Revision : R1

Date : 28.12.2020
21.11.2017

Best Practice:

QC at Winder
Flowtite Visual Standard:
Visual defects on pipes.

Table of Contents
1 Purpose & Scope ............................................................................................................ 1
2 Responsibility .................................................................................................................. 1
3 Objective ........................................................................................................................ 1
4 Visual defects definitions ................................................................................................ 1
5 Visual defects in detail .................................................................................................... 3
6 Repair methods,pipe ......................................................................................................35

“All the content of this manual is proprietary and strictly confidential. It must not in any form be shown, copied, reproduced or
distributed to outside parties without written approval of Amiblu Technology AS”
1 Purpose & Scope
This primer is a supplement to chapters 7.5 Detection and Repair of defects in pipes
and 7.6 Repair methods, pipe in the 121210 Flowtite Pipe Technologies manual.
The purpose is to present guidelines and recommendations for the detection, classification
and repair of defects in GRP pipes at the pipe manufacturing plant.
If the machine setup is according to the specifications in setup sheets, and raw materials are
tested and approved, there are normally no problems. But sometimes process variables
change during production and may cause defects on pipes. Pictures and text in this manual
will help you to visually identify defects on pipes, how to repair them and suggest corrective
actions to avoid these defects.

2 Responsibility
Plant management is ultimately responsible for the quality of pipes produced, but it is the
winder crew who is in the position to detect defects at the earliest possible time. This means
management must make sure the winder crew(s) have sufficient training in the visual
standard as presented here. QC people must also be trained in this topic, because they will
be involved in the final classification and repair of pipes with defects.

3 Objective
The primary objective is to be able to detect a defect as early as possible, then
analyze/classify the defect and adjust the manufacturing process to avoid/eliminate the
defects. The secondary objective is being able to correctly repair pipes having one or more of
the visual defects described in this primer.

4 Visual defects definitions

Index:

VISUAL DEFECT DEFINITION

1. Cracks Lines in circumferential direction.

2. Craze Star shaped figure on inner or outer surface.

3. Blister Light colored areas with entrapped air.

Small air pockets or voids through or just beneath the

4. Surface void
surface mat. Air pockets can be broken with a ball pen.

Pit > 1.5mm in diameter and 1.5 mm deep.

5. Surface pit
Pits regarding FS pipes.

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6. Wrinkles, indentations
Spiraling impressions near the liner surface.
or band impressions

7. Dry area Glass not impregnated with resin.

8. Edge delamination Separation of layers longer than 25 mm.

Objects such as glass clumps, insects etc. which are

9. Encapsulated materials
foreign to the laminate composition.

10. White spots White spots caused by water drops.

11. Protruding fibers Resin coated glass fibers or resin lumps sticking.

12. Sand rich interior Sand in the inner liner.

13. Surface scrapes White scrape marks on surface.

14. Uncured areas Any areas that does not have Barcol > 35.

15. Missing or wrinkled

Areas where surface mat is missing or wrinkled.
surface mat

16. Corrugated Surface Circular exterior furrows.

17. Weeping Weeping of water by pressure testing.

18. Delamination Splitting between the various laminate layers (separation).

19. Damaged skin Local damage.

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5 Visual defects in detail
VISUAL
DEFINITION WHAT TO DO? CAUSES / HOW TO PREVENT
DEFECT

Excess resin cured without chop glass

fiber reinforcement or resin cured at too
Lines in
high temp. Check also hoop tension.
circumferential Repair all with
1. and axial method no. 1.
Left picture:
Cracks direction
Repair if area is Tangential direction
not too wide
(External)
Right picture
Axial direction
Pictures.

