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Vendor's name Future Pipe Industries – Abu Dhabi

P.O. No.: 0-6798-PJ216A-109-A110_00

ITEM No.: All

ITEM NAME: GRE/GRV & GRP Piping

DOCUMENT TITLE:
Installation, Operation and Maintenance (IOM) manual

VENDOR's Doc. No.: AI-1133-FPI-DW-CFP-MS-FHT

NEXT REVISION IS APPLCIABLE ONLY IF THERE IS ANY

MODIFICATION IN THIS DOCUMENT.

KNPC CLEAN FUELS PROJECT

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ISSUE PURPOSE:
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JOB. NO 0-6798-2 Doc Type Code I94
COMPANY REV
DOC.no. VP-PV216A-109-A-000-I94-001
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DOC.no. VV216A-109-A-801

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WAVISTRONG
INSTALLATION GUIDE FOR GRE PIPE SYSTEMS

Date issued : May 01, 2011

Replaces issue of : -

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Terms of use
All information was correct at the time of going to press. However, we reserve the right to alter, amend and update any
products, systems and services described in this brochure.
We accept no responsibility for the interpretation of statements made.

© Copyright by Future Pipe Industries.

This document contains confidential and proprietary information. Reproduction or disclosure of any part of this document is
only allowed with written authorisation by Future Pipe Industries.
All rights are vested at Future Pipe Industries.

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Table of contents

Section Page

1. Introduction ................................................................................................................................................ 1
1.1. Scope ................................................................................................................................................. 1
1.2. References .......................................................................................................................................... 1
1.3. Notification ......................................................................................................................................... 2
2. Product introduction .................................................................................................................................... 3
2.1. Systems .............................................................................................................................................. 3
2.2. Pipe fabrication process ....................................................................................................................... 3
2.3. Advantages and disadvantages of GRE compared with steel ..................................................................... 4
2.3.1. Advantages ............................................................................................................................... 4
2.3.2. Disadvantages ........................................................................................................................... 4
2.4. Product identification ............................................................................................................................ 4
3. Material handling, storage and transportation ................................................................................................ 5
3.1. Handling ............................................................................................................................................ 5
3.1.1. Loading .................................................................................................................................... 5
3.1.2. Unloading ................................................................................................................................. 6
3.2. Storage .............................................................................................................................................. 6
4. Joining systems and preparation methods ...................................................................................................... 8
4.1. Conical-Cylindrical bonded joint ............................................................................................................ 8
4.2. Taper-Taper bonded joint ...................................................................................................................... 8
4.3. Laminate Joint ...................................................................................................................................... 9
4.4. Flange Joint ......................................................................................................................................... 9
4.5. Mechanical O-Ring Lock Joint .............................................................................................................. 10
4.6. Mechanical O-Ring Joint ..................................................................................................................... 10
4.7. Mechanical Coupler ........................................................................................................................... 10
5. Tools and materials ................................................................................................................................... 11
5.1. Tools ................................................................................................................................................ 11
5.1.1. Non-consumables ..................................................................................................................... 11
5.1.2. Consumables ........................................................................................................................... 12
5.2. Materials .......................................................................................................................................... 13
5.2.1. Adhesive ................................................................................................................................. 13
5.2.2. O-ring ..................................................................................................................................... 13
5.2.3. Locking key ............................................................................................................................. 13
5.3. Check of incoming material ................................................................................................................. 14
5.3.1. Quality check .......................................................................................................................... 14
5.3.2. Quantity check ......................................................................................................................... 14

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6. Installation of underground pipe systems ..................................................................................................... 15

6.1. Trench construction ............................................................................................................................. 15
6.2. System assembly ................................................................................................................................ 16
6.2.1. Positioning components in the plant ............................................................................................ 16
6.2.2. Joining of components .............................................................................................................. 16
6.3. Backfilling ......................................................................................................................................... 17
6.3.1. Procedure and requirements ...................................................................................................... 17
6.3.2. Backfill material specification ..................................................................................................... 18
6.3.3. Other backfilling methods ......................................................................................................... 18
6.4. Special underground installations ......................................................................................................... 19
6.4.1. Road crossing .......................................................................................................................... 19
6.4.2. Channel crossing ..................................................................................................................... 20
6.5. Alignment ......................................................................................................................................... 20
6.6. Settlement ......................................................................................................................................... 20
6.7. Pipe cast in concrete .......................................................................................................................... 21
7. Installation of aboveground pipe systems ..................................................................................................... 22
7.1. Supports ........................................................................................................................................... 22
7.1.1. General .................................................................................................................................. 22
7.1.2. Fixed support points ................................................................................................................. 23
7.2. Pipe clamps ...................................................................................................................................... 24
7.3. Valves .............................................................................................................................................. 24
7.4. Bellows ............................................................................................................................................. 25
7.5. Pipe connections through walls ............................................................................................................ 25
7.5.1. GRE pipe with sealing puddle flange .......................................................................................... 25
7.5.2. Sand coated GRE pipe ............................................................................................................. 25
7.5.3. Link seal .................................................................................................................................. 26
7.5.4. Special sealing shape ............................................................................................................... 26
7.5.5. Plain wall passing .................................................................................................................... 27
7.6. Joining with other materials ................................................................................................................. 27
7.7. UV-resistance ..................................................................................................................................... 27
8. Quality Control/Quality Assurance .............................................................................................................. 28
8.1. General ............................................................................................................................................ 28
8.2. Joint traceability ................................................................................................................................. 28
8.3. Possible installation defects ................................................................................................................. 28
9. Field Test Procedure ................................................................................................................................... 29
9.1. General ............................................................................................................................................ 29
9.2. Preparation ....................................................................................................................................... 29
9.3. Filling, stabilizing, testing and depressurizing ........................................................................................ 30
9.3.1. Filling and stabilizing ............................................................................................................... 30
9.3.2. Testing .................................................................................................................................... 30
9.3.3. Depressurising ......................................................................................................................... 31
10. Repair ..................................................................................................................................................... 32
11. Tolerances ................................................................................................................................................ 33
12. Safety precautions ..................................................................................................................................... 34
12.1. Resin, hardener, adhesive and lamination sets ..................................................................................... 34
12.2. Cutting, shaving and sanding ............................................................................................................ 34
12.3. Environment .................................................................................................................................... 34

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1. Introduction More specific and detailed information about

underground and aboveground installations, as well
1.1. Scope as various joining methods, is given in manufacturers’
referenced documents.
This manual gives general information about various
aspects that are relevant for the installation of Glassfiber
Reinforced Epoxy (GRE) pipe systems. Respect for the
requirements, methods and recommendations given in this
guide will contribute to a successful operating pipeline
system.

Authorized, trained and certified personnel can only

contribute to a reliable pipeline system. Note that the
remarks about the various joints in this document are for
guidance only.

Fig. 1.1. Offshore unit

1.2. References

Following documentation gives additional and detailed information about various subjects, which are described in this
manual.

Section Subject Documentation

2.4. Product Identification. Marking of products.

Wavistrong assembly instructions

4.1.;5.2.1. Conical-Cylindrical adhesive bonded joint, CB-CS.
Conical-Cylindrical (CB-CS) adhesive bonded joint.
Wavistrong assembly instructions
4.2.;5.2.1. Taper-Taper adhesive bonded joint, TB-TS.
Taper-Taper (TB-TS) adhesive bonded joint.

4.3. Laminate joint. Wavistrong Easy-Fit field laminate instructions.

4.4. Flange joint. Wavistrong flange guide.

4.5.; 4.6.;
Mechanical O-ring (lock) joint. Wavistrong Rubber Seal (Lock) Joint instructions.
5.2.2.; 5.2.3.
Wavistrong shaver instructions CB-CS:
* ID 25 – 50 mm.
* ID 80 – 250 mm.
5.1.1.1. Shavers. * ID 200 – 400 mm.
Wavistrong shaver instructions TB-TS:
* ID 80 – 300 mm.
* ID 250 – 600 mm.
Wavistrong installation of underground
6. Underground installations.
pipe systems.
Wavistrong installation of aboveground
7. Aboveground installations.
pipe systems.

10. Repair. Wavistrong repair manual ES system.

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1.3. Notification

This manual provides the following information:

• A general overview on tooling and materials for

pipe system installation
• A description of joining methods and systems
• Handling, storage and transporting materials
• Installation systems and procedures
• System control and safety measures.

Please note that the instructions in this manual are for

guidance only. Specifications written for a particular
project will be normative. Fig. 1.2. Water transmission

We cannot describe all possible circumstances met in the

field. For this reason, our experienced supervisors may
deviate from given descriptions in order to achieve the
optimum solution for the particular situation, using the
latest techniques and methods.

Fig. 1.3. Oil supply

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2. Product introduction
2.1. Systems

GRE pipeline systems are made from glass fibers, which

are impregnated with an aromatic- or cyclo-aliphatic
amine cured epoxy resin.

This thermoset resin system offers superior corrosion

resistance together with excellent mechanical, physical
and thermal properties.

The glass fiber reinforced epoxy pipeline is resistant to the Fig. 2.1. Filament winding process
corrosive effects of mixtures with a low concentration of
acids, neutral or nearly neutral salts, solvents and caustic
substances, both under internal and external pressure.

A reinforced resin liner can protect the helical wound

continuous glass fibers of the reinforced wall of the pipes
and the structural reinforcement of the fittings internally.

2.2. Pipe fabrication process

GRE pipes are manufactured using the filament winding

method. In this mechanical process, continuous glass fiber
rovings are impregnated with epoxy resin. Fig. 2.2. Structure GRE pipe wall

The production of GRE starts with the preparation of a

steel mandrel, which may be completed with a socket
mould. The dimensions of these tools determine the inner
dimensions of the pipe, fitting and joint system.

Glass fibers are guided through a resin bath, which is

filled with epoxy resin and are wound under constant
tension in a specific pattern around the polished mandrel.

This process continues until the required wall thickness

is reached. Generally, the higher the pressure class, the
greater the wall thickness of the product will be.
The winding process ends with curing the epoxy resin Fig. 2.3. Spool manufacturing
in an oven, extraction of the mandrel/ mould from the
product, finishing the product by cutting to length and
machining the ends.

The products are subjected to visual and dimensional

controls as well as a hydro test.

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2.3. Advantages and disadvantages of GRE 2.4. Product identification

compared with steel
Products are marked with labels, which contain relevant
2.3.1. Advantages product information.
For specific and detailed information, reference is made
Glass Reinforced Epoxy pipe systems have a number of to manufacturers’ documentation.
advantages over conventional pipe systems, of which the
most important are:

• Durable/corrosion resistant
GRE piping is resistant, both internally and
externally, to the corrosive effects of water, oil
and many chemicals.
Cathodic protection or coating is not required.

• Low weight/easy to install

The specific weight of GRE is only 25 % of
steel; due to the low weight, GRE pipeline
components are easier to handle without the
need of heavy (lifting) equipment. Fig. 2.4. GRE is durable/corrosion resistant

• No initial painting or conservation

The epoxy topcoat on the outer surface of GRE
pipe components is resistant to the influences of
the installation environment and an additional
external conservation is initially not required.

2.3.2. Disadvantages

Attention should be paid to the following disadvantages

of GRE when comparing with conventional pipe systems,
such as:
Fig. 2.5. GRE has low weight
• Impact resistance
The pipe system is more susceptible to impact
damage due to the brittle nature of the
thermoset resin system.

• Handling
GRE installations require more and careful
preparation due to other joining methods,
handling- and transportation requirements and
installation techniques.

• Flexibility
The flexible GRE piping system requires specific
support design. Fig. 2.6. GRE needs no initial painting or conservation

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3. Material handling, storage and transportation

3.1. Handling

GRE products must be handled carefully to avoid any

damage. Handling and transportation of GRE is not
restricted by temperature. This section lists the most
important requirements for handling materials before and
after shipment and for storage.

