MANUAL

FOR

UNDERGROUND
INSTALLATION OF
GRP PIPES
IN THE TRENCHES

BALAJI FIBER REINFORCE PVT. LTD. Page 1 of 37

 INDEX

• INTRODUCTION – Section contains the details of

procedures to imply in handling and installation of
underground GRP Helical winding piping in trenches.

• PURPOSE – Section contains easy to follow directions

to help the customer/contractor to understand the
requirement for the successful GRP pipes handling and
installation. In case of any problem, please contact
BALAJI FIBER REINFORCE PVT. LTD., SURVEY
293-1 & 2, SAKARDA BHADARVA ROAD, Nr.
POICHA CROSSING, VILL. :POICHA, TA: SAVLI,
DIST.: VADODARA – 391780, GUJARAT (INDIA)
TELEFAX : +91-2667-244795,
FAX: +91-265-2250333,
Email: balajiuasb@yahoo.co.in,
bfrpl@yahoo.co.in

• SCOPE – Section contains details for underground pipe

installation in soil conditions as prevalent in the project
area. The type of installation based on the site
conditions and terrain in the project area.

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1. General Instruction

1.1 Transportation and handling of GRP

Pipes

From the lay-down area to the trench site, the pipes shall
be transported through trailers.

• Prior to unloading of pipes from trailers, all items shall

be inspected for any visual/transportation damages.
• Single pipes must be unloaded and handled
separately (one at a time). Use pliable straps, slings
or ropes to lift single pipes.

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 • Do not use steel cables or chains to lift or transport
the pipe.
• Care shall be taken to prevent pipes from rolling or
falling from flat bed trailer and this shall be attained
by using proper supports.
• If at any time during handling or installation of the
pipe, any damage such as cracks, de-lamination or
fracture occurs, the pipe should be repaired before
the section is installed. Contact BFRPL for inspection
of damage and for recommendation for repair method
or the replacement.
• The rubber gaskets received along with the pipes and
fittings shall be stored in shelter with original packing
until it is used at site.
• The gaskets must be protected from exposures to
grease or oils, which are petroleum derivatives, and
from solvents and other deleterious substances.

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 • Always use only special vegetable soap (which is free
from grease/petroleum products). The lubricant paste
shall be mixed with equal ratio of water (1:1) while
using it.

1.2 Handling of nested pipes:

We propose to nest various diameter pipes during
transportation. Always lift nested bundles using at least
two pliable ropes. Always keep nested pipes on site in the
original transporting package only. Stacking of these pipes
is not advisable. De-nesting of pipes should be done
carefully at pre allocated station. Inside pipe may be
removed by lifting slightly with an inserted padded boom
to suspend the section & carefully move it out without
damaging the outer pipe.

1.3 Pipes Preparation at site storage area:

• It is convenient and more practical to fix one coupling

on each pipe end prior to lower into the trench.
Following is the method to join the coupling:
• Clean the coupling thoroughly from inside, specially the
internal groove, from dirt, grease or any material
deposition.

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• Insert the gasket into the grooves, leaving two or more
uniform loops of rubber (depending on pipe diameter)
extending out of the groove.
• Do not put any lubricant in the coupling grooves or on
the gasket at this stage. There should be a minimum of
one loop for each 450 mm of gasket ring circumference.
• With uniform pressure, push each loop of the rubber
gasket into the gasket groove.
• When installed, pull carefully on the gasket in the radial
direction around the whole circumference to check for
well distributed compression of the gasket.
• Apply lubricant on gasket that will facilitate easily fixing
of coupling to the pipe.
• Also, apply a thin film of lubricant on pipe spigot & align
the coupling with pipe.
• Never use a petroleum based lubricant for GRP pipe
jointing.
• Fix a cross bar on the coupling face. Use two nylon
slings & fix the come-along jacks (pullers) at each side
of the pipe spring line.
• Ensure that the coupling & pipe is aligned.
• Start tightening the puller from both ends same time.
The coupling will insert the pipe spigot gradually.
• Make sure that the black home line marked on the pipe
is matching equally in circumference.
• Loose the pullers & move to other coupling.

