Future Pipe Group

Fiberstrong Aboveground Pipe System

Selection & Installation Guide
Preface

All the contents and data published in this brochure are the property of the Future Pipe Group. No
photocopies, microfilms of this brochure are allowed without a prior written authorization from the
Future Pipe Group.

The Future Pipe Group reserves its right to change the published data in this brochure without any
prior notification. Published data can be changed, by the Future Pipe Group, in the case of a specif-
ic project requirements.

For any technical query, please consult the Future Pipe Group engineers.

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 Table of Content
I Introduction Page 4
Product Range
Applicable Standards/Codes
II- Construction Page 5
Type of Resin
Thickness Calculation
III- Physical / Mechanical Properties Page 6
Dimensions
Thermal Expansion
Poisson Ratio
Flow Characteristic
Material Properties
IV- JOINTS Page 8
Lamination
Flanges
V- Fiberglass Flanges Page 11
Connection Against Raised Face Flange
Tightening Sequence of Fiberglass Flanges
Gasket and Torques
Flange 1500 mm and Lager
IV Handling Page 17
Receiving
Unloading
Storing
Handling of Nested Pipes
VII- Accessories Page 20
Supports
Valves
Bellows
Connection to Other Materials
Threaded Nipple
VIII- U.V. Resistance Page 23

IX- Pipe Connection Through Concrete Walls Page 24

3
I- Introduction

1.0 Product Range

Fiberstrong pipes for aboveground applications, are Glass Reinforced Plastics (GRP), flexible, self-
restrained, corrosion resistant and are designed for aboveground and underground installations. It
consists of a thermosetting chemical-resistant resin and fiberglass reinforcements. Fiberstrong pipes
are manufactured using the continuous filament winding or the reciprocal filament winding process,
according to AWWA M 45. Nominal internal diameter is 25 mm up to 2500 mm. Larger diameters
are available upon request.

Available standard pressure classes are 7, 10, 12, 16, 20 and 25 bar. Higher-pressure ratings are
available upon request. The same pipes can be designed for use under full vacuum conditions and
also can be used for underground applications.

Fiberstrong pipes 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.

2.0 Applicable Codes / Standards

ASTM D 2996 : Standard Specification for Filament-Wound “Fiberglass”

(Glass-Fiber-Reinforced Thermosetting-Resin ) Pipe

ASTM D-3517 : Standard Specification for “Fiberglass”

(Glass-Fiber-Reinforced Thermosetting-Resin ) Pressure Pipe

ASTM D-3262 : Standard Specification for “Fiberglass”

(Glass-Fiber-Reinforced Thermosetting-Resin ) Sewer Pipe
ASTM D-3754 : Standard Specification for “Fiberglass”
(Glass-Fiber-ReinforcedThermosetting-Resin) Sewerand -
Industrial Pressure Pipe

AWWA C-950 : Fiberglass Pressure Pipe

AWWA M45 : Fiberglass Pipe Design Manual

ASME B31.3 : Process Piping

BS 5480 : British Standard Specification for Glass reinforced plastics

(GRP) pipes, joints and fittings for use for water supply or –
sewerage

BS 7159 : British Standard Code of practice for Design and construction of glass
reinforced plastics ( GRP) piping systems for individual plants or sites

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 II- Construction

The pipe is a composite laminate consisting of a corrosion resistant liner, a structural layer and an
exterior resin rich layer.

External Layer

Structure layer

Inner layer

Figure 1

1.0 The type of resins used in the Fiberstrong pipe construction:

Resin System
Liner Structure
Isophtalic polyester Isophtalic polyester
Epoxy based vinylester Isophtalic polyester
Epoxy based vinylester Epoxy based vinylester

Table 1

*Maximum service temperature can change depending on the service requirements. Please consult our
engineers.