3.1.1. Loading

Mind following requirements: Fig. 3.1. Airfreight in wooden crate

• Pipes, fittings and prefabricated parts (spools)

must be transported by suitable trucks, having
flat bed floors

• Forklifts may be used for handling provided that

the forks are padded with a protective material
such as rubber or plastic

• Check for and remove any projections, nails

or other sharp edges from the supporting floor
before each load Fig. 3.2. Spool handling

• Any contact of the truck or steel container with

GRE products shall be separated by wood or
rubber

• Avoid direct contact between individual GRE

products during transportation

• Pipes and spools shall be lifted at least at two

points by using nylon or canvas sling belts with
a minimum width of 100 mm. Use the largest
spool diameter to balance the load during the Fig. 3.3. Pipe handling
lift

• Secure materials by wooden wedges and

supports having a minimum width of 100 mm

• Pipe supports shall be spaced at ≈3 m intervals,

minimal 1 m from the ends; the support distance
of nested pipes shall not exceed ≈2 m.

• Tie the products in place by using either nylon or

canvas sling belts
Fig. 3.4. Multiple support spool lifting

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• Chains and steel cables may never be used for

lifting or fixation

• Avoid support on sharp edges

• Fittings can be properly transported in crates or

on pallets

• Flanges must be secured against sliding when

stored on the sealing face
Fig. 3.5. Protected pipe/spool ends
• Pipe ends and machined surfaces must be
protected (e.g. with PE-foil).

3.1.2. Unloading

The client is responsible for unloading ordered material,

unless agreed otherwise.
Mind following:

• Use nylon or canvas sling belts with a minimum

width of 100 mm Fig. 3.6. Dual crane handling

• Standard pipe lengths shall be lifted at minimal

two supporting points

• Fix at least one sling belt around the section with

the greatest diameter

• Unload one (packed) item at a time.

3.2. Storage

In order to avoid damage to GRE products, the following

recommendations shall be respected: Fig. 3.7. Packaging in crates

• Provide a flat and horizontal supporting surface

• Do not store the pipes directly on the ground,

onto rails or concrete floors

• Ensure suitable supports such as clean, nail free

wooden beams

• Pipes shall be carefully stacked

• Machined ends must be protected (e.g. with PE-foil)

• Bell and/or spigot ends may not touch each other Fig. 3.8. Stacked pipe in stock

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• Pipes can be stacked economically by If any damage is observed due to transportation or during
alternating the orientation of spigot- and socket installation (e.g. excessive scratches, cracks) contact the
end supplier.

• Avoid pipe bending by locating supports Never use damaged materials.

between the layers of stacked pipe vertically
above each other

• Supports must be spaced at a maximum interval

of 3 m and ≈1 m from each pipe end

• The allowable stacking height is 1.5 m or 2

layers, whichever is higher

• Product diameters may flatten when stacked

too high and/or too long, specially at elevated
temperature
Fig. 3.9. Pipe stacking
• Long term storage is recommended under
tarpaulins or PE-sheets

• Pipe stacks must have side supports (e.g.

wooden wedges) to prevent rolling or slipping

• Unprotected flange sealing faces shall not be

placed directly on the ground or on supporting
floors

• Spools shall not be stacked

• No other materials shall be loaded on top of

GRE products
Fig. 3.10. Wooden wedge side supports
• Do not drop, walk, or stand on GRE products

• Avoid point loading due to careless stacking.

Raw materials such as O-rings, gaskets, locking keys,

adhesive kits, resin, hardener, woven roving and
lubricants shall be stored in the original packaging, in a
dry environment, at recommended temperatures.

The shelf life of adhesives and resins must be respected.

It is advised to order on demand.

Fig. 3.11. Packing and storage of fittings

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4. Joining systems and preparation methods

For the joining of GRE pipe components, various types of
joints can be used. This section details the characteristics
of each of these joints.

4.1. Conical-Cylindrical bonded joint

This type of adhesive bonded joint consists of a slightly

conical socket and a cylindrical spigot. This joint allows
for an accurate assembly length with narrow tolerance
and may be used for above- and underground pipe
systems.

For this adhesive joint the following tools and materials Fig. 4.1.a. Scheme Conical-Cylindrical bonded joint
are required:

• Gloves, dust mask, safety glasses

• Measuring tape, marker, bench, pipe fitters
wrap around
• Angle cutter, hand saw or jig saw
• Shaver, grinding tools
• Rubber scraper, pulling equipment, adhesive kit
• Heating blanket or air gun, insulation blanket,
digital temperature gauge
• Cleaning brush, non-fluffy cleaning rags,
cleaning fluids. Fig. 4.1.b. Conical-Cylindrical bonded joint

Summarized, the bonding procedure consists of cutting,

cleaning, machining, application of adhesive, joining and
curing.
The installation time depends on proper preparation,
diameter and personnel.
For specific and detailed information, reference is made
to manufacturers’ documentation.

4.2. Taper-Taper bonded joint

Fig. 4.2.a. Scheme Taper-Taper bonded joint
This adhesive bonded joint consists of a conical socket
and conical spigot.
When comparing with the conical-cylindrical adhesive
bonded joint this type of joint is also available in higher-
pressure classes.
For specific dimensions, specific instructions are required.
The tools, materials, joining procedure and installation
time for the taper-taper bonded joint are similar to those
of the conical-cylindrical adhesive bonded joint.

Fig. 4.2.b. Taper-Taper bonded joint

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4.3. Laminate Joint

The laminate joint is used to join plain-ended pipe

sections. After preparation of the pipe surfaces, a specific
thickness of resin impregnated glass reinforcement is
wrapped over a certain length around the pipes to be
joined; the thickness and the length of the laminate are
related to diameter and pressure.

This joint requires following tools/materials:

• Gloves, dust mask and safety glasses Fig. 4.3.a. Scheme laminate joint
• Measuring tape, marker and pipe fitters wrap
around
• Angle cutter, jig saw or hand saw
• Grinding tools and flexible support disc
• Rubber scraper, scissors, brushes, resin,
hardener and glass reinforcement
• Air gun, gas burner or field oven with insulation
blanket and digital temperature gauge
• Cleaning brush, non-fluffy cleaning rags and
cleaning fluids.

The successive activities for a laminate joint are cutting,

sanding, cleaning, mixing, fitting, laminating and curing. Fig. 4.3.b. Laminate joint
For specific and detailed information, reference is made
to manufacturers’ documentation.

4.4. Flange Joint

The flange joint connects appendages and equipment

as well as other lines of different materials. Based on the
application and pressure, several types are available.

For a flange joint following tools and materials are

required:
Fig. 4.4. Flanged joint
• Ring spanner, torque wrench
• Bolts, nuts and washers
• Gasket.

It is of major importance that GRE flanges are aligned

with the counter flange. Excessive misalignment may
cause high stresses, which lead to premature material
failure.
Generally, flange joints facilitate connections with steel
piping and allow easy assembly and disassembly of
piping systems.
For specific and detailed information, reference is made
to manufacturers’ documentation. Fig. 4.5. Flange detail

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4.5. Mechanical O-Ring Lock Joint Specific information can be obtained from the supplier of
the coupler.
The mechanical O-ring lock joint is a tensile resistant The joining necessitates the use of an Allen key, torque
type of joint. This restrained type of joint can be used in wrench and a ring spanner.
unrestrained environments, e.g. aboveground.
The following tools and materials are required to make
such a joint:

• Pipe clamps and pulling equipment

• Lubricant, O-ring, locking key(s) and plastic
or wooden mallet to drive the locking key in
position
• Non-fluffy cleaning rags and cleaning fluids.

The assembly procedure starts with cleaning and

lubricating surfaces, then mounting clamps, aligning, Fig. 4.6. Mechanical O-ring lock joint with two keys
pulling the spigot in the socket and mounting the locking
key(s). The joint can be disassembled, but is not designed
as such.
For specific and detailed information, reference is made
to manufacturers’ documentation.

4.6. Mechanical O-Ring Joint

The mechanical O-ring joint is a non-tensile resistant type

of joint. This unrestrained type of joint can be used in a
restrained environment, e.g. underground. Fig. 4.7. Mechanical O-ring lock joint with one key
This type of joint is made with the following tools and
materials:

• Pipe clamps and pulling equipment

• Lubricant, O-ring
• Non-fluffy cleaning rags and cleaning fluids.

Joining starts with cleaning and lubricating surfaces; then

mounting clamps, aligning and pulling of the spigot in the
socket.
For specific and detailed information, reference is made
to manufacturers’ documentation. Fig. 4.8.a. Scheme mechanical coupler

4.7. Mechanical Coupler

Generally, mechanical couplers are used for joining plain-

ended GRE pipes to pipes made from other materials. A
step coupler can join pipes with different outer diameters.
This type of joint is unrestrained. These couplers can also
be used for preliminary repairs.

Fig. 4.8.b. Various mechanical couplers

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5. Tools and materials

For details on tooling and materials, reference is made to
manufacturers’ detailed documentation.

5.1. Tools

Tools are divided in two main categories:

non-consumables and consumables.

5.1.1. Non-consumables

Non-consumable tools can be used multiple times. Fig. 5.1. Shaver set

5.1.1.1. Shaver

A GRE pipe shaver is a custom designed tool, which is

used to prepare a spigot end for an adhesive bonded
joint on a pipe. Pipes are standard supplied with the
appropriate end figuration, but an adjustment to length at
site requires shaving of a spigot in the field.

The shaver is mounted on an arbor.

The arbor is mounted and centred in the pipe and fixed
against the inner surface of the pipe by expanding the
diameter.
The shaver arm rotates around the central shaft of the
arbor; the machining tool shapes the spigot end. Fig. 5.2. Shaving of a spigot end

5.1.1.2. Heating blanket

Heating blankets are designed to cure adhesive bonded

and laminated joints.
Blankets are made from a coiled resistance wire, which is
sandwiched between two layers of silicon rubber.

To control the temperature, each blanket is furnished with

a thermostat.
It is important to store the heating blanket properly in
order to keep this tool in an optimal condition.

Heating blankets shall never be folded; these blankets

may only be stored flat or rolled. Fig. 5.3. Heating blanket

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5.1.1.3. Pullers and band clamps

Pullers and band clamps are used to make Taper-Taper

adhesive bonded joints, large diameter Conical-
Cylindrical bonded joints and mechanical O-ring (lock)
joints.

Band-clamps with pulling lugs must be applied at both

pipe ends to be joined. The positions of the pulling lugs
shall face each other.

The Taper-Taper joint must be kept under tension until

curing of the adhesive is completed to avoid joint
detachment.

Rubber protection pads are placed underneath the Fig. 5.4. Pulled adhesive joint
ratchets before tightening the band clamps. Put a wooden
wedge between the pipe and the pulling lug to create a
gap for mounting of the heating blanket.
For bonding of large diameters 3 to 4 pullers are
required. Check the pullers on defects on a regular base.

5.1.1.4 Others

Other non-consumables may be required such as:

• Air gun, gas burner or field oven

• Angle cutter, hand saw or jig saw
• Pipe fitters wrap around
• Grinding tool
• Insulation blankets
• Digital temperature gauge
• Generator. Fig. 5.5. Curing of adhesive joint under tension

5.1.2. Consumables

Consumable tools can only be used once.

Following tools are supposed to be consumable:

• Measuring tape
• Pair of scissors
• Marker
• Sand paper/grinding discs P40 – P60
• Brushes
• Rubber scrappers, bucket
• Cleaning fluids, joint lubricant
• Dust masks, gloves and safety glasses.

Fig. 5.6. Consumables

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5.2. Materials

5.2.1. Adhesive

Different types of adhesive are available depending on

the application. Adhesive can be conductive or non-
conductive.

An adhesive kit contains resin, hardener, mixing spatula

and bonding instructions.
Adhesive kits contain chemicals that are sensitive to
temperature and moisture.

