Design Manual

RPS Design Manual

Engineered Composite Solutions

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 Design Manual

TABLE OF CONTENTS

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ABOVE GROUND PIPE & FITTING DESIGN . . . . . . . . . . . . . . . . . . . 10

DESCRIPTION OF FRP MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Filament Wound Pipe Design. . . . . . . . . . . . . . . . . . . . . . . 10
Glass Reinforcements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Contact Molded Pipe & Fitting Design. . . . . . . . . . . . . . . . 11
Resins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Pressure Stress Multipliers and Fitting Design. . . . . . . . . 11
Additives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Design for Vacuum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MANUFACTURING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ABOVE GROUND PIPING SYSTEM DESIGN. . . . . . . . . . . . . . . . . . . 13
Filament Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Differences between FRP and Steel & General
Custom Contact Molding. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PIPE PROPERTIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Recommended Hanger Spacing for 150 psi
General Physical Properties. . . . . . . . . . . . . . . . . . . . . . . . . .7 Rated Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Mechanical Properties of Filament Wound Pipe. . . . . . . . . 7 Pipe Supports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Mechanical Properties of Hand Lay-up Pipe and Fittings. 7 Design for Thermal Expansion. . . . . . . . . . . . . . . . . . . . . . 15
Mechanical Properties of Corrosion Barrier. . . . . . . . . . . . . 7 Pipe Stress Analysis and Allowable Stress. . . . . . . . . . . . . 19
Composite Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 BURIED PIPE DESIGN & INSTALLATION. . . . . . . . . . . . . . . . . . . . . 21
HYDRAULICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 JOINING SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Friction Loss Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 QUALITY ASSURANCE and RESEARCH & DEVELOPMENT. . . . . . 28
Head Loss in Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REFERENCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Transient Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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INTRODUCTION
RPS COMPOSITES (RPS) produces fibreglass reinforced plastic (FRP)
pipe and fittings intended for use in a wide variety of applications.
The intent of this manual is to provide designers and users with the
tools necessary to confidently design or specify above-ground or
buried piping systems utilizing RPS components.

DESCRIPTION OF FRP MATERIALS

• Fibreglass reinforced plastics are composite products consisting
of glass reinforcement embedded in thermosetting resin. The glass fibres are not continuous, it is difficult for chemicals to
usage of FRP has grown steadily over the past three decades penetrate the laminate by following along the fibre. Thus, the
due to the advantages that FRP offers over traditional materials. chopped strand mat in the corrosion barrier is often referred to
Some of the advantages of FRP are: as the “anti-wicking” barrier. Chopped strand mat is available
• Excellent Corrosion Resistance in a variety of weights with 1-1/2 oz. per square foot the most
• High strength to weight ratio commonly utilized.
• Light weight compared to most metals • WOVEN ROVING – Also commonly used, this type of
• Non-conductive to electricity reinforcement utilizes glass fibres orientated in the 0°/90°direc-
• Dimensionally stable tions. Unlike chopped stand mat, the fibres are continuous and
• Low maintenance costs no binder is used to hold the arrangement together. Woven
• Unlimited shape/size configurations roving lacks the chemical resistance of chopped strand mat
• Orthotropic in nature (different properties in different directions) due to the continuity of the glass fibres and high glass content;
• FRP consists of three main components: however; it does offer increased strength. Typically, laminates
• Glass Reinforcements over ¼” thick should incorporate woven roving, where possible,
• Resin to improve strength properties. Woven roving layers should
• Additives always be preceded and followed by chopped strand mat layers
to maximize adhesion. Woven Roving is commonly used with a
A description of these components, and how they are used at RPS is glass weight of 24 oz. per square yard (2.67 oz. per square foot).
summarized below:
• CONTINUOUS ROVING – This type of reinforcement is used in the
Glass Reinforcements structural layers of filament wound piping and in the structural
The mechanical strength of FRP depends on the type, amount, and layers of some fittings, such as on the exterior of larger diameter
orientation of the glass reinforcement within the part. The strength elbows. The high glass content (low resin content) created by
of an FRP laminate will increase as more layers of glass reinforcement applying the continuous rovings provides high strength in the
are used and as the ratio of glass to resin is increased.(i.e more glass direction of the fibre. Continuous rovings should not be exposed
per unit volume). Several types of glass reinforcements are utilized at to chemical environments as they could allow “wicking” of
RPS and can be summarized as follows: chemicals into the laminate.

• CHOPPED STRAND MAT – This type of reinforcement utilizes • SURFACING VEIL – As the name implies, surfacing veils are
short glass fibres (typically ½” to 2” long), randomly oriented generally only used on the surface of laminates. The veil layer
and held together with a resinous binder. Chopped strand mat provides a high resin to reinforcement ratio (typically 90:10),
provides good chemical resistance due to the high resin, low which creates excellent chemical resistance at the part’s surface,
glass ratio achieved in the application of the material. Since the where it is most needed. All corrosion barriers in RPS products
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are started with one layer of surfacing veil. For increased Isophthalic’s or “Iso’s” offer good chemical resistance at lower
chemical resistance, two layers of veil can be used; however, cost compared to vinyl esters. In mild to moderate corrosive
beyond this, the corrosion barrier may be susceptible to cracking applications, isophthalic’s can be an economical alternative.
due to the high resin content created with the surfacing veil.
• FIRE RETARDENT RESINS – All of the resin types mentioned
Nexus surfacing veil is a polyester product, which provides
above are available in fire retardant versions. These fire
good chemical resistance, appearance and workability. “C”
retardant derivatives generally incorporate bromine and
glass veil is a corrosion resistant glass veil which also provides
antimony compounds to improve fire resistance and create a
good characteristics. The choice to use C glass veil versus Nexus
laminate, which is self-extinguishing when the flame source is
is usually a matter of preference concerning workability, with
removed. Most fire retardant resins will provide a Class 1 flame
most manufacturers using one or the other. It should be noted,
spread rating when tested in accordance to ASTM E-84.
however, that C glass veil is not generally recommended in
services containing fluorides. • OTHER RESINS – RPS also has experience in the use of many
other resins including:
• OTHER REINFORCEMENTS – A wide variety of reinforcements
exist which can be used to meet specific needs (e.g. Carbon veil oo Chlorendic Polyesters
for electrical conductivity). RPS is experienced in the design of oo Bisphenol Fumarates
products utilizing various reinforcements and can provide assis-
tance in choosing the right reinforcements for the job. oo Phenolics

