GRP Pipes

(Glass Reinforced Plastic Pipes)

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GRP Pipes
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 History of GRP

In 1930s extensive researches were being done on fiber reinforced plastic for
commercializing its use. It was of main interest to aviation industry due to its
strength, weather resistant qualities, and it’s relative weight.
Mass production of glass strands was accidentally discovered in 1932 when a
researcher at the Owens-Illinois accidentally directed a jet of compressed air at a
stream of molten glass and produced fibers. Owens joined up with the Corning
company in 1935 and the method was adapted by Owens Corning to produce its
patented "Fiberglas”. A suitable resin for combining the "Fiberglas" with a plastic
was developed in 1936 by du Pont.
During World War II it was developed as a replacement for the molded plywood
used in aircraft radomes (fiberglass being transparent to microwaves). Its first main
civilian application was for building of boats and sports car bodies, where it gained
acceptance in the 1950s.
It is loved for its considerable design flexibility, which is a combination of its relative
light weightiness with a strong inherent strength. In addition, its weather resistant
finish can be achieved in a variety of surface textures and an amazing array of
colors.

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 Why GRP ???

 Corrosion resistant
 Abundance of raw material
 Chemically resistant to a large extent
 Less manufacturing cost
 Safer manufacturing process
 Fabrication/fit up is easy at site
 Less maintenance required
 Longer life
 Lighter in weight

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 Application of GRP Pipes

 Water distribution (civil and industrial)

 Sewer systems (urban and industrial)
 Irrigation networks
 Water intakes for cooling water systems
 Waste water outfalls to sea
 Process lines for industrial plants
 Fire fighting networks
 Corrosive fluids and vent gas stacks
 Chemical Process Piping

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 Our relation with GRP

As Adani we are major purchaser of GRP Pipes in our Mundra TPP, Dahej TPP &
Mundra port because of its anti corrosive nature.
Following are the major area of usage:
 CW Blow Down System
 Integrate Ash Handling System
 Sea Water Flue Gas Desulphurization Pipe
 Domestic Sewage Treatment Plant
 Industrial Waste water treatment Plant
Chlorination Plant
 ETP Waste Water Pump House

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 CODES AND STANDARDS
IS 12709
Standard Specification for GRP pipe, fittings & joints using for potable water
supply.
IS 14402
Standard Specification for GRP/GRE pipe, fittings & joints using for
sewerage water supply
ASTM D2996
Standard Specification for Filament-Wound "Fiberglass" (Glass-Fiber
Reinforced Thermosetting-Resin) Pipe
ASTM D3262
Standard Specification for "Fiberglass" (Glass-Fiber-Reinforced
Thermosetting-Resin) Sewer Pipe

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 CODES AND STANDARDS(contd.)

ASTM D3517
Standard Specification for "Fiberglass" (Glass-Fiber-Reinforced
Thermosetting-Resin) Pressure Pipe
ASTM D3754
Standard Specification for "Fiberglass" (Glass-Fiber-Reinforced
Thermosetting-Resin) Sewer and Industrial Pressure Pipe
ASTM D4161
Standard Specification for "Fiberglass" (Glass-Fiber-Reinforced
Thermosetting-Resin) Pipe Joints Using Flexible Elastomeric Seals

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Manufacturing of GRP Pipes

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Manufacturing of GRP Pipes

Layers of GRP Pipe

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 Basic Ingredients

GRP pipes are made using the following raw materials:

1) Thermoset Resins - such as vinyl ester or isophthalic polyester
resin.
2) Glass Fibre Reinforcements - such as low density surface
veils, Chopped Strand Mats (CSM) and rovings (woven or
continuous)
3) Additives like silica sand
4) Accelerators / Promoters - such as DEA, DMA and cobalt
naphthenate

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 Resins

 Isophthalic Polyester & Orthopthalic Resins

It has a good corrosion resistant to water and fluids with low acid
content up to a maximum operating temperature of about 60 °C.
 Bisphenol Polyester
This resin shows a high chemical inertness to both strong acids and
bases also at elevated temperature.
 Vinylester resin
It combines a very good chemical inertness to strong acids and bases
with high mechanical properties of the laminates. The suggested
uses are applications where either chemical resistance and
toughness are needed.
Appropriate type of unsaturated polyester resin systems conforming to
IS 6746 shall be used

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 Glass reinforcements

Typical glass reinforcements used are:

Surfacing "C" veil,

CSM (chopped strand mat) "E" glass
CR (continuous roving) "E" glass
WR (woven roving) “E” glass

Glass Fiber reinforcement shall conform to IS 11273, IS 11320 or IS 11551

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 Surface Veil
Surfacing "C" veil, consisting of randomly dispersed glass fibers bonded into
sheet by a polyester resin generally used as reinforcement for the first layer of
the laminate

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 Chopped Strand Mat
CSM (chopped strand mat) "E" glass, made of chopped strands bonded in
mat form with a powder binder and used in hand lay-up or contact molding
processes.

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 Fiber glass continuous roving
CR (continuous roving) "E" glass specially designed for fast wet-out, good
processing and handling characteristics as well as excellent adhesion with
polyester and vinyl ester used in filament winding processes.