It is important to check the expiry date of the adhesive,

which is printed on the package.
Do not use adhesive or resin after indicated expiry date. Fig. 5.7. Adhesive kit

5.2.2. O-ring

A rubber O-Ring provides the sealing of the mechanical

O-ring (lock) joint. Standard O-rings are made of Nitryl
Butadiene Rubber (NBR).

Depending on the medium and/or temperature, other

types of rubber can be supplied.

O-rings must be stored properly and flat, in a dry, cool

and dark environment, free from dust and chemicals,
which may attack the material.

Direct sunlight must be avoided.

Fig. 5.8. O-rings

5.2.3. Locking key

Locking keys block the longitudinal displacement of the

spigot in the socket of a mechanical O-ring lock joint.
Locking keys must be stored in a dry and cool location
without direct exposure of sunlight. Improper storage may
affect the mechanical properties negatively. For further
details, reference is made to manufacturers’ detailed
documentation.

Fig. 5.9. Locking keys

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5.3. Check of incoming material 5.3.2. Quantity check

5.3.1. Quality check
The condition of containers, crates, boxes and pallets
must be checked on possible damage upon arrival. If
damage has occurred to any material package, the
contents might be damaged too.
Check pipes and fittings on impact damage. Materials
and tooling must be dry at arrival.
Check the delivered quantities and the reported quantities
on the packaging list. The recipient is advised to check
the contents of the deliveries.
Quantity, size and configuration of materials and
products should be physically checked against the data
on the packing list.
Any deviation from the packing list must be reported
immediately.

The damaged state of materials and/or products when

delivered must be reported and documented (e.g.
clarified with pictures). Damaged materials shall be
separated and quarantined from undamaged materials to
avoid unintentional use.

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6. Installation of underground pipe systems

GRE pipes are used for various applications in various
soils conditions.
Underground pipeline systems require accurate trench
structuring, product assembly and installation.
For detailed information about underground installation,
reference is made to manufacturers’ documentation.

6.1. Trench construction

The trench construction highly depends on the soil

parameters, such as type, density and moisture content.
The construction of the trench should comply with
following requirements and recommendations:
Fig. 6.1. Trench in unstable soil
• The trench shape is determined by the
classification of the soil, which can be unstable
or stable

• Top sides of the trench must be cleared from

rocks or any other sharp/heavy materials

• The trench foundation shall consist of a

compacted sand layer without stones or sharp
objects

• Loosen a hard and uneven trench foundation in

order to prevent point loading

• Keep the trench dry during installation; if

necessary use of a pumping system and Fig. 6.2. Trench in stable soil
drainage

• The minimum width (W) at the bottom of the

trench for a single pipe shall be:
W = 1.25 * OD + 300 mm

• The space between the pipe and the trench

wall must be 150 mm wider than the used
compaction equipment

• Respecting pipe stiffness, operating conditions,

soil characteristics and wheel load the minimum
burial depth is 0.8 m

• The crown of the pipe must be installed below

frost level. Fig. 6.3. General scheme of trench construction

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6.2. System assembly • Standard pipe lengths may be doubled in order

to reduce the installation time
The assembly procedure of a piping system may vary per
project. Generally, this procedure deals with positioning • Ensure sufficient space around joints for proper
and joining of components in the plant. alignment and joining

• Keep the system centred in the trench

6.2.1. Positioning components in the plant

After positioning of the pipe system elements next to the

trench, these components have to be handled into final
position in the trench.

• Small diameter pipe sections can be lowered

manually using ropes, slings or light lifting
devices

• Large diameter piping requires heavier

equipment during final positioning

• To avoid damage the minimum bending radius

of a pipe shall be respected

• Avoid unwanted objects falling into the trench Fig. 6.4. Assembly in process
during lowering pipe sections

• Use nylon sling belts or special designed

equipment during product handling.

6.2.2. Joining of components

Respect next requirements and recommendations for

joining of underground pipe systems:

• Inspect all products before installation

• Components with mechanical O-ring joints shall

be assembled in the trench

• Adhesive bonded and laminated joints can be

assembled either inside or outside the trench

• Never move or disturb a joint during the curing

process

Fig. 6.5. Assembly in the trench

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• Respect the allowable joint angular deflection

and pipe bending radius

• Bending of a joint shall be avoided unless

allowable by system design

• Changes in directions in non-restrained pipeline

systems must be anchored

• Ensure stretching of the O-ring lock joints; this

prevents axial displacement of the pipeline and
overloading of fittings when pressurising the
system

• The pipeline can be stretched by pressurizing at

0.8 * operating pressure. Mechanical stretching
is recommended. Precautions shall be taken to
avoid overloading of fittings

• Branches shall be left free or are installed after

stretching of the header completely.

6.3. Backfilling

Backfilling shall be performed according standard

procedures. Trench filling, proper compaction and
stabilizing of the system shall be performed in
accordance with the requirements.

6.3.1. Procedure and requirements

The procedure and the requirements comprise:

• Temporary installation devices must be removed

prior to backfilling Fig. 6.6. Scheme trench construction stable soil

• The maximum particle size for pipe zone

embedment is related to the pipe diameter and
is described in the backfill material specification

• Dumping large quantities of backfill material at

one spot on top of the pipe may cause damage;
spread the applied backfill material

• Backfill material shall be compacted in layers of

150 mm. The pipe may not be displaced due to
backfilling

Fig. 6.7. Scheme trench construction unstable soil

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• When reaching a compaction height of 0.3 * ID

below the crown of the pipe, compaction may
be continued in layers of 300 mm

• Each layer of backfill shall have a compaction

grade of at least 85 % Standard Proctor Density
(SPD)

• Compaction is performed on both sides of the

pipe, never across the pipe. A vibrating plate
with an impact force of 3000 N is used

• Do not use heavy pneumatic hammers or

vibrating equipment until having reached a
backfill level of 500 mm over the crown of the
pipe

• Avoid any contact between compaction tools

and GRE-product. Fig. 6.8. Pipe assembly in process in prepared trench

6.3.2. Backfill material specification

For classification of various backfill materials and types of

embedment, reference is made to AWWA Manual M45
or ASTM D 3839.

Note that highly plastic and organic soil materials are

not suitable for backfilling and must be excluded from the
pipe zone embedment.

6.3.3. Other backfilling methods

Use of the saturation method does not give any better

result than the above-described method.

The grade of compaction is lost if compaction by

saturation is performed after mechanical compaction.
When saturating the trench, avoid floating of the pipeline
as well as erosion of the side support. Do not backfill if
the ground is already saturated.

The saturation method may only be used for free draining

soils, when the drainage pumps are kept in operation and
the pipe system is completely filled with liquid.
Fig. 6.9. Compaction of backfill material

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6.4. Special underground installations 6.4.1.4. Pipe stiffness

Road crossings and channel crossings demand particular Pipes with higher stiffness are better resistant to external
attention and requirements. loads due to traffic loads. Stiffness of pipe can be
increased by increasing the wall thickness.

6.4.1. Road crossing

Precautions shall be taken to protect pipes, which cross

underneath roads against the possible consequences of
traffic loads.
Possible alternatives are:

• Jacket pipe
• Relief plate
• Burial depth
• Pipe stiffness.

6.4.1.1. Jacket pipe

The GRE pipe is nested in a jacket pipe. In order to avoid

direct contact between both pipes, spacers centre the
GRE pipe. These spacers also support the GRE pipe at
a maximum distance of 3 m. The jacket pipe should be
longer than the width of the road.

6.4.1.2. Relief plates

Relief plates are used if pipes are installed at shallow

depth in well compacted sandy soils or in case the
soil- and traffic load cause an excessive loading or Fig. 6.10. Jacket pipe at road crossing
deformation of the GRE.
The plate is specially designed and dimensioned to
minimise the transfer of wheel load on the pipe.

6.4.1.3. Burial depth

Generally, the influence of the wheel load of traffic

passing a buried pipe reduces with increasing burial
depth.
However, with increasing burial depth the soil load on the
buried pipe increases.
Our engineers may assist to determine an optimal Fig. 6.11. Relief plate
solution.

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6.4.2. Channel crossing

The common method to install underwater mains is to

assemble the pipe on the bank of the canal or river. The
pipe can be lowered using a floating crane or other lifting
equipment; care should be taken to ensure sufficient pipe
supports.

The process starts by sealing the ends of the pipe and

pulling the system into the water; the pipe keeps floating.
Then, the pipe is filled and carefully sunk into its final
position.

Flexible joints can be used for underwater piping if the

installation is performed using a cofferdam construction;
this makes the installation similar to an onshore assembly. Fig. 6.12. Lowering underwater main

Note that underwater pipes should be covered sufficiently

to prevent floating and damage (e.g. by anchors).

6.5. Alignment

Undulating land levels with minor difference in height can

be followed by the flexibility of the system.
Joints or pipe bending, if assessed by system design,
ensures no lateral displacement while allowing angular
deflection.

6.6. Settlement
Fig. 6.13. Pipe alignment
Flexible joints have to be installed in pairs; one joint is
placed at the beginning of the deviation while the other is
located at the end of this area, in order to create a rocker
pipe. The rocker pipe will act as a hinge.

The longer the rocker pipe, the higher the loads on the
joints. This can be avoided by adding more joints that
are flexible. Based on the soil parameters, the number of
joints is determined.

Note that the length of the sections shall be limited in

order to avoid excessive bending which may result in
failure of pipe or joint.
The section length = ID + minimal 0.5 m. Mechanical Fig. 6.14. Settlement
O-ring joints shall be installed at both ends to
accommodate further settlements.

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6.7. Pipe cast in concrete

In some cases, pipe systems may be cast in concrete.

Such applications require following:

• Do not pour concrete directly onto pipe

• The vibrating poker must be kept at least 300
mm away from the pipe
• The pipe system must be pressure tested prior to
casting
• Cradles are provided with steel clamps and
rubber lining in order to prevent floating
• Buckling of the pipe during casting can be
prevented by pressurizing the system.

Note that concrete shrinks when setting; this may result

in extra loading of the GRE pipe system. Ensure that the
allowable pressure is not exceeded by using pressure Fig. 6.15. Pipe cast in concrete
relief valves.

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7. Installation of aboveground pipe systems

Aboveground pipe systems may be subjected to various
loadings resulting from operation of the system.
Next to the information in this section, reference is made
to specific manufacturers’ documentation.

7.1. Supports

Supports not only provide system fixation, loading

relief and clinching, but protection. Prior to installation,
supports are checked for location, type and span as
detailed in drawings and specifications of the project.
Supports can be differentiated as fixed, guided sliding
and free sliding supports.

Fig. 7.1. Aboveground pipe system

7.1.1. General

Functional pipe supporting can be obtained with the aid

of system design analysis.
Following aspects need to be respected:

• Pipes resting on sleepers are supplied with 180°

saddles, which are bonded to the pipe at the
support location to protect the pipe against wear
damage from possible pipe movements

• The length of the wear saddle must be 50 mm

longer than the calculated pipe displacement
plus the support width

• Allow pipe expansion within a clamp

Fig. 7.2. Pipe supports
• In vertical pipe assemblies, the sockets of O-ring
joints shall point downwards, so water cannot
be trapped in the socket.
Entrapped water in the socket may cause joint
damage when freezing

• For clamp dimensions, reference is made to

manufacturers’ detailed documentation

• Mechanical O-ring joints require minimal one

support per pipe length.
The distance of the support to the joint is
maximal 20 % of the pipe length.

Fig. 7.3. Overhead supports

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7.1.2. Fixed support points

Fixed points may never be realized by tightening the bolts

of the pipe clamps. This may lead to pipe deformations
and excessive wall stresses.