Resins oo Terephthalic

The second major component oo And others

of FRP piping is the resin Additives
system. FRP is fabricated using
thermosetting resins. These • A number of additives are used in FRP laminates. Some of the
types of resins are cured using most common additives are briefly described below:
chemical additives; and once • Catalyst/Promoters – Thermosetting resins require both
cured, are essentially infusible catalysts and promoters to cure. Again, a wide variety of options
(unlike thermoplastic resins, exist such as MEKP (methyl ethyl ketone peroxide), BPO (benzoyl
which can be re-melted). In peroxide), CHP (cumene hydrogen peroxide), DMA (dimethyl
an FRP laminate, the resin acts analine), CoNap (cobolt napthenate) and others. Resin suppliers
to hold the reinforcement in provide recommendations regarding correct levels of catalysts
place and the resin system is and promoters, and these should be strictly adhered to. The
chosen for its chemical, mechanical and thermal properties as well choice of which catalyst/promoter system to use is usually a
as its processing ability. matter of fabricator preference, however, in some applications,
RPS uses a wide variety of resins as summarized below: superior performance can be achieved with one over the other
(eg. BPO/DMA for Sodium Hypochlorite service).
• BIS-A VINYL ESTER – The most commonly used resin at RPS,
vinyl esters provide excellent chemical resistance, excellent • Thixotropes – These are generally silica based products which
resilience and good workability. add thixotropy to minimize drain-out of resin.
• EPOXY NOVOLAC VINYL ESTER – Used in RPS “H” series piping, • Gel Time Retarders – Chemicals such as 2,4-Pentanedione
Epoxy Novolacs offer increased chemical resistance to strong slow the cure process. They are generally used in large
acids and higher temperature capability compared to BIS-A parts fabrication.
type vinyl esters.
• ISOPHTHALIC POLYESTER – Used in RPS “I” series piping,
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• Pigments – Pigments can be added to laminates and exterior

coatings to impart unlimited colour options and to provide
resistance to UV degradation.
• Antimony Compounds – These compounds increase fire resis-
tance when used with a fire retardent resin.
• Paraffin – Used in top coats of laminates to seal the surface and
allow for proper cure at the surface.
• Abrasion Resistant Fillers – RPS “A” and “AA” series pipe and
fittings include abrasion resistant fillers added to the corrosion
barrier for use in services where abrasion is a concern.
the desired thickness is achieved. RPS utilizes both mechanical
• Others – Other additives such as antifoaming agents, carbon and computerized electromechanical filament winding machines
black, and milled fibres, are used to impart specific properties. to produce high quality, consistent parts. The tension of the glass
fibres produces a laminate with high glass content, typically 70%
by weight, creating a strong structural cage, highly orthotropic
MANUFACTURING
in nature. Prior to filament winding, a corrosion barrier, generally
RPS manufactures FRP piping systems, duct, tanks and stacks from 1” consisting of surfacing veil and chopped strand glass reinforcement,
(25mm) to 18’ (5.5m) diameter. A variety of techniques using varying is applied to the mandrel by contact molding.
degrees of automation are used to fabricate the various components.
Custom Contact Molding
In contrast to piping, the majority of fittings at RPS are manufactured
using the custom contact molding technique. Using this approach,
resin and glass are applied by spray gun, or by hand to stationary or

Each technique produces a product with unique characteristics.

These techniques are summarized below:
Filament Winding
The majority of pipe and ducting produced at RPS is manufactured rotating molds. The resin/reinforcement combination is “rolled out”
by the filament winding process. Filament winding involves pulling to remove entrapped air, compact the layers, and ensure complete
glass fibres, under controlled tension, through a catalyzed resin bath. wet-out of the glass fibres. The number of layers that can be continu-
The resin bath travels back and forth past a rotating mandrel, with ously applied to the mold is limited since heat generated by the resin
the angle of fibre placement determined by the translational speed cure may create blistering in the part. To prevent this, laminates are
of the resin bath relative to the rotational speed of the mandrel. laid-up in stages, which are allowed to cure and cool before the next
Through this motion, a pattern is established and repeated until stage of reinforcement is applied. Each sequence of reinforcement

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must begin and end with a layer of chopped strand glass to provide Alternatively, a chopper gun
proper adhesion. can be used to mechanically
apply the glass reinforcement.
The contact molding technique provides for an unlimited number
With this technique, one or
of plies and orientation of reinforcement, allowing the designer to
more strands of glass fibre
place the material where it is most needed. This creates parts which
are fed into a gun which cuts
or “chops” the glass to a set
length (typically 1” to 1¼”
long). The chopped glass is
then propelled into a stream
of catalyzed resin. Glass
content is controlled by adjusting the flow of resin relative to the
speed of the chop. The amount of time the chopper gun is held in
one spot determines how thick or how much material is applied. The
chopper gun can be used alone to produce an “all chop” component,
which would be similar to a laminate made of “all chopped strand
mat”. Alternatively, the chopper gun can be used in conjunction with
hand lay-up material, such as woven roving, to produce a laminate
range from quasi-isotropic to highly orthotropic. The manual nature
with higher glass content and strength. The resin spraying ability of
of the technique means a high skill level is required to produce a
the chopper gun can also be used alone to “wet-out” hand lay-up
high quality, consistent part. Materials such as chopped strand glass,
laminates, which can reduce labour costs on larger parts.
woven roving, Nexus veil, C-veil, and unidirectional reinforcement
are all applied using this technique. Traditionally, most corrosion
barriers are applied by contact molding.
As mentioned above, the contact molding technique is generally
broken down into two sub-methods; namely, hand lay-up and
spray-up. As the name implies, hand lay-up involves saturating glass
reinforcement and applying this material by hand to the mold.

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PIPE AND FITTING PROPERTIES

Mechanical Properties of A-150 & P-150
FRP is a composite material and can have different properties in Filament Wound Structural Layers
Ultimate Tensile & Compressive Strength
different directions. Some general physical properties are essen-
Hoop 40,000 psi (276 Mpa)
tially the same for all FRP products produced at RPS. However,
Axial (due to pressure) 20,000 psi (138 Mpa)
most mechanical properties are significantly different in the Axial
Axial (due to bending) 12,000 psi ( 83 Mpa)
(Longitudinal) versus Hoop (Circumferential) directions. It should be Tensile & Compressive Modulus of Elasticity
noted that the corrosion/abrasion layer included in all RPS products Hoop 2.3 x 106 psi (15,860 Mpa)
is generally not considered in structural design of pipe; however, it is Axial 1.4 x 106 psi ( 9,655 Mpa)
often necessary to know the properties of the corrosion liner and the Poisson’s Ratio
composite properties of the laminate (refer to the section Pipe Stress Change in axial strain caused by hoop stress 0.7
Analysis for more information on this subject). Change in hoop strain caused by axial stress 0.4