Repair if area is not too wide

Comments:

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 VISUAL
DEFINITION WHAT TO DO? CAUSES / HOW TO PREVENT
DEFECT

Star shaped
All crazes must
figure on Sharp impacts or rough transport or
2. Craze be repaired with
inner or outer handling.
method no. 1
surface.
Picture:

Comments:

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 VISUAL
DEFINITION WHAT TO DO? CAUSES / HOW TO PREVENT
DEFECT
Internal
Single blister: - Too high peak temp.
if diam.>10mm: - Curing speed liner too high. Check
repair pipe gel times.
3. - Steel band temp too high. Reduce
Blisters Group of induction heating.
Light colored
blisters: - Wet raw material
areas with
Internal - if more than 4
entrapped air.
blisters per 0.1 External
External m2and Ø < 10 - Too high peak temp.
mm: - Curing speed too high. Check gel times.
repair with Reduce IR heating.
method no.1. - Wet raw material.

Internal blisters:

continues

QC at Winder - Flowtite Visual Standard (visual defects and repair methods) 5|Page
 External blisters:

Comment:

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 VISUAL
DEFINITION WHAT TO DO? CAUSES / HOW TO PREVENT
DEFECT
Single void:
If >1.5mm deep
or >15mm
Small air diameter, then
pockets or repair.
- Curing speed is too fast. Check geltime.
voids
and steel band temp. Steel band temp
4. beneath the Group of voids:
should not exceed 100 °C when re-
Surface surface mat. Only repair if
entering the mandrel.
voids Air pockets there are more
can be than 4 voids per
(Styrene is entrapped in surface.)
broken with 0.1m² and diam.
ball pen. <15 mm and
depth <1.5 mm:
Repair method
no. 2.
Picture.

Comment:

QC at Winder - Flowtite Visual Standard (visual defects and repair methods) 7|Page
 VISUAL
DEFINITION WHAT TO DO? CAUSES / HOW TO PREVENT
DEFECT

Open air pockets in inner liner or outer

surface:
Curing speed is too fast. Check gel time.
If gel time ok, check:
Inner liner:
Check Steel Band Temp
- Reduce Induction Heating

Check curing speed, too fast?

Check steel band temperature.

Are the Pits/ porosity located in surface

glass mat overlap area? See picture
Lack of resin?
Check liner trough - some holes blocked?
If trough ok, increase resin in liner
Pit > 1.5mm All pits have to slightly.
in diam and be repaired with
1.5 mm deep. method no. 2 Objects falling from chopper platform?
5. Use vacuum cleaner to clean chopper
Surface area.
pit
FS pipes: Repair with Check Steel Band surface: Old residues
Pipes with method 2 if: of resin? Keep Steel Band clean
sand in liner Pits > 10mm in
diam. /length Check surface-mat veil, objects between
> 1.0mm deep the layers?
Tension on surface-mat: Use some
tension to ensure good wet out.

Release film: Wrinkles from release film:

adjust to correct angle when entering
mandrel. Use some tension. See picture
below.

Other:

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 Pictures.

Check: Liner geltime - too fast? Reduce Induction Heating?

FS pipes

Pits in Surface mat overlap

continues

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 FS pipes

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 VISUAL WHAT TO
DEFINITION CAUSES / HOW TO PREVENT
DEFECT DO?

a-1.
Steel band not properly installed, or too high
steel band tension.
Adjust Return head, especially where the
steel band leaves the rods on the return
head.

Mylar tangled on return head bearings?

Loose bearing rods on return head?

Make sure that the mandrel is built correctly

with no differences between neighbouring
discs’ diameter more than 0.2mm.
Check also the condition of the bearings:
Broken bearings which create differences in
height between the steel band laps?
Check adjustment of the return head:
Especially where the steel band leaves the
>3mm deep: mandrel.
Repair pipe,
method no. 1. a-2.
6. Lifting tables: make sure that the lifting tables
Spiralling are adjusted in a straight line, so the pipe
Wrinkles,
impressions isn’t bended in any directions.
indentations 0-3 mm deep:
in the liner
or band Repair if more
surface b.
impressions than1/3 of
Curing: Do not run with the peak position too
nom. far out (close to the return head) it will make
thickness, the pipe more sensitive to errors on mandrel /
then repair return head.
with method Check geltimes, peak position, day tank
no. 1. mixing, height of lifting tables, position of pipe
support wheels.