Mind the following requirements for fixed points:

• Fixation saddles shall be positioned on both

sides, at the shoe side of the clamp

• Laminated fixation saddles shall be applied on

both sides of the clamp

• When using non-restrained jointing systems each

pipe shall be fixed Fig. 7.4. Support with fixed point

• Each change of direction in a non-restrained

pipeline shall be anchored to prevent pipe joints
coming apart

• Check whether the positions of pipe supports

are still in accordance with the installation
requirements after testing. The supporting
elements might be dislocated due to test
pressure.

Note that the mechanical O-ring lock joints must be

fully stretched to avoid movement of pipe sections and
consequently possible overloading. For further details
on this type of joint, reference is made to manufacturers’
documentation.
Fig. 7.5. Fixed point with bonded saddles

Fig. 7.6. Collars on both sides of the pipe clamp

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7.2. Pipe clamps

Various types of pipe supports are available.

Following considerations must be respected:

• Avoid point loads by using clamps made of flat

strips instead of U-bolts.
The width of the strip is related to the pipe
diameter. For large diameter pipe double
clamps may be applied

• The inside of the clamp is furnished with a

rubber or cork liner to compensate the uneven
pipe outer surface and to minimise abrasion due
to pipe movement and vibration

• Longitudinal movement in the clamps is not

advised. Generally, movement between the Fig. 7.7. Overhead supported pipeline
clamp shoe and the support structure shall
realize sliding of supports.

For detailed information on clamps, reference is made to

manufacturers’ documentation.

7.3. Valves

To avoid overstressing of pipes by the weight of valves

or other heavy equipment it is advised to support pipe
accessories on the flange bolts.

The load on the pipeline by operating the valve shall be

carried by the support of the pipe structure. In case of a
GRE flange mounted against a steel flange, the support is
preferably fixed to the steel flange. Fig. 7.8. Double pipe clamp

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7.4. Bellows

GRE products can absorb low amplitude vibrations due to

the flexible properties of the composite material.
To eliminate high amplitude vibrations caused by e.g.
pumps and to compensate soil settlement or expansion of
e.g. tanks joined with pipes, bellows can be applied.

Bellows facilitate dismantling of pipe sections, valves,

orifice flanges and gaskets. This equipment also
absorbs pipe movements due to cyclic pressure and/or
temperature in pipe systems that are joined with relatively
stiff adhesive bonded joints.

In many cases, bellows are directly joined to the vibrating

item by means of flanges. Note that the pipe section next Fig. 7.9. Bellow
to the bellow shall be supported separately to absorb the
pipe loads.

7.5. Pipe connections through walls

Several alternatives are available for passing pipes

through walls. In case of anticipated settlement of the wall
or pipeline, flexible couplings must be installed on both
sides of the wall.
The joints shall be positioned as close as possible outside
the wall.

7.5.1. GRE pipe with sealing puddle flange

The factory made puddle flange consists of a GRE ring, Fig. 7.10. Puddle flange
which is laminated on the pipe.

7.5.2. Sand coated GRE pipe

A sand coating on a GRE pipe offers an excellent

adhesion between concrete and GRE.

Fig. 7.11. Sand coated GRE pipe casted in concrete

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7.5.3. Link seal

This type of wall penetration consists of several linked

rubber parts, which fit in the circular space between the
outer surface of a GRE pipe and the diameter of a hole in
a wall.
A sufficiently smooth inner surface of the wall can be
obtained by:

• Mounting a steel pipe section with water seal

before pouring mortar

• Drilling a hole with a crown drill having

diamond inlays

• Fixing a removable plastic casing pipe section Fig. 7.12. Sketch link seal
before pouring mortar.

The rubber parts are linked together with bolts and form
a rubber chain. The rubber sections are compressed by
tightening the bolts.
All components of the link seal can be made of various
material qualities.

Link seals allow for some angular deflection and lateral

movement. After having mounted the GRE pipe in the link
seal the rubber elements are compressed by tightening
the bolts evenly. The expanded rubber sections seal the
room between GRE and concrete.

7.5.4. Special sealing shape

Fig. 7.13. Link seal
This wall penetration consists of a steel pipe, which is
provided with flanges. One of the flanges is profiled to fit
a sealing element.
By tightening the nuts, the seal is compressed in the
annular space between the flange and the pipe and
provides an excellent seal.

Fig. 7.14. Special sealing shape

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7.5.5. Plain wall passing

When passing a pipe through a wall, the outer surface of

the pipe must be protected with a flexible material, e.g.
a 5 mm thick rubber layer, protruding 100 mm at both
sides of the wall.

7.6. Joining with other materials

The most appropriate method to join objects of different

materials is by using a flange. A mechanical coupler
might be an alternative. For details about these joints,
reference is made to manufacturers’ documentation.

Flanges can be drilled according most of the relevant Fig. 7.15. Plain wall passing
standards. When a flanged GRE pipe section is
joined with a metal pipe section, the metal section
must be anchored to avoid transmission of loads and
displacements to the GRE pipe sections.

Instrument connections can be made using a saddle and

a bushing.

7.7. UV-resistance

The topcoat of GRE pipes and fittings consist of a resin

rich layer. This layer offers sufficient protection against
UV-radiation.
When exposed to weather conditions the epoxy topcoat
may be attacked on the long term; this may result in a
chalked outer surface.

After several years of operation, the chalked layer may

be removed and replaced by a resistant, protective
polyurethane paint coating.
Contact the manufacturer for advice. Fig. 7.16. Joining to other materials

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8. Quality Control/Quality Assurance 8.2. Joint traceability

8.1. General As part of the quality control and on behalf of the

To assure good workmanship, only qualified and certified
personnel shall be allowed to work on the installation of
GRE pipeline systems.
Always strictly follow the installation manuals next to the
necessary instruction guidelines. When making joints, it
is necessary to execute the required steps in the correct
sequence.
Never compromise on work quality and follow the
instructions assigned from handling and storing through
joining and installing GRE materials.
traceability of adhesive bonded joint data, the following
information should be registered during installation for
each joint:
1. Name or registration info of the pipe-fitter
2. Joint identification (number)
3. Start/end of the curing process
4. Heat blanket identification (number)
5. Identification (number) of adhesive batch
6. Temperature of heating blanket (optional).

8.3. Possible installation defects

Following table lists a number of defect types along with acceptance criteria and recommended corrective actions:

Table 8.1. Defect, acceptance criterion, corrective action

Inspection Corrective
Defect Cause Acceptance criterion
method action

Can difference be compensated Accept

Incorrect spool
Visual Incorrect prefabrication elsewhere in the system?
dimensions
Can system not be compensated? Reject

Can difference be compensated Accept

Misaligned
Visual Misaligned components e.g. flanges elsewhere in the system?
spools
Can system not be compensated? Reject

Misaligned Movement during cure.

Visual Not permitted Reject
joint Incorrect shave dimensions

Maximum height (h) of adhesive If accessible,

Diameter restriction Visual Application of too much adhesive seam is 0.05 * ID or 10 mm, whi- remove by
chever is smaller grinding
Major defect:
Impact, wear, According to ISO 14692, replace
Visual Incorrect transport or handling
or abrasive damage Annex A, Table A1 Minor defect:
Repair

Leaking joint Hydro test Joining not properly performed Not permitted Reject

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9. Field Test Procedure
9.1. General
Before the installed pipeline system is operational, the
system has to be hydro tested to ensure the integrity and
leak tightness. Hydro testing of the pipeline system will be
performed in two steps:
1. Integrity test
The test pressure shall be increased over an
agreed duration at an agreed pressure level in
order to prove the maximum pressure resistance
of the system.
2. Leak tightness test
The test pressure shall be increased to an agreed
pressure level at which the joints can be inspected
visually.
Pressure level and test duration can be stated in an
Inspection and Test section of the Site Quality Plan.
All safety precautions must be applied.
It is important to test the integrity of the system first, to
avoid the risk of injury during visual inspection.
All pressure gauges and pumps must be suitable and
calibrated. Ensure that the pipeline can be vented and
drained.
The pressure gauge must be mounted between a valve
and the pipeline system in order to indicate the test
pressure in the GRE system after having closed the valve,
which is mounted after the pump.
Due to the head of water, the pressure gauge should be
located at the lowest point in the system. The pressure
gauge should have a maximum scale reading of
approximately twice the test pressure.
If the system is not designed to withstand any negative
pressure, which might occur during testing, then the
system needs to be protected by an air release valve.
Trapped air should be released by using vent(s).
The application of GRE pipeline systems may vary from
long, (buried) line pipe applications to small skid piping
systems.
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Joint types might vary from laminate joints to mechanical
joints with O-ring seal, with or without locking strip.
Each system requires its specific testing method. For each
system, the test procedure has to be described in the
Inspection and Testing Plan (ITP) of the Site Quality Plan.
This ITP must be established before the project starts.
The advices for testing mentioned in the following
paragraphs are for guidance only and are not
mandatory.
9.2. Preparation
Prior to hydro testing, the following issues shall be
checked:
• All material that should not be on the inside of
the pipeline system shall be removed
• All joining procedures shall be completed
• Trenches should be partially backfilled and
compacted; the joints should be left exposed
• All supports, guides, and (temporary) anchors
shall be in place and functional before
pressurizing the system
• All temporary supports and installation aids shall
be removed
• Unless stated otherwise, all valves should be
through-body tested
• All check valves shall be removed to enable
monitoring of the full line
• Flange bolts shall be made up to the correct
torque
• Buried pipe systems must be backfilled
sufficiently to restrain the system
29

9.3. Filling, stabilizing, testing and
depressurizing
9.3.1. Filling and stabilizing
Fill the pipeline at the lowest point with water using a
small diameter branch connection and vent the trapped
air at the highest point(s) of the system. Long straight
sections may be vented using an inflatable ball or foam
pig to expel any air and impurities.
Fig. 9.1. Various pipe pigs
After filling, the line is pressurized gradually up to 0.8 *
Design Pressure; the pressure shall be maintained for 24
hours in order to allow the system to set and the pressure
to stabilise. For small above ground systems, it is allowed
to reduce the stabilising time.
9.3.2. Testing
Once the pressure is stabilised, the integrity of the pipe
system is tested first in accordance with agreements.
Depending on the system a pressure drop might occur.
In all cases, leakage of joints, pipes or fittings is not
allowed. For safety reasons, an inspection of the system
because of a possible leakage is not permitted when the
pipeline is loaded at integrity test pressure level. This has
to be mentioned in the ITP.
When the integrity test has been completed successfully,
depressurise the system to leak tightness test pressure
level. Duration of the leak tightness test normally depends
on the time needed to inspect all joints, pipes and fittings
visually.
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It is preferable to test the line in sections, for example
the length of one-day installation. The line is temporarily
closed using, e.g. a test plug and a flange at the end. The
blind flange should be provided with an air release valve.
Fig. 9.2. Field testing
After testing of the installed section the test plug, needs
to be pushed back about 2 meters by pressuring air via
the air release valve. The excess water is released by
opening the valve at the begin of the line. After securing
of the test plug, e.g. by inflation, the temporary flange
connection can be removed and the assembly may
proceed. The advantage of this method is that the test
medium stays in the tested section and does not need to
be re-filled for hydro testing of the next section.
Any leak caused by incorrect assembly of the joint can be
detected easily.
Extreme movements can be prevented by partially filling
and compacting of the trench.
Note that temperature changes over a 24 hours period
will affect the pressure in a closed system.
A drop in pressure during the night does not always
indicate that there is a leak in the system. When testing a
system the ambient temperature should be measured.
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GRE material behaves different from steel due to the low
weight, the flexibility of the joint and elasticity of the
material.
In case of a failure during hydro testing, the line will
move due to the sudden release of stored energy; there
might be a risk of injury to personnel.
Note that testing with air or gas is extremely dangerous
and should be avoided. Systems shall never be tested
with an inflammable fluid or gas.
The manufacturer of GRE pipe systems does not take any
responsibility for any damage resulting from the use of
these methods.
The following causes may affect pressure drop and
consequently result in hydro test failures:
• Leakage of pipeline accessories
• Leakage of gaskets
• Leaking joints
• Leakage of pipes.
The system shall be considered to have passed the hydro
test if there is no leaking of water from the piping at any
location and there is no significant pressure loss that can
be accounted for by usual engineering considerations.
10. Repair
In the unlikely event, GRE pipes, joints and/or fittings may
have to be repaired. Repair on the pipeline system shall
be performed according described instructions.
The repair procedure shall be prepared and qualified by
the contractor in accordance with the pipe manufacturer’s
recommendations. It shall be demonstrated that the repair
method restores the specified properties.
Leaks in pipe, fittings and joints are repaired by replacing
the defective part. In some cases, especially for buried
systems, insufficient space and/or difficult accessibility to
pipes and fittings may occur.
Each application of a GRE pipe system and each type
of product or design requires a different repair and/or
replacement procedure.
For further details, reference is made to manufacturers’
documentation.