General Physical Properties Mechanical Properties of A-150 & P-150

of RPS FRP Pipe & Fittings* Hand Lay-Up Structural Layers
Coefficient of 1.2 to 1.5 x 10-5 in./in./deg. F. 2.2 to 2.7 x 10-5 mm./mm./deg. C. Ultimate Tensile & Compressive Strength
Thermal Expansion Hoop/Axial (laminates < 1/4” thick*) 14,000 psi ( 96 Mpa)
Thermal Conductivity 1.3 BTU in./ft.2/deg.F/hr. 188 (W-mm.)/(m2 deg. C) Hoop/Axial (laminates ≥ 1/4” thick**) 20,000 psi (138 Mpa)
Density 0.058 lb./in.3 1.61 g/cm.3 Tensile & Compressive Modulus of Elasticity
Hazen Williams’s 150 Hoop/Axial (laminates < 1/4” thick*) 1.2 x 106 psi ( 8,276 Mpa)
Flow Coefficient Hoop/Axial (laminates ≥ 1/4” thick**) 1.7 x 106 psi (11,724 Mpa)
Manning’s Flow 0.009 Poisson’s Ratio, hoop/axial & axial/hoop . . . 0.34*, 0.255**
Coefficient *Indicates “all mat” construction ** Indicates mat and woven roving construction
*These are approximate values, if exact values are required consult RPS Engineering

Mechanical Properties A-150 & P-150

Corrosion Barrier
Ultimate Tensile & Compressive Strength
Hoop/Axial 10,000 psi (69 Mpa)
Tensile & Compressive Modulus of Elasticity
Hoop/Axial 1.0 x 106 psi (6,897 Mpa)
Poisson’s Ratio, hoop/axial & axial/hoop . . . 0.34

Composite Properties

The composite properties of an FRP laminate can be estimated by simply propor-

tioning structure and liner properties with thickness. This is demonstrated below.

Example: 12” diameter Filament Wound Pipe

t liner = 0.11”
t winding = 0.26”
total thickness = 0.37”

Composite Tensile Modulus = Modulus of Liner x Liner thickness + Modulus of Structure x Structure thickness
(hoop) Total thickness Total Thickness
= 1.0 e 6 x 0.11 + 2.3 e 6 x 0.26 = 1.91 e 6 psi
0.37 0.37

This technique can also be used to estimate other composite properties such as
Poisson’s ratio.

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HYDRAULICS Qm = (1.486 / n) (S) 0.5 · A · R 0.667

where,
Qm = Flow rate, cfs
n = Manning’s coefficient = 0.009 for RPS pipe
S = Hydraulic gradient of slope
A = Cross sectional area of pipe, ft2
R = Hydraulic radius = Area / wetted perimeter, ft.
Darcy-Weisbach Equation – This equation applies to all fluids
and full pipe flows. The primary advantage of the equation is that
it is valid for laminar and turbulent flow. However, the friction factor
used in the equation is variable.
HF = f · L (V2) / (2 · ID · g)
RPS fibreglass piping offers significant advantages over steel piping where,
in terms of flow characteristics. The smooth interior of FRP piping
HF = Head loss, ft
minimizes friction loss. Furthermore, it is not necessary to degrade
f = Friction factor (see below)
friction factors as the surface remains smooth over time for most
L = Total length of pipe, ft
applications. The inside diameter of RPS FRP is also larger than most
V = Fluid velocity, fps
schedule steel piping providing increased capacity.
ID = Inside diameter, ft
Friction Loss Calculations g = Gravitational constant = 32.2 ft/sec2
Friction loss, or head loss, is generally calculated using one of three The friction factor depends on the flow regime.
methods. Namely, Hazens-Williams, Manning’s, or Darcy-Weisbach.
For laminar flow, f = 64/Re
Each of the methods has its relative merits, disadvantages, and
limitations; and the designer should be aware of which formula to Where,
use for the given application. The equations and parameters, which
Re = Reynold’s number = ID · V / µ
relate to RPS FRP piping, are summarized below:
and,
Hazen-Williams Equation – This equation is valid for turbulent
flows for piping under full flow, and generally provides a conser- µ = Fluid kinematic viscosity, ft2/sec
vative solution for head loss in FRP pipe. For turbulent flow (i.e Re>3000) the friction factor can
hf = 0.2083 (100 · Q / C ) / d
1.85 4.87 be determined using the Moody diagram. RPS FRP piping
has a surface roughness parameter (e) equal to 1.7 x 10-5
where,
ft. The roughness parameter divided by the diameter (ft.)
hf = Friction loss, ft H2O/100 ft of piping is known as the relative roughness. By using the relative
C = Hazen William’s coefficient = 150 for RPS pipe roughness and Reynold’s number, the designer can look-up
Q = Flow rate, gpm (U.S.) the appropriate friction factor using the smooth pipe
d = Inside diameter, inches segment of the Moody Diagram.
Manning’s Equation – This equation is generally used to determine
the head loss in sewers and drains since it is valid for partial flow
under the influence of elevation head only.

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Head Loss in Fittings Where,

The above equations can be used to calculate the head loss for a a = Wave velocity (ft/s) = 12/[(ρ/g)(1/k + d/(E ∙ t))]0.5
given length of piping. However, when fittings are introduced into ρ = Fluid density (lb/ft3)
the system, the head loss can be significantly increased. A common g = Gravitational constant (32.2 ft/s2)
method for dealing with head loss in fittings is to calculate an k = Bulk modulus of fluid (300,000 psi for water)
“equivalent pipe length” which is added to the straight run of pipe. d = Pipe ID (in.)
An alternative and more accurate method for determining head loss t = Pipe wall thickness (in.)
in fittings is to determine the appropriate loss coefficients or “K” E = Modulus of elasticity of pipe (psi)
Type of Fitting K Factor
SG = Specific gravity (dimensionless)
Δ V = Change in velocity of fluid (ft./sec.)
90° smoth radius elbow 0.5

90° single-mitered elbow 1.4 The inherent flexibility of FRP piping minimizes the magnitude
90° double-mitered elbow 0.8 of water hammer; however, care must be taken when starting-up
90° triple-mitered elbow 0.6
systems and opening and closing valves. In general, steps should be
taken to minimize or eliminate water hammer in FRP piping systems.
Tee, straight flow 0.4

Tee, flow to branch 1.4 Gas Flows

Tee, flow from branch 1.7 Fibreglass piping is generally recommended for above ground gas
Reducer, single size reduction 0.7 lines only when the operating pressure is very low. The table below
Reducer, double size reduction 3.3 lists the recommended maximum allowable pressure for gas flows
versus diameter. For pressures above those listed in the table,
external protection is recommended per ASME/ANSI B31.8 “Gas
factors. The K factors depend only on the fitting type and do not Transmissions and Distribution Piping Systems.”
involve diameter. All the factors are simply summed together and
incorporated into the loss equation. This is demonstrated below Gas Line Pressure
using the Darcy Weisbach formula. Diameter Maximum Recommended Pressure
(in.) (psi)
Hf = { sum K’s + ft (L/ID) } (V /2g) 2
<6” 25
Following Typical “K” factors for FRP fittings are summarized: 8”” 14

