w-p-ss-004

0 02-02-2002 Approved Issuerev. date Description/issued for prepared authorised

client: ADWEAproject: STANDARD SPECIFICATIONS FOR WATER WORKStitle: SPECIFICATION FOR GRP PIPES, FITTINGS AND ACCESSORIES

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

SPECIFICATION FOR GRP PIPES,

FITTINGS AND ACCESSORIES

Client ADWEAProject: STANDARD SPECIFICATIONS FOR WATER WORKSTitle: SPECIFICATION FOR GRP PIPES, FITTINGS AND ACCESSORIES


Table of Contents page

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

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

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

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

5. TECHNICAL REQUIREMENTS.............................................................55.1 General........................................................................................55.2 Materials......................................................................................65.3 Raw Material................................................................................65.4 Wall Thickness ............................................................................75.5 Length .........................................................................................85.6 Diameter......................................................................................85.7 Stiffness.......................................................................................85.8 Longitudinal Strength...................................................................85.9 Hoop Tensile Strength.................................................................85.10 Joints ...........................................................................................85.11 Workmanship...............................................................................95.12 Fittings.......................................................................................10

6. INSPECTION & TESTING ...................................................................106.1 Inspection ..................................................................................106.2 Testing.......................................................................................10

7. PACKING AND SHIPMENT ................................................................117.1 Storage......................................................................................117.2 Marking......................................................................................12

8. VENDOR DOCUMENTATION .............................................................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 woundmanufacturing process. The sizes covered are DN 100mm up to DN 2000mm.

The Manufacturer's design shall satisfy the minimum requirements set herein. Thisspecification 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 themanufacturer of GRP Pipe Systems and are referenced through out the specification asappropriate.

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 loadingcharacteristics of Plastic pipe by Parallel plate loading.

ASTM D 2290 Standard Test Method for Apparent Tensile Strength of ring or tubularplastics 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 forhuman consumption with regard to their effect on the quality of thewater.

BS 7159 Code of Practice for Design and Construction of Glass ReinforcedPlastics (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 ofpolyester 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 andepoxy resin systems.



BS 3749 Specification for E glass fibre woven roving fabrics for reinforcement ofpolyester 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 apurpose - built facility for the production of such materials. The Manufacturer shall haveexperience in the production of the similar pipe sizes and lengths. Evidence of previousexperience shall be presented to the main Project CONTRACTOR during the bidding stage.The Manufacturer shall have an approved Quality Management System complying with ISO9002 or 9001 which shall cover all activities being undertaken during the manufacturing, ofthe 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 flangeconnections and provide general recommendations on installation of associatedequipment such as valves, expansion bellows, nuts and bolts and other accessories.

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

c) Inspection and testing at the Manufacture's works in accordance with specifiedrequirements 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 Manufactureror 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 ofwithstanding 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)



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 pipeSafety 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 foreach GRP Pipe system.

The GRP pipe design shall be established in accordance with AWWA M45. Supportrequirements for complex above ground piping systems shall be based on computer flexibilityanalysis (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 fordrinking water service

5. TECHNICAL REQUIREMENTS

5.1 General

GRP pipe shall be machine-made consisting of a corrosion resistant liner, one or morestructural 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 Isophthalicpolyester resin and glass reinforcements.

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



d) External Layer

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

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. Noresin fillers shall be used.

No dark pigments shall be used in the GRP pipe or joints. No additives shall be used exceptwhen 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 forcompliance with the manufacturers specification suited only material that conforming to themanufacturers 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 BarcolHardness recommended by the resin manufacturers when measured in accordance toASTM D 2583.

The temperature of deflection of the resin shall not be less than 20°C higher than themaximum service temperature at which the pipe work is to be used, if known, andotherwise 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



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 3691or BS 3749.

The glass reinforcement can be of different forms viz. Continuous Roving, ChoppedRoving, 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 asgraded Silica Sand (min. Silica Content in the form of Si02 shall be 95%). Themoisture 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 themanufacturer to meet the design pressure and stiffness requirements. The pipe workingpressure class shall be based on the long term (60 years) Hydrostatic Design Stress (HDS) ofthe pipe with design factor 1.8.