9.3.3. Depressurising

Depressurisation of the system must be carried out

carefully to avoid a negative pressure.

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11. Tolerances
It is recommended to consider and use the dimensional tolerances illustrated and figured below.

Tolerances to Dimensional Reference

Internal Diameter (mm) A B C D E F

25 – 200 ± 5mm ± 3mm ± 0.5° ± 3mm ± 1mm ± 0.5°
200 – 300 ± 5mm ± 3mm ± 0.3° ± 3mm ± 1mm ± 0.5°
350 – 400 ± 5mm ± 3mm ± 0.3° ± 3mm ± 2mm ± 0.5°
450 – 600 ± 10mm ± 5mm ± 0.3° ± 3mm ± 2mm ± 0.5°
700 – 900 ± 10mm ± 5mm ± 0.2° ± 4mm ± 3mm ± 0.5°
1000 – 1200 ± 10mm ± 5mm ± 0.15° ± 6mm ± 3mm ± 0.5°
The maximum gap shall be limited to 6 mm.

Dimension A
a. Face to Face dimensions
b. Center to Face dimensions
c. Location of attachments
d. Center to Center dimensions

Dimension B
Lateral transition of branches or connections

Dimension C
Rotation of flanges, from the indicated position

Dimension D
End preparations

Dimension E
Cut of alignment of flanges from the indicated position,
measured across the full gasket face

Dimension F
Angular deflection

Fig. 11.1 Tolerances

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Wavistrong Instalation Guide for GRE Pipe Systems
 WAVISTRONG
Installation
Guide

12. Safety precautions 12.2. Cutting, shaving and sanding

The following safety precautions should be respected
when using GRE products.
The required rescue and safety measures when using
resin and hardener for adhesive or lamination sets are
shown under the R- and S- code numbers, which are listed
in manufacturers’ documentation.
12.1. Resin, hardener, adhesive and
lamination sets
In order to avoid irritation of the respiratory system,
satisfactory ventilation should be provided. If a system is
hydro tested, adequate safety precautions must be taken,
as a “safe test pressure” does not exist. Any pressure in
itself is dangerous.
Experienced personnel must operate the test equipment.
Persons not involved in the test or inspection are not
allowed in the immediate area of the tested system. Only
one person should be in charge and everyone else must
follow his/her instructions.
When cutting or grinding GRE materials the following
personal protection is necessary to protect eyes and skin:
• A dust mask covering nose and mouth
• A pair of safety goggles
• Gloves and overall
• Close overall sleeves with adhesive tape to keep
the dust out
• Wear protective clothing to protect the body
• Machining should be carried in a well-ventilated
room or in open air.
12.3. Environment
Always clean up the work area. GRE and cured adhesive
are chemically inert and do not have to be treated as
chemical waste.
Waste shall always be disposed in an environment
friendly manner.

Do not change anything on the pipe system when it is

under pressure. Leaking joints may only be repaired after
the pressure has been fully released.

The test equipment must be installed at a safe distance

from the connection to the pipe system.
If welding needs to take place, the GRE material must be
protected from hot works.

Fig. 12.1. Personal protective equipment

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Wavistrong Instalation Guide for GRE Pipe Systems 33
 INSTALLATION FOR UNDER GROUND PIPE SYSTEM

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 INSTALLATION GUIDE FOR
UNDERGROUNG PIPE SYSTEM

Date Issued: 01/November/2010

FS TCD 002 E rev.0 20101101
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 ABOVEGROUND INSTALLATION MANUAL

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 Date Issued: 01/August/2010
FS TCD 001E rev.0 20100801
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 Table of Contents
1 Introduction 2
1.1 General 2
1.2 Product Range 2
1.3 Applicable International Codes and Standards 2
2 Pipe Construction 3
2.1 General 3
2.2 Resins 3
2.3 Thickness Calculations 3
3 Physical And Mechanical Properties 5
3.1 Tolerances on Dimensions 5
3.2 Flow Characteristics 5
3.3 U.V. Resistance 5
4 Lamination (Butt Wrap) Joints 5
4.1 Preparation 5
4.2 Cutting Procedure 6
4.3 Lamination 6
5 Flanged Joints 9
5.1 General 9
5.2 Determination of the Bolt Lengths 10
5.3 Flange Drilling Standards 10
5.4 Gaskets Types 11
5.5 Notes 13
5.6 Tightening of Flanges 13
6 Fiberstrong® Rubber Seal Lock Joint 15
6.1 Guidelines for the Installation of Fiberstrong® RSLJ Joints 15
6.2 Guidelines for the Dismantling of Fiberstrong RSLJ Joints
®
18
7 Handling of Fiberstrong Material: Transport and Storage
®
19
7.1 Receiving 19
7.2 Pipe Offloading 19
7.3 Storing Fiberstrong® Pipes on Site 20
8 Accessories 22
8.1 Pipe Supports 22
8.2 Valves 24
8.3 Bellows 25
8.4 Connection to Other Materials 25
8.5 Pipe Connections Through Walls 26
9 Field Test Procedure 28
9.1 Filling, Stabilizing, and Testing 28

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 1 Introduction 2. Pipe Construction
1.1 General 2.1 General
Fiberstrong® pipes for aboveground applications are Glass Reinforced Plastics (GRP) The pipe is a composite laminate consisting of a corrosion resistant liner, a structural layer
consisting of a thermosetting chemical–resistant resin and fiberglass reinforcements. and an exterior resin rich layer.

GRP pipes are flexible, corrosion resistant and can be used for a wide range of
applications, such as cooling water, industrial waste water and effluents, fire water lines,
seawater lines, acid cleaning and chlorination lines.

1.2 Product Range

Fiberstrong® pipes are manufactured using the continuous or the reciprocal filament
winding process, according to the International Standards listed below, with nominal
internal diameters ranging from 25 mm up to 4,000 mm.
Fig. 1: Fiberstrong® Pipe structure
Available standard pressure classes are 4, 7, 10, 12 and 16 bar. Higher pressure classes
are available upon request. Additionally, Fiberstrong® pipes can be designed for use 2.2 Resins
under full–vacuum conditions as well as for underground applications. The type of resins used in the manufacturing of Fiberstrong® pipes are given in
Table 2. Generally, pressure and temperature requirements govern the resin system
1.3 Applicable International Codes and Standards selection; therefore, maximum service temperatures can change depending on the service
Standard Title requirements. For more information please consult FPI Engineers.
ASTM D 2996 Standard Specification for Filament–Wound “Fiberglass”
(Glass– Fiber–Reinforced Thermosetting–Resin) Pipe. Resin System
ASTM D-3262 Standard Specification for “Fiberglass” (Glass-Fiber-Reinforced Liner Structure
Thermosetting-Resin) Sewer Pipe. Isophthalic Polyester Isophthalic Polyester
ASTM D-3517 Standard Specification for “Fiberglass” (Glass-Fiber-Reinforced Epoxy based Vinyl Ester Isophthalic Polyester
Thermosetting-Resin) Pressure Pipe. Epoxy based Vinyl Ester Epoxy based Vinyl Ester
ASTM D-3754 Standard Specification for “Fiberglass”(Glass-Fiber-Reinforced
Table 2: Resin Systems
Thermosetting-Resin) Sewer and Industrial Pressure Pipe.
AWWA C-950 Fiberglass Pressure Pipe. 2.3 Thickness Calculations
AWWA M-45 Fiberglass Pipe Design Manual. The pipe minimum reinforced wall thickness, tE, is the largest of:
ASME B31.1 Power Piping.
A. Pressure Requirement
ASME B31.3 Process Piping.
The pipe structural wall thickness needed to meet the pressure requirement is:
ISO 14692 Petroleum and Natural Gas Industries - Glass-Reinforced
Plastics -Piping.
BS EN 1796 Plastics Piping Systems for Water Supply With or Without
Pressure - Glass-Reinforced Thermosetting Plastics (GRP) Based Where:
on Unsaturated Polyester Resin (UP). tp = Structural wall thickness (mm)
BS EN 14364 Plastics Piping Systems for Drainage and Sewerage With P = Design pressure (MPa)
or Without Pressure - Glass-Reinforced Thermosetting D = Pipe internal diameter (mm)
Plastics (GRP) Based on Unsaturated Polyester Resin (UP) - σh = Allowable hoop stress (MPa)
Specifications for Pipes, Fittings and Joints.
Table 1: Applicable International Standards

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 3. Physical and Mechanical Properties
B. Stiffness Requirement 3.1 Tolerances on Dimensions
The pipe structural wall thickness needed to meet the stiffness requirement is: Dimension Specification Tolerance
Pipe Inside Diameter (ID) Equal to DN 4 mm or 1.0% whichever is
smaller

Where: Length 3, 10 or 11.8 meters ± 25 mm

ts = Pipe structural wall thickness (mm) Roundness Deviation Pipes shall be round +1.0%
Dm = Pipe mean diameter (mm) End Squareness and End Ends shall be both square Not more than 2 mm +
S = Pipe specific tangential initial stiffness (Pa) Plainness to axis of the pipe and 0.005 x DN
EHF = Structural hoop flexural modulus (MPa) plane
Table 3: Tolerances
C. Buckling Requirement
The pipe structural wall thickness needed to meet the buckling requirement depends on the 3.2 Flow Characteristics
pipe installation. Pipe wall friction factors:
• Darcy, Fanning, Weisbach f = 0.010 to 0.018
I. Buried Installation • Hazen Williams C1 = 130 to 150
If: • Manning n = 0.0095 to 0.012

3.3 U.V. Resistance

Fiberstrong® pipes contain a U.V. inhibitor in their structure. This layer offers sufficient
Then use: protection against U.V. radiation.

4. Lamination (Butt Wrap) Joints

Otherwise, use:
It is recommended that the pipe manufacturer provides assistance for this type of joint.
Bond area Lamination Thickness
Joint
Where:
tb = Pipe structural wall thickness (mm)
v 2
= Product of both Poisson ratios, due to axial load and hoop load Pipe Segment Pipe Segment
Dm = Pipe mean diameter (mm)

ND
PB = Buckling pressure (MPa)
EHF = Structural hoop flexural modulus (MPa)
L = Distance between stiff ends (support span) (mm)
SFb = Buckling safety factor Figure 2: Typical Butt Wrap Joint Profile
Rm = Pipe mean radius (mm)
The below procedure describes the steps to be followed for field joint lamination of
II. Buried Installation Fiberstrong® pipes (Figures 3A to 3U):
For buried installation, use the methodology of AWWA M45, Section 5.7.5.
4.1 Preparation
The final pipe structural wall thickness (tE) is the largest of tp, ts, and tb. The final pipe total 1. Check the pipe routing as per the approved drawings.
wall thickness, T = tE + tu where tu= un-reinforced layers thickness (mm). 2. Check the alignment and level of the pipes.
3. Check if any damage has occurred during unloading and/or laying.
Note that the stiffness and aboveground buckling equations are iterative. Start by using the Dm
4. Ensure that the gap between the two pipes to be laminated is within the allowable limit.
resulting from the pressure calculation then use the calculated thickness to refine the answer.