Transient Pressures 10” 9

12” 6
Transient pressures such as “Water Hammer” can occur when fluid
velocity inside piping is rapidly changed. The change in velocity can 14” 5

be caused by pump start-ups or valve closings. Under certain condi- 16” 4

tions, the magnitude of the transient can be sufficient to seriously
damage or rupture the piping. The magnitude of water hammer is References
related to the fluid type, pipe thickness, pipe diameter, pipe elastic For more information on hydraulics refer to:
modulus, and the change in fluid velocity. The pressure surge, which
is in addition to the operating pressure in the system, can be calcu- Pipe Fabricators Institute / SPI - “Fiberglass Pipe Handbook”
lated as follows: American Water Works Association - “Fiberglass Pipe Design –
Ps = (a/g) · (SG/2.3) · (Δ V) AWWA M45”

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ABOVE GROUND PIPE & FITTING or

DESIGN Structural Thickness = Pressure x Diameter
As mentioned earlier, FRP piping utilizes glass fibres to reinforce a 2 x HDS
resin matrix. The fibres can be orientated in any direction to provide
For piping which does not have an HDB rating, the structural wall
optimum properties. This feature high-lights the advantage and
thickness is based on the short term burst strength (determined in
complexity of FRP design. The methods used to design pipe and
accordance with ASTM D1599).
fittings are briefly summarized below:
This provides a conservative estimate of the required wall thickness,
Filament Wound Pipe Design
calculated as follows:
RPS A150 and P150 piping have internal pressure ratings based on
Structural Thickness = Pressure x Diameter x FOS
ASTM D2992. This standard provides two methods for determining
2 x hoop strength
the “Hydrostatic Design Basis” or “HDB”, which is the hoop stress
(or strain) that provides an estimated life of 100,000 hours (per the where,
static test method) or 150 million cycles (per the cyclic test method).
Pressure = Design pressure of the system
The static test method involves subjecting numerous samples of
piping to various levels of stress such that failures occur in both the Diameter = Inside pipe diameter
short term and long term (10,000 hours maximum). The data is then FOS = Required factor of safety (typically 6 to 10)
plotted on a logarithmic scale, and extrapolated to 11.4 years and
50 years to determine the HDB. Similarly, the cyclic method tests Hoop strength = Short term hoop strength (typically 40,000 psi for
samples for up to 15 million cycles, and the data is extrapolated to pipe wound at 55°)
150 million cycles to determine the HDB. A service factor equal to Corrosion Barrier Addition: The corrosion barrier (liner) is generally
1.0 or less for the cyclic method and 0.5 or less for the static method added to the thickness calculated above, as follows:
is then applied to the HDB to determine the corresponding pressure
rating or hydrostatic design strength (HDS). t total = tliner + tstructure

With the hydrostatic design strength, the required wall thickness can However, in less aggressive environments, the designer may choose
be calculated using the ISO formula, as follows: to include the corrosion barrier (or some portion thereof) in the
structural calculations.
Structural Thickness = Pressure x Diameter
2 x HDB x Service Factor In some cases, the structural thickness may be increased to accom-
modate other factors such as vacuum or stiffness requirements.
Small diameter adhesively bonded piping may also have increased
thickness to provide adequate bond length in the joint.

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Filament Wound Pipe Wall Thickness‡ (in.) Example: 6”Ø 150 psi, contact molded pipe with 10:1 FOS
Butt Joint System Adhesive Joint System
Unit Hoop Stress = Pressure x diameter x FOS / 2
150 psi 100 psi 50 psi 150 psi 100/50 psi
= 150 x 6 x 10 / 2 = 4500 lb/in.
Total Total Total Total Total
Diameter** Thickness Thickness Thickness Thickness Thickness Unit Axial Stress = Pressure x diameter x FOS / 4
1 0.19 0.19 0.19 0.19 0.19 = 150 x 6 x 10 / 4 = 2250 lb/in.
1.5 0.19 0.19 0.19 0.19 0.19 A variety of possible reinforcements could be used to meet these
2 0.19 0.19 0.19 0.19 0.19 requirements. However, a trial and error approach is generally
3 0.19 0.19 0.19 0.19 0.19 required. For example, if this pipe were to be constructed from 1.5
4 0.19 0.19 0.19 0.20 0.20
oz/ft2 chopped strand and 24 oz/yd2 woven roving, the following
combination could be used:
6 0.22 0.19 0.19 0.24 0.24

8 0.26 0.21 0.19 0.28 0.24 4 layers of chopped strand @ 600 lb/in. = 2400 lb/in.
10 0.30 0.24 0.19 0.32 0.27 2 layers of woven roving @ 1250 lb/in. = 2500 lb/in.
12 0.34 0.26 0.19 0.37 0.31 Total Strength = ( 2400 + 2500 ) = 4900 lb/in.
14 0.37 0.29 0.20 N/A N/A
This would satisfy both the hoop and axial strength requirements.
16 0.41 0.31 0.21 N/A N/A

18 0.45 0.34 0.22 N/A N/A

Pressure Stress Multipliers and Fitting Design
20 0.49 0.36 0.24 N/A N/A Many fittings are subject to higher pressure stress than the ISO
24 0.56 0.41 0.26 N/A N/A formula would indicate due to their geometric configuration. For
30 0.67 0.49 0.30 N/A N/A
example, size on size tees typically have a pressure stress of approx-
imately 2 times that of the same diameter pipe. To compensate for
36 0.79 0.56 0.34 N/A N/A.
this, the designer should include “pressure stress multipliers” (PSM)
* Includes 0.11” non-structural Corrsion Barrier
in the ISO equation.
** See Dimensional Catalogue for exact ID’s. Contact RPS for pipe and fitting OD’s. Fitting OD’s will be consid-
erably greater than pipe OD’s.
Unit Hoop Stress = Pressure x Diameter x FOS x PSM / 2
By not including a pressure stress multiplier (PSM) in the stress calcu-
Contact Molded Pipe and Fitting Design lation, the true factor of safety is reduced. Therefore, the appropriate
The design of contact molded pipe and fittings is based on the short multiplier should be calculated and included in the fitting design. It
term ultimate strength properties of the liner and structural layers. should be noted that the above mentioned increased stress may only
The design method involves calculating the total number and type be localized, and thus, the reinforcement required to compensate
of reinforcing layers required rather than an overall thickness. Based for the effect may also only need to be localized. This needs to be
on in-house testing and industry standards, the short-term unit examined on a case by case basis and may require hydrostatic testing
strength of the various types of reinforcement used at RPS has been and/or finite element analysis for verification.
determined. This is compared with the overall strength required per The nature of fitting construction and the effect of the pressure stress
the ISO formula. Factors of Safety (FOS), typically in the range of 6 to multiplier results in fittings which may be considerably thicker than
10, are applied to the stress calculation. the adjoining pipe, particularly in the case of tees. This needs to be
considered with respect to clearances with structural steel and other
pipe lines or equipment.

