexural Strength ISO 14125 MPa ≥ 160 ≥ 120


Compressive Strength ISO 14126

Method A

MPa ≥ 117 NR4

Compressive modulus

GPa ≥ 6 NR4


ISO 14130 MPa 15 – 18 11.25 – 13.5

Water Absorption ISO 62 70 mg maximum NR4



Centrifugal Casting

Appearance Visual - Viscous Clear slight Yellow Liquid

Viscous Clear slight Yellow Liquid

Light Yellow /Light Green Liquid


Gel time*

EN ISO 2535

minutes 10 – 20 10 – 20 20 – 30

Time to peak Exotherm*

minutes 15 – 25 15 – 25 40 – 60


°C > 160 > 160 100 – 150

Viscosity Brookfield Viscometer

EN ISO 2555 cP 260 – 480 260 – 480 400 – 600

Non-Volatile Content EN ISO 3251 % 52 – 58 52 – 58 58 – 62

Acid Value EN ISO 2114 mg KOH/g 7 – 11 7 – 11 > 15

* 100g Resin with 20% DMA solution in Styrene, 1% Cobalt Octoate Accelerator (Cobalt Metal Content of 1%) and 1.5% MEKP (9% Active Oxygen, Eg.: Butanox M-50 or equivalent) OR As suggested by the Resin Manufacturer


2.2.3.3 Vinyl Ester Resin

Table A10: Vinyl Ester Liquid Resin Properties

Table A9: Isophthalate Unsaturated Polyester Laminate Properties1,2

• Laminates with Chopped Strand Mat Only.

• Minimum Values for Properties of Laminate & valid for a maximum Glass Content of 45%. Laminates for testing of Dry and Wet value tests should be same.

• Test specimens immersed in distilled water at 35±2°C for 28 days, cooled to room temperature in distilled water for 30 minutes, dried with a cloth and tested within one hour.

• NR: Not Required


36



Centrifugal Casting

Barcol Hardness EN 59 - > 35 > 35 30 – 40

Density ISO 1183 g/cc 1.12 – 1.16 1.12 – 1.16 1.10

Tensile Strength

EN ISO 527-2

MPa ≥ 75 ≥ 75 ≥ 10

Elongation at Break

% ≥ 4.0 ≥ 4.0 8 - 12

Tensile Modulus GPa ≥ 3.3 ≥ 3.3 2.0 - 3.0

Flexural StrengthEN ISO 178

MPa ≥ 130 ≥ 130 100 - 120

Flexural Modulus GPa ≥ 3.4 ≥ 3.4 1.5 – 2.5



°C ≥ 100 ≥ 100 > 50


EN ISO 62 % w/w < 0.10 < 0.10 < 0.15

Table A11: Vinyl Ester Cast Resin Properties

Properties Test Methods Unit Dry Value Wet Value3


Glass Content - % 30 – 45 30 – 45



ISO 527-4 GPa ≥ 6.9 ≥ 5.2

Flexural Strength ISO 14125 MPa ≥ 160 ≥ 120


Compressive Strength

ISO 14126 Method A

MPa ≥ 117 NR4

Compressive modulus

ISO 14126 Method A

GPa ≥ 6 NR4


ISO 14130 MPa 15 – 18 11.25 – 13.5

Water Absorption ISO 62 70 mg maximum NR4

Table A12: Vinyl Ester Laminate Properties1,2

• Laminates with Chopped Strand Mat Only.

• Minimum Values for Properties of Laminate & valid for a maximum Glass Content of 45%. Laminates for Dry and Wet value tests should be same.

• Test specimens immersed in distilled water at 35±2°C for 28 days, cooled to room temperature in distilled water for 30 minutes, dried with a cloth and tested within one hour.

• NR: Not Required


37

3. General Notes: Qualification, Approval and Registration / Certification of Different Grades of Resin

Individual product grades need to be Qualified and Supplied for production of pipes by various production methods. This would be product approval type testing and registration / certification for use in pipe manufacturing, accredited by TPI. Relevant data and quality norms would be maintained by the Registration Authority.

3.1 Validity of Approval

• Initial approval, where granted, will be for a period of five years. Thereafter, approval may be extended for successive periods of five years, following re-testing and the submission of satisfactory test data.

• The approval will be limited to a nominated site of manufacture. Where the product is manufactured at other sites, these are to be approved separately.

3.2 Withdrawal of Approval

• Approval is given on the assumption that production material, when examined, will exhibit similar test results to those submitted, allowing for normal batch to batch variation.

• Approval is contingent on the adherence to the stated specification. Approval will be withdrawn if:

a) The properties of the resin are found to deviate significantly from those on which the approval was originally granted.

b) The resin proves to be intractable in use.

c) The quality control procedures are not adhered to consistently.

d) The manufacturer makes changes to the formulation, product name or reference number without notifying Registration Authority.


38

Conveying Fluids Efficiently!www.cppiping.com

R

––

MFGIL

Initiative Contributors


39


40

The Confederation of Indian Industry (CII) works to create and sustain an environment

conducive to the development of India, partnering industry, Government, and civil society,

through advisory and consultative processes.

CII is a non-government, not-for-profit, industry-led and industry-managed organization,

playing a proactive role in India’s development process. Founded in 1895, India’s premier

business association has around 9000 members, from the private as well as public sectors,

including SMEs and MNCs, and an indirect membership of over 300,000 enterprises from

around 265 national and regional sectoral industry bodies.

CII charts change by working closely with Government on policy issues, interfacing with

thought leaders, and enhancing efficiency, competitiveness and business opportunities

for industry through a range of specialized services and strategic global linkages. It also

provides a platform for consensus-building and networking on key issues.

Extending its agenda beyond business, CII assists industry to identify and execute

corporate citizenship programmes. Partnerships with civil society organizations carry

forward corporate initiatives for integrated and inclusive development across diverse

domains including affirmative action, healthcare, education, livelihood, diversity

management, skill development, empowerment of women, and water, to name a few.

As a developmental institution working towards India’s overall growth with a special focus

on India@75 in 2022, the CII theme for 2018-19, India RISE : Responsible. Inclusive. Sustainable. Entrepreneurial emphasizes Industry’s role in partnering Government to

accelerate India’s growth and development. The focus will be on key enablers such as

job creation; skill development; financing growth; promoting next gen manufacturing;

sustainability; corporate social responsibility and governance and transparency.

With 65 offices, including 9 Centres of Excellence, in India, and 11 overseas offices in

Australia, China, Dubai, Egypt, France, Germany, Iran, Singapore, South Africa, UK,

and USA, as well as institutional partnerships with 355 counterpart organizations in 126

countries, CII serves as a reference point for Indian industry and the international business

community.

Confederation of Indian Industry

The Mantosh Sondhi Centre

23, Institutional Area, Lodi Road, New Delhi – 110 003 (India)

T: 91 11 45771000 / 24629994-7 • F: 91 11 24626149

E: [email protected] • W: www.cii.in

Follow us on :

Reach us via our Membership Helpline: 00-91-124-4592966 / 00-91-99104 46244

cii.in/facebook cii.in/twitter cii.in/youtube cii.in/linkedin


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