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Y - 2 017 FIBERSTRONG® Aboveground Installation Manual FIBERSTRONG® Aboveground Installation Manual Page 5 of 28
 4.2 Cutting Procedure
1. The selected pipe segments are marked using a “wraparound” first. Proceed after that
with cutting of the pipes (if needed) using a diamond wheeled cutter, (Figure 3A).
2. When cutting the pipe, make sure that it is being done exactly square to its central axis,
(Figure 3B).
3. Pipe beveling is carried out to provide a proper jointing of the pipe sections,
(Figure 3C).
4. For pressure applications, grind the edges of the cut curve of the pipe sections at an
angle of maximum 10° to the pipe axis. For non–pressure applications, pipe beveling is
not required, (Figure 3D).
4.3 Lamination
A. Fit layer
1. Measure the fit layer bond length from the end of each pipe.
2. Grind the above area to remove the surface layer of the pipes.
3. Clean this area and ensure that it is fully dry.
4. Fill the gap, if any, between the two pipes with cab–o–seal putty, (Figure 3G and 3H).
5. Mix the resin and catalyst as per the quantities specified in the recipe to maintain the
correct ratio.
6. Impregnate the roughened area with the above mixture.
7. Apply two layers of woven roving glass 270 g/m2 using a 50% overlap between
each two consecutive windings so that wrapping the full surface will end up with two
layers of glass, (Figure 3I)
8. Impregnate the above layers with the resin/catalyst mixture.
9. Repeat the above two steps until the required number of layers is achieved.
10. Allow the lamination to cure under ambient temperature.
B. Main Laminate
1. Measure the bond length on each pipe from the middle of the fit layer.
2. Grind the above area to remove the surface layer, (Figure 3J)
3. Clean this area and ensure that it is fully dry.
4. Mix the resin and catalyst as per the quantities specified in the recipe to maintain the
right ratio.
5. Impregnate the above area with the resin/catalyst mixture (Figure 3K).
6. Apply two layers of woven roving glass 270 g/m2 using 50% overlap between each
two consecutive windings so that wrapping the full surface will end up with two layers
of glass, (Figure 3L).
7. Impregnate the above layers with the resin/catalyst mixture.
8. Repeat the above two steps till the required number of layers is applied.
9. Depending on the pipe diameter and pressure class, the type of glass and the number
of layers are specified in the lamination recipe. If glass 270 g/m2 is to be used only,
skip all the below steps – except the last one – and end the lamination with two layers
of Top Tape. Otherwise, move to the next step.
10. Apply two layers of woven roving glass 360 g/m2 using 50% overlap between each
two consecutive windings so that wrapping the full surface will end up with two layers
of glass.
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Y - 2 017 FIBERSTRONG® Aboveground Installation Manual
11. Impregnate the above layers with the resin/catalyst mixture.
12. Repeat the above two steps until the required number of layers is applied. A maximum
of 12 layers should be applied at this stage.
13. If more layers are to be applied, move to the following steps. Otherwise, skip all the
below steps – except the last one – and end the lamination with two layers of Top
Tape.
14. Apply the specified number of layers of woven roving 580 g/m2 and 360 g/m2
alternatively. Each type of glass should be applied in four consecutive layers before
changing to the other type. Every two layers should be impregnated before applying
the second two layers of the same type.
15. Apply two layers of woven roving glass 360 g/m2 (Figure 3O).
16. Impregnate the above layers with the resin/catalyst mixture.
17. Wind two layers of top tape glass around the laminate to extract the excess quantity
of resin and to provide a smooth surface (Figure 3Q).
C. Internal Lamination
The following steps are to be carried out inside the pipes, if access is possible:
1. Measure the required bond length from the end of each pipe.
2. Grind the above area to remove the internal liner of the pipe (Figure 3R).
3. Cut several pieces of woven roving glass 270 g/m2 to the required length.
4. Mix the right quantity of resin and catalyst.
5. Wet the surface area of internal layer with the mixture.
6. Stack several pieces of woven roving on a flat surface and impregnate with the resin
mixture.
7. Place the above impregnated woven roving on the joint.
8. Evenly press the surface to flush air traps and blisters using a steel roller (Figure 3S).
9. Repeat the above three steps until the required thickness is reached.
10. Cover the above laminate with two layers of surface mat to provide a smooth resin–
rich laminate surface.
Figure 3A: Marking by Figure3B: Cutting the pipe Figure 3C: Cutting the edges of
wraparound the pipe
Figure 3D: Beveling at 10˚ angle Figure 3E: Adjustment of pipe Figure 3F: Alignment of pipe
segments segments
FIBERSTRONG® Aboveground Installation Manual Page 7 of 28
 5. Flanged Joints
5.1 General
Before assembling the Flanged Joints, all safety precautions need to be taken. Ensure that
all necessary tools and materials are available.

The necessary tools for the assembly of flanges are:

• Ring spanner with the required bolt head size
Figure 3G: Sealing outside gap Figure 3H: Sealing inside gap with Figure 3I: Application of fit layers • Torque wrench with the required socket size
with putty putty

Figure 3J: Grinding of bonding Figure 3K: Applying resin on Figure 3L: Winding a layer of WR Figure 4: Flanged Joint
area bonding area 270 g/m²

GRP flanges are flat faced. These flanges must always be accurately aligned and not
subject to any stress. On the GRP side of the flanged joint, the bolts and nuts must have
washers to avoid exceeding the permitted surface pressure. As an alternative, a steel
backing ring can be installed.
butterfly valve space
underlay ring underlay ring

Figure 3M: Folding of Fabric Figure 3N: Filling of beveled area Figure 3O: Winding using WR
with WR 360 g/m² 360g/m²
CRP CRP

Figure 5: Flanges Connected to a Butterfly Valve

When assembling a wafer–type butterfly valve, the bolts should be tightened first by hand.
Figure 3P: Impregnated by resin Figure 3Q: Winding a layer of Figure 3R: Inside grinding of If leakage occurs during pressure tests, the bolts can be tightened up to the maximum
top tape bonding surface values. To prevent damage of the flanges when tightening, spacers may be placed
between the GRP flanges.

Figure 3S: Inside lamination Figure 3T: Finished laminated joint Figure 3U: Finished laminated joint
(outside) (inside)

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 5.2 Determination of the Bolt Lengths Drilling Related Flange Standard Drilling Related Flange Standard
Indication Indication
API 605 Class 75 BS 4504-PN 16
API Class 75
ASME B 16.47 Class 75 Series B DIN 2501 ND 16
API 605 Class 150 DIN 2507 ND 16
API Class 150 DIN 2533
ASME B 16.47 Class 150 Series B
P TF r m DIN 2633
L API 300 API 605 Class 300 PN 16 DIN EN 1092-2 PN 16
ANSI/ASME B 16.1 Class 125 ISO 2084 PN 16
Figure 6: Bolt Length Calculation ISO 7005 PN 16
ANSI/ASME B 16.5 Class 150
ASA 150 NF E 29-203 PN 16
ASME B 16.47 Class 150 Series A
There are four different types of flanged connections: NF E 29-209 PN 16
AWWA C207 Class D and E
1. GRP to steel - connected with bolt and nut. NF 29-223
2. GRP to GRP - connected with bolt and nut. ANSI/ASME B 16.1 Class 250
ASA 300 BS 4504-PN 25
3. GRP to steel - connected with stud bolt and two nuts. ANSI/ASME B 16.5 Class 300
DIN 2501 ND 25
4. GRP to GRP - connected with stud bolt and two nuts. ASA 600 ANSI/ASME B 16.5 Class 600
DIN 2527 ND 25
BS 4504-PN 6 DIn 2534
The lengths can be calculated with the following formulas respectively: DIN 2501 ND 6 PN 25 DIN 2634
Case 1. L = T + t + p + r + m + a DIN 2527 ND 6 DIN EN 1092-2PN 10
Case 2. L = 2T + p + 2r + m + a DIN 2531 ISO 2084 PN 25
Case 3. L = T + t + p + 2r + 2m + a DIN 2631 ISO 7005 PN 25
PN 6 NF E 29-209 PN 25
Case 4. L = 2T + p + 2r + 2m + 2a DIN EN 1092-2 PN6
ISO 2084 PN 6 BS 4504-Pn 40
Where: ISO 7005 PN 6 DIN 2501 ND 40
T = Thickness of GRP flange (mm) NF E 29-209 PN 6 DIN 2527 ND 40
t = Thickness of the steel flange (mm) NF 29-221 PN 40 DIN 2535
p = Thickness of the gasket (mm) BS 4504-PN 10 DIN 2635
r = Thickness of the washer (mm) DIN 2501 ND 10 ISO 2084 PN 40
m = Height of the nut (mm) DIN 2527 ND 10 ISO 7005 PN 40
a = Allowance in addition to the tolerance of the flange thickness: DIN 2532 PN 50 ISO 7005 PN 50
DN 25 to 300: 0, + 3 mm DIN 2632 PN 63 DIN EN 1092-2 PN 63
DN 350 to 1,200: 0, + 5 mm PN 10 DIN EN 1092-2 PN 10 JIS 5K JIS B 2210 5K
DN 1,300 to 2,000: 0, + 8 mm ISO 2084 PN 10
DN 2,100 to 3,000: 0, + 12 mm JIS 10K JIS B 2210 10K
ISO 7005 PN 10
DN 3,100 to 4,000: 0, + 15 mm NF E 29-203 PN 10 JIS 16K JIS B 2210 16K
NF E 29-209 PN 10 ASME B 16.47 Class 300 Series A
5.3 Flange Drilling Standards MSS 300
NF 29-222 MSS SP-44 Class300
Standard flanges are drilled to ASA 150 pattern. Other drilling standards are also
Table 5: Summary of Flange Drilling Standards
available, see Table 5.

5.4 Gaskets Types

Future Pipe Industries Fiberstrong® flanges have a flat face for diameters up to and
including DN 1,400. Larger diameter flanges have a grooved face suitable for an
“O-ring” rubber gasket. The recommended gaskets by FPI are:

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 A. DN 25 to DN 1,400 These flanges are low torque where the sealing is maintained by an “O-ring” contained in
1. Kroll & Ziller type G–ST–P/K a groove machined on the face of the flange.
2. Kroll & Ziller type G–ST–P/S
3. Kempchen type WG2

Kroll & Ziller Kempchen

type G-ST-P/S & G-ST-P/K type WG2

Figure 7: Gasket Cross Section

The recommended bolt torques are given in Table 6.

Torque (Nm)
ID (mm) Figure 9: Grooved Flange details
PN ≤ 12.5 PN 16 - 20 PN 25 - 32 PN 40 - 50
(bar) (bar) (bar) (bar)
5.5 Notes
25 - - 10 10 • Two flanges with an O-ring cannot be jointed to each other. In this case one of the
40 – 50 - - 15 15 flanges must have a flat face (non-grooved).
80 – 100 - - 25 25 • The O-ring used for sealing may be made of EPDM or natural rubber with a shore
150 – 200 - 35 50 50 hardness of 65 ± 5.
• The Indicated torque values are valid for ASA 150, ASA 300 and, BS/DIN PN6 to
250 – 300 50 50 75 100
PN40 drilling standards.
350 – 500 75 100 125 150
600 – 700 100 200 300 - 5.6 Tightening of Flanges
750 – 800 200 300 - - Tightening of the bolts of a flange connection must be done according to the diagonal
sequence as described in ASTM D4024.The flange must be connected perpendicular to
900 – 1,400 300 400 - -
the axis of the pipe.
Table 6: Recommended Bolt Torques for Kroll & Ziller and Kempchen Gaskets
The allowable for flange parallelism is shown in Figure 10 where the values for ‘x’ are
B. DN 1,500 to DN 4,000 defined in Table 8.
The flanges have a grooved face suitable for an “O–ring” gasket and the recommended
bolt torques are given in Table 7.
A // x A

Figure 8: Flange O-Ring

Torque (Nm)
ID (mm)
All Pressure Classes Figure 10: Parallelism of Flanges.