c.
If the spirals are located at one side of the
pipe, check the pressure on the pipe rotation
wheel: Too high pressure will push the pipe
and mandrel sideways during saw sequence.
Check also saw blade: Worn out? Change
saw blade or adjust cm³ in Citect to a lower
value to avoid saw feeder pushing the pipe
(as a temporary solution).

d.
Wrinkles on release film. Adjust entering angle on
mandrel. Increase tension slightly.

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 Pictures.

a-1.

a-2.

Check cam-plate adjustment and lifting tables

continues

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 b.

Curing: too long gel times, peak position is too close to the end of the mandrel

c.
Spirals at one side: (Missing picture)

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 d.

Comment: Wrinkles on release film. Adjust entering angle on mandrel. Increase tension slightly.

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 VISUAL
DEFINITION WHAT TO DO? CAUSES / HOW TO PREVENT
DEFECT

a.
- Accumulated
- Chop glass falls on laminate during
cleaning of chopper.
- Resin flow is too low or viscosity is too
high.
Blocked Resin Trough.
Too fast geltime.

b.
Glass not
None allowed. Porosity in core:
impregnated
Repair all. Poor wet out in core:
with resin
Method no1. - check sand temp, shall be approx. 20°C
above ambient temp
- check hoop tension
- check position of compaction rollers
- check Resin trough width

- Check resin temp (too low?) and

Cut / remove viscosity (too high?)
7. Dry Porosity in
area on pipe - Check resin geltime (too fast?)
areas core
with porosity
-or downgrade
to PN1 (Gravity) c.
Check wet out in core especially in front
of outer skin;
Use netting

- check sand temp, shall be approx. 20°C

Dry areas at
Cut / remove dry above ambient temp.
inner and
parts - check hoop tension
outer skins
- check position of compaction rollers
- check Resin trough width

- Check resin temp (too low?) and

viscosity (too high?).
- Check resin geltime (too fast?).

- Liner: Check Induction Heater

Too high Steel Band temp?
Reduce Induction Heater kW.

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 Pictures.

a.

b.

Porosity in core

continues

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 c.

See comment c.

continues

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 (a. and c.)

See comment a. and c. (NB! This is not caused by too high hoop tension.)

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 VISUAL
DEFINITION WHAT TO DO? CAUSES / HOW TO PREVENT
DEFECT

8. Edge
None allowed. Edge:
delamination Separation of
Pipe to be - Saw impact
layers longer
repaired, cut if - Lifting tables
See also than 25 mm
necessary .pipe handling
point 18

Pictures.

Comment:

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 VISUAL
DEFINITION WHAT TO DO? CAUSES / HOW TO PREVENT
DEFECT
Objects such
as glass
lumps, None allowed.
9. insects etc. Pipe to be
Encapsulated which are repaired.
materials foreign to the Repair method
laminate 1.
composition.

Pictures.

Comment:

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 VISUAL
DEFINITION WHAT TO DO? CAUSES / HOW TO PREVENT
DEFECT

10. White spots Avoid water on laminate

Repair by
White caused by Wet raw material?
method 1 or 2.
spots water drops Check for leakages.

Pictures.

Comment:

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 VISUAL
DEFINITION WHAT TO DO? CAUSES / HOW TO PREVENT
DEFECT

Check position of chop

Missing material?
Reduce Resin?
Resin coated If > 5mm, then
Chop / hoop lumps
11. Protruding glass fibers or repair if
Clean chopper guide and
fibers resin lumps necessary by
porcelain eyes and chopper
sticking out method no. 2
cleaners

Surface mat to cover all resin

lumps on the surface.

