SD - GRP Pipes Revised - 27062022021358

STORMWATER & SUBSOIL DRAINAGE SYSTEMS VOLUME IV- TECHNICAL SPECIFICATIONS
18 GRP PIPES (SECTION 02630)

18.1 Part 1 General
18.1.1 Introduction
A. This section of the specification gives the requirements for Glass Reinforced
Plastic (GRP) pipeline materials and the
he installation
inst and testing. The
Manufacturer's design shall satisfy the minimum
inimum requirements set herein.
mum require
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18.1.2 Related Documents
A. The following sections of the specification shall b
be read
ad in conjunction with this
C -
section.
y
C
Section 01300-Submittals
tals
C
Section 01400 -Quality
Quality
y Control
Section 01600
0 --Material
00 equipment
Material and eq
quipment
ipm
Q
Section 02222 --Excavation

Excavati
Excavatio
Section 02223-Backfilling
kf
Section 02225 -Trenching
18.1.3 Standards
A. All activities relating to this section of the standard specification shall comply
with the following or approved equal standards
ASTM D2584 Standard test method for ignition loss of cured reinforced
resins.
ASTM D4161 Standard specification for “fiberglass” (Glass fibre reinforced

thermosetting resin) pipe joints using flexible elastomeric
seals.
BS 3532 Aerospace Series. Steel FE – PM2701.
BS 4549-1 Guide to quality control requirements for reinforced plastics

moldings. Guide to the preparation of a scheme to control the
quality of glass reinforced polyester mouldings.
BS EN 681 Elastomeric seals. Material requirements for pipe joint seals

used in water and drainage applications.
PAGE 89
DIVISION-02-SECTION 02630 FIRST EDITION -DECEMBER 2016
BS EN 1394 Plastic piping system Glass reinforced thermosetting plastic

(GRP) pipes. Determination of the apparent initial
circumferential tensile strength
BS EN 1092-2 Circular flanges for pipes, valves and fittings (PN designated).
Steel, cast iron and copper alloy flanges. Specification for cast
iron flanges.
BS EN 14364 Plastic piping system forr drainage

drainag and sewerage with or
op V1
without pressure. Glass
s reinforced-thermosetting
lass reinforced plastics
(GRP) based on
n unsaturated
unsatur polyester resin (UP).
Specification for
or pipes and fittings
fittin
C -
BS 5840 Specification
on rreinforced
n for glass fibre reinforc
orced plastic (GRP) pipes and
ed pla
plast
y
ISO 9000
C fittings for use for water
management
Quality man
manage
wate supply
s
mentt systems.
y or sewerag
sewerage.
C
ISO 10468 -Glass-
Gla - Reinforced thermosetting
Plastic Piping Systems -Glass
Plastic (GRP)) pipes.
stic (G
(GR pip
Q
DIN/BS EN 14364 Plastics piping

364 Pla
P systems for drainage and sewerage with or
g syste
without pressure – Glass-reinforced
Gl thermosetting plastics
(GRP) based on unsaturated polyester resin (UP)
DIN-53769- Part 3 Testing of GRP pipes - Determination of Initial and Long

term Ring stiffness
DIN-53769 - Part 6 Testing of GRP pipes under pulsating internal pressure
DIN EN 1120 Plastics piping systems – Glass-reinforced thermosetting

plastics (GRP) pipes and fittings – Determination of the
resistance to chemical attack from the inside of a section in a
deflected condition
DIN EN ISO 75 Plastics – Determination of temperature of deflection under

load
DIN EN 1119 Plastics piping systems – Joints for glass-reinforced

thermosetting plastics (GRP) pipes and fittings – Test methods
for leak tightness and resistance to damage of flexible and
reduced articulation joints
PAGE 90
DIN EN 1447 Plastics piping systems – Glass-reinforced thermosetting

plastics (GRP) pipes – Determination of long-term resistance
to internal pressure
ASTM C-581 Standard Practice for Determining Chemical Resistance of

Thermosetting Resins Used in Glass-Fibre-Reinforced
Structures Intended for Liquid Service
ASTM D3681 Standard Test Method for Chemical Resistance of
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e–Reinforced
Reinforced
“Fiberglass(Glass–Fibre–Reinforced Thermosetting-Resin)
Pipe in a Deflected Condition
DIN 53769 Testing of glass

ass fibre reinforced
reinforced plastics
stic pipes; determination
plastic
C -
of the longitudinal
gitudinal
udinal shea strength
shear stre pipe fittings
ngth of type B p
y
ASTM D2992 C Standard
dard Practice fo
Design
esign
gn Basis
for Obtaining
for
fo
or
Hydrostatic or Pressure
taining Hydrosta
Hydro
“Fiberglass” (Glass-Fibre-Reinforced
(G
C
Thermosetting-Resin)
Thermosetting-R
Thermosetting Resin)
Resin) Pipe and Fittin
Fittings
Fitting
18.1.4 Submittals
als
s
Q
18.1.4.1 Products and Materials

Materi
Materia Approval
val
In order to verify compliance with the specification the Contractor shall submit
information for all products and materials used in the Works to the Engineer for
approval sufficiently in advance of their use in accordance with the Contract
programme allowing for ordering and approval times. Reference shall also be
made to Section 01600 of the specification on products and materials approval.
Information to be submitted shall comprise but not necessarily be limited to:
i. The manufacturers design calculations, complete and detailed

specification, standard Quality Control test results including the latest
Type Tests (Long Term test) results not later than three years from
the date of approval submission of the proposed GRP pipes and
fittings required for the Works including Manufacturers Certificates of
compliance with this section of the standard specification. Information
on all items listed in Table 18.1 below shall be given.
ii. Should any details, including materials of the pipes and fittings be
altered in any way during manufacture from those proposed and
approved by the Engineer, submit for the Engineer's approval the
PAGE 91
revised details and test results, including Type Test results [in case of
altering of material (Long Term 10,000hrs tests.)]
iii. Submit to the Engineer the results of all standard quality control tests
carried out on the manufactured pipes and fittings as soon as
practicable after testing as and in any case not later than the time of
delivery of the relevant pipes and fittings to the site.
iv. Pipe manufacturer’s guarantee that the pipe and its materials are
suitable for its intended use and
nd application.
pplication.
v. Joint materials and gaskets.

ets.
vi. Standard produced pipe lengt

lengths sh
shall 12 meter for Filament
all be 1
Wound (FW) and Centrifugal
nd 6 meter for Cen
ntrifugal (CC). Tolerance shall
gal Cast ((CC
y
be governed by the relevant manufacturing
m
maanufacturing standard.
acturing standa
standard
op
Table 18-1:
8-1: Product
P Information
In
Inform
mation Pi and
n for GRP Pipe a Fittings
C
Product Information
formation Units
Q
C
Manufacturing
acturing D
acturi Details
Name of manufacturer -
Manufacturing process for pipes -
Manufacturing process for bends and fittings -
Joint type -
Summary of Design Criteria
Nominal internal /external diameter mm
Pressure Class of pipe (PN) kN/m2
Minimum depth of cover m
Maximum depth of cover m
Maximum working pressure kN/m2
PAGE 92
Product Information Units
Design test pressure kN/m2
Internal vacuum pressure kN/m2
Pipe Wall Structure
Nominal total wall thickness mm

m
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Inner liner Resin** Type %
Glass* Type %
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y
ThicknessC mm
C
Structural wall Resin** Type %
Chopped Glass** Type %