1,500 – 4,000 100

Table 7: Recommended Bolt Torques for O-ring Gaskets

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 6. Fiberstrong® Rubber Seal Lock Joint
ID (mm) Maximum allowable parallelism, x (mm) The Fiberstrong® Rubber Seal Lock Joint (RSLJ) consists of a fixed spigot and a coupler.
The sealing is ensured by rubber Reka rings. The axial thrust load is carried by the nylon
25 – 200 0.5
locking strips. Due to length limitations of the locking strips, for diameters DN 800 mm
250 – 500 1 and above, two locking strips 180° apart are used for one joint.
600 – 800 2
900 – 1,200 3 The schematic cross section and picture of Fiberstrong® RSLJ are shown below.
1,300 – 1,500 4 Coupler
≥ 1,600 5

Table 8: Maximum Allowable Parallelism

Fiberglass flanges must always be installed tension free. Therefore, flanges must be
accurately aligned. Pipelines must never be pulled by means of the flange bolts. If a Locking Strip
Reka Ring Spigot Pipe
Fiberglass pipeline is connected to a metal line, this metal line must be anchored to ID
Pipe
prevent any movements or loads being transmitted to the Fiberglass line.
Centre Line

Tightening of the bolts of a flanged joint shall be executed first diagonally, and second Figure 12: Cross Section – Fiberstrong® RSLJ
clockwise:
• Diagonally as per the bolt torque sequence described in ASTM D4024 and shown
on Figure 11. For flanges with more than 20 bolts, similar alternating bolt tightening
sequences shall be used, as detailed in the method statements. Bolts shall be tightened,
following the bolt torque sequence, first up to 60% of the recommended value and
second up to 100% of the recommended value.
• Clockwise using the recommended bolt torque. This step has to be repeated until all
bolts have been assembled at the prescribed bolt torque.
• In case bolts are not properly lubricated, or when the flange joint is not sealing,
it is allowed to increase the bolt torque value up to a maximum of 150% of the
recommended bolt torque.
• Bolts and nuts must have washers to avoid exceeding the permitted surface stress.
• Flanges must be properly aligned and shall not be subjected to any overload to meet
each other.
7 1 11 1
3 1 7 5
3 6
3 9 Figure 13: Fiberstrong® RSLJ
6 4 10 4
2 4 6 8
2 8 2 12
6.1 Guidelines for the Installation of Fiberstrong® RSLJ Joints
The locking strip(s) is inserted into the joint to restrain and mechanically lock the two pipe
19 1 sections. The joint assembly shall be done as per the following instructions:
15 5
11 15 1 5 11 9 1. Mark the depth of entry on the spigot end.
7 9 7 13 2. The depth of mark on the spigot end is half of coupler length ‘BA’ minus the play
3 13 3 17 dimension ‘C’, see Figures 14, and 15, as well as Table 10.
14 4 18 4
10 8 14 8
6
2 16 12 10 12
6 16
2 20

Figure 11: Bolt Torque Sequence as per ASTM D4024

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 BA 5. Ensure that the spigot end is positioned right in front of the coupler and both the spigot
and coupler sections are fully aligned.
6. Attach the chain tackles on both sides of the joint and ease the spigot end slowly and
gradually into the coupler until the mark on the spigot end is in line with the front of the
Mark C
coupler end.
7. Lightly lubricate the first 150 – 200 mm section of locking strip.
8. The beveled end of the locking strip should be resting against the inside surface of the
coupler when inserting. The insertion should be made using a plastic hammer or a piece
of wood to tap the key until it resists against the first part of the strip, see Figure 16.

locking strip

Mark

Mark

spigot end
Figure 14: Position the Reka ring into the coupler
socket end
3. Lubricate the exposed Reka ring on the coupler. Avoid applying the lubricant under the
Reka ring in order to prevent it from slipping from the groove.
4. The joint should be assembled in such a way that the position of the insertion hole in
the coupler allows the locking strip to be inserted easily.
Figure 16: Inserting the Locking Strip

LMark (mm)
ID (mm) 9. For large diameter RSLJ, where the length of the locking strip is relatively long, it is
7 bar 10 bar 12 bar 16 bar
recommended to attach a metal clamp to the locking strip. By positioning this clamp close
350 260 260 260 260 to the coupler, as shown in Figure 17, this will limit the “buckling” of the locking strip
400 260 260 260 260 during insertion. A pneumatic hammer can also be used to further ease the insertion.
450 260 260 260 260
500 304 304 304 304
600 344 344 344 344
700 380 380 380 380
750 400 400 400 400
800 420 420 420 420
900 440 440 440 440
1,000 500 500 500 500
1,100 500 500 500 -
1,200 520 520 520 -
1,300 520 520 520 -
1,400 540 540 540 -
1,500 540 540 540 -
Figure 17: Insertion of Locking Strips on Large Diameter Joints
Table 10: LMark Dimensions for Metric Series

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 10. For diameters DN 800 mm (DN 33 inch) and above, two locking strips shall be used
for one joint. This is due to limitation in length of nylon locking strips. Insertion of two
locking strips on one joint is schematically shown in Figure 18. Locking
strip 1
Locking
strip 1 Locking
strip 2
Locking Locking
strip 1 strip 1

Locking Locking VIEW A-A VIEW A-A VIEW A-A

strip 1 strip 1
Remove Locking Strip 2 Grind slot Remove Locking Strip 1

Figure 20: Removal of the Locking Strips

VIEW A-A VIEW A-A VIEW A-A
Insert Locking Strip 1 Insert Locking Strip 2 Assembled Joint

Figure 18: Insertion of Two Locking Strips

11. The end of the locking strips, sticks out by approximately 100 mm. This allows
disassembly of the newly assembled joint.
12. Ensure that the locked joint is stretched after assembly and both the spigot stop and
the coupler stop are in contact with the locking strip.
13. The angular deflections are in line with ASTM D4161. The maximum allowable
angular deflection of the Fiberstrong® RSLJ measured between the pipes, as
shown in Figure 19, is 3° for diameters up to 500 mm (20”) and 2° for larger sizes.
It is not recommended to reach these values during installation.
Angular
Deflection
7. Handling of Fiberstrong® Material: Transport and
Storage
7.1 Receiving
Generally pipes will be handed over to the Contractor or his representative at the factory
or at the job site, or as agreed upon in the Contractor’s purchase order. In the case of an
Ex–works delivery, the pipes and fittings shall be loaded on the Contractor’s trucks, by
the factory loading staff. If the loading staff considers the transport unsuitable they will
advise the Contractor or his representative accordingly. Thorough inspection is made by
the factory loading staff of the goods being loaded; nevertheless, the Contractor or his
representative should make their own inspection of the goods during dispatch.

Figure 19: Angular Deflection of the Joint
6.2 Guidelines for the Dismantling of Fiberstrong® RSLJ Joints
In the unlikely event that the joint needs to be disassembled, all locking strips need to
be removed from the joint. For diameters up to DN 800, this can be achieved relatively
simply by gripping the protruding ends of the locking strips and pulling them out of the
joint. For nominal diameters DN 800 and above, some additional steps are required to
disassemble the joint, see Figure 20.
1. First pull out the 2nd locking strip, which will have its one end protruding out from the joint.
2. Grind carefully the locking strips holes (slots) on the coupler using a grinding machine
as shown below.
3. Pull out the first locking strip through grinded locking strip hole and disassemble the joint.
The Contractor should make the following inspection at the time of the reception of the
goods:
• Each item should be inspected with care upon its arrival.
• Total quantity of pipes, fittings, etc. should be carefully checked against our delivery notes.
• Any damaged or missing item must be pointed out to the dispatcher or driver and
noted on the delivery note.
Materials that have been damaged during transportation should be isolated and stored
separately on site, until the material is checked by our site representative and repaired or
replaced. Damaged material must not be used before it is repaired.
7.2 Pipe Offloading
Offloading at the jobsite must be carried out carefully under the control and responsibility
of the Contractor. Care should be taken to avoid impact with any solid object (i.e. other
pipes, ground stones, truck side etc.)
A. Offloading by Hand
Unloading by hand with two men should be done for small diameter pipes, not exceeding 60 kg.

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 B. Mechanical Offloading
Mechanical offloading is required for pipes heavier than 60 kg. Flexible slings or
straps should be used combined with a mobile crane. When offloading is done with a
mobile crane, care must be taken that the pipes do not slide off the slings. Therefore it
is recommended to use two slings or nylon lifting straps to hold and lift the pipes. Steel
cables must not be used for lifting or handling Fiberstrong® pipes. Fiberstrong®
pipes can also be lifted with one sling or strap balanced in the middle with the aid of a
guide rope.
Caution: Hooks must not be used at the pipe ends to lift the pipes, nor should the pipe be
lifted by passing a rope or sling through it.
7.3 Storing Fiberstrong® Pipes on Site
A. Distribution Along the Trench
Avoid placing the pipes where they can be damaged by traffic or blasting operation.
Also avoid laying the pipes on sharp rocks or objects that may damage and affect their
function. Store the pipes if possible on soft level ground (e.g. sand), timber bearers or
sand bags.
C. Handling of Nested Pipes
For some projects, pipes may be delivered “nested” (i.e. one or more small pipes inside a
larger pipe). Special handling procedures must be followed when handling and
de–nesting such pipe loads.
When handling nested pipes, never use only one sling or strap. Nested pipes must always
be lifted using at least two straps or slings. A spreader bar will help to ensure that the load
is lifted at one level. Mobile lifting equipment should move slowly when handling nested
pipes and all such movements should be kept to a minimum to ensure the safety of site
personnel. The Contractor should ensure that the crane operator realizes that the nested
pipes in the inside may slip out and fall during movement. All necessary precautions
should be taken.
De–nesting a load is easily accomplished by inserting a forklift fork into a padded boom,
the forklift lifting capacity should be appropriate to handle the weight and length of pipes
being de–nested. Figure 22 shows how this is accomplished. Proper padding is essential;
rubber, several wraps of corrugated cardboard sheets, a PVC pipe or PE pipe slipped
over the boom are all suitable options to avoid damaging the inside of the pipes.

Caution: Pipes must not be stored on rocks.

B. Storing in Stock Piles

Care must be taken that the storage surface has the same level, firm as possible and clear
of rocks or solid objects that might damage the pipes. Store the pipes in separate stock–
piles according to their class and nominal diameter. Pipes are to be placed on wooden
timber at a maximum spacing of 6 meters. Any extraneous materials are to be removed
from the area. Stock piles should not exceed the heights shown in Table 11. This height is
limited for safety purpose and to avoid excessive loads on the pipe during storage.

Figure 22: De nesting of pipes

DN 80 – 400 450 – 600 700 – 800 900 – 1,400 ≥ 1,500
Layers per 5 4 3 2 1 The Forklift operator should lift the innermost pipe above the pipe around it sufficiently so
stock pile the pipes do not touch each other when the inner pipe is being pulled out.
hmax < 2m < 2.4 m < 2.4 m < 2.8 m -

Table 11: Storing and Stacking Height of Fiberstrong® Pipes

Wooden wedges, used in order to prevent the pipe stack from sliding, should be placed
on both sides of the stack, on the timber bearer, as shown in Figure 21.