Pictures.

Resin drops

Chop / hoop lumps

continues

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 Other examples:

Comment:

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 VISUAL
DEFINITION WHAT TO DO? CAUSES / HOW TO PREVENT
DEFECT

1.
Adjust the material application width,
12. position according to spec.?
Sand Check platform height, too high?
rich None allowed, (sand bouncing)
1. Sand in the use repair
interior inner liner method 1 or 2.
reject. Adjust the material application width,
2. position according to spec.?
exterior . Check platform height, too high?
(sand bouncing)
Too much resin
Pictures.

Sand in liner: Picture missing

Sand in exterior

Sand in outer liner: too much resin

Comment:

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 VISUAL
DEFINITION WHAT TO DO? CAUSES / HOW TO PREVENT
DEFECT

None allowed,
13. Surface White scrape use repair
Handling
scrapes marks on surface method 1 or
reject.

Pictures.

Comment:

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 VISUAL
DEFINITION WHAT TO DO? CAUSES / HOW TO PREVENT
DEFECT

Any areas
None allowed,
that do not
use repair
14. have
method 1;
Uncured Barcol > 35 Missing catalyst or insufficient curing.
after-cure with
areas
IR oven
For flexible
- or reject.
liner: > 14
Pictures.

Comment:

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 VISUAL
DEFINITION WHAT TO DO? CAUSES / HOW TO PREVENT
DEFECT

15. Check material application:

Missing Areas where Resin width and position
or surface mat Repair method Hoop tension
wrinkled is missing or no. 2. Check compaction rollers, correct position
surface wrinkled. and pressure?
mat Too much resin

Pictures.

Surface mat floating on top of the excessive resin

Comment:

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 VISUAL
DEFINITION WHAT TO DO? CAUSES / HOW TO PREVENT
DEFECT
Circular
exterior - Too high tension on hoop treads.
furrows Position of Hoop
16. Two hoop in one slot?
If > 3mm:
Corrugated Too much resin
Repair or reject
surface?
Circular Check height of lifting tables
internal Check camplate
grooves
Pictures.

continues

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 Internal

continues

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 Comment:

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 VISUAL
DEFINITION WHAT TO DO? CAUSES / HOW TO PREVENT
DEFECT

- Check material application, especially in

the inner liner area.
Weeping of
- Check compaction rollers
17. water by Repair method
- Check wet out, lack of Resin?
Weeping pressure no. 3.
- Check sand temp
testing.
- Check hoop tension
- Check mandrel condition

Pictures.

Comment:

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 VISUAL WHAT TO
DEFINITION CAUSES / HOW TO PREVENT
DEFECT DO?

- Lack of Resin
-wrong distribution of resin
-Lack of Hoop tension
Splitting
between the - Check chop roving area of
18. various None allowed, delamination. Check wetout. Check
Delamination laminate cut the pipe peak temp and position.
layers - Check steelband return unit.
(separation). -Check condition of mandrel: More
than 0.4 mm difference in diameter
between discs?
Broken bearings?

Pictures.

Lack of Resin under outer skin. Lack of Hoop Tension.

Check peak temperature, too high?
Lack of Resin in grinding layer

Comment:

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 VISUAL
DEFINITION WHAT TO DO? CAUSES / HOW TO PREVENT
DEFECT

19.
Local Repair method
Damaged - Check handling.
damage. no. 5.
skin
Pictures.

continues

Principles for choice of repair method:

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 Comment.

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6 Repair methods, pipe
(Corresponds with ch.7.6 in the Pipe manual.)
All repairs shall be on a ground surface. By repairing with glass fiber mats the patches shall
have square edges and be rectangular in shape. Overlapping areas at ends of each lay-up
shall be neat and tapered smooth. Lay-up thickness shall be equal to the removed pipe
thickness

(7.6.1) Procedure no. 1:

To be used for repair of cracks, crazes, wrinkles, indentations, blisters, band impressions,
dry areas, encapsulated materials, large white spots, missing liner and skin etc.