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BALAJI FIBER REINFORCE PVT. LTD. Page 9 of 37
1.4 Angular Deflection of Double Bell
Couplings:

• Maximum angular deflection (turn) at each coupling

joint must not exceed the amounts given in Table – A

Table A
Nominal Pipe Diameter Angular Deflection
(mm) (Degrees)
350 ≤ DN ≤ 600 2
1100 ≤ DN ≤ 1300 1
1400 ≤ DN ≤ 1800 0.5
Above 1800 mm dia 0.25

• The pipes should be joined in straight alignment and

thereafter deflected angularly as required (see figure
below)
Pipe - A
GRP Coupling
Pipe - B

Offset

Deflection Angle
Radial Curvature

Figure

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2. UNDERGROUND INSTALLATIONIN
TRENCHES

2.1 Trench excavation – trench dewatering

• In stable soil condition, the trench excavation shall be
made as shown in the below figure:

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 • In unstable soil condition, the trench width shall be
extended to minimum half of pipe diameter at each
side.
• Minimum cover depth above pipe crown should be as
below 1.25 mtr or one diameter, whichever is more to
take care of buoyancy & full vacuum.
• In case of high ground water table, adequate
dewatering shall be requiring through suction pumps
or through well-point system depending on the
ground water condition.

2.2 BED & pipe Zone Backfill Materials

Most coarse-grained soils (gravel, crushed stone, good

clean murrum and sand) are the recommended bedding &
pipe zone backfill materials. Gravel is easier to compact
than sand and allows the pipe to be installed deeper, if
required.

Maximum Particle Size

Table B
Pipe Diameter Maximum Gravel
or
Stone Size
More than 600 mm 25 mm
Below 600 mm 19 mm

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2.3 Use of Native Soils

Where native soil is used as backfill above the pipe zone,

the following conditions apply:

a) No rocks greater than maximum gravel size.

b) No soil clumps greater than 2 times the maximum
gravel size
c) No organic material
d) No debris like tires, bottles, metals, etc.

2.4 Burial Limitation – Minimum cover on pipe

crown

The minimum backfill requirement above pipe crown as

given above take care of anti buoyancy of empty pipe in
high water table area, allow AA class vehicular load
(AASHTO-HS20) vehicular traffic on pipe & full vacuum
condition.

2.5 Pipe Bedding

Pipe bedding material shall be sand or gravel in

accordance to the requirements. The bedding shall be
placed after the trench bottom is compacted to provide
proper support. Minimum compaction of the bed shall be
90% Standard Proctor Density (70% of maximum relative

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density for crushed rock, crushed stone or gravels) Please
note the maximum particle size as given in Table B.

The bed must be over-excavated (manual digging is

enough) at each coupling joint location to ensure that the
pipe will have a continuous support and does not rest on
the couplings. However, this area must be properly
bedded and backfilled after the joint assembly is
completed.

2.6 Pipe Jointing in the Trench

• Position the crane near the trench at a safe distance.

• Unload the pipe and place into the trench.

• Make sure that the bedding is mechanically

compacted prior to pipe laying as per the required
specification.

• After placing the first pipe bring the second pipe near
the pipe placed and install it with clamps, chain
blocks/pullers as shown in next page.

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2.7 Backfilling Pipe:

• When gravel or crushed stone is used as backfill,

immediate backfilling after joining is always advisable,
to prevent floating of pipe in case of unforeseen
monsoon or sudden water flow in the trench.
• Floating of pipe can damage the pipe and create
unnecessary reinstallation costs.
• Proper selection, placement and compaction of pipe
zone backfill are important for controlling the vertical
deflection and are critical for pipe performance.
• Attention must be paid so that the backfill material is
not contaminated with debris or other foreign
materials that could damage the pipe or cause loss of
side support.
• During backfilling, the granular material should flow
completely under the pipe to provide full support.
• A blunt tool may be used to push and compact the
backfill under the pipe.

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 • Proper backfilling should be done in 150 mm to 300
mm lifts depending on backfill material and
compaction material, 300 mm lifts will be adequate
since gravel is relatively easy to compact. Sand needs
more compaction efforts.
• The compaction of sandy backfill is most easily
accomplished when the material is at or near its
optimum moisture content. When backfilling reaches
pipe spring-line, all compaction shall be done first
near the trench sides and proceeds towards the pipe.
• It is recommended that placing and compacting of the
pipe zone backfill is done in such a way as to cause
the pipe ovalize slightly in the vertical direction.