Q
Hoop Glass** Type %
Aggregate** Type %
Thickness mm
External layer Resin***Type %
Glass***Type %
Thickness mm
Minimum Initial Pipe Properties
Stiffness (SN) N/m2
Longitudinal tensile strength N/mm
Hoop flexural modulus GN/m2
Hoop tensile strength N/mm2
PAGE 93
Product Information Units
Last date of publishing the Type Test (Long Term) results
Notes to Table 18.1
a) Pipe data to be provided for every diameter in each class of pipe.
* By weight of liner.
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** By weight of structural wall.
*** By weight of layer.
18.1.4.2 Method Statements
C -
y
A. The Contractor shall submit
mit method sta
statem
statements
mentss to the Enginee
Engi
Engineer for approval, 4-
C
8 weeks in advance of commencing the
01300 of the specification.
ation. These
cification.
the site activity in accordance
Thes shall
accor
acco with Section
shall comprise but not necessarily be limited
C
to:
Q
i. Procedures
cedures for handling,
ocedures ha
h installation of pipes.
ng, storage and in
ii. Hydrostatic
atic testing procedures
ures for GRP non pressure pipelines
iii. Hydrostatic testing procedures for GRP pressure pipelines.
iv. Deflection measurement procedures for GRP pipelines, where

necessary, as per manufacturing standard.
18.1.4.3 Drawings
A. The Contractor shall submit drawings to the Engineer for approval well in
advance of commencing the site activity in accordance with Section 01300 of
the specification. These shall comprise but not necessarily be limited to:
i. Drawings of the pipes, fittings, joints, pipe specials and the assembly
thereof.
ii. Pipe laying diagram and schedule showing location, length, design
designation and designation by number of each pipe section and pipe
special to be furnished and installed.
iii. All data on curve and bends for both horizontal and vertical alignment.
PAGE 94
18.1.5 Quality Control

Inspection of the products by the manufacturer shall be in accordance with the
definitions in the product standards and in additional quality specification, as per
the selected technique of the manufacturing.
A. Prior to dispatch of any product and/or material from source the Contractor shall
notify the Engineer in writing in sufficient time
m to allow the Engineer the
im
opportunity to inspect and test the productt and/or material prior to delivery in
accordance with Section 01400 of the specification.
pecification.
fica
B. Products and materials shall be from manufacturer/supplier who operates a

rom a manufacture
manufa
quality control system which is registered to ISO 9000 series or approved equal.
9000 se
ser
C. To allow the Engineer to

o inspect
nspect the Works
Works the Contractor
Contract shall give the
Contr
y
Engineer a minimum off 48 hours notice of rrying out the following
o carrying fo
follo activities on
site:
i. Installation
ation of pipeline.
op
C
ii. Hydrostatic
ostatic testing of pipeline.
rostatic ipeline.
pelin
iii. Deflection measurement of pipeline.

n mea
18.1.6 Delivery, Storage and Handling

A. Delivery, storage and handling of products and materials shall be in
accordance with the manufacturer’s recommendations, Section 01600 of the
specification and the following provisions:
a) Delivery storage and handling shall at all times be performed in a manner

to avoid product damage.
b) Pipes and fittings shall not come in contact with any sharp projections that
may cause damage to the pipes and fittings during transportation loading
and unloading. Ensure that pipes and fittings are well secured during
transit and adequately supported along their length. Cover pipes and
fittings of plastic materials during transportation. Do not allow pipe to
overhang the end of a vehicle during transportation.
c) Ensure that pipes and fittings are lifted using nylon or large diameter rope
slings positioned at a quarter of the pipe length from each end. Do not allow
the use of wire rope chains or unpadded forks or clamps on forklifts to lift
pipes.
PAGE 95
d) Store pipes and fittings on a flat level area as recommended by the pipe
manufacturer. Ensure that pipes and fittings supplied either on pallets or
crated, remain on the pallets or in their crates until required.
i. Stack non-crated pipes to the approval of the Engineer.
ii. Stack spigot and socket pipes so that successive pipe layers have
sockets protruding at opposite ends of th
the stack.
iii. Stack pipes of different sizes and thickness separately.

hickness se
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iv. Do not allow stacked pipes to
o exceed 2 height or as recommended
2m in he
by the supplier whichever is the lesser.
esser.
e) Store GRP pipes and fittings

gs under opaque
opa cover
c o of direct sunlight at
r and out
C -
y
all times. Maintain a free ow of air around
ee flow ar nd the
aroun e pipes at all times.
a tim
f)
C
Store rubber joint
nt rings in a well
well-ventilated
tilated place free from exposure to
we ventilated
C
sunlight and in packing
n their original pack
pa king needed.
ing until they are n
nee
g) The Contractor
tractor visually
actor shall visua
vi ly inspect all products
produc upon delivery to site and
pro
Q
report any damage to th

the Engineer.
ineer.
neer
i. Any products
cts damaged during
ng delivery,
de storage and handling shall be
marked by the Contractor and set aside.
ii. Proposals for repair of any repairable products shall be submitted in

writing to the Engineer for approval.
iii. Any damaged products deemed unsuitable for repair by the Engineer
shall be removed from the site and replaced, with an equal.
18.2 Part 2 Products

18.2.1 Pipe Design Requirements
The design requirements for GRP pipes shall be, as given below unless
otherwise indicated on the drawings or on recommendations of Manufacturer
depending on site conditions (soil, installation, compaction, loads etc.) in
compliance to the Special Warranty conditions, quoted elsewhere in this
document.
Design Requirements of GRP pipes
a) Minimum initial specific stiffness shall be
PAGE 96
i. For gravity pipelines in buried installation with cover depths less than 6m
shall be 5000 N/m2.
ii. For gravity pipelines in buried installation with cover depth more than 6m
shall be 10,000 N/m2
iii. For all pressure main shall be 10,000 N/m2 (SN10000).
iv. For all exposed pipe line shall be 10,000 N/m2

m2 (SN10000).
b) Any variance due to the site condition

dition as native soil condition,
ion such a
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installation, burial depths, deflection
flection limits,
l buckling
b and vacuum
requirements or others which necessitates
ates increasing
ecessitates inc sing the stiffness (SN) value
increa
of GRP pipe shall be governed Manufacturer’s
ned by the Manufa
M cturer’s
sddesign.
de
C -
y
c) Pressure mains shall be designed as per the requirement
requiremen of Table 15 of
requirem
C
BS/DIN EN 14364.
C
d) GRP pipe length
ngth concrete
gth used in concr
con rete surround
ete bed and surroun
surro shall be 3.0m unless
otherwise specified
pecified in the drawings.
the d
dra
awings.
win
Q
e) All GRP pipes installed up to 10.0m cover

pes installe co depth
d shall be buried in granular
bed and surround
ound or as specified
ied by tthe Manufacturer according to the
ground conditions. For cover depths exceeding 10.0m, the pipe shall have
concrete surround or Manufacturer to suggest suitable higher stiffness pipe.
18.2.2 Pipes and Fittings

18.2.2.1 Buried GRP
General
a) All GRP components shall be designed and fabricated by one manufacturer.
b) GRP pipes and fittings shall be manufactured in compliance with BS/DIN EN

14364 and fabricated to meet the minimum strength requirements.
c) Manufacture all pipes by an approved process utilizing a rotating mould or

mandrel besides equipment which accurately control the quantities and
placement of all resins, glass and aggregates.
d) Use resins, reinforcements, and aggregates to produce pipes and fittings

when combined as a composite structure to satisfy the performance
requirements of this section of the specification. Pipes and fittings must be
PAGE 97
designed to achieve a minimum working life of 60 years under all applicable

standard loadings, environmental and installation conditions.
e) Both internal and external surfaces shall be free from irregularities, which
would impair the ability of the component to conform to the requirements of
European Standard BS/DIN EN 14364.
Materials and pipe wall construction
The pipe or fitting shall be constructed using

ng chopped
sing choppe and/or continuous glass
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filaments, strands or roving, mats or fabric,
abric, synthetic veils,
vve and polyester/ vinyl
ester resin without fillers and if applicable
able additives
plicable additiv necessary
n to impart specific
properties to the resin. The pipe
e as whole and the
pe tthe part
rt of
o pipe used for fittings
C -
may also incorporate aggregates.
ates. All the
egates. th raw materials
erials used
u shall be from the
y
I.
C
approved list of suppliers.
s.
Filamentt Wound (FW)