Figure 21: Pipe storage

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 8. Accessories
8.1 Pipe Supports
A. Pipe Protection
In order to avoid pipe damage by stones and other sharp objects, it is advisable to
support the pipe, for example by means of wooden or concrete sleepers. Using these
kinds of support, it is necessary to bond a 180° saddle to the bottom of the pipe at the
support locations, in order to protect the pipe against damage caused by possible pipe
movements. The length of this saddle with respect to the width of the support must be 50
mm longer than the calculated displacement of the pipe. The support width itself must
be at least 100 mm. The jointing systems are the same as those used in underground
installations. To avoid sideways displacements, a metal clamp is sufficient.
B. Additional Supports
To avoid overloading caused by heavy valves, these must be supported separately. When
connecting to tanks and pumps, additional forces and movements caused by pumps and
tanks fluctuations must be eliminated. It could be necessary to include an expansion loop
to absorb these movements. Overhead installation on pipe bridges requires compliance
with the rules, which are also applicable in the previous case of installation on wooden or
concrete sleepers.
C. Fixed Support Points
Fixed points in GRP systems may never be constructed by clamping with pipe clips. This
could result in deformations and excessive wall stresses. The pipe must be allowed to
expand within its clip. The pipes at fixed points must have additional laminates or bonded
collars on both sides of the clip, see Figure 23.
Figure 23: Fixed Support points.
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Page 22 of 28 FIBERSTRONG® Aboveground Installation Manual
Choose fixed points so that the loads are balanced. As a result of pumps and tanks
fluctuation, branch connections may need rubber seal joints so that these can follow the
movements of the main line. Vertical pipe sections with rubber seal joints, in areas where
the temperature can drop below zero degrees centigrade, should be positioned so that no
water will remain in between the socket and spigot parts.
When using non-locked rubber seal joints or mechanical couplers, pipelines must be
anchored at each change in pipe direction, to prevent the pipes coming apart. Sideways
movement is prevented by clamping. Where mechanical couplers are fitted, sideways
movement can be avoided by securing the coupler itself.
D. Pipe Clips
To support Fiberstrong® pipes, several types of pipe clips may be used. As point loads
on Fiberstrong® pipes are to be avoided, flat clips instead of u–bolts (see Figure 24)
must be used. The inside should be covered with a rubber or cork–rubber layer in order to
minimize abrasion, caused by pipe vibrations or movements.
Clips which allow axial movement of pipes, must be provided with a PTFE, PE, or PA
sliding layer. This sliding layer can be placed inside the clip or between the clip and
the supporting beam. When the clip has to accommodate movement in more than one
direction (expansion loop), a slide plate under the clip is needed to create a floating
support.
rubber lining rubber lining
rubber lining
rubber lining
HDPE sliding layer
HDPE sliding
Figure 24: Different Types of Pipe Clips
FIBERSTRONG® Aboveground Installation Manual Page 23 of 28
 8.2 Valves
To avoid Fiberstrong® pipes being overstressed by bending, valves, butterfly valves or
other heavy accessories must be supported separately. This can be done by direct support
of the valve or indirectly by means of the flange bolts.
8.3 Bellows
Low amplitude vibrations will have little effect on Fiberstrong® pipes, because these will
be absorbed due to the low E–modulus material. To eliminate high amplitude vibrations
caused by e.g. pumps, and to eliminate soil settlements or expansion of tanks to which
Fiberstrong® pipes are connected, bellows can be used. In many cases, it will be
possible to connect a bellow directly to the vibrating item by means of flanged joints.
Immediately next to this bellow, the pipe section must be supported separately to absorb
the pipe loads.

steel compensator GRP pipe

butterfly valve
support

concrete
foundation

Figure 25: Valve Support

If a Fiberstrong® flange is connected to a steel flange, the support should preferably 8

be situated at the side of the steel flange. This is also applicable for underground
applications. Pipe sections should not become overloaded by the weight of the
accessories, for example by soil settlement. One suggestion would be concrete supports
provided with steel connections, able to carry the full load of the valve. Also bending
Figure 28: Bellows
and torque forces caused by opening and closing of valves should be absorbed. Hand
operated butterfly valves can be supported or mounted in a manhole as follows: Bellows can also be employed to facilitate removal of pipe sections, valves, orifice flanges
concrete wall water baffle
or gaskets for repair purposes. The flexibility of the bellow allows a play of some 10 to 20
mm so that it is possible to disconnect and connect flanged parts easily.

8.4 Connection to Other Materials

butterfly valve

support

Figure 26: Support for flange

butterfly valve

Figure 29: Mechanical Couplers

The most appropriate way to connect objects of different materials is the flanged joint,
rubber inlay with the mechanical coupler as an alternative. The flanged connections can be used
with standard Fiberstrong® products. When a flanged Fiberstrong® pipe section is
connected to a metal pipe section, this metal part must be anchored so that no contraction
or expansion forces will be transmitted to the Fiberstrong® pipe section.
concrete support

Figure 27: Support for flange

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 8.5 Pipe Connections Through Walls The wall penetration consists of a steel pipe provided with flanges. One of these flanges is
Several alternatives are available for GRP pipe connections through walls (concrete or profiled to fit the shape of the sealing element. By tightening the nuts, the seal will be pressed
otherwise): in the wedge–shaped space between flange and pipe, thus creating an excellent seal.
1. GRP pipe piece provided with a puddle flange, (Figure 30).
2. Link–Seal, (Figure 31). When a pipe has to pass through a wall, the outside of the pipe must be protected by a
3. Casting and sand-coated GRP pipe into the wall, (Figure 32). flexible material (a rubber layer, with a minimum thickness of 5 mm) protruding some
4. Rolling ring, (Figure 33). 100 mm outside the wall at each side. In order to allow for setting of the adjoining pipe
5. Special shaped sealing, (Figure 34). sections, flexible couplings must be installed on both sides of the wall. Joints must not be
6. No connection of the pipe to the wall, (Figure 35). located at a distance of more than 1 x ID outside the wall, with a maximum of 0.5m.

The puddle flange which is already in the factory connected to the pipe body consists of a
ring with a suitable thickness and a height of 80 mm greater than the pipe outer diameter.
This puddle flange is connected to the pipe part by means of a lamination and placed into
a recess in the wall, after which it is fixed with concrete or mortar.

Link–Seals consist of several linked rubber parts shaped to fit the circular space
between the GRP pipe and the inside of an insert in the wall. The rubber parts are
interconnected by steel bolts, to form a rubber chain. Under each bolt head and nut,
pressure rings are placed.

After assembly of the GRP pipe with the rubber “chain” into the circular wall insert, the
rubber is compressed by tightening of the bolts, thus ensuring a complete watertight
Figure 30: Puddle flange Figure 31: A Link–Seal Figure 32: Casting and sand–coated
construction. Link–Seals are available in various materials. The rubber elements are made
GRP pipe into the concrete wall
of EPDM, silicone or Nitrile Rubber. Bolts are of stainless steel, zinc or cadmium plated
or phosphated steel. The pressure rings are made of acetal polymer. As an additional
advantage, constructions with Link–Seals allow the GRP pipe a certain angular deflection
and movement in an eccentric direction.

A sufficiently smooth surface of the hole inside the concrete wall can be obtained in
various ways:

1. By fixing a steel pipe piece with water seal before pouring mortar.
2. By drilling a hole in the wall with a crown drill with diamond inlays.
3. By fixing a removable plastic casing pipe piece before pouring mortar. After removal
of the casing pipe piece, the quality of the whole surface has to be checked.

Sand-coating of GRP pipe must be carried out as follows: Sand the pipe at the spot where Figure 33: A rolling ring Figure 34: A special shaped Figure 35: No connection of the
it fits in the wall, over a length at least equal to the wall thickness. Apply a mixture of sealing pipe to the wall

resin and catalyst equal to that used for bonding or laminating Fiberstrong® pipes
with the aid of a brush, a roller or a spatula to the sanded surface. Pour sharp sand over
the prepared surface and allow the resin mixture to cure. Through this sand–coating an
excellent adherence between concrete and GRP is obtained.

Using the rolling ring construction, pipes going into the wall should be provided with a
guide–way in order to allow the ring to roll between pipe and wall-casting.

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 9. Field Test Procedure
Before the installed pipe system can be used, it needs to be tested to ensure that all the
joints function correctly. The test equipment must be suited to the diameter and pressure,
and be able to reach the required test pressure. If the pipe system ends with a flange,
a steel blind flange, which has connections for filling and air release, can easily be
connected. The pressure gauge must be connected between the valve and the system
in order to indicate the pressure after the valve is closed. Due to the head of water, the
pressure gauge should be located at the lowest point. The pressure gauge should have a
full scale reading of about twice the test pressure. If the system has not been designed to
withstand any negative pressures and this occurs during testing, the system needs to be
protected by an air release valve. Trapped air can be released using a vent at the highest
point in the system

9.1 Filling, Stabilizing, and Testing

Fill with water at the lowest point in the line using a small diameter branch connection and
vent the trapped air at the highest point(s). Long straight sections may be vented using an
inflatable ball or foam pig to expel any air and impurities.

Figure 36: Foam Pig

After filling, the line must be pressurized gradually at 0.8 times the working pressure and
must be maintained for twenty-four hours allowing the pipe system to set. After the system
is stabilized, the pressure must be raised gradually to 1.5 times the working pressure and
maintained for four hours.

After four hours, the pressure may have dropped by 0.5 bar for diameters less than
or equal 450 mm and 0.3 bar for diameters larger than or equal 500 mm per 1,000
meter length. The test pressure and its tolerance should be determined in advance. It
is preferable to test the line in sections, for example the length of one day installation,
which will be shut off by a temporary flanged joint and a ball. The blind flange should be
provided with an air release valve. After testing the section, the ball needs to be pushed
back about two meters using air via the air release valve. The excess water needs to be
released by opening the valve at the start of the line. After the ball has been secured by
inflating it, the temporary flange connection can be removed and assembly can continue.
The advantage of this method is that the line does not need to be re–filled every time.

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Page 28 of 28 FIBERSTRONG® Aboveground Installation Manual
 Teekay Flange Adaptors Installation

Fitting Instructions
• Do not disassemble the Teekay Flange Adaptor.
• Lubricate the pipe.
• Remove any burrs, surface dirt, etc from the end of the pipe.
• Remove any dirt etc from the Teekay Flange Adaptor coupling screws and sealing sleeve.
1. Fit a gasket to the Teekay Flange Adaptor flange, & bolt up to the mating flange using standard pipeline procedure
2. Mark the pipe and the flange adaptor spigot with chalk or crayon in a suitable position as shown below.
3. Butt the pipe end against the end of the spigot. Loosen the bolts on the connecting Teekay Coupling with either an Allen
key or a torque wrench until the coupling is loose on the spigot. Do not remove the screws. Slide the coupling over the
joints so that the pipe marks are visible.
4. Installation should be completed in one operation. Tighten the coupling screws evenly with a torque wrench to the value
written on the coupling label.

= At least half the coupling width

5a. Two Screwed Coupling Tighten the first Screw until it “bites”. Then tighten the second Screw bring-
ing the retaining bars parallel. Continue tightening in cycles until the torque
value is reached.

✔ ✔ ✔ ✘

5b. Three Screwed Coupling Tighten the middle screw until it “bites”. Then tighten the retaining bars par-
allel. Continue tightening in cycles until the torque value is reached.

✔ ✔ ✔ ✘

6. The torque value is reached when the torque wrench clicks off simultaneously on ALL screws.
IMPORTANT
• Do not completely tighten one screw first.
• Couplings for diameters 300mm and above are fitted with nuts that are locked into retaining bars.
• Do not tighten the nuts, only the screws.
• We recommend that you use Teekay Torque Wrenches for installation.

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Teekay Couplings Ltd. Disraeli House, 12 Aylesbury End, Old Beaconsfield, Bucks HP9 1LW Tel: +44 (0) 1494 679500 Fax: +44 (0) 1494 679505 Email: info@teekaycouplings.com
(Print Ref: 4) Issue 3: 16.04.2002