3. Thrust Blocks

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RCC thrust block will be constructed at the places of
bends, tees, reducer or at he places of blinds. It is always
recommended to use coupling at both the edges of thrust
blocks where pipe comes out of the thrust block. We
advise to wrap a band of rubber around the coupling prior
to placement of any concrete. Rubber should protrude
(25mm) from the thrust block edge, Rubber thickness 10
mm & of 50 Durometer. It is always recommended to cast
thrust blocks as laying progresses. Before the hydro test
all thrust blocks should be completed. We always
recommend to fix a short pipe piece of 1 to 2 mtr length
on each side of thrust block (immediately after block) with
coupling joint. This acts as a rocker pipe to provide
additional flexibility to the system in case of uneven
settlement if any.

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BALAJI FIBER REINFORCE PVT. LTD. Page 18 of 37
 10 mm
20 mm
300 mm
Rubber Wrap Configuration -
Rubber shall be 50 Durometer

Immediately after thrust blocks we should provide one

small pipe piece (1 to 2 mtr length) with coupling on each
side of block to take care of uneven settlement.

4. Buoyancy

Minimum cover required on pipe crown to avoid upliftment

of empty pipes in high water table areas is one meter or
one diameter which ever is more. If sufficient cover is not
available and the area has the possibility of high water
table RCC precast blocks or institution blocks of required
weight are to be used to counteract unbalanced uplift
forces.

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4.1 River/Nalah crossing/Road crossing

We need to encase the pipe min 300 mm all around with

M20 grade concrete & balance portion of the trench
should be backfilled with crushed rock/gravel up to the top
of trench. The minimum back fill cover on the pipe should
be 1.5 mtr.

4.2 Concrete Encasement:

When pipes (or fittings) must be encased in concrete such

as for thrust blocks, stress blocks, or to carry unusual
loads, specific additions to the installation procedures as
given in 4.3 must be observed.

4.3 Concrete Pouring

The concrete must be place in stages allowing sufficient

time between layers for the cement to set and no longer
exert buoyant forces. Maximum lift (500 mm) is the
maximum depth of concrete that can be poured at one
time for a given nominal stiffness class.

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4.4 Flooded trench

When the ground water table is above trench bottom, the

water level must be lowered to at least the trench bottom
(preferably about 200 mm below) prior to preparation of
the bed. Different techniques may be used depending on
the nature of the native material for sandy and silty soils a
system of well point to a header pipe and a pump is
recommended. The spacing between individual well point
and the depth at which they will be driven depends on the
ground water table and the permeability of the soil. It is
important to use a filter around the suction point (coarse
sand or gravel) to prevent clogging of the well-point will
not work. Dewatering is more difficult to achieve in this
case. The use of sumps and pumps is recommended. If
the water cannot be maintained below the top of the
bedding, sub-drain must be provided. The sub-drain
should be made using single size aggregate (20-25 mm)
totally embedded in filter cloth. The depth of the sub-drain
under the bed depends on the amount of water in the
trench. If the groundwater can still not be maintained
below the bed, filter cloth should be used to surround the
bed (and if necessary the pipe zone area as well) to
prevent it from being contaminated by the native material.
Gravel or crushed stone should be used for bed and
backfill. The following cautions should be noted when
dewatering:

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 • Avoid pumping long distance through the backfill
material or native soil, which could cause loss of
support to previously installed pipes due to removal of
material or migration of the soil.
• Do not turn of the dewatering system until sufficient
cover depth has been reached to prevent pipe
floatation.

5. Post installation checks

5.1 Checking the installed pipes

Requirement: Maximum installed diametrical deflection

must not exceed the value in the Table initially or long
term. Bulges, Flat areas or other abrupt changes of pipe
wall curvature are not permitted. Pipes installed outside of
these limitations may not perform as intended.