(FW GRP
GRP pipes
pes and fittings:
fitti
C
a) Resins.
Q
- Vinyl ester
ster shall be used
d in the internal
inte rresin rich liner of the pipe and
fittings. Isophthalic
ophtha or vinyl ester
ophthal ster shall
sh b be used in the structural wall of the
pipes and fittings, as per the design
esig application requirements. All resins
shall be tested in accordance with ASTM C-581or applicable standard.
Provide resin systems to the requirements of BS 3532 type-B or to
applicable standard.
- Resins shall be cured to achieve 90% of the manufacturer’s

recommended Barcol hardness value, and may be tested by external
laboratories for their authenticity of type by random sampling, during the
project.
b) Additives.
- The use of additives such as fire retardant, UV inhibitors or coloured

pigments or dyes shall be subject to the approval of the Engineer and will
only be approved in exceptional circumstances.
c) Aggregates and fillers.
- Sand aggregates shall be clean, graded silica sand containing no

impurities and be in accordance with BS/DIN EN 14364.
PAGE 98
- Fillers (other than sand aggregates) shall be permitted in accordance to

BS/DIN/ EN 14364, provided the necessity is scientifically tested, justified
and approved by the Engineer on all accounts of performance, including
Qualifying Tests using Long Term type tests, at minimum a of 10,000 hrs.
Note: Filled pipes and fittings shall only be allowed on a project once the
satisfactory Long Term test results are in hand & all conditions as stipulated
above are met in advance.
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d) Wall construction
- Liner layer
i. All pipes and fittings

tings shall have a resin
sin rich
r liner having an
C -
approximate thickness
kness of 2.5
hickness 2 mmm comprising
omprising an innermost layer
y
C (i.e., that in contact with the
1.5mm in thickness inc
he liquid)
th
incorporating
orporating
quid) of approximately
appro
approxim
rating two layers
l
1.0mm to
of "C” glass. The
C
remainder
mainder of the liner consist of at least two layers
line construction shall co
con
power
of 450 g/m2 powe
p er bound "E" glass chopped strand mat having a
glas ch
Q
glass content between

ass conten en 25 percent
perc and
a 35 percent by weight or the
equivalent
alent of chopped strand "E" glass depending on the method of
trand "E
manufacture. No chopped strands or sand are allowed in the inner
face layer of the resin rich liner.
ii. The resin used in this inner liner layer must conform to requirements
given in BS/ DIN EN 14364 and to stipulation of section “a” as above.
iii. Resins shall be cured to achieve 90% of the manufacturer’s

recommended Barcol hardness value.
- Structural layer
i. Build up the structural layers by acid resistant glass chop roving or

continuous roving with a glass content of between 25% and 35%
by weight.
ii. The structural layer shall consist of glass reinforcement and a

thermosetting isopathalic polyester resin with or without sand
aggregates.
PAGE 99
iii. Aggregates can be used as per the manufacturing techniques

applied, however ensure no aggregate becomes embedded in the
internal resin rich liner layer.
- Outer layer
i. Pipes shall be provided with an external vinyl ester resin rich layer,
with C- glass Veil.
ii. The resin used in the outerr layer will

wil be Vinyl ester and in
op V1
4364 shall h
accordance to BS/DIN EN 14364 have a Glass Transition
st 75 °C. In addition
temperature of at least additio
a a sample shall be tested
for HDT in accordance DIN EN ISO 75 - 2.
ance with Method A of DI
C -
iii. The use of special
pecial
cial constructions
construction
constru ns is permitted
permitte when
w the pipe is
y
C expected
ground
d to be exposed to extreme
conditions, for example
nd conditions
climatic environmental or
xtreme climatic,
provision for the inclusion of
ample provis
C
pigments inhibitors
igments or inhib
inhibi climatic conditions or fire
tors for extreme clim
cl
retardation, upo
upon
u n the
he approval of the
t E Engineer.
Q
e) Wall thickness
ss
i. The minimum total walll thickness,

th including the liner shall be
declared by the manufacturer.
ii. Use pipes with wall thickness that achieve a minimum hoop
flexural modulus of 15.0 GN/m2 over the whole pipe wall thickness
for pipes of 350mm diameter and above, and 12.0 GN/m2 for
pipes of less than 350mm diameter. This shall be demonstrated
by the application of the equation S = (EI)/D3 to show that the
hoop flexural modulus of a pipe is not less than the required
minimum figure where S is the stiffness of the manufactured pipe,
D is the mean diameter of the manufactured pipe, E the required
hoop flexural modulus and “I “being given by t3/12 where t is the
whole wall thickness of the manufactured pipe.
f) Fittings
i. Fittings shall be manufactured similar to the pipe construction or

better thereof as per the existing worldwide standard
manufacturing techniques, complying with applicable standards on
performance and testing.
PAGE 100
II. Centrifugally cast (CC) GRP pipes and fittings:
a) Resin
i. Vinyl ester shall be used in the internal resin rich liner of the pipe
and fittings. Isophthalic or vinyl ester shall be used in the structural
wall of the pipes and fittings, as per the design application
requirements. All resins shall be tested
te in accordance with ASTM
C-581or applicable standard. Provide resin systems to the
d. Provid
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requirements of BS 3532 type-
type-B
-B or to applicable
app
appl standard.
ii. The resin used in the liner layer

lay will
w be Vinyl ester and in
accordance to BS/DIN/EN
S/DIN/EN 14364 shall h
have a Glass Transition
ha
C -
temperature of at least 75 °C. In addition
ition a sample
ssam shall be tested
y
iii.
C for HDT in accordance wit
Resins
with Method
s shall be ccured to achieve 90%

90
E IISO 75 - 2.
M od A of DIN EN
of the manufacturer’s
o
C
recommended Barcol
ecommended Ba col hardness value and may be tested by
Barc
laboratories
external labo
laborat ies for their authenticity
ories a
authe of type by random
Q
during the
sampling, d
du e project.
he
b) Additives.
i. The use of additives such as fire retardant, UV inhibitors or

coloured pigments or dyes shall be subject to the approval of the
Engineer and will only be approved in exceptional circumstances.
c) Aggregates and fillers.
i. Sand aggregates shall be clean, graded silica sand containing no

impurities and be in accordance with BS/DIN EN 14364.
ii. Fillers (other than sand aggregates) shall be permitted in

accordance to BS/DIN/ EN 14364, provided the necessity is
scientifically tested, justified and approved by the Consultant and
the Client on all accounts of performance, including Qualifying
Tests using Long Term type tests, at minimum a of 10,000 hrs.
iii. Note: Filled pipes and fittings shall only be allowed on a project
once the satisfactory Long Term test results are in hand & all
conditions as stipulated above are met in advance.
d) Wall construction
PAGE 101
- Liner layer
i. The inner liner layer shall comprise minimum 1.5 mm thick pure
Vinyl ester Resin without Glass reinforcement and sand aggregates.
ii. The pure resin used in this inner liner layer must conform to
requirements given in BS/DIN EN 14364 and to stipulation of
section “a” as above.
iii. Resins shall be cured to achieve

chieve 90%
90 of the manufacturer’s
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ness value.
recommended Barcol hardness va
- Structural layer
i. The structural layer