5
2.0 Thickness Calculation:
The pipe minimum reinforced wall thickness, TE , is the largest of:

TEP = PN x ID
2SA,W - PN

Pressure Thickness (based on hoop stress)

Where:
TEP = minimum reinforced wall thickness (mm)
ID = inner diameter (mm)
SA,W = Design Stress for determination of wall
thickness (N/mm_)
PN = Nominal Pressure (Pressure Class)
(MPa)

Buckling Thickness (for aboveground installation use)

4 4 6 2 3 1/10
PB L DM (1-v )
TEB =
0.107 EHF4

Where:
TEB = pipe structural wall thickness (mm)
2
ν = product of both Poisson ratios
Dm = pipe mean diameter (mm)
PB = required buckling pressure (MPa)
EHF = structural hoop flexural modulus (MPa)
L = length between stiff ends (mm)
(generally support distance)

III- Physical/Mechanical Properties

1.0 Dimensions

DIMENSIONS SPECIFICATION TOLERANCE

Pipe Inside 4 mm or 1.0%,
Diameter (D) Equal to ND whichever is larger
Length 3, 10 or 11.8 meters +/- 25 mm
Roundness
Deviation Pipes shall be round + 1.0%
End Squareness End shall be both Not more than
End Plainness Square to the 2 mm + 0.005 x D
Axis of pipe and
plane

Table 2

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 2.0 Thermal Expansion

-6
The axial co-efficient of thermal expansion is 18 to 27 x 10 cm/cm x ºC (measured according to
ASTM D696).

3.0 Poisson’s Ratio

Axial/Hoop due to Load in Hoop direction 0.3

Hoop/Axial due to Load in Axial direction 0.25

4.0 Flow Characteristics

Pipe wall friction factors:

Darcy, Fanning, Weisbach f = 0.010 to 0.018
Hazen Williams C1 = 130 to 145
Manning n = 0.0095 to 0.012

5.0 Material Properties

Property Test Method Value Unit

Axial Tensile Modulus ASTM D 2105 11000 MPa

Axial Tensile Strength ASTM D 2015 75 MPa
Hoop Tensile Modulus ASTM D 2290 20000/20500 MPa
Hoop Flexural Modulus ASTM D 2412 20 000 MPa
Hoop Tensile Strength ASTM D 2290 210/250 MPa
Shear Modulus 11700 MPa
Laminate Density 1.750 kg/m_

Table 3

Volumetric Elasticity modulus : Ev = 22000 N/mm2 for a restrained system.

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 IV- Joints

1.0 Lamination

It is recommended that the pipe manufacturer provides assistance for this type of joint.

Figure 2

This procedure describes the steps to be followed for Field Joint Lamination of GRP pipes

I Preparations
A. Check the pipes routing as per approved drawings

B. Check the alignment and level of pipes.

C. Check if any damage has occurred during unloading and/or laying.

D. Ensure that the gap between the two pipes to be laminated is within the allowable limit.

II Procedure
A. External Lamination
1. Fit layer
a. Measure the fit layer bond length from the end of each pipe

b. Grind the above area to remove the surface layer of the pipes

c. Clean this area and ensure that it is fully dry

d. Fill the gap, if any, between the two pipes with cab-o-seal putty

e. Mix the resin and hardener as per the quantities specified in the recipe to maintain the
right ratio

f. Impregnate the roughened area with the above mixture

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 g. Apply 2 layers of woven roving glass 280 using a 50% overlap between each two con
secutive windings so that wrapping the full surface will end up with two layers of glass

h. Impregnate the above layers with the resin/hardener mixture

i. Repeat the above two steps till the required number of layers is applied

j. Wait till the lamination is cured under ambient temperature

2. Main Laminate

a. Measure the bond length on each pipe from the middle of the fit layer

b. Grind the above area to remove the surface layer.

c. Clean this area and ensure that it is fully dry

d. Mix the resin and hardener as per the quantities specified in the recipe to maintain the
right ratio

e. Impregnate the above area with the resin/hardener mixture

f. Apply 2 layers of woven roving glass 280 using 50% overlap between each two consec
utive windings so that wrapping the full surface will end up with two layers of glass

g. Impregnate the above layers with the resin/hardener mixture

h. Repeat the above two steps till the required number of layers is applied

i. Depending on the pipe diameter and pressure class, the type of glass and the number of
layers are specified in the lamination recipe. If only glass 280 should be used, skip all
the below steps except the last one to end up the lamination with two layers of Top
Tape. Otherwise, move to the next step.

j. Apply 2 layers of woven roving glass 360 using 50% overlap between each two consec
utive windings so that wrapping the full surface will end up with two layers of glass

k. Impregnate the above layers with the resin/hardener mixture

l. Repeat the above two steps till the required number of layers is applied. A maximum of
12 layers should be applied at this stage

m. If more layers should be applied, move to the following steps. Otherwise, skip all the
below steps except the last one to end up the lamination with two layers of Top Tape

n. Apply the specified number of layers of woven roving 580 and 360 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

o. Apply two layers of woven roving glass 360

p. Impregnate the above layers with the resin/hardener mixture

q. Wind 2 layers of top tape glass around the laminate to extract the excess quantity of
resin and to provide smooth surface.