11
 Design Manual

Design for Vacuum Where,

Eh = Hoop flexural modulus of pipe/duct
t = Wall thickness of pipe/duct
nT/L = Poisson’s ratio for hoop stress causing axial strain
nL/T = Poisson’s ratio for axial stress causing hoop strain
R = Pipe/Duct outside radius
For Pipe/Duct with ribs
Pcr = 5.5 · kn · Ax1/4 Dq · 3/4
L·R·√R
Where,
Very often, thin-walled piping, and particularly ducting, must kn = “knockdown factor” = 0.9
be designed to handle vacuum loads. The resistance to vacuum is Ax = Ea · t
related to the stiffness of the pipe or duct, which is related to the
thickness and modulus of elasticity. Generally, the design for vacuum Dq = Eh · t3
service follows two approaches. 12 · ( 1 – nT/L · nL/T)

Low to Moderate Vacuum Rating / Small Diameters: Ea = Axial tensile modulus of pipe/duct (psi)

• Increase wall thickness to provide required collapse pressure. L = Length between ribs (in.)

High Vacuum Requirements / Large Diameters: R = Pipe/Duct outside radius

• Use Stiffening Ribs to provide required collapse pressure Corrosion Barrier Addition: The corrosion barrier (liner) is generally
added to the thickness calculated above, as follows:
The decision to use stiffening ribs is generally a question of
economics. That is, stiffening ribs are used at the point when the cost t total = tliner + tstructure
associated with the required increase in pipe wall thickness exceeds In less aggressive environments, the designer may choose to include
the cost of applying the ribs. the corrosion barrier (or some portion there of) in the structural
For pressure piping, vacuum resistance is generally achieved through calculations. However, the composite properties (i.e Hoop Modulus
increased wall thickness as the application of ribs could create high of total wall, Poisson Ratio’s of total wall, etc.) must be determined
local stresses when the pipe operates under pressure. and used in the calculations. This is particularly important in vacuum
design since the collapse pressure is related to the thickness cubed (
The collapse pressure of pipe or ducting is calculated based on the Pcritical a t3 )
“Structural Plastic Design Manual” equations.
For Pipe/Duct without ribs
(assumed to be an infinitely long cyclinder)
Pcr = Eht3
4•(1- nT/L · nL/T)•R3

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 Design Manual

ABOVE GROUND PIPING SYSTEM Differences between FRP and Steel

DESIGN FRP has greater flexibility oo Requires closer support
than steel. (EFRP ≈ 1/20th spacing
Esteel) oo Larger oscillations occur
more easily
oo Earlier column failure
possible
oo Loads on supports are
lower for a given amount of
expansion

FRP has a lower longitudinal oo Requires closer support

strength than steel spacing
oo Requires support of heavy
valves
oo Requires prevention of
severe water hammer
oo Longitudinal loads are
relatively more important

The design of piping systems using RPS piping, or most other FRP FRP does not yield (no plastic oo Stress concentrations and
piping, differs from steel piping system design. The differences deformation) point loads must be avoided
in design are related to the differences in mechanical and physical
Cold Temperature Design oo Most properties including
properties between FRP and steel. Following are some important
impact resistance remain
points to consider: unchanged for temperatures
down to -50 deg. F

FRP has a greater coefficient of oo Requires greater allowance

thermal expansion (about 2.5 for movement
times steel)
Strength and rigidity drop rapidly oo Careful design needed at
above 200 deg. F. high temperatures.
oo Hot spots must be avoided

Creep oo FRP will creep under long

term steady load, however,
this will vary greatly with
fiber orientation. The high
safety factors used in FRP
design (typically 6 to 10)
generally account for this.

Note:
FRP fittings may be significantly thicker than the adjoining FRP
pipe. Give careful consideration to clearances in tight areas.

13
 Design Manual

General Recommendations and Comments on Recommended Hanger Spacing

FRP Piping Systems Design Note: Refer also to information on guide spacing to prevent
column-type buckling (page 19).
• Give early consideration to supports since FRP piping generally
requires closer support spacing than steel piping. Support Spacing (ft.) @ 150 deg. F*
for RPS P150 & A150 piping.
• FRP piping is flexible and undesirable longitudinal oscillations Single Span Continuous Span
can occur at pump start-up etc.. To prevent this, anchor each Diameter SG = 1.0 SG = 1.3 SG = 1.0 SG = 1.3
straight leg once, and only once. 1 7.0 7.0 9.0 9.0

• Control side-ways oscillations by replacing every forth hanger 1-1/2 7.3 7.1 9.3 8.7

with a guide 2 8.0 7.5 9.8 9.2

3 8.4 7.7 10.3 9.5

• All clamps, hangers and anchors should have an 1/8” rubber
lining to prevent chafing of the FRP and provide a uniform 4 8.7 8.0 10.7 9.8

contact surface 6 10.9 10.0 13.3 12.2

8 10.9 10.0 13.1 12.0

• Expansion joints should be used sparingly (see pg. 19 for more
10 13.0 11.6 15.6 13.9
detail)
12 13.7 13.0 16.4 15.6
• Do not rely on friction for support of risers and anchors, use FRP
14 13.7 13.0 16.4 15.6
thrust collars
16 15.2 14.0 18.2 16.8
• Friction clamps should only be relied on to support or resist very 18 16.7 15.0 20.0 18.0
small longitudinal loads, when in doubt use FRP thrust collars.
20 17.4 15.5 20.9 18.6
• Include guides as required to prevent column-type bucking 24 19.1 17.0 22.9 20.4
failure (see ahead for more detail) 30 20.5 18.3 24.6 22.0

• Heavy valves must be supported independently 36 22.1 19.7 26.5 23.6

• Water-hammer must be minimized Criteria: Strength Ratio (SR) in structures > 1.6; Deflection < 0.5”
*For 180 deg. F service, derate span by 0.90
• Incorporate field joints generally at each change of direction.
Keep in mind that FRP flanges should not be “drawn” into place For information on support spacing for pressure ratings,
and should freely line-up. specific gravities, or diameters other than those listed
above, please contact RPS directly
• Avoid bolting full face FRP flanges to raised face flanges. Use
FRP Vanstone style flanges or spacers as required.
• For other than flange supports, avoid locating supports at or
adjacent to fittings. Allow enough room between the support
and the fitting for the joint overlay.