ayer shall consist
co of glass re
reinforcement and a
C -
y
thermosetting
g isopathalic polyester
pathalic polyes
po ster resin with sand
sa a aggregates.
ii.
C
Aggregates
ates
es can be use
used
d as per the manuf
manufacturing techniques
C
applied, ensure
ed, however ensu becomes embedded in the
en re no aggregate b
bec
internal
nter nal resin rich liliner.
ternal ner.
er.
Q
- Outer layer
ayer
yer
i. This layer
aye shall be formed
ed of mortar in vinyl ester resin with sand
aggregates and without reinforcement of glass or synthetic
filaments.
ii. The resin used in the outer layer will be Vinyl ester and in
accordance to BS/DIN EN 14364 shall have a Glass Transition
temperature of at least 75 °C. In addition a sample shall be tested
for HDT in accordance with Method A of DIN EN ISO 75 - 2.
iii. The outer protective layer shall have a sand content with a minimum
percentage of 65 % of sand for corrosion protection.
iv. The use of special constructions is permitted when the pipe is

expected to be exposed to extreme climatic, environmental or
ground conditions, for example provision for the inclusion of
pigments or inhibitors for extreme climatic conditions or fire
retardation, upon the approval of the Engineer.
e) Wall thickness
PAGE 102
i. The minimum total wall thickness, including the liner and outer
protective layer shall be declared by the manufacturer, which shall
be complying to the standard performance criteria.
ii. Use pipes with wall thickness that achieve a minimum hoop flexural
modulus of 15.0 GN/m2 over the reinforced wall thickness for pipes
of 350mm diameter and above, and 12.0 GN/m2 for pipes of less
than 350mm diameter. This shall
hall be demonstrated by the
application of the equation S = (EI)/D3 to show that the hoop
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pe is not less than
flexural modulus of a pipe tha the required minimum
e stiffness
figure where S is the ess of the
th manufactured
m
man pipe, D is the
mean diameter of the manufactured
manufacturred pipe,
manu pe, E the required hoop
C -
flexural modulus
lus and I bein given
being giv y t3/12 where
en by wh t is the reinforced
y
f) Fittings
C
wall thickness manufactured
ness of the manuf
manufa ed pipe.
ctured
C
i. Fittings
ttings shall be m
manufactured
anufactured similar
sim tto the pipe construction or
Q
etter thereof
better thereo ass per the existing
exis standard manufacturing
techniques,
hnique complying
hniques g with applicable
app standards on performance
and testing.
III. Mechanical and other characteristics
The pipe class for a specific application shall depend on the required diameter
(DN), the pressure rating (PN) necessary for the application, and the pipe
stiffness (SN) derived from the structural analysis depending on site conditions
(soil, installation, compaction, loads etc.).
a) Minimum initial specific stiffness.
- As detailed in section 2.1.as above.
- For other nominal stiffness class in certain areas in accordance to defined

parameters of BS/DIN EN 14364.
b) Minimum initial specific longitudinal tensile strength shall be in
accordance to BS/DIN EN 14364.
c) Fabricate pipes and fittings capable of withstanding the working pressures,

test pressures and loadings specified.
PAGE 103
d) Pipes and fittings shall be suitable for carrying domestic sewage at

temperatures up to 50ºC and having a maximum sulphide concentration of 50
mg/litre.
e) Pipes and fittings to be designed to withstand up to 5% long term deflection in

their installed conditions.
f) Conform to BS/DIN EN 14364 for pipe dimensions

ns and tolerances. Deviations
in diameters and wall thicknesses of pipe
pe ends and
a coupling shall be such
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that the seal at the joints is not affected.
ed.
g) Ensure that the internal surfaces

es of the pipes
pipe an
and fittings are smooth, and
that the internal and externall surfaces are cle
clean nd free from defects such
an and
C -
as protruding fibres, pits,
s, cracks, blisters
bli tackiness
ness and
an embedded foreign
y
C
matter. The core of the
de-bonding.
he pipe wall shall
sha be free bubbles, vvoids, cracks and
ee of bubble
C
h) All bends shall
hall be long radiu
rad
radius
us bends unless oth
otherwise approved by the
Engineer..
Q
i) Latest Type Tests (Lo

(Long Term test) results
resu notn later than three years from the
date of submission
sion of the proposed
ed GRP
GR pipes and fittings required for the
Works including Manufacturers Certificates of compliance with this section of
the standard specification, to be provided.
Joints
General
Joint performance shall be according to section 07 of BS/DIN EN 14364; in general.
a) All buried joints shall be Non-end-load-bearing flexible joints of spigot and

socket type (including double socket designs) with EPDM rubber in full faced
elements or rings in accordance with BS/DIN EN 681; manufactured
according to the individual manufacturing technique and supplied as integral
part of the pipe or separately. The sealing rings shall be supplied by the pipe
manufacturer.
b) Non-end-load-bearing flexible joints with elastomeric seals shall be tested

using test pieces conforming to BS/DIN EN 14364, for conformance to the
test performance requirements under hydrostatic pressure.
PAGE 104
c) For pipes up to and including 600mm nominal internal diameter joints shall be
capable of withstanding a deflection of not less than one and a half degrees
in any direction and remaining watertight. For pipes over 600mm nominal
internal diameter joints shall be capable of withstanding a deflection of half
degree in any direction and remaining watertight.
d) Joints shall be capable of withstanding a draw of 13mm over and above the
initial jointing allowance and remaining watertight. The initial jointing
g wat
allowance is the gap between the spigot
got and the shoulder of the socket
pigot
op V1
measured parallel to the centre line
e of the pipeline
pi and must not be less than
an
6mm or greater than 13mm or as recommended b tthe pipe manufacturer.
mmende by
e) Additionally the pipe joints

nts
ts shall be capa
capable
ble of with
withst
withstanding an external
C -
y
pressure equivalent to
o 10
0 m head of water
er without leakage
leak in both the
C
straight and deflected
ted
ed positions.
C
f) Joint couplers
s may be used ad
adja
adjacent
cent to structures or
o special
s fittings.
g) When a pipe
pe is cut or tur
turned
ned
d down in ord
order tto form a joint fully seal the
Q
exposed surfaces
rfaces with a continuous
urfaces coating of
nuous coa o vinyl ester resin.
h) Do not use butt/wrap

t/w joints without
ut obt
obtaining the approval of the Engineer.
Approval will only be given if the Contractor can demonstrate that this type of
joint is the most suitable method of forming the joint. Such joints will be
formed by specialist operatives under the supervision of the pipe
manufacturer and fully in accordance with his recommendations. Use
materials to be compatible with the pipes to be joined. Obtain the Engineer’s
approval for the material along with the method, before work commences.
Table 18-2:: Summary of test requirements for non-end-load-bearing flexible joints
Property to be Tests to be performed Test pressure in Duration

tested Bars
Initial Leakage Initial Pressure 1.5 x PN 15 min
External pressure Negative pressure a - 0.8 bar (- 0.08 1 h

differential MPa)
Misalignment and Positive static pressure 2.0 x PN 24 h

Draw
PAGE 105
Property to be Tests to be performed Test pressure in Duration

tested Bars
Angular deflection Initial pressure 1.5 x PN 15 min

and draw
Positive static pressure 2.0 x PN 24 h
a) Relative to atmospheric, i.e. approximately 0.2