Deflection %
of Diameter
Large Diameter 3.0
(DN≥300)

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Checking to ensure that the initial deflection requirements
have been met is easy to do and should be done for each
pipe immediately after completion of installation (typically
within 24 hours after reaching maximum cover). The
expected initial pipe deflection after backfilling to gravel
level is less than 2% for most installation. A value
exceeding the amount indicates that the desired quality of
the installation has not been achieved and should be
improved for the next pipe (i.e. increased pipe zone
backfill compaction, coarser grained pipe zone backfill
material or wider trench, etc.) Deflection measurements in
each pipe installed area recommended as good check on
pipe installation quality. Never let pipe-laying get too far
ahead before verifying the installation quality. This will
permit early correction of inadequate installation methods.
Pipes installed with initial deflection exceeding the value in
table must be reinstalled so the initial deflection is less
than those values. See next section, correcting Over-
Deflected pipe, for limitations applicable to this work.

Procedure for checking the initial diametrical deflection for

installed pipes:

1. Complete backfilling to grade.

2. Complete removal of temporary sheeting (if used)
3. Turn of the dewatering system (if used).

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4. Measure and record the pipe’s vertical diameter.
Note: For smaller diameter pipes, a deflection testing
device (commonly called a pig) may be pulled through the
pipes to measure the vertical diameter.
5. Calculate vertical deflection:
(Actual I.D. – Installed Vertical I.D.)
% Deflection = ------------------------------------------- x 100
Actual I.D.

Actual I.D. may be verified or determined by measuring

the diameters of a pipe not yet installed laying loose (no
pipes stacked above) on a reasonable plane surface.
Calculate as follows:
Actual I.D. = (vertical I.D. + Horizontal I.D.)/2.

I.D.

I.D.

Determining Actual Pipe

ID on pipe not yet installed

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5.2 Correction Over-Deflected Pipes

Pipes installed with diametrical deflection exceeding the

value in the above table must be corrected to ensure the
long-term performance on the pipe.

Procedure

For pipe deflected up to 8% of diameter.

1. Excavate down to the haunch area, which is
approximately 85% of the pipe diameter. Excavation
just above at the sides of the pipe should be done
utilizing hand tools avoid impacting the pipe with
heavy equipment.
2. Inspect the pipe for damage. Damaged pipe should
be repaired or replaced.
3. Re-compact haunch backfilling, insuring it is not
contaminated with unacceptable back fill material soil.
4. Re-back fill the pipe zone in lifts with the appropriate
material, compacting each layer top required relative
compaction density.
5. Back fill to grade and check the pipe deflection to
verify they have not exceeded the initial values in
Table 5.1.

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 6. For pipe deflected greater than 8% pipe diameter.
Pipes with over 8% deflection should be replaced
completely.

Caution: Do not attempt to jack or wedge the

installed over-deflected pipe in to a round condition.
This may cause damage to the pipe.
If excavating multiple pipes, care must be taken to
not mound the cover from one pipe over the adjacent
one. The extra cover and reduction of side support
could magnify an over-deflected situation.

Important note:
For any further details please refer installation manual
given by us. Please note that it is always
recommended to use that as the basic guideline for
GRP pipes, in above method statement we have
added only those points related to this project,
however, it is always recommended to get familiar
with our manual, which represents our experience for
last 30 years.
For further assistance, contact:
Balaji Fiber Reinforce Pvt. Ltd.
Survey No. 293-1 & 2, Sakarda Bhadarva Road,
Near Poicha Crossing, Village: poicha (Khandi),
Ta: Savli, Dist.: Vadodara – 391 780 Gujarat, INDIA
Telefax: +91-2667-244795, FAX: +91-2667-2250333
Email: balajiuasb@yahoo.co.in, bfrpl@yahoo.co.in

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 FIELD HYDROTEST STATEMENT FOR
UNDERGROUND INSTALLATION OF GRP
PIPES

Balaji Fiber Reinforce Pvt. Ltd.

Survey 293-1 & 2, Sakarda Bhadarva Road,
Near Poicha Crossing, Vill. :Poicha, Ta: Savli,
Dist.: Vadodara – 391780 Gujarat(India)
TELEFAX : +91-2667-244795,
FAX: +91-265-2250333
Email: balajiuasb@yahoo.co.in,
bfrpl@yahoo.co.in

BALAJI FIBER REINFORCE PVT. LTD. Page 27 of 37

FIELD HYDROTEST – GRP PIPING

UNDER GROUND PIPING SYSTEM-COUPLING

JOINTS.