1. Grind away the defect and grind the laminate surface 50 mm beyond the defect.

2. Cut needed mat patches for the repair.

3. Wet out the ground surface with polyester resin (curing agents added) and build up the laminate.
Do not apply resin outside the ground area.

4. Use aluminum roller to wet out the fibers and remove entrapped air. Rolling shall be performed
for every mat layer.

5. Finish the lay-up with a surface mat.

6. Cure the laminate at room temperature or better by elevated temperature using for example an
IR oven.

(7.6.2) Procedure no. 2:

To be used for repair of surface pits, surface voids, protruded fibers, resin lumps, surface
scrapes, missing or wrinkled surface mat, small white spots etc.

1. Grind the laminate surface with defects and 50 mm beyond the defects.

2. Cut needed surface mat for the repair

3. Wet out the ground surface with polyester resin (curing agents added), cover the ground area
with surface mat and wet out with resin

4. Cure the surface layer at room temperature or better by elevated temperature using for example
an IR oven.

(7.6.3) Procedure 3.

Weeping
Wet surfaces or drops of water at the exterior pipe surface detected during hydro testing at
the plant. Generally weeping appear over a substantial area rather than a specific individual
point. Visible dark spots or areas during standard hydro testing procedure are also classified
as weeping.
Leaks
Any other loss of water during hydro testing at the plant.

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Actions and methods
If the weeping or leaking area is concentrated, consider to cut away this part and re-test the
remaining pipe(s).
The Manufacturing Specification for Fittings is the basis for this pipe repair recommendation.
See Fittings manual, chapter 6.3 for lay-up material specification.
Fault classification

DESCRIPTION

TYPE Amount Source Structural ACTION

damage

a Weep Several points No Down rate pipe

b Weep / leak Single identifiable No Patch

c Weep / leak Non identifiable No Wrap

d Leak Identifiable Yes Wrap

e Multiple leaks Multiple Yes/No Scrap

A: Weeps from several points and without structural damage

Reduce the test pressure to 2 bar. If there is no leak, the pipe may be classified as gravity
pipe and used without repair.
Note that a water pipe can only be down rated to sewer if it is made with ECR-glass.
Scrap the pipe if it is still leaking at 2 bar and it is not practical to cut away weeping area.
B:Weeps or leaks with a single identifiable source and without structural damage

See Manufacturing Specification for Fittings (Fittings manual), chapter 6.3, for lay-up
preparation of pipes with diameter 600 mm or above.
Cut away leaking part if the diameter is less than 600 mm as entry is not possible.

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Exterior lay-ups are alternate plies of 450 g/m2 chopped strand mat and 820 g/m2 woven
roving. The first and last plies are chopped strand mat. The table below gives the number of
plies.

Pipe pressure 6 bar 9 bar 10 bar 12 bar 15 bar 16 bar

No. of plies 3 5 5 5 7 7

Lay-up width is 250 mm for all pressures. This includes provision for a 4/1 slope at laying
edges.
Seal the interior pipe surface with two plies of chopped strand mat and one ply of surface
mat. The lay-up shall extend minimum 150 mm outside leaking area. Grind properly for
adequate bond.
Note: Many customers will not accept individual patches. This should be evaluated by
Sales/marketing before committing to the work. Alternatively a full 360 deg lay-up as a
‘butt wrap joint’. See Fittings manual, chapter 6 for details.
C: Weeps or leaks without identifiable source and without structural damage

Cut away leaking part if the diameter is less than 600 mm as entry is not possible.
Repair the pipe as a ‘butt wrap joint’ if pipe diameter is 600 mm or above. Exterior lay-ups
are alternate plies of 450 g/m2 chopped strand mat and 820 g/m2 woven roving. The first
and last plies are chopped strand mat. The table below gives the number of plies.