2 bar (0.02 MPa) absolute.
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Marking
Ensure that all pipes including cut lengths

ngths and fittings
nd all fit
fittin before dispatch from the
gs b
pipe manufacturer's works are indelibly follows:
elibly marked as follows:
C -
y
i. The manufacturer's name,
ame, initials, or identification
identification
ation mark.
ii.
C
The nominal internal
nal mm.
al diameter in mm
mm.
C
iii. The length in
n m.
iv. Mark the classification i.e. pressure

assification i.e ressure rating, stiffness.
ssure ratin stiffn
Q
v. The date of manufacture

anufa
anufac and batch
tch number.
ch numbe
nu
vi. A stamp to show that they meet the required inspection requirements and
hydraulic tests (where applicable) at the point of manufacturer.
vii. Stencil in legible letters the pipe identification number on the inside and
outside at each end. Ensure that the same number appears on all record
sheets and documents relating to the manufacture delivery and testing of that
pipe.
viii. The manufacturing standard.
ix. The project or contract number.
18.2.2.2 Exposed GRP

GRP pipes and fittings utilized for exposed service inside pumping stations, and
valve chambers shall be designed to resist all bending stresses, thrust forces,
surge pressures, negative pressures and vibratory forces.
Exposed pipe and fittings shall be manufactured in the same manner and with
the same materials as buried pipe, along with the following requirements unless
otherwise approved by the Engineer.
PAGE 106
i. Resin in the structural wall shall be Isophthalic or Vinyl ester.
ii. Additional exterior stiffeners may be required to maintain circularity on large

diameter pipes and shall be installed to the manufacturer’s requirements.
iii. Design of the outer layer of the pipes shall be formed of an vinyl ester resin
with or without sand aggregates and with or without reinforcement of glass.
The outer protective layer shall have a minimum
in
n thickness of 1 mm and
protect the structural layer against extraneous
extraneo causes (atmospheric
op V1
conditions, mechanical damage, UV and
d chemical sstress). For Centrifugally
Cast GRP Pipe the outer protective
ve layer shall
tive sh have
ha a sand content with a
minimum percentage of 65 % of sand against ult
ultra
ra – violet
v influences.
C -
iv. Use flanged joints for all exposed pipes
pip and
and fittings inside treatment plants,
tings in
y
C
process structures, pumping
v. Flanges shall be
e filament
lament wo
stations, and
umping stations
wound, tape
and valve
alve chamber
chambers.
e wound, contact
con moulded, hot or cold
C
pressed with epoxy or vinyl ester
es er resins only.
est
vi. All bolts shall stainles steel

all be stainless teel
el grade 31
316.
Q
vii. Flanged pipe joints must incorporate

porate an annular gasket at the joints and
these gaskets must cover the full face of the flange with holes cut in them
corresponding to the bolt holes in the flanges. Drill flanges to BS EN 1092
(metric units) type PN16. If approved by the Engineer, use a plain ring
covering the flange between the bolt circle and the bore of the pipe. Use 3mm
thick gaskets incorporating two layers of cotton fabric insertions evenly
spaced in the gasket. When flanged joints are to be made, secure the bolts
and the nuts initially to finger tightness. Thereafter the final tightening of the
nuts shall be effected by torque spanners in such sequence that diametrically
opposite nuts are tightened together to achieve the manufacturers
recommended torque.
viii. All joints shall be in accordance with the manufacturer's instructions.
18.2.3 Quality Control Tests

18.2.3.1 GRP Pipes and Fittings
a) Routine Factory Quality Control Tests.
i. Carry out the quality control tests listed below at the frequency stated.
PAGE 107
ii. Ensure that records of all tests and inspections are maintained by the
manufacturer.
iii. Provide the Engineer with two copies of all test certificates and reports.
b) Raw Material Inspection.
i. Inspect all raw materials to ensure that they comply with the relevant
standard.
ii. Check all deliveries of resin for consistency

nsistency by viscosity and reactivity.
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Do not use any resins deviating
ating from the manufacturer's
iating m published
figures.
iii. Check all deliveries of sand and

an aggregates
ag gates for grading, moisture
ggregates
C -
y
content and purity.
y.
C
iv. All resin type authenticity in external
e may be tested for quality and auth
C
laboratories
ies deemed
es as and when de Engineer.
eemed fit by the Eng
Engin
c) Hydraulic relevant
c Test as per releva
re testing standard
antt manufacturing & te
Q
For Filament wound GRP

GR pipes.
G
a) Perform an internal hydraulic pre

pressure test for every pipe at the
manufacturer's works prior to delivery.
b) Apply 1.5 times the pipe design pressure or surge pressure, whichever is
greater for all pressure pipes. Apply the test pressure for a minimum period of
5 minutes without signs of leakage.
c) In addition to the above:
i. Maintain at test pressure the first pipe and thereafter every 360 meter of
pressure pipe of each diameter produced for a minimum of 4 hours
without signs of leakage.
ii. Perform an internal low pressure air test for every pipe fitting at the
manufacturer's works prior to delivery. Apply a test pressure of 0.1 bars
for a minimum period of 5 minutes without signs of leakage or distress.
Manufacture fittings which are of mitred construction from pipe which has
successfully passed the tests defined above.
iii. Follow section (k) ,given below for Rejections
For Centrifugally cast GRP pipes
PAGE 108
a) Perform an internal hydraulic burst pressure test for minimum 1 pipe

specimen or 360 meters, whichever comes first of pressure pipes produced.
b) Burst pressure shall be more than 4 times the pressure rating of the Pipe.
Testing is to be carried out as per relevant standard.
c) In addition to the above.
i. Maintain at test pressure the first pipe and

nd thereafter every 360 meter of
pressure pipe of each diameter produced for a minimum of 4 hours
roduced fo
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without signs of leakage.
ii. Perform an internal low pressure

ressure test ffor
e air tes or every pipe fitting at the
manufacturer's works prior
rior to delivery.
delive Ap Apply test pressure of 0.1 bars
pply a tes
C -
for a minimum period minutes w
od of 5 minut without leakage or distress.
ithoutt signs of lea
y
C
Manufacture fittings
ngs which are of mitred
successfully passed
ssed the te
m d construction ffro
defined
tests d ed above.
efined
from pipe which has
C
iii. For all gravity pipes app y a test pressure of 15m
apply 1 water head (1.5 bars)
for pressure
ssure pipes a
ressure apply
ply 1.5
y 1 me the design pressure or working
.5 times
Q
pressure plus sur

surge pressure
surg whichever is greater for a minimum period
ure whicheve
which
of 5 minutes w
without a sign of leakage.
eakag
d) Wall Thickness.
i. Measure the wall thickness for each pipe and fitting. Maintain the total
thickness of nowhere less than the minimum or greater than the
maximum quoted by the manufacturer's specification relating to initial
stiffness. However, minimum is governed by section 5.1.2 of
BS/EN/14364.
e) Stiffness.
i. Test a minimum of one pipe, for every 360 m pipe length manufactured or
any pipe length supplied for a project, whichever comes first to determine
the initial specific stiffness in accordance with the test method detailed in
BS/DIN EN 14364.
ii. Test a minimum of one pipe of each class and diameter of pipe.
iii. Ensure that no test specimen has an initial specific stiffness of less than
as defined in section 2.1.
iv. In addition.
PAGE 109
- Deflect each of the stiffness test specimens to the amounts indicated in

Table 18-3 below according to its nominal stiffness. Ensure that at the
lower deflection there is no visible damage as evidenced by surface
cracks, and at the higher deflection there is no indication of structural
damage as evidenced by inter laminar separation, separation of the liner
or coating (if incorporated) from the structural wall, tensile failure of the
glass fibre reinforcement, fracture or buckling
buck
uck of the pipe wall as per
standard for inspection available.
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Table 18-3: GRP Quality Control
Co Tests
Te
Nominal Stiffness 10,000N/m2
C -
y
C
No visible damage
surface cracks
age in liner lay
layer as evidenced b
of:
ks at a deflection of:
by 9%
C
f)
No structural
uctural damage at a deflection of: 15%
Q
L
ongitudinal Tensile Strength.
ensile S
Measure in accordance with BS/DIN