Field hydro test could be conducted in segments or as

complete piping system.

Segment Hydro testing:

Distances of 500 mtrs to 1 KM (min length) will be decided

by BFRPL installation engineer according to site conditions
to test the installed piping system in segments. A
clearance (undisturbed original soil) of 10 meters
minimum shall be maintained between the segments
which will take care of end thrust to be transmitted
through end caps. In this gap will be later installed as
Make-Up pipe piece with double spigot calibrated piece to
facilitate the jointing on existing segment.

FIXING TEST PLUGS

1. USING BLIND CAPS: Blind end cap is MS/GRP

coupling with one end closed through lamination, while

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the other end is with groove for rubber gasket to work as
sealing the end. MS end caps having one end machined
same as dia of spigot OD can also work.

Fix the end cap on the last pipe end to be tested after
placing the rubber gasket into end cap groove. Join with
the spigot pipe end through pullers/ come-along jacks.
Necessary openings could be provided to the end caps for
ventilation/pressure gauge. Pressure gauges can be fixed
on these opening (there is a screw type connection). After
segment test, these end caps could be removed through
pullers & upon rubber gasket replacement, could be re-
used for other segments.

END CAPS ARE AVAILABLE ON SEPARATE

PURCHASE ORDER OR INSTALLATION
CONTRACTOR CAN ALSO GET THEM FABRICATED.
WE WILL PROVIDE SPIGOT OD FOR MACHINING.
Drawings and end cap can be supplied by Balaji Fiber
Reinforce Pvt. Ltd.

2. Hydrotest using flange & blind flange – Flange will be of

GRP & Blind flange can be metallic.

Adequate concrete block supports shall be provided to the

end cap to prevent the pipe movement during hydro test.
After removal of the end caps after the hydro-test, there
will no movement of the pipe.

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NOTE: CONCRETE BLOCK SUPPORT TO THE BOTH
ENDS IS MUST TO TAKE CARE OF END THRUST.

PREPARATION PRIOR TO HYDROTEST:

Make sure that the test method statement is available with

full understanding of implementation to the testing team.
Fixing ventilation at highest points, minimum two pressure
gauges and filling points with valves or all the ventilation,
fill points with valves can be fabricated on end cap.

Drawings and end cap can be supplied by Balaji Fiber

Reinforce Pvt. Ltd.

The values and reading at the pressure shall be calculated

taking into account the static head between the lowest
pipe invert level along the complete line and the level of
the pressure gauge. All flanges are tightened to the
specified torque bolt sequence. The method is as follows.

• Thoroughly clean the flange face and the O-ring

groove.
• Ensure the sealing gasket is clean and undamaged.
• Position sealing gasket in groove.
• Align flanges to be joined.

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• Insert bolts, washers and nuts. All hardware must be
clean and lubricated to avoid incorrect tightening.
Washers must be used on all GRP flanges.
• Tighten all bolts by a torque wrench, following
standard flange bolt tightening sequences.
• Repeat this procedure, raising the bolt torque until the
flanges touch at their inside edges. Do not exceed this
torque. To do so may cause permanent damage to
GRP flanges.

FLANGED JOINT

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Make sure that the valves are anchored and the above
ground piping, if any is supported as specified.

FOR 600 OR ABOVE DIA PIPES, SINGLE PERSON

SHOULD NOT BE ALLOWED TO GET INSIDE OF
PIPING FOR INSPECTION

Wooden ladder shall be available at each

manhole/opening during the inspection of more than 1200
mm dia GRP pipe. Pipe fittings like valves should be
closed, gauges should be fit properly.

Upon verification of the inspection, when the findings are

all judged acceptable & recorded, manhole covers shall be
closed.

Prior to start water filling, temporary piping & blinds shall

be installed, checked & verified by the clients/ consultant/
contractor representatives.