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 Design Manual

Pipe Supports Thermal Expansion Design

Supports for RPS FRP piping should be designed with the principles FRP piping will expand when heated. The amount of expansion that
mentioned in the previous sections borne in mind. For example, the occurs depends on:
supports should ensure point loading of the pipe does not occur, and
• The difference between the maximum operating and installed
they should ensure there is no chafing or abrasion between the pipe
temperatures
and the support. A complete line of standard supports suitable for
• The coefficient of thermal expansion (which typically equals 1.4
RPS FRP piping is included in the RPS Pipe Support Catalog. The type
x 10-5 in/in/deg.F for RPS piping )
of support to use for a specific application will depend upon a number
• The length of pipe that is free to expand
of factors, the most important of which are the intended function of
the support and the configuration of the available structural steel. To deal with thermal expansion, the designer generally follows one
The basic types of supports are weight supports, guides, and anchors. of two approaches:
Various configurations of each of these types of supports are shown
• Create a semi-rigid support system
in the RPS Pipe Support Catalog. The choice of which type of weight
• Create a rigid (anchored) support system
support to use for example, would depend on whether the pipe will
be supported from underneath the pipe, or from above the pipe. In These two types of approaches are explained in more detail below.
the first case, a Slide Shield, a Flange Slide, or a Base Slide would all Semi-Rigid Piping System
be suitable support types. In the latter case, a Clamp or Clevis Hanger
would be appropriate choices. As mentioned above, FRP will want to expand when heated. If the
piping is totally free to expand, it will do so, and no stress will be intro-
The supports shown in the RPS Pipe Support Catalog are standard
duced into the piping system as a result of the temperature change.
types of supports only. Custom-designed supports are also available
However, this is not normally the case as changes in direction and
as required to suit particular project requirements. Please contact
pipe supports generally provide some resistance to expansion. This
RPS for further information.
creates stress in the piping and introduces forces on the supports.
By controlling the length of straight runs of piping and the length
of off-set legs, the designer can most generally control the thermal
expansion. The two basic principals that must be satisfied are:
• Provide sufficient support to carry the self weight of the pipe
and other loads such wind and snow.
• Provide enough flexibility to absorb thermal expansion
These two principals are often in conflict with one another, which
can make the design process a trial and error procedure. The recom-
mended hanger spacings, listed at the start of this section, provide
sufficient support for self weight. The most common method of
providing the required flexibility in the system is with changes in
direction or offset legs. It should be noted, however, that the change
in direction should generally be at an elbow, not at branch connec-
tions such as tees or saddles.

15
 Design Manual

The required length of an offset leg can be calculated as follows:

Lleg = 1/12 · { 3 · E · I · D L / M }0.5 (ft.)
Where,
E = Axial Modulus of elasticity
I = Moment of Inertia of total wall
= p /64 (OD4 – ID4)
D L = Change in length = Ce · Lf · D T
and
Ce = Coefficient of thermal expansion
Lf = Length from anchor
D T = Difference between max. operating and
Laterally Free Length Required at Elbow*
installed temperatures
Expansion (in.)
M = Allowable Bending Moment = Sb · Zs
ID 0.2 0.4 0.6 0.8 1 2 4
and 1 1.9 2.7 3.3 3.8 4.2 5.9 8.4

1.5 2.3 3.3 4.0 4.6 5.2 7.3 10.3

Sb = Allowable bending stress
Zs = Section Modulus of structure 2 2.8 4.0 4.9 5.7 6.4 9.0 12.7

= 2 · Is / OD 3 4.0 5.7 6.9 8.0 8.9 12.6 17.9

Is = Moment of Inertia of structure 4 5.3 7.4 9.1 10.5 11.8 16.6 23.5
= p/64 (OD4 – (ID+2 · tl)4) 6 5.9 8.3 10.2 11.7 13.1 18.6 26.3

Example: What is the required offset length for the given piping 8 7.7 10.9 13.4 15.5 17.3 24.4 34.6

arrangement and parameters? 10 8.4 11.9 14.6 16.9 18.8 26.7 37.7

12 9.1 12.8 15.7 18.1 20.3 28.7 40.6

OD = 8.52 in. T = 0.26 in. Ts = 0.15 in.
Sb = 650 psi E = 1.29e6 psi 14 9.7 13.7 16.7 19.3 21.6 30.6 43.2

Lf = 24 ft. = 288 in. DT = 100 deg. F 16 10.3 14.6 17.8 20.6 23.0 32.6 46.0
Ce = 1.4 x 10-5 in/in/deg.F 18 10.8 15.3 18.7 21.6 24.2 34.2 48.4

20 11.3 16.0 19.6 22.7 25.3 35.8 50.6

24 12.2 17.3 21.1 24.4 27.3 38.6 54.6

30 13.4 19.0 23.2 26.8 30.0 42.4 60.0

36 14.6 20.6 25.2 29.1 32.6 46.1 65.2

* When the offset leg terminates at a flange or tee, the free length
should be increased by 20%

16
 Design Manual

Solution: absorb the thermal growth and force. The length of the loop will be
the same as the free leg length calculated in the above example. The
Itotal = p/64 · (8.524 – 8.04) = 57.6 in4
axial portion of the loop is normally taken as ½ of the leg length.
DL = 1.4 x 10-5 · 288 · 100 = 0.40 in.
Guides should be included immediately upstream and downstream
Istruct = p/64 · (8.524 – (8.0+0.11x2)4) = 34.5 in4
of the expansion loop.
Zstruct = 2 · Is / OD = 2 · 34.5/8.52 = 8.1 in3
Mallow = Sb · Zs = 650 x 8.1 = 5265.0 in-lb Rigid Piping System
Therefore, An alternative to the semi-rigid piping system is the rigidly restrained
piping system. With this system, thermal expansion is prevented by
Lleg= 1/12 · { 3 · 1.29E6 · 57.6 · 0.40/5265.0}0.5 =10.85 ft.
anchoring the pipe in various locations. The corresponding forces
This is the minimum offset that should be used to ensure the bending are transferred into the support structure and the piping itself.
stress in the piping is maintained at an acceptable level. This system is possible due to the low elastic modulus of FRP in
comparison to steel. As demonstrated in the example calculation,
Corrosion Barrier Addition: When calculating thermal forces and
the low elastic modulus creates forces which are often easily handled
stresses, it is very important to consider the effect of the corrosion
by the support structure.
barrier. This is summarized below:
Force = E · A · Ce · D T
• The thermal force should be calculated based on the total wall
area (i.e include the corrosion barrier in this calculation). Where:
• The composite modulus should be used to calculate the thermal
E = Axial modulus of elasticity
load. However, since the structural modulus is generally slightly
A = Cross sectional Area of piping
higher, the structural modulus can be used to provide a slightly
Ce = Coefficient of thermal expansion
more conservative result.
DT = Difference between operating and installed
• The structural wall area should be used to determine the pipe
temperature
stress resulting from the thermal force. In some less aggressive
environments, the designer may choose to consider the contri- Example Part A: What is the thermal force at anchor #1 for the given
bution of the corrosion barrier (or some part there of) for the piping arrangement?
stress calculation.
OD = 6.48 in.
Expansion Loops ID = 6.00 in.
Ce = 1.4 x 10-5 in/in/deg.F
When changes in direction are not possible or practical, the designer
E = 1.5e6 psi
may want to consider creating an expansion loop in the system to
DT = 50 deg. F

17
 Design Manual

Solution: ID = 6.0 in.