N EN 14364 the tensile strength of a
minimum of one pipe, for every 360 m pipe length manufactured or any pipe
length supplied for a project, whichever comes first for each class and
diameter, as per applied standard.
g) Cure.
Perform in accordance with BS 4549 Part 1 Barcol hardness test on a

minimum of one in every 30 pipes manufactured.
h) Loss on Ignition.
Test in accordance with ASTM D2584 a minimum of one pipe, for every 360
m pipe length manufactured or any pipe length supplied for a project,
whichever comes first for each class and diameter, as per applied standard.
i) Joint Tests.
Test in accordance with the requirements of ASTM D4161 or, DIN EN 1119 a
minimum of two jointed pipes in every 1200 meter of pipes manufactured with
the following additions.
PAGE 110
- Conduct the positive test pressure.
- Conduct the negative pressure test to determine the adequacy of the joint
design against infiltration. Apply an external test pressure of 2.0 bar
(gauge) to two sections of pipe assembled with a deflected joint for non-
pressure pipe system and twice the rating pressure for pressure pipe
system in accordance with ASTM D1161.96 Article 7 Laboratory
Performance Requirement Item 7.1.1
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j) Initial Circumferential Tensile strength.
h.
Determine the initial circumferential

al tensile strength
ential stren of pressure pipes in
accordance with BS/DIN EN 1394.
139
C -
k) Rejection
y
i. C
Proceed as stipulated
pulated
quality control
any
ulated below if any pipe or fitting which fails any one of the
ests as per thiss section
trol tests tion 2.3.
C
ii. In the event of a pipe failing
ailing any of the
th tests
te outlined, carry out the
Q
relevant
ntt test on a further
fur
fu meters of pipes
r 120 meter p of that class and diameter
as follows:
- Carry out the relevant test on 60 meters of these pipes produced

sequentially and immediately prior to the failed pipe and 60 meters
immediately following.
- If any one of these test on 120 meters of length fails, cease the
manufacturing of pipes of that class and diameter. Discussions will be
held between the Contractor and the Engineer to establish the
significance of the failures. The suitability of manufactured pipes for
the proposed installation conditions will be determined in the light of
the test failures and the Engineer reserves the right to reject all the
pipes of that class and diameter.
Use the results of appropriate type tests to the proposed pipes and fittings to
determine the properties of pipes. Carry out each type test on representative
samples of the pipes. If the manufacturer does not have results of these tests
available or if alterations are proposed to the method of manufacture, pipe design
or laminate structure, carry out all the type tests required by the Engineer to prove
the adequacy of the proposed pipes. Conduct the type tests as stipulated in Table
18-4 in accordance with the requirements of the mentioned standards and that
PAGE 111
the tests will be conducted at 23 +/-2ºC ambient temperature except for strain
corrosion & long term failure pressure which will be tested at 40ºC +/- 2ºC.Table
18-4 – GRP Type Tests (Long Term Tests for a minimum of 10,000 hrs)
Table 18-4:: GRP Type of Tests (Long Term Tests for a minimum of 10,000
hrs)
Property Testt method to BS/EN/14364
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Long term specific stiffness and ISO 10468,
468, ISO 1482
14828, IS
ISO 10471, DIN 53769 the
creep factor under wet and test results shall b extrapolated
be extrapo
ap to 60 years.
C -
deflected condition.(min 18 Section 5.2.2 of BS/EN/DIN
ection 5.2. /EN/DIN 14364 shall be
y
samples)
C
Long term resistance to strain
ain ASTM
TM D
governing.
D3681,
3681, DIN 53769,
53769 DIN
D EN 1120, the test
C
corrosion .(min 18 samples)
ples) results
resu s to be extrapolated tto 60 years. Section 5.2.8
result
o BS/EN/DIN
of /EN/DIN 14364
1 shall
s be governing. However,
Q
the 95%
% lower confidence
con limit failure strain must
not be less than 0.85%,
Long term failure pressure.(min ASTM D2992, DIN EN 1447, DIN 53769-2 the test
18 samples) results shall be extrapolated to 60 years Section
5.2.7 of BS/EN/DIN 14364 shall be governing.
18.2.4 Product Warranty

A. A corporate product warranty shall be provided by the Manufacturer for intended
use/application of the product for a period of 60 years from the date of the Final
Acceptance Certificate of the project issued by the Client.
18.3 Part 3 Execution

18.3.1 Pipe Installation
A. Trench excavation shall be carried out in accordance with Section 02225 of the
specification.
B. Install pipe, fittings, and accessories in accordance with BS 8010, EN 1610 and
manufacturer's instructions.
PAGE 112
i. Provide qualification details of the manufacturer's technical expert to be

assigned to the Contract. The technical expert shall have expertise,
experience and skills necessary for advising and monitoring all aspects of
transport, storage, handling and installation of pipes as appropriate.
ii. The technical expert shall provide comprehensive technical assistance to

the Contractor throughout the Contract and regularly monitor the
Contractor's activities and report on shortcomings.
coming
ming
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iii. The Contractor shall provide the Engineer
er copies of all instructions advice or
gineer
reports given by the manufacturer's
er's technical
rer's technic expert
exp to him. The technical
expert shall immediately inform
rm the Engineer omission, variations and
ngineer of any o
detractions from the approved handling and installation
oved handlin allation sspecification.
C -
y
C.
C
Install bedding, surround
specification and shown
own
nd and backfill as
drawings.
wn on the drawin
drawing
s specified
gs.
Section 02223 of the
ecified in Sectio
Se
C
D. Lay pipes from downstream to up
upstream socket end at the upstream
stream with the sock
so
end of each pipe.
pe
Q
E. The pipeline shall be within 20mm
mm specified
m of the specifie
s line and the invert level shall
be within 6mm of the specified
sp
s value
ue and shall
sha be such that there is no back fall
at any point on a gravity pipeline.
F. Obtain satisfactory initial deflection test results for sections of pipeline laid
between consecutive manholes or chambers prior to commencement of pipe
laying in further sections.
G. When cut pipe is required, ensure that the cutting is done by a machine, leaving
a smooth cut at right angles to the axis of the pipe.
H. When installing pipes, ensure the joint is cleaned and lubricated and that the
rubber gasket is inserted in the groove of the socket end of the pipe. Align the
spigot and insert home in the socket end. Use a metal feeler to check that the
rubber gasket is correctly located. Spigot and socket flexible joints shall have
the annular space between the pipe and socket sealed with an approved joint
sealant to prevent the ingress of loose material or concrete. This sealing shall
be carried out immediately on completion of a satisfactory initial hydraulic test
prior to concreting or backfilling.
I. Ensure that all pipes and fittings are sound and clean before laying. When pipe
laying is not in progress, ensure that the pipe ends are at all times fitted with
watertight plugs or caps. The plugs or caps shall only be removed for the
PAGE 113
purposes of making a connection of the pipe end or testing the pipeline. The
plugs or cap shall be replaced immediately on completion of the test.
J. Protect bolted connections by an approved heat shrunk PVC sheath. Wrap the
PVC sheath with a protective wrapping tape prior to backfilling in accordance
with the specification.
K. Excavation for or laying of GRP shall not proceed until an approved device for
gauging pipe deflections is on site.
i. Use a suitable mechanized device

ce to tthe
vice approval of the Engineer
he a
op V1
forgauging pipe deflections.
s. Maintain
Mainta devices for gauging pipe
devi
deflections in good working
ng order.
er. Submit calibration certificates before
Subm ccalib
every period of use.
C -
y
For pipes of less
ess than 600mm
600 diameter: Diametric dimensional
ameter: Dia
Diame
C
measurementt of the pipe, both vertically
and recorded.
rded.. Each deflection
deflect
def
horizontally shall be made
ally and horizon
horizo
ion measurement taken
tak along the length of
C
the pipeline
peline shall be ide
identified
ntified and recorded. Provide a continuous print
out orr a visual dis
display
displ measurements on a remote monitor. The
y of the mea
measureme
Q
device shall be ccalibrated before each

e pipe length is tested.
For pipes of 600mm diameter

ter and greater. Measure deflection by
physical entry into the pipes. Use a regularly calibrated telescopic
spring loaded graduated rod to measure percentage deflections in each
diameter. Provide a suitable trolley to facilitate access into the pipe.
Record all measurements.
Form cut-off walls or barriers in granular bedding and/or surround to pipes to

prevent the bedding acting as subsoil drainage. Provide barriers at suitable
locations along the length of the pipeline and at manholes or chambers. Ensure
that the maximum spacing is 50m. Use concrete barriers of Class C concrete
installed across the full cross section of the granular bedding. Provide concrete
barrier of at least 300mm in length along the axis of the pipelines. Pipe wrap
placed around pipe at stanks shall be self advisable water proof membrane or
other self adhesive tape as approved by the Engineer.
18.3.2 Mandatory Installation Monitoring

It shall be absolutely mandatory for the manufacturer to give proper training with
certification to educate contractor’s representative (name of the person and
copy of the certificate to be provided) for installation procedures for their
PAGE 114
products and depute qualified personnel to monitor the installations

intermittently throughout the course of the project execution and till the final
commissioning test approvals from the designated authority. Any discrepancies
or non-compliance thereof, if observed, shall be promptly reported to Engineer
or Client for remedial measures. NOTE: In case of non-compliance to the
installation procedures set forth by the Manufacturer, further installation shall be
stopped with immediate effect, by the Engineer
err without
w placing any project time
lapse liability on the Engineer or Client, by Contractor of award until it
y the main C
op V1
is otherwise advised. However a project
ct delay clause may be applied on
ay penalty ccl
the main Contractor as per the rules nd regulations
s and regulati set
s by Client.
18.3.3 Field Hydrostatic Testing

ing of Pip
Pipeline
Pipelines
es
C -
y
18.3.3.1 General.
A.
C
Submit for the Engineer's
gineer's
neer's approval
approva details
ails of the propo
proposed methods and
C
program for testing,
sting, including d details equipment. Arrange for all
etails of test equ
equip
tests to be witnessed by th the
e Engineer or other
ot person appointed by the
Q
Engineer. Provide
rovide everything
every
ever ng necessary fo
g necessa for carrying out testing and
ding wa
cleaning including ss, gau
water, pumps, gauges
gauges, piped connections, stop ends
En
and all other temporary works. Ensure that pipelines are properly
completed and supported before being put under test except as
hereinafter detailed.
i. No testing will be permitted until seven days after thrust blocks and other
holding down works have been completed.
ii. In addition to any tests of individual joints or other interim tests, which may
be specified elsewhere, submit all parts of the pipelines to a final test.
iii. Notwithstanding the foregoing, carry out at any stage of construction other
tests that the Engineer considers desirable to check materials and
workmanship on the pipeline. Ensure that the obligations to perform
successful tests under the Contract are achieved.
B. Use potable water for hydrostatic testing and pipeline cleaning.

C. Test the pipeline in lengths between valve pits or such shorter lengths as
the Engineer may direct or permit.
PAGE 115
D. Use properly designed fittings for the purpose of temporarily closing the
openings in pipelines to be tested. Use fittings adequately strutted to
withstand the pressure specified.
E. Ensure that the arrangement for testing a pipeline includes provision for
the purging of air from the pipeline prior to a water test.
F. Where multiple pipelines are laid in common
on trench, test only one line at
any one time.
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G. Ensure that gauges used for testing elines have a dial diameter of not
g pipelines
less than 100mm and a full scale calee reading not greater than twice the
specified test pressure. Before any gauge ga ge is used, arrange for
gau
C -
independent laboratory to o check the accuracy
accuracy y of the
th gauge.
g Provide a
y
H.
C
dated certificate of its accuracy/calibration
The Contractor must
accuracy/calib ion to
accuracy/calibrat
st make his own arrangement
o the Engine
arrangeme for
Engineer.
Engineer
f the supply and
C
disposal of water
ater used for testing
testing which must be o
tes obtained from a source
accepted byy the Engineer.
Enginee
Q
I. The Contractor ccomplete the pipeline

or must co pipelines
pipe between the ends of laid and
tested lengths of pipeline by tie-in
-in ssections of the shortest practical
length.
J. Any other testing method if intended to be used shall be according to the

adequate and satisfactory reference provided along with Engineer &
Client approval.
K. Field testing of GRP pipes shall be in accordance with Section 02810.
18.3.3.2 Field Hydrostatic Testing of Pressure Pipelines

A. Divide pressure pipelines into sections not exceeding 500m in length or as
directed by Engineer. Test each section separately.
B. Before pressure testing is started, re-check the pipes and the valves for
cleanliness, and re-check the operation of all valves. Cap off the open ends of
the pipeline (or sections thereof) with blank flanges or cap ends additionally
secured where necessary with temporary struts and wedges. Complete all
anchor and thrust blocks and fasten securely all pipe straps and other devices
intended to prevent the movement of pipes.
PAGE 116
C. Apply test pressure to the entire pipeline or section being tested to 1.5 times
working pressure or 1.5 times the surge pressure whichever is greater.
Immediately prior to commissioning, complete the pipeline and test the entire
pipeline.
i. Fill each pipeline or section with water and displace all free air from the
pipeline.
ii. Raise the pressure in the pipeline by pumping

umping water
w until the highest of the
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working pressure/surge pressure is attained in the lowest part of the
section.
iii. Maintain at this level by further

urther untill it is st
rther pumping un
unt steady for a period of not
ste
C -
less than 24 hours.
y
iv. C
Monitor the pipeline
peline over a p
pressurization..
period
eriod hours without further
d of 24 hou
C
v. At the end
nd measure
d of this period, measure the reduced pressure
p in the pipeline, the
original
al test pressure restored
estored
tored by pumping
p and the loss measured by
Q
drawing off water or

o air from
m the pipeline
pipelin
pip until the pressure has fallen to
match the reduced
duc pressure previously
vious noted.
vi. Ensure that the loss does not exceed 0.02 liter per millimeter of pipe
diameter per kilometer of pipe per day for each bar of head applied.
vii. If the pipeline fails the test, locate the faults, repair the repairable or
replace with equivalent and retest the pipeline until it passes.
viii. Visually inspect all exposed pipe, fittings, valves and joints during the
tests.
ix. After satisfactory completion of the 24 hour period test, bring the pipeline
to test pressure and maintain it at this pressure, by pumping if necessary,
for one hour. Disconnect the pumping and no water is allowed to enter the
pipeline for a further period of two hours.
x. At the end of the two hours period, restore the original test pressure by
pumping water into the pipeline. Determine the volume of makeup water
required to achieve the test pressure specified and deemed to represent
the cumulative loss during the two hour period of test.
PAGE 117
xi. Ensure the loss does not exceed the limit stated in ‘vi’ above. If the
pipeline fails the test, locate and repair the faults and repeat the test.
D. Ensure that all valves in the pipeline are satisfactorily operating under working
pressure and that the pipelines have been finally cleaned out as specified
hereafter.
E. Do not test pipes against closed valves.
18.3.4 Hydrostatic Testing of Non Pressure