Pipe pressure 6 bar 9 bar 10 bar 12 bar 15 bar 16 bar

No. of plies 3 5 5 5 7 7

The lay-up shall extend minimum 150 mm outside leaking area. This includes provision for a
4/1 slope at lay-up edges.
Seal the interior pipe surface with two plies of chopped strand mat and one ply of surface
mat. Grind properly for adequate bond.
D: Leaks caused by structural damage
Cut away leaking part if the diameter is less than 600 mm as entry is not possible.
The following details is for pipes with diameter 600 mm or above.

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d1 Delaminated pipe:
Cut away delaminated pipe and re-test the remaining part.

d2 Damaged area wider than 500 mm along the pipe:

Cut away the damaged area and re-test the remaining pipe(s).

d3 Damaged area smaller than 500 mm along the pipe:

Repair the pipe as detailed below. This is based on a Butt Wrap Joint, Fittings manual chapter 6

See Fittings manual, chapter 6.1 for lay-up preparation.

See Fittings manual, chapter 6.3 for lay-up description

Total lay-up width = Length of damaged area + 2 times bond length from tables, Fittings
manual, enclosures 10.2 to 10.8.

E: Multiple leaks along the pipe

Cut away the leaking part and re-test the remaining pipe(s) or scrap the pipe.

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(7.6.4) Procedure no. 4

To be used for repair of internal surface delamination in interior surface mat and liner.
Samples of such delaminations are rip-offs caused by the saw or rough handling of the pipe.
Evaluate degree of delamination.

A. Damage is in the interior surface mat:

1. Grind away the delaminated area.

2. Remove dust

3. Coat the ground surface with resin

B. Damage is deep into the liner

1. Grind the pipe surface beyond the delaminated area

2. Remove dust from the surface.

3. Wet out the ground surface with resin.

4. Apply 1 layer of 450 g/m2 chopped strand mat.

5. Coat with resin.

6. After curing, grind off excess material and protruding fibres.

(7.6.5) Procedure no. 5.

To be used for repair of local outside damage going down into the outer skin.
1. Grind away the damaged part of the laminate

2A. Gravity pipe.

Grind the pipe surface beyond the damaged part in all directions in a distance
according to the Fittings Manual.

Wet out the ground surface with resin and build up a laminate to fill the groove, with
chop mat + woven roving or combine. Start with a chop mat and alternate with
woven roving plies. When the groove is filled continue the lamination extending it to
cover all the ground surface. The laminate should have a thickness according to the
Fittings Manual and be tapered to pipe wall over a distance of 4 times the thickness
of the overlapping laminate.

The first and the last ply in the lamination should be a chop mat.

2B. Pressure pipe

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 Grind the pipe surface on both sides of the damaged spot in axial direction in a
distance according to the Fittings Manual, and all around the circumference of the
pipe.

Remove dust from the surface.

Wet out the ground area with resin just prior to application of the first ply of mat.

Build up a laminate to fill the groove of the damaged spot with chop mat + woven
roving or combine. Start with a chop mat and alternate with woven roving plies.

When the groove is filled continue the lamination and extend it to cover all the
ground surface. The laminate should have a thickness according to the Fittings
Manual (910101), sections 10.3 to 10.8, and be tapered to pipe wall over a distance
of 4 times the thickness of the overlapping laminate.

Finish the lamination with a surface veil.

After any repair, the pipe shall be inspected to see if the repair job is done satisfactory. The
repairs shall be logged in a pipe repair report.
Based on the controls and inspections the pipes are marked and sorted in different
categories.
A. Meets specifications
B. Further controls required
C. Will meet specifications after repair
D. Cannot be repaired to meet specification, but can be used for special applications.
E. Scrap, cannot be used
Example of sorting procedure and marking is shown in a separate section in the Pipe
Technologies manual.

(7.6.6) Health and safety

See the 961101 Occupational Health and Safety manual.

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