WATER FILLING & PRESSURIZING THE SYSTEM:

(It shall be confirmed that all vent points are fully opened
to atmosphere, prior to start of water filling to allow the
release of air from the pipeline as the water is filled)

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Start water filling through temporary hosing & pump at
lowest point. Pump capacity shall be chosen according to
the pipe diameter and segment/system linear length.

The sign of complete water filling when the water starts

coming through higher point ventilation opened valves
ensure that no air entrapment is left.
Stop water pumps at this stage & check the flanges,
valves and connected accessories for any seepage/
leakage while keeping the vents open.

PRESSURIZING:
Start pressurizing the segment/ system through pump.
Once the water starts coming out through vent opening,
close the valves at low elevation. Later, on the high
elevation end the vent. Valves shall be closed as well after
water starts coming. The pressure increment shall be
maintained at 0.5 Bar/10 minutes at this stage. When the
pressure reaches up to working pressure then the pump
shall be stopped.

Keep this stoppage for 15-20 minutes. During this time,

following checks shall be made:
A) Pressure at each test gauge shall be checked &
recorded on inspection sheet.
B) Watch the pressure at the water feed point for any
decrease in pressure.

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 C) Walk through along with the underground lines to
observe any traces of wet soil and any unusual at
every interval of 30-45 minutes. The length of test
section as already stated is between 500 mtrs. to 1
Km.

Continue this till the required pressure is achieved.

The inspection sheet shall be maintained for the

observations & find.

ANY PRESSURE DROP, VALVE LEAKAGES SHALL BE

IMMEDIATELY REPORTED TO THE TEAM LEADER.

1. Unless there are no findings which prevent the test

from continuing, the segment/ system shall be further
pressurized.
2. Connect the hose with the pressure pump and start
pressurizing the line. At this stage, slightly open the
vent. Valve fixed at higher elevation to ensure that no
entrapped air is present.
3. Upon confirmation of water coming out, the vent.
Valve shall be closed. The system is now totally
closed and under pressure.
4. Continue the pressure pump until it reaches to filled
test pressure. During this operation, the pump shall
be constantly attended for pressure control.

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 5. Stop the pressure pump once it reaches to filled test
pressure and let it to stabilize.
6. There could be a drop in pressure due thermal
expansion, which could either be make-up by re
starting the pump or keep it as is & record on the
inspection sheet.
7. Keep this stoppage for about 30 minutes. During this
period, repeat the same sequence of inspection as
described earlier.
8. The findings & observations shall be recorded on
inspection sheets.

ANY PRESSURE DROP, VALVE LEAKAGES SHALL BE

IMMEDIATELY REPORTED TO THE TEAM LEADER.

Unless there are no findings which prevent the test from

continuing, the segment/system shall be further
pressurized to a field test pressure as per

THIS TEST PRESSURE SHALL BE MAINTAINED FOR

PERIOD OF MAXIMUM THIRTY MINUTES AFTER
PRESSURE STABILZATION.

Through inspection shall be made as FINAL INSPECTION.

After the test pressure is reached then check for any drop
in pressure. Fill up the inspection sheets accordingly.

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The test shall be considered as “PASS” if no signs
of leakage are observed, the inspection sheet(s)
shall be signed by the authorities.

POST HYDROTEST:
After completion of the test, open all vent valves. Drain or
flush out the filled water from the pipe segment/system
through drain valves. This pressure release shall be made
slowly at 2 Bar/ 5 minutes.

Remove the end cap from the segment as per procedure

and close the same with temporary cover to avoid any
particles from entering inside the line. BFRPL
installation/site engineer will advice you in this process.

Prepare the pipe end to be ready for next installation.

Connect the adjacent segment ends with closure pipe

piece.

Continue the installation for the segments & conduct the

hydro test in the similar manner as described earlier, keep
connecting the segments through closure spools.

The clearance maintained between the two segments can

be later installed as Make-Up pipe piece with double spigot
calibration to facilitate the jointing on existing pipe

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segment. The test of this Make-Up pipe piece can be done
during the time of commissioning.

THIS PROCEDURE IN MANDATORY TO THE

INSTALLER ANY DEVIATION SHALL BE CONSULTED
WITH BALAJI FIBER REINFORCE PVT. LTD. SITE
SUPERVISOR

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