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 B. Internal Lamination
The following steps are to be done inside the pipes if access is possible:

a. Measure a length of 50 mm from the end of each pipe

b. Grind the above area to remove the internal liner of the pipe
c. Cut several pieces of woven roving glass 280/100 with equal length
d. Mix the right quantity of resin and hardener
e. Wet the surface area of internal layer with the mixture
f. Stack several pieces of woven roving on a flat surface and impregnate with the resin mixture
j. Place the above impregnated woven roving on the joint
i. Evenly press the surface to flush air traps and blisters using steel roller
k. Repeat the above three steps until the required thickness is reached
l. Cover the above laminate with two layers of surface mat to provide a smooth resin-rich lami
nate surface

2.0 Flanges

Standard flanges are drilled to BS 4504 PN-10 pattern. Other drilling standards are also available.

Figure 3

V- Fiberglass Flanges

These instructions present our recommendation for the proper installation and use of fiberglass
flanges.

1.0 Connection Against Raised Face flange:

Fiberglass flanges must be connected against flat faced flanges. If this is not possible, special pre
cautions should be taken.

The gap between the raised face and the flat face must be filled with a stainless steel washer or a hard
gasket (C.A.F.) of a thickness equal to the raised face. Fiberglass spacers may also be used as an
alternative.
10
 Figure 4

A second alternative is removing the raised face if possible.

1.1 Tightening sequence of Fiberglass Flanges

Figure 5

Tightening of the bolts of a flange connection must be done according to the diagonal sequence
as shown in the above example.

The flange must be connected perpendicular to the axis of the pipe.

The maximum allowable deviation is as follows:

- For pipe diameter 300 mm and below : 1 mm

- For pipe diameter 350 to 600 mm : 2 mm
- For pipe diameter 700 mm and larger. : 3 mm

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 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 Fiberglass pipeline is connected to a metal
line, this metal line must be anchored to prevent any movements or loads being transmitted to the
Fiberglass line.

1.2 Gaskets and Torques

As sealing for Fiberglass flanges, several gaskets types may be used, depending on the diameter,
system pressure or specific requirements of the client.

When assembling Fiberglass flanges, bolts should be tightened by hand first, then using a torque wrench
up to 30 % of the max. torque value shown below and on the following pages. If flanges are not leak
tight, torques should be increased up to 60 % of the max. torque values shown. After all bolts have been
tightened to the recommended torque, recheck the torque on each soil in the same sequence, since previ-
ously tightened bolts may have relaxed. Max. torque values shown are `Ultimate’ and should be avoided
under normal site conditions. Always follow the correct torqueing sequence specified. Consult the man-
ufacturer for further assistance. Excess torque can prevent sealing and can damage flanges.

 CAF (Compressed Asbestos Fibres)

Recommended quality IT-c (acc. DIN 3754)

Type Size : Full face t = 3 mm
Trade Name : Frenzelit-chemie, Reinz Universal, walkerite
Application : diam. 25 mm to 300 mm.

Torques if assembled against flat faced flanges

ID (mm) Max torque (Nm) Max torque (Nm) Max torque (Nm)
DIN 1882 DIN 2502 ND 16 DIN 2501 ND 25
DIN 2501 ND 10 ASA 150 ASA 300

25 70 70 100
40 100 100 150
50 100 100 150
80 100 100 150
100 100 100 250
150 150 150 250
200 150 150 300
250 150 300 500
300 150 300 550

Table 4.a

Torques if assembled against raised-face flanges

ID Torque
(mm) (Nm)

25 - 80 25
100, 150 50
200, 250 75
300 100
Table 4.b

Note : The above values are valid for pressure up to 25 bar and for all mentioned bores.

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 CAF with O-ring Seal.