Ce = 1.4 x 10-5 in/in/deg.F
Area = p · (6.482 – 6.002) / 4 = 4.70 sq.in.
E = 1.5e6 psi
Force = 1.5 x 106 · 4.70 · 1.4 x 10-5 · 50 DT = 50 deg. F
= 4,940 lbs Lf = 100 ft.
Note: this is the actual force and does not include a design Solution: The support spacing must first be determined. For RPS 6”0,
factor (or factor of safety). 150psi rated piping, the maximum support spacing would be 10.9’
(see “Recommended Hanger Spacing Table”)
Example Part B: What is the stress on the piping given the above
anchoring force. Support Spacing < 10.9 feet*
Solution: * This could be increased to 13.3’ after three (3) simple supports since
the arrangement would be considered a continuous support.
Stress = Force / Structural Area
The thermal force on the anchor would be:
Where,
Force = E · A · Ce · DT
Structural Area = p · (6.482 – 6.222) / 4
= 2.59 sq.in. where, Area = p · (6.482 – 6.002) / 4 = 4.70 sq.in.
Stress = 4940 lbs / 2.59 sq.in. Force = 1.5 x 106 · 4.70 · 1.4 x 10-5 · 50 = 4,940 lbs
= 1905 psi*
The guide spacing depends on the critical bucking load of the piping
*Note: This is the stress on the structural wall assuming a 0.11”
arrangement calculated as follows:
thick corrosion liner.
Pcritical = p2 · E · I / L2
Guide Spacing and Column-type Bucking
The equation can be re-arranged to solve to L (the critical buckling
In the general recommendations for supporting FRP piping is was
length)
pointed out that every 4th hanger should be replaced by a
guide to prevent unwanted oscillations. However, guides are Lcritical = (p2 · E · I / Papplied )1/2
also required to prevent column-type buckling in a rigid system. This
Where,
is demonstrated in the example below:
E = Axial modulus of pipe = 1.5 e 6 psi
Example: Determine the required hanger and guide spacing for the
I = Moment of inertia of cross section
rack piping shown below. As shown in the sketch, the piping is rigidly
= p/64 · (OD4 – ID4)
restrained at the valve and at the change in direction.
= p/64 · (6.484 – 6.04) = 22.93 in4
OD = 6.48 in.
Papplied = Applied compressive force = 4940 lbs.
Lcritical = (p2 · 1.5e6 · 22.93 / 4940 )1/2
= 262 in = 21.8 feet
Therefore, for this example, every second support (which were
required at approximately 10’ intervals) should be replaced by a
guide to prevent column-type buckling.

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 Design Manual

Expansion Joint Use and Design oo Different modulus values are required for each diameter or
In some situations, it is not possible or practical to deal with diameter range.
expansion using changes in direction oo Different coefficients of thermal expansion are required for
or expansion loops and/or the forces each diameter or diameter range.
associated with a rigid system are too
oo Different Poisson’s ratios are required for each diameter or
high for the piping or supports. In these
diameter range.
situations, expansion joints can be used
to absorb thermal growth. Some general oo The same allowable stress can be used for all sizes, since
comments regarding expansion joints and the analysis is based on the structural wall only.
FRP piping are summarized below: TIP – Consider setting-up a computer spreadsheet to quickly
calculate the composite pipe properties for the required diameters!
• Expansion joints are not normally
required on small bore FRP piping systems • Consider entering the “maximum operating pressure” rather
as they are generally inherently flexible. than the “rated pressure”. Very often companies purchase,
for example, 150 psi rated piping, and use the piping for low
• Expansion joints may be required to absorb large differential
pressure or even gravity feed. By using the maximum operating
expansion between, for example, steel tanks and FRP piping.
pressure in the pipe stress analysis, the user may be able to solve
• Expansion joints may be used to isolate the FRP piping system many stress problems.
from vibrating equipment such as large pumps or fans.
• Stress analysis without a corrosion allowance (i.e. including
• When choosing expansion joints, the designer needs to consider some contribution of the corrosion barrier in the stress calcu-
that the required activation force needs to be smaller than lations) requires different allowable stresses for different
would normally be suitable on similar diameter steel piping. diameter ranges, since the corrosion barrier will contribute less
and less structurally as the diameter increases. This makes the
• The use of tie-rods or limiting rods should be avoided if possible
analysis more complex and the designer should contact RPS
as these act to concentrate forces on the FRP flange and could
directly for more information on this approach.
result in damage to the FRP flange. If tie-rods are necessary, the
FRP flange may require a steel backing ring to better distribute Allowable Stresses
the pressure load.
RPS piping is filament wound and highly orthotropic in nature.
Pipe Stress Analysis and Allowable Stresses In particular, the piping has different strength values related to
pressure and bending.
An ever increasing number of companies are choosing to design and
analyze their piping systems using computerized pipe stress analysis For stress analysis based on the structural wall only (i.e. total
programs. These programs can quickly provide the user with infor- thickness less the corrosion allowance). The following allowable
mation on deflections, stresses and forces. Below are some general stresses apply:
tips for analyzing RPS FRP piping using computerized analysis
Allowable Stress 1” – 2500 psi
programs.
@ 150 psi 1.5” – 2300 psi
• An easy, yet accurate and conservative way to analyze FRP 2” – 2400 psi
piping is to input a total wall thickness and a corrosion 3” – 2550 psi
allowance. This will allow the program to calculate forces and ≥ 4” – 2600 psi
weights based on the total wall but determine stress based on
the structural or corroded wall. The inputs should be based on
composite wall properties, keeping in mind the following:

19
 Design Manual

Allowable Stress 1” – 2500 psi Elbows

(150 psi Rated)
@ 0 psi > 1” – 2000 psi Reducing Branches
(150 psi Rated)
(Use linear interpolation for all pressures in between 0 and 150 psi) ID SIF
d/D* SIF
1 1.5
Example: What is the allowable stress of 4” Ø RPS 150 psi rated ≥ 0.5 2.3
2 1.5
piping operating at 80 psi? < 0.2 1.5
3 2.0
*Use linear inter-
Allowable stress at 80 psi = 80 · (2600-2000) + 2000 4 2.0
polation between
(150-0) 6 2.0 these valvues
8 3.0
= 2320 psi
10 3.0
The above mentioned allowable stresses provide a combined factor 12 3.0
of safety of 6 to 1 14 3.4
16 3.5 Tee’s & Laterals
Note: 18 3.7 (150 psi Rated)
1. Many codes require the use of a “hot” and “cold” allowable 20 3.7 ID SIF
stress; however the allowable stress for FRP piping applies to 24 3.8 < 12” 2.3
both the “hot” and “cold” allowable. 30 4.0 > 12” 2.5
36 4.1
2. The analysis of thermal loads as separate from other loads such
as pressure and weight is not appropriate for FRP piping. The
stresses resulting from the combined loads, including thermal General Comments on SIF’s
loads, must comply with the allowable stresses. • SIF’s will generally be higher than those listed for fittings with a
3. Allowable stresses for elbows are typically different than for lower pressure rating.
filament wound pipe. The following values can be used: • The flexibility factor (k) for FRP fittings is often assumed to
Allowable Stress 1” – 3” – 1500 psi be 1.0. For larger diameter piping (eg. > 12” diameter), and
@ 150 psi 4” – 6” – 1800 psi for thin-walled piping, it may be helpful to take advantage of
> 6” – 2600 psi the inherent flexibility of elbows. More accurate values for the
flexibility factor of these elbows can be calculated from:
Allowable Stress 1” – 3” – 1500 psi
@ 0 psi 4” – 6” – 1800 psi K = 0.6 / h
>6” – 2900 psi where,
Stress Intensification Factors (SIF’s) h = Elbow thickness · Bend radius
Proper pipe stress analysis requires an understanding of stress (Diameter / 2 )2
intensification factors (SIF’s). These factors are required to account
for the increased bending stresses that occur in fittings as compared
to straight pipe. Exact determination of SIF requires testing and/or
finite element analysis. Typical SIF’s are listed below. Please contact
RPS for additional information.

20
 Design Manual

BURIED PIPE DESIGN & INSTALLATION WL = Live load on pipe = P · If / (144 · L1 · L2), psi
and
P = wheel load = 16,000 lbs for HS-20
If = Impact factor
= 1.1 for 2’ < H < 3’
= 1.0 for H > 3’
L1 = load width parallel to direction of travel
= 0.83 + 1.75 H
L2 = load width in direction perpendicular to travel
= 1.67 + 1.75H for 2’ < H < 2.48’
= (43.67 + 1.75H)/8 for H > 2.48’
Kx = Bedding coefficient = 0.083 to 0.1
FRP piping is considered to be flexible pipe and the design relies on
the passive support of the soil around the pipe to resist loads from PS = Pipe stiffness = EI / {0.149 (r + ∆ y/2)3 }
above. Therefore the designer needs to appreciate that the proper E’ = Modulus of soil reaction, psi
installation of buried FRP piping is at least as important as a proper (depends on soil type and compaction)
design.
The designer can examine the effects of the deflection in terms
Buried Pipe Design of stress or strain by using an empirical equation, which has been
The design of buried FRP piping generally follows the guidelines of shown to provide a good correlation between field measurements
the American Water Works Association document AWWA M45. This and experimental results.
manual superseeds the design information previously presented in σ b = Df · E · ∆ya tt (stress due to deflection)
AWWA C950. Buried pipe deflection is predicted using the Spangler D D
equation which combines material properties with soil properties
and live loads to predict an overall deflection. ε b = Df · ∆ya tt (strain due to deflection)
D D
∆ y = (Dl · Wc + WL) · Kx (deflection)
D 0.149 · PS + 0.061 · E’ where,

where, Df = Shape factor based on soil and pipe stiffness

Dl = Deflection Lag factor (typically 1.5) E = Ring flexural modulus, psi

Wc = Vertical soil load = γs · H / 144 , psi ∆ ya = Maximum allowable long term deflection, in.

and tt = Pipe total wall thickness, in.

γ s = Unit weight of overburden, lb/ft3 D = Mean pipe diameter, in.

H = Burial depth to top of pipe, ft

21
 Design Manual

These values are compared with the long term ring bending strain for stress basis,
divided by a design factor.
σpr ≤ 1 – { (σb · rc) / (Sb · E) }
σb ≤ Sb · E HDB FSpr
FS
and
or
σb · rc ≤ 1 – { σpr / HDB }
εb ≤ Sb Sb · E FSb
FS
for strain basis,
where,
εpr ≤ 1 – { (εb · rc) /Sb }
Sb = Long term ring bending strain HDB FSpr
FS = Design factor = 1.5 and
The effects of pressure also need to be examined and the pressure εb · rc ≤ 1 – { εpr / HDB }
class of the piping determined based on the HDB. Sb FSb
for stress basis, where,
Pc < {HDB/FS} · {2· t/D) FSpr = Pressure design factor = 1.8
for strain basis, FSb = Bending design factor = 1.5
Pc < {HDB/FS} · {2 · Eh · t / D) σpr = Working stress due to pressure, psi
where, = Pw · D / 2 · t

Pc = Pressure class, psi σb = Bending stress due to max. deflection, psi

=Df · E · ( δ d/D)(tt/D)
HDB = Hydrostatic design basis (psi for stress basis and in/.in for
strain basis) rc = Rerounding coefficient due to internal pressure

FS = Minimum design factor = 1.8 εpr = Working strain due to internal pressure
= Pw · D / (2 · t · Eh)
t = Thickness of pipe reinforced wall, in.
εb = Working strain due to max. deflection
D = Mean diameter of pipe, in. = Df · (δ d/D)(tt/D)
Eh = Hoop tensile modulus, psi δ d = Maximum permitted long term installed deflection, in.
The working pressure must be less than the pressure class denoted The possibility of buckling also needs to be examined with the
as: allowable buckling pressure calculated as follows:
Pw ≤ Pc qa = ( 1/FS) { 32 · Rw · B’ · E’ · EI / D3 }1/2
The surge pressure should be less than: where,
Ps ≤ 1.4 · Pc - Pw FS = Design factor = 2.5
The effects of combined loading of pressure and bending are also Rw = Water buoyancy factor
examined and evaluated as follows: = 1 – 0.33 (hw/h) ≥ 0

22
 Design Manual

and (typically >98% Proctor) using hand equipment and small

machinery.
hw = Height of water above pipe, ft.
• The remainder of the fill in the pipe-zone should be placed in
B’ = Empirical coefficient of elastic support
reasonable lifts (typically 6” at a time) and must be well graded
= 1 / ( 1 + 4e-0.065H )
to allow for proper drainage and well compacted (typically >
h ≈ H = Height of soil above pipe, ft. 98% Proctor) to provide support for the pipe side walls. Care
must be taken, however, to ensure the piping does not go out
E’ = Modulus of soil reaction, psi
of round during backfilling & compacting.
This equation is valid for:
• In-situ or native soil can generally be applied in 12” lifts to fill
2’ ≤ H ≤ 80’ without vacuum outside of the pipe zone. The top layer of the material should be
4’ ≤ H ≤ 80’ with vacuum stabilized to prevent erosