DEFINATION

A complex non-isotropic material, in which two or

more distinct, structurally complementary substances,
glass fiber and thermoset polymer resin, combine to
produce structural or functional properties not present
in the individual component

GLASS FIBERS :- strength and stiffness
RESIN :- impact resistance, compressive strength, and
corrosion resistance
GRP-GLASS REINFORCE POLYEASTER
GRV-GLASS REINFORCE VENYLEASTER
GRE-GLASS REINFORCE EPOXY

RESINS-will provide the thermal and chemical
properties such as glass transition temperature,
resistance to heat, chemical resistance etc.
required for the finished product.
GRP Pipes are made from the dual helical winding
technology. The major raw materials used for this
are fiber glass, Iso-phtahlic resin and sand (certain
cases).
Inner liner consists of surface tissue and vinyl ester
resin for maximum chemical resistance and will
enhance abrasion resistance.
The structural layer consists of E- glass and Iso-
pthalic resin.
Outer Liner is a thinl layer with structure similar to
the structural layer.Diameters of pipes produced
range from 25mm to 2000mm currently.

GRV Pipes are made from the dual helical winding
technology. The major raw materials used for this are
fiber glass, Vinyl Ester resin and sand (certain cases).
Inner liner consists of surface tissue and Vinyl ester
resin for maximum chemical resistance and will
enhance abrasion resistance.
The structural layer consists of E- glass and Vinyl Ester
resin.
Outer Liner is a thin layer with structure similar to the
structural layer.
GRVE Pipes have better mechanical and chemical
Properties when compared to GRP Pipes. Diameters of
pipes produced range from 25mm to 2000mm
currently.

GRE Pipes are made from the dual helical winding
technology. The major raw materials used for this are
fiber glass, Amine Cured Epoxy resin and sand (certain
cases).
Inner liner consists of surface tissue and Amine Cured
Epoxy resin for maximum chemical resistance and will
enhance abrasion resistance.
The structural layer consists of E- glass and Amine
Cured Epoxy resin.
Outer Liner is a small layer with structure similar to
the structural layer. Diameters of pipes produced range
from 25mm to 2000mm currently.


GLASS FIBERS REINFORCEMNENT (IN THE
FORM OF VAIL)
THERMOSETTING RESIN
CHOPPED STRANDS
WOVEN ROVING
AUXILIARY COMPONENT
1) CATALYST FOR POLYESTER RESIN
2) ACCELERATOR
3) INHIBITOR
4) SILICA SAND
GRP pipe wall consists of three layers perfectly
adherent to each other and having different
characteristics and properties in relation to
their function.

Inner Liner
Structural Wall
External Liner

PIPE COMPOSITION
GRP pipe wall consists of
three layers perfectly
adherent to each other and
having different
characteristics and
properties in relation to their
function

1) Inner Liner
2) Structural Wall
3) External Liner

Liner or chemically resistant layer is the internal layer of the
pipe. It is in direct contact with the conveyed fluid. This
layer has the function to guarantee the resistance to the
chemical corrosion and the impermeability to the pipe. Liner
has the internal surface, namely be one in contact with the
conveyed fluid, particularly smooth. This characteristic of
smoothness reduces the fluid head losses to the minimum
and opposes the growth of mineral deposits and algae. The
liner is made of two monolithic sub layers. The inner one, in
direct contact with the fluid, is reinforced with glass veil,
with a resin content of 90% and the outer one is reinforced
with CSM glass, with a resin content of 70% by weight. The
standard liner thickness, is about 0.5 to 1.5 mm, higher
thickness can be produced on request.

Glass reinforced layers guarantee the
mechanical resistance of the whole pipe against
stresses due to internal and external pressure,
external loads and thermal loads. For
GRP/GRV pipes, this layer is obtained by
applying on the previous partly cured liner,
continuous roving of glass wetted with resin,
under controlled tension. For GRE pipes, the
structural wall is wound directly on a wet liner.
This layer can contain aggregates like silica
sand. Thickness of the mechanical layer
depends on the design condition. .
Top coat or external liner is the outer layer of
the pipe which consists of pure resin added
with UV protectors to protect the pipe from
sun exposure. In case of severe exposure
condition like aggressive soils or very corrosive
environment, the external liner can be
reinforced with a surfacing veil or added with
fillers or pigments
PERCENTAGE OF DIFFERENT TYPE OF MATERIAL IN FRP PIPE
WITH RESPECT TO LAYERS
HAND LAY-UP OPERATION

SPRAY LAY-UP OPERATION

PULTRUSION OPERATION

CHOPPED STRAND MAT

FILAMENT WINDING
DESIGN TEMPERATURE
DESIGN PRESSURE
DESIGN STRESS
DENSITY
THERMAL EXPANSION
PRESSURE EXPANSION
MODULUS OF ELASTICITY
THERMAL CONDUCTIVITY

Resin is mixed with a catalyst or hardener if working with epoxy,
otherwise it will not cure (harden) for days/weeks. Next, the mold is
wetted out with the mixture.
The sheets of fiberglass are placed over the mold and rolled down into the
mold using steel rollers. The material must be securely attached to the
mold, air must not be trapped in between the fiberglass and the mold.
Additional resin is applied and possibly additional sheets of fiberglass.
Rollers are used to make sure the resin is between all the layers, the glass
is wetted throughout the entire thickness of the laminate, and any air
pockets are removed.
The work must be done quickly enough to complete the job before the
resin starts to cure. Various curing times can be achieved by altering the
amount of catalyst employed. It is important to use the correct ratio of
catalyst to resin to ensure the correct curing time.
1% catalyst is a slow cure, 2% is the recommended ratio, and 3% will give
a fast cure. Adding more than 4% may result in the resin failing to cure at
all.To finish the process, a weight is applied from the top to press out any
excess resin and trapped air. Stops (like coins) are used to maintain the
thickness which the weight could otherwise compress beyond the desired
limit.

The fiberglass spray lay-up process is similar to the hand
lay-up process but the difference comes from the application
of the fiber and resin material to the mold.
Spray-up is an open-molding composites fabrication process
where resin and reinforcements are sprayed onto a mold.
The resin and glass may be applied separately or
simultaneously "chopped" in a combined stream from a
chopper gun.
Workers roll out the spray-up to compact the laminate.
Wood, foam or other core material may then be added, and
a secondary spray-up layer imbeds the core between the
laminates.
The part is then cured, cooled and removed from the
reusable mold.

Pultrusion is a manufacturing method used to make
strong light weight composite materials, in this case
fiberglass.
Fibers (the glass material) are pulled from spools
through a device that coats them with a resin.
They are then typically heat treated and cut to length.
Pultrusions can be made in a variety of shapes or cross-
sections such as a W or S cross-section.
The word pultrusion describes the method of moving
the fibers through the machinery. It is pulled through
using either a hand over hand method or a continuous
roller method.
This is opposed to an extrusion, which would push the
material through dies.

Chopped strand mat or CSM is a form of
reinforcement used in fiberglass. It consists
of glass-fibers laid randomly across each other
and held together by a binder.
It is typically processed using the hand lay-up
technique, where sheets of material are placed
in a mold and brushed with resin. Because the
binder dissolves in resin, the material easily
conforms to different shapes when wetted out.
After the resin cures, the hardened product can
be taken from the mold and finished.

Filament-wound fiberglass pipe and fittings are
machine-made products made on a rotating male
mold.
The mold forms the inside diameter of the part.
Filament wound parts are made with or without
resin-rich interior corrosion barriers.
Corrosion barriers are made the same as with the
hand layup process but may be applied by hand or
by the machine.
The reinforced wall for filament-wound pipe and
fittings made by drawing glass roving through a
resin bath or with a resin-impregnated tape.
The resin-saturated roving or tape is placed on
the outside of the corrosion barrier by a fiber
placement head.
travels in relation to the rotating mold to properly
position the reinforcement on the part.
The roving or tape-on filament-wound pipe is
usually placed on the part at a helical angle.
This angle is normally optimized for maximum
internal pressure ratings but may be changed for
improved pipe stiffness, axial strength, or
unsupported span spacing.
The number of layers of reinforcement used on
filament wound parts is determined by the strength
requirements for the part.
A barrier can be added to the exterior of filament-
wound products for corrosion or abrasion
protection.
Low weight of pipes lengths that allows for the
use of light laying and transport means.
Possibility of nesting of different diameters of
pipe thus allowing additional saving in
transport operations.
Easy installation procedures due to the kind of
mechanical bell and spigot joint.
Corrosion resistance, both of the external wall
in contact with the conveyed fluid. No
protections such as coating, painting or
cathodic are then necessary.

Smoothness of the internal wall that minimizes the
head losses and avoids the formation of deposits.
High mechanical resistance due to the glass
reinforcement.
Absolute impermeability of pipes and joints both
from external to internal and vice-versa.
Very long life of the material virtually infinite, which
does not need maintaining.
higher resistance surge pressure with high stiffness
offering very less chance of bursting of pipe
have excellent thermal insulating properties and
there is no need for the pipes to be insulated
externally to maintain the temperature inside the
pipe

Performance and durability of GRP pipes may be sensitive to
damage incurred by poor handling and installation practices.
External impact can induce star cracking of the barrier layer on the
pipe bore with no apparent damage to the surface of the pipe.
They are not suitable under major urban carriageways or where
there is high risk of third party interference after installation.
Though GRP pipes have excellent corrosion resistant properties,
they can suffer strain corrosion in acidic environments.
Anchor blocks must be designed to withstand the bursting stress
generated when the GRP pipeline is under pressure.
Even though, pipe cost is higher than HDPE, the total installation
cost would compare with any other pipe material and the time
saved in construction is significant



Fiberglass piping is available with a wide range of
joining systems to fit the particular application.

IMPORTANT FACTORS WHEN SELECTING
THE JOINTING METHOD
A) CRITICALITY
B) RELIABILITY
C) EASE OF JOINT ASSEMBLY
D) EASE OF REPAIR,AND FUTURE
MODIFICATION AND TIE-IN
UNRESTRAINED JOINT (withstand hoop
pressure only.)
1) COUPLING OR SOCKET AND SPIGOT
GASKET


RESTRAINED JOINT (which can resists longitudinal force
and hoop pressure)
1) BUTT AND STRAP JOINT
2) FIXED FLANGED JOINT
3) STUB END WITH STEEL LOOSE FLANGE

ADHESIVE BONDED JOINTS
LAMINATED JOINTS
ELASTOMERIC BELL AND SPIGOT SEALED
JOINTS
FLANGED JOINTS
THREADED JOINTS
METALLIC/GRP INTERFACES
OTHER METALLIC JOINTS
BUTT AND STRAP
The butt and strap joining method (also known as the butt
and wrap, the butt weld, and the reinforcedoverlay joint;
and sometimes referred to as an adhesive) is the oldest and
most reliable joining method inthe industry today. The butt
and strap is made as it is described - two pieces of pipe are
butted togetherand layers of chopped strand mat and
woven roving are wrapped around the pipe in a resin
matrix. Theweld is applied to the exterior of the pipe and, if
accessible, the interior as well (usually on pipe largerthan
18" nominal I.D.). Refer to Figure 1 for a typical butt weld
joint. By using the same materials as thepipe, the butt weld
joint can be designed with axial and bending strength
properties equal to or superiorthan the
A second type of joint was developed to act as
a "joint of convenience" in the industry. This is
the adhesive bonded joint. There are three
common types of adhesive bonded joints:
1) taper by taper,
2)straight by taper
3) straight by straight.
The taper by taper joint uses a fitting with a
tapered I.D. and a pipe with a tapered O.D.,
matched and joined by a thin glue line. This
joint is slower to make than the other joints, but
it is the strongest of the adhesive-bonded joints.
A compromise to the taper by taper is the
straight by taper joint which replacesthe pipe's
tapered O.D. with a plain end uniform O.D.
Less installation time is involved, but a thin
glueline is not always ensured, thus
compromising strength.
Can have a lower first time cost
Less labor intensive
Good under simple tensile and pressure testing
Under extremely adverse installation
conditions, may be preferred over the butt
&strap
Less reliable joining method
NDT, outside of field hydrotesting and some X-
ray, unavailable
Very weak under bending loads
Installation time can equal the butt & strap
Experienced knowledge of joining method
required to obtain a reliable joint
Special tooling may be required
Normally requires passive fire protection when
exposed to fire conditions
Most reliable joining method
Excellent mechanical properties
By utilizing the same materials in the pipe, the
butt & strap has axial and bending
strengths equal to or greater than the pipe
No special tooling required
When exposed to certain fire conditions, a fire
retardant version of the joint may
not require additional passive fire protection
Can have a higher first time cost
Labor intensive
Some installation experience required
NDT limited to visual inspection, cure testing,
and hydrotesting
The following codes are generally followed for GRP
piping stress analysis.

BS 7159
ANSI B31.3, chapter VII, part 5.
UKOOA
ISO 14692

It is recommended to follow BS 7159 unless otherwise
the client specifically requires any other codes




INPUT
A) OERTATING AND DESIGN PRESSURE,TEMPERATURE OF THE PIPE
B) MASS PER UNIT LENGHT OF PIPE AND CONTAIN
C) AXIAL AND HOOP EXPANSTION COEFFICIENT OF PIPE MATERIAL
D) AXIAL AND HOOP MODULUS OF ELASTICITY OF PIPE MATERTIAL
E) POISSONS RATIO (LONGITUDINAL AND CIRCUMFERNCIAL)
F) PIPE DIAMETER AND WALL THICKNESS FOR PIPE
G) ROUTING DIMENTION AND MASSES OF ALL VALVE AND OTHER IN
LINE ITEMS
H) VALVE TYPES AND CLOSURE TIMES
I) ENVIRONMENTAL LOADINGS
J) STRESS INTENSITY FACTOR
K) FLEXIBILTTY FACTOR
L) THE ALLOWABLE STRESS FOR THE MATERIAL
pressure induced stresses
Bending stress due to pipe weight and its
contents(fluid, insulation and rigid)
Bending stress due to thermal expansion or
contraction.
Bending stress due to Occasional load (wind,
seismic, etc)

The specific requirement of BS 7159 is the maximum
combined stresses of four of above calculated
stresses should not exceed the allowable design
stress.

THE GENERAL REQUIREMENT IS THAT
THE SUM OF ALL AXIAL STRESSES AND
ALL HOOP STRESSES IN ANY COMPONENT
IN PIPING SYSTEM DUE TO
PRESSURE,MASS AND OTHER SUSTAINED
LOADING AND OF THE STRESSES
PRODUCED BY OCCASIONAL LOADS
SUCH AS WIND,BLAST OR EARTHQUAKE
SHALL NOT EXCEEDS VALUES DEFINED
BY THE FACTORED LONG TERM DESIGN
ENVELOPE.
FORMULAE
A) s-qs = f1 * LTHS (For A1=A2=A3=1)
B) s-a = r * s-qs /2
C) r = 2 * s-sa / s-sh

s-qs - Qualified stress
s-a- Extrapolated long term axial strength, MPa
r Biaxial stress ratio.
s-sa Short term axial strength from D2105
s-sh Short term hoop strength from D15994
f2 = load factor depending on design case.
f2 = 0.67 for sustained loads
f2 = 0.83 for operating plus sustained loads
f3 = 0.89 for occasional loads (water hammer, wind, earthquakes)