This is a CAF gasket with an o-ring seal placed at the innerside.

The material of this o-ring depends on the medium to be transported.

Type Size : Full face t = 5

O Ring size : The diameter of the ‘O’ Ring is 8 mm.
Application : diameters 350 mm through 800 mm, pressure up to16 bar
diameters 900 mm through 1200 mm, pressure up to10 bar

Torques if assembled against flat faced flanges

ID (mm) Torque (Nm)

350-450 400
500-600 500
700-1400 700
Table 5

Note : The above values are valid for above mentioned classes and all bores.

 Rubber Gasket with Inner Layer.

The kind of rubber depends on the medium to be transported.

Type Size : Full-face t = 5 mm

Trade name : Eriks, Reinz
Application : All diameters, pressure class up to 10 bar.

Torques if assembled against flat faced flanges

ID (mm) Max Torque (Nm)

350-450 400
500-600 500
700-1400 700
Table 6

 Rubber Gasket with Steel Inner Layer.

This gasket is located on the inside of the bolt circle.

Type/Size : The kind of rubber depends on the medium to be transported.

The thickness depends on the diameter.

Trade Name : Kroll & Ziller

Application : diameters 25 mm to 300 mm, pressure class up to 25 bar.
diameters 350 mm to 1400 mm, pressure class up to 8 bar.

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 ID (mm) Max* Torque (Nm)

25-80 25
100,150 50
200,250 75
300 100
350-1400 150
Table 7

Note : The above mentioned values are also valid for butterfly valves with integral rubber sealing gaskets
located inside the bolt circle. For this type of butterfly valves no other gasket is required.

 Neoprene rubber gasket with “O” Ring Seal

This gasket can be used for pressures up to 10 bars (150 psi).

Type/Size : Full face (t = 5 mm with shore `A’ durometer_

hardness of 60 ± 5 for sizes large the 300 mm or t = 3 mm for other sizes.

“O” Ring size:8 mm (For sizes larger than 300 mm)

Trade Name: Neoprene sheet rubber gasket.

Applications: Diameters up to 1400 mm pressure class up to 10 bars.

Torques in N. m

ID (mm) Max* Torque (Nm)

25 – 100 55 N.m
150 55 N. m
200 100 N.m
250 110 N.m
300 125 N.m
350 – 450 300 N m
500 – 600 400 N m
700 - 1400 500 N m

Table 8

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Flanges 1500 mm and Larger

These flanges are low torque flanges. The sealing is by an “O” ring contained in a groove mold-
ed into the flange face. This “O” ring minimizes problems due to excessive bolt torque loads,
which can result in flange damage.

Note : Two flanges with an “O” ring cannot be jointed to each other. In this case one of the
flanges must be made without a groove.

The “O” ring used for the sealing may be made of EPDM or natural rubber with a shore hard-
ness of 60.

Figure 6

Maximum Torque value is 100 N m

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VI- Handling

1.0 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.
Inspection is thoroughly 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.

The Contractor should make the following inspection at the time of the reception of the goods:

a- Each item should be inspected with care upon its arrival.

b- Total quantity of pipes, fittings, etc… should be carefully checked against our delivery notes.
c- Any damaged or missing item must be pointed out to the dispatcher or driver and noted on the deliv-
ery 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.

Note: Damaged material must not be used before it is repaired.

2.0 Unloading Pipe

Unloading at the job site 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...)

2.1 Unloading by hand

Unloading by hand with two men should be done for small diameter pipes, not exceeding 60 kg.

2.2 Mechanical unloading

Mechanical unloading is required for pipes heavier than 60 kg. Flexible slings or straps should be used
combined with a mobile crane. When unloading 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 the pipe.

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3.0 Storing FIBERSTRONG Pipes on Site
3.1 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 pipes if possible on
soft level ground (e.g sand), timber bearers or sand bags.

Caution : Pipes must not be stored on rocks.

3.2 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 the below table. This height is limited for safety purpose and to avoid excessive loads on the pipe dur-
ing storage.

DN 80 - 400 450 - 600 700 - 800 900 – 1400 ≥ 1500

Layers in stock pile 5 4 3 2 1

h max. <2m < 2.4 m < 2.4 m < 2.8 m

Table 9 : Storing/stacking height

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 below figure.