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 Woven Resin
WR (woven roving) “E” glass composed of direct roving woven into a fabric
and designed to be compatible with most polyester hand lay-up resins.

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 Mechanically resistant layer

Glass reinforced layers guarantee the mechanical resistance of

the whole pipe against stresses due to internal and/or external
pressure, external loads due to handling and installation, thermal
loads.
The layer is obtained by applying, on the previous partly cured
liner, continuous rovings of glass wetted with resin. This layer can
contain aggregates (inert granular material such as silica sand) in
order to increase the stiffness of the whole pipe. Thickness of
mechanical resistant layer depends on the design conditions.
Size of the silica sand should be between 0.05mm to 0.8mm

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 Auxiliary raw materials

Auxiliary raw materials are all the technological additives used for
processing of reinforced resins such as promoters, accelerators,
catalysts, inhibitors, viscosity and density additives, aggregates, filler and
pigments.

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 GRP Pipe manufacturing methods

 Filament winding
• Reciprocal method
• Continuous methods
• Multiple mandrel method
• Ring and oscillating mandrel method
 Centrifugal Casting
• Preformed glass reinforcement sleeve method
• Chopped glass reinforcement method

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Schematic diagram of CFW machine

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CFW Machine

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 Hydraulic characteristics of GRP Pipes

The smooth interior results in low fluid resistance, which could lower horsepower
requirements for pump systems.
The interior surface typically remains smooth over the time in most fluid services.
Hence fluid resistance does not increase with age.
Smoother interior allows the pipe diameter to be reduced while maintaining the
desired flow.
Inside diameter (ID) is typically larger than IDs of many other pipe materials of
same nominal size and provide a larger pathway for fluid flow.

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 Mechanical Properties

Sr. No. Mechanical properties SI Unit

1 Tensile strength 50 – 550 MPa
2 Tensile modulus 3.5x103 - 34.5x103 MPa
3 Flexural strength 70 to 480 MPa
4 Flexural modulus 6.9x103 - 34.5x103 MPa
Coefficient of thermal
5 14x10-6 - 54x10-6 (mm/mm/ oC)
expansion
6 Specific gravity 1.2 – 2.3
7 Compressive strength 70 – 280 MPa

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 Physical Properties
Chemical Resistance
All fibre glass pipes provide excellent resistance to water and native ground
conditions. They are not subject to general corrosion attack, galvanic corrosion,
aerobic corrosion, pitting, dezincification, etc. It may subject to environmental
stresses and ageing effect.
Temperature resistance
For typical use in water supply systems fibreglass pipe is unaffected by service
temperature. The upper limit of the service temperature is influenced by the
chemical environment, stress condition and the type of resin used.
Abrasion Resistance
GRP pipes provides generally good abrasion resistance and can be custom
made for extremely abrasive services by providing silica flour / carborundum
lining / ceramic bedding.
Flame retardants
Thermal stability of the GRP pipes can be improved by using resin systems that
contains halogens or phosphorous, hydrated fillers, antimony oxide.

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 Physical Properties
Weathering Resistance
Weathering studies have shown that structural integrity of the GRP pipe remains
unaffected by exposure to UV rays. Any surface degradation can be controlled by
adding UV stabilizers in the resin system used in the layer to be exposed.
Resistance to biological attack
GRP pipes does not deteriorate break down under the attack from bacteria or other
micro-organism. No special engineering or installation procedures are required to
protect GRP pipes from biological attack.

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 Features & Benefits over other pipes :
Sl. No. FEATURES BENEFITS
1 Inherent Corrosion • Long, maintenance-free service life
Resistance • No add-on linings or coatings to damage,
repair, inspect or maintain.
• Lowest Life Cycle cost
2 Smooth I.D. • Superior hydraulic characteristics
• High flow capacity
• Significant energy savings in pumped
systems
3 Lightweight • Less expensive equipment for handling
4 Long Length Sections • Fewer joints to assemble
5 Resilient Inner Liner • Excellent abrasion and crack resistance
6 Computer Controlled • Consistent high quality pipe
Production • Reduced risk with fewer problems

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 Features & Benefits over other pipes :
Sl. No. FEATURES
7 High Stiffness, Solid Pipe
Wall with High Compressive
Load Capacity
8 Gasket-Sealed, Push-
Together Joints
9 Leak-free Joints
10 Smooth, Dimensionally
Consistent O.D.
BENEFITS
• Easy to bury using routine methods
• Predictable performance
• Easily handles deep covers
• Fast, fool-proof assembly
• No bonding agents, bolts or welding
needed
• Zero infiltration, lower treatment costs
• No ground water pollution
• Field length adjustments easy – pipe
may be cut anywhere along length and
assembled with gasketed joint
• Lowest jacking loads
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 Disadvantages of GRP pipes
 Performance and durability of GRP pipes may be sensitive to damage
incurred by poor handling and installation practices.
 External impact can induce star cracking of the barrier layer on the pipe bore with
no apparent damage to the surface of the pipe.
 They are not suitable where there is high risk of third party interference after
installation.
 Though GRP pipes have excellent corrosion resistant properties, they can suffer
strain corrosion in acidic environments.
 Anchor blocks must be designed to withstand the bursting stress generated when
the GRP pipeline is under pressure.