5.5 Length

GRP pipe shall be manufactured in standard lengths of 10 or 12 Meters Random shortlengths, if supplied, shall not exceed 10% of the quantity supplied of each size. The toleranceon 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 insidediameter. The actual inside diameter shall not vary from the nominal inside diameter by morethan 1% or 4mm whichever is greater.

5.7 Stiffness

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

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

5.8 Longitudinal Strength

The GRP pipe shall meet the minimum longitudinal tensile strength requirements in AWWA C950 for the appropriate pressure class specified when tested in accordance with ASTM D638.

The above requirements are intended to provide adequate strength for normal handling andunder ground conditions. Pipe intended to withstand the end load resulting from internalpressure at changes of direction or the beam load resulting from above ground installationshall 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 inAWWA C950 for the appropriate pipe operating pressure class, when tested in accordancewith ASTM D 2290.

5.10 Joints

a) Flexible Joints

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



shall conform to BS 2494 or ASTM F477. Joints shall allow for at least 1 degreedeviation while remaining water tight at 1.5 times the pipe operating pressure.EDPM Rubber shall be the sole element depended upon for water tightness. Thesejoints shall be used where no unbalanced forces exits. At the change of directionsand where unbalanced forces occurs (inside the restrained length) restrained jointsas 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 tobe 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 flangesmay be used for sizes 2000 mm and larger. Flanges shall be manufactured with Epoxyor vinylester Resin. Flanges shall be flat faced with full or 'O' ring type gaskets. Gasketmaterial and design shall be per the Manufacturer's recommendations. The pipeManufacturer shall provide the torque sequence and maximum tightening torque asappropriate for each flange size and design. Washers shall be used under all nuts andbolts heads with special spacers to be used at connections with raised faced flanges asrequired.

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 reinforcementimpregnated with vinylester or epoxy resin. The wall thickness, tensile and axial strengthof the reinforced overlay shall meet or exceed the design strength of the adjoining pipesections. Butt & Wrap joints on site shall be performed only by or under the supervisionof the pipe Manufacturer. The joints shall be tensile resistance and suitable for useabove or under ground with no thrust blocks.

Note: Only vegetable based lubricant shall be used while connecting the joints. Thelubricant 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 glassfiber reinforcements shall penetrate the interior surface of the pipe wall.

Joint sealing surfaces shall be free of dents, gouges, de-laminations, or other surfaceirregularities 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.



5.12 Fittings

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

Standard fittings shall be filament wound on a collapsible mold (25-300 mm Diameter) ormitered (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 abend, tee, junction etc. shall not exceed ± 1 degree.

The tolerance on the Manufacturer's declared length of fitting shall be ± 10 mm taken from thepoint 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 fittingsarrangements may be pre-assembled by the pipe Manufacturer in the factory such that fieldjoints are kept to a minimum.

All pipes used for conveyance of potable water shall be certified by an independent agencyconfirming 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 bythis specifications to assure compliance with the requirements herein. An Inspection andTesting Plan (ITP) should be forwarded to ADWEA/ENGINEER for approval prior to start ofmanufacture. Plant inspection by ADWEA's qualified personnel or the omission of suchinspection shall not relieve the Manufacturer of the responsibility to furnish productscomplying with the requirements of these specifications. Reporting should be done inaccordance with DIN 50049 and 2.2 certificate should be issued accordingly.

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

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

6.2 Testing

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



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 withAWWA C950.

The following tests shall be conducted on pipe samples at a frequency of not less than oneper 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 besubmitted by the CONTRACTOR for each lot delivered to Site.

Pipe dimensions, test pressure requirements, minimum pipe stiffness shall be in accordancewith 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. Whenpipes are stored directly on the ground, it should be ensured that the surface is smooth androck free. Each row of pipes with wooden supports shall be firmly secured. Pipes shall not berolled 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 insatisfactory condition, acceptable to ADWEA/ENGINEER.

Pipe ends shall be protected with suitable protective covers securely attached. The bottom ofthe 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 pressureclass, the nominal diameter and identification code. Markings for identification shall be madein such a manner as not to impair the integrity of pipes/fittings material.



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 consideredincomplete, and liable to be rejected.

Documents

w-p-ss-004