Figure 7 : pipe storage

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4.0 Handling of Nested Pipes

For some projects, pipes may be delivered nested (i.e. one or more small pipe 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 insure 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 insure the safety of site personnel. The Contractor should insure 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 lift-
ing capacity should be appropriate to handle the weight and length of pipes being de-nested. Below fig-
ure 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 damag-
ing the inside of the pipes.

The Forklift operator should lift the innermost pipe above the pipe around it sufficiently so the pipes do
not touch each other when the inner pipe is being pulled out.

Figure 8: pipes De-nesting

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VII- Accessories
1.0 Supports

Above ground systems should be properly supported to control pipe movements and accommodate the
various stresses from operations. The location and function of the supports along the pipeline should
be identified by an experienced engineer, who will base his recommendations on a stress and/or surge
analysis of the system. All the relevant information should be made available to enable the engineer
to consider all the factors related to the loads built up in the system.

Below figures show the details of sample pipe and flange supports.

Figure 9

Figure 10

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1.1 Valves

To avoid the pipes being over-stressed by bending, gate 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.

Figure 11

If a Fiberstrong flange is connected to a steel flange, the support shall be located at the side
of the steel flange. Hand operated butterfly valves can be supported or mounted.

Note : For the valves installed on branch saddles, care shall be taken to install gussets plates to
reinforce the branch. A valve support may also be required for heavy flanges.

1.2 Bellows

Low amplitude vibrations are easily absorbed by Fibertsrong due to the low E-modulus of
Fibertsrong material.

To eliminate high amplitude vibrations caused by pumps and to eliminate soil settlements
or expansion of tanks connected to the Fibertsrong pipes, bellows may be employed.
Bellows may also be employed where straight piece of pipe is used and no expansion loops
can be applied, or for branches if main pipeline may expand and move (and such movement
may affect the rigid joint between the branch and main line).

In many cases it is 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 sepa-
rately to absorb the pipe loads.

Figure 12

20
Bellows may also be employed to facilitate the removal of the pipe sections, valves, orifice flanges
or gaskets for repair purposes. The flexibility of the bellow provides a play of 10 mm up to 20 mm,
which allows an easy and quick dismantling and installation of flanged components.

1.3 Connection to other materials

The most appropriate joint to interconnect piping components of different materials is the
flanged joint. Also, the mechanical coupler can be used as an alternative.
Flange drillings are made according to the international standards. The flanged connec-
tions can be used with standard Fibertsrong products.

Figure 13

When a flanged Fibertsrong 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
Fibertsrong pipe section.

1.4 The case of threaded nipple

Threaded nipple connections are available up to 1.5”, the type of thread is to be selected.

21
VIII- U.V. Resistance
Fiberstrong pipes contains U.V. inhibitor. This layer offers sufficient protection against
U.V. radiation.

After a long exposure to the ambient atmosphere (sunlight, etc…) the topcoat layer might
show some chalking. This chalky layer has a superficial effect and doesn’t affect the
integrity of the product. If the appearance of pipes is important a protective polyurethane
paint coating can easily be applied.

Painting procedure is as follows:

- Clean the outside surface with thinner (e.g. Redox 0256 thinner or equivalent).

- Apply one layer of primer (e.g. EP 3200 Redox sealer, colour red brown or beige,
recoatable after 8 hours at 20°C. approx. coverage 5.5 m2/l).

- Apply one layer of topcoat (e.g. Redox PUR 3355 polyurethane HB, colour white,
recoatable after 8 hours at 20°C, approx. coverage 4.8 m2/l).

If painting of a recently installed pipe is required, the surface of the pipe shall be rough-
ened in order to get a proper adhesion.

IX- Pipe Connections Through Concrete Walls

When a pipe is passing through a concrete wall, two alternatives can be followed:

a) Rubber Wrapping:
Wrap the outer diameter of Fibrestrong pipe with Neoprene rubber of 50 shore
hardness. The rubber wrapping is continuous along the wall thickness and should
protrude 10 cm from the wall. The rubber thickness is to be calculated based on the
wall settlement and rubber compressibility.

b) Pipe Sleeve
The Fibrestrong pipe should pass though a sleeve cast in concrete wall. The annu-
lar space in between the pipe and sleeve is filled with polyurethane foam.

22