ssure
sure Pip
Pipelines
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A. Test all non-pressure pipelines up to 1000m
1000mm diame
diameter after completion of
concrete or granular bedding up to the soffit of the pipeline.
pip Clear the bedding
around pipe joints to allow for visual inspection
inspec ffor
or leaks. Ensure that the trench
ks. E
C -
is kept dry. Apply water head
ead
d for testing invert plus 1.0m, or
testin of eitherr depth to inv
y
pipeline.
C
5.0m, whichever is the
e greater. Measure
he Meas re the
Measu he head at the
th lower end of the
C
B. Maintain the water head ove
overr a period of 30 minutes
mi and if necessary,
add water from
om a measuring
measur
meas ng vessel at 10 minute
m intervals. Record the
Q
quantity of water
ater
ter adde
added from the
he measuring
measu vessel.
i. The leakage in (litres) out of quantity

tity of water added, shall not exceed 0.5 X
pipe diameter (m) X length of pipe under test (m).
C. For non-pressure pipes greater than 1000mm diameter, inspection for

water tightness, workmanship and compliance to this specification shall
be carried out by man entry.
D. Not more than 7 days prior to handover all pipelines shall be subject to an
infiltration test as follows:
i. Test the pipeline in lengths between manholes or such shorter lengths as

the Engineer may direct or permit. Maximum length to be tested shall be 1
kilometer.
ii. Dewatering shall have been discontinued for at least 3 days prior to test.
iii. Volume of water infiltrating into the pipe shall be accurately measured for a
minimum period of 1 hour.
iv. Maximum infiltration shall not exceed 1 liter per millimeter of pipe diameter
per kilometer of pipe per day.
PAGE 118
E. Keep a record of all tests and make them available for inspection. Hand over
test records to the Engineer for approval.
F. Pipes or joints shall not be accepted if any leakage or damage is visible during
an internal inspection.
G. If the result of any test or inspection does not comply with the requirements of
the specification, the Contractor shall investigate
ga the reason and carry out
remedial work to the approval of the Engineer
eer at no cost to ADM The pipeline
neer
shall then be re-tested. This process shall
all be repeated u
until the requirements of
the specification are satisfied.
H. The Contractor may be required incorporate

ired to incorpora
incorporat 300mm tee on property
e a 300
30
connection laterals near the
e junction
unction of the
t main
ain drain
ma rain and this
th tee may be used
y
to insert an expanding stopper in the la
lateral purposes.
aterall for testing pur On the
op
satisfactory completion
tion tests,, remove
on of such test
tests temporary fittings from the
move all tempora
lateral. Provide the watertight
he tee with a wate
wa rtight or plug.
18.3.5 Field Deflection

lection
ection Measurement
Measu
Me rement
ement of Pipelines
Pip
Pipeli
C
A. For pipeline length
ength gre
grea
greater than
n 6.0m measure
mea the horizontal and vertical
deflections for all GRP
GR pipes at each end at
a points 100mm away from the joint,
1.5m away from the joint and at 3.0m intervals hereafter. For pipeline lengths of
equal to and less than 6.0m, measure the mentioned deflections at each end at
a point 100mm away from the joint, and at the mid-point. For GRP pipes
installed with granular bed and surround, take measurements on at least three
separate occasions as follows.
i. After the pipe surround material has been placed and compacted to
150mm above the pipe crown. Do not proceed with further pipe laying until
this test has been satisfactorily completed.
ii. On completion of all backfill material up to ground level but before the
dewatering is removed. Take this measurement within one day of the
completion of backfilling.
iii. Immediately prior to the issue of a Provisional Acceptance Certificate.
B. For GRP pipes with concrete surround, carry out the deflection testing as
in stages (i) and (ii) above. For proving the pipes immediately prior to the
issue of the Provisional Acceptance Certificate, draw a pig or ball through
the pipeline, sized so that it will not pass any point in the pipeline which
PAGE 119
has been deflected to a greater degree than that permitted in the long
term.
C. For pipes exhibiting any negative deflection in the vertical in excess of 2%
in (i) above and pipes exhibiting any deflection in excess of 4% in (ii)
above, expose the pipe and replace and re-compact the surrounding
bedding material. Replace the pipe should the deflection exceed 5% in
(iii) above. Any pipe to be replaced must be taken
tak away from site and not
be incorporated into the permanent works.
orks.
ks.
op V1
D. Subject pipes exposed for re-compaction
ompaction
mpaction a and pipes
p replaced for other
reasons, to the three deflection
n checkss listed in clause
u 3.4.a above. Carry
n clau
out deflection checks on adjacent pipes
pip for
for 50m either
eith
e side of the re-
C -
y
compacted or replacement
ment pipes.
pi
E.
C
Tabulate the results
ts of the deflection
deflection measurements.
easurements. Submit
Su copies of the
C
results to the Engineer immediately
ngineer immed
immedia tely after each se
ately set o
of measurements has
been taken.
Q
END
ND OF SEC
SECTION
PAGE 120

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STORMWATER & SUBSOIL DRAINAGE SYSTEMS VOLUME IV- TECHNICAL SPECIFICATIONS

18 GRP PIPES (SECTION 02630)

Section 02222 --Excavation

Section 02225 -Trenching

ASTM D4161 Standard specification for “fiberglass” (Glass fibre reinforced

BS 3532 Aerospace Series. Steel FE – PM2701.

BS 4549-1 Guide to quality control requirements for reinforced plastics

BS EN 681 Elastomeric seals. Material requirements for pipe joint seals

BS EN 1394 Plastic piping system Glass reinforced thermosetting plastic

BS EN 14364 Plastic piping system forr drainage

DIN/BS EN 14364 Plastics piping

DIN-53769- Part 3 Testing of GRP pipes - Determination of Initial and Long

DIN-53769 - Part 6 Testing of GRP pipes under pulsating internal pressure

DIN EN 1120 Plastics piping systems – Glass-reinforced thermosetting

DIN EN ISO 75 Plastics – Determination of temperature of deflection under

DIN EN 1119 Plastics piping systems – Joints for glass-reinforced

DIN EN 1447 Plastics piping systems – Glass-reinforced thermosetting

ASTM C-581 Standard Practice for Determining Chemical Resistance of

ASTM D3681 Standard Test Method for Chemical Resistance of

DIN 53769 Testing of glass

18.1.4.1 Products and Materials

i. The manufacturers design calculations, complete and detailed

v. Joint materials and gaskets.

vi. Standard produced pipe lengt

Manufacturing process for pipes -

Manufacturing process for bends and fittings -

Summary of Design Criteria

Nominal internal /external diameter mm

Pressure Class of pipe (PN) kN/m2

Minimum depth of cover m

Maximum depth of cover m

Maximum working pressure kN/m2

Product Information Units

Design test pressure kN/m2

Internal vacuum pressure kN/m2

Pipe Wall Structure

Nominal total wall thickness mm

Chopped Glass** Type %

Hoop Glass** Type %

External layer Resin***Type %

Minimum Initial Pipe Properties

Stiffness (SN) N/m2

Longitudinal tensile strength N/mm

Hoop flexural modulus GN/m2

Hoop tensile strength N/mm2

Product Information Units

Last date of publishing the Type Test (Long Term) results

Notes to Table 18.1

a) Pipe data to be provided for every diameter in each class of pipe.

*** By weight of layer.

18.1.4.2 Method Statements

iii. Hydrostatic testing procedures for GRP pressure pipelines.

iv. Deflection measurement procedures for GRP pipelines, where

18.1.5 Quality Control

B. Products and materials shall be from manufacturer/supplier who operates a

C. To allow the Engineer to

iii. Deflection measurement of pipeline.

18.1.6 Delivery, Storage and Handling

a) Delivery storage and handling shall at all times be performed in a manner