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 Test Methods

IS 12709 : 1994

Standard Specification for GRP pipe, fittings & joints using for potable
water supply.
IS 14402 : 1996
Standard Specification for GRP/GRE pipe, fittings & joints using for
sewerage water supply
ASTM D1598
Standard Test Method for Time-to-Failure of Plastic Pipe Under
Constant Internal Pressure
ASTM D1599
Standard Test Method for Short Term Hydraulic Failure Pressure of
Plastic Pipe, Tubing and Fittings

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 Test Methods

ASTM D2412
Standard Test Method for Determination of External Loading
Characteristics of Plastics Pipe by Parallel-Plate Loading
ASTM D2924
Standard Test Method for External Pressure Resistance of Reinforced
Thermosetting-Resin Pipe
ASTM D3681
Standard Test Method for Chemical Resistance of "Fiberglass”(Glass-
Fiber-Reinforced Thermosetting-Resin) Pipe in a Deflected Condition

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 Testing of GRP Pipes

Visual Inspection

Mechanical Testing

Chemical Testing
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 Visual Inspection

What we do in it?
 Check for surface defects like
• Cracks,
 Comparison
• Dry spot,
 Workmanship • Pits
 Check dimension • Excess resin,

 Hardness of pipe • Wrinkles,

• Blisters,
• Foreign inclusions,
• Resin starved areas,
• Indentations,
• Delaminations,
• Pin holes etc.

A list of all visual defects is in table 3 of IS 14402

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 Dimensional Inspection
 Inside Diameter shall be measured at 150mm away from each end
of pipe section using a steel tape or an inside micrometer with
graduation of 1mm or less. Two 90° opposing measurement at each
point of measurement shall be made & average of the readings to be
taken.
 Outside Diameter shall be measured 150mm away from each end
of pipe.
 Length of the pipe shall be measured by a steel tape by laying the
tape inside the pipe. Tolerance: ±15mm
 Wall thickness shall be measured by micrometer at 4 points equally
spaced on the circumference of the pipe. Tolerance:
negative tolerance not allowed
 Squareness of the pipe shall be measured by rotating the pipe on
mandrel & measuring the runout of ends with help of a dial indicator .
Tolerance: ±6.5mm or ±0.5 percent of nominal dia of pipe whichever is
greater

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 Mechanical Tests

 Hydro test of pipes & assembly with fitting (1 type)

 Hoop tensile strength
 Longitudinal strength
 Stiffness
 Long term hydrostatic design pressure test

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Hydro Test

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Hoop Tensile Test

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Hoop Tensile Testing Machine

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Longitudinal Strength test

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Universal Tensile Testing Machine

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Stiffness Test

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Long term hydrostatic design pressure test

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 Chemical Tests
Item Characteristics Relevant Standards Acceptance Norms
Relative density
Viscosity
Resin Material Properties IS 14402 clause 2 IS 14402 clause 2
(Vinyl Ester, Isopthalic resin) Gel time (IS 6746:1994) (IS 6746:1994)
Volatile content
Acid value
Roving weight (Tex.) ± 8%
Moisture content Max 0.3%
IS 14402 clause 2
Fire glass roving Loss on ignition ±20%
(IS 11320:1997)
Cross breaking strength of rod Dry-585MPa Wet-490 Mpa
Conductivity of water extract Max 1.25 mS/m
% variation in mass per unit area 19%
Moisture content Max 0.5%
IS 14402 clause 2
Chopped Strand Mat
Conductivity of water extract (IS 11551:1986) Max 1.25 mS/m

Cross breaking strength of laminate Dry-180 MPa Wet-135 Mpa

TC review IS 14402 IS 14402

Silica sand
Chemical IS 14402 IS 14402

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 Joint Design

BELL & SPIGOT WITH RUBBER SEALING RINGS

COUPLER WITH RUBBER SEALING RINGS

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 Joint Design
BUTT & WRAP JOINT (LAMINATED OVERLAY)

FLANGED JOINT

Elastomeric Gaskets when used with pipe shall conform to the

requirement of IS 5382
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 Precaution to be taken during laying of pipes

 Fit up should be as per manufacturer’s guidelines

 Pipes should be properly cleaned including ring groove
 Qualified & skilled person to perform the joining
 Proper sand bed to be made before laying of pipes
 Benchmark & depth of ditch to be monitored regularly
 Sand bedding to be made up from coarse to medium grade sand
 The backfill soil should not contain silt, peat, nugget etc.
 Compacting should achieve 90% of relative density
 Sand cover on the top of pipe shall be as per design & manufacture’s guidelines
 Trench should be as per the drawing & must have min 300mm of space from
both ends of pipe
 Compaction to be checked at min 3 places i.e. at set bed, after half of the dia of
pipe is covered by backfill & after completly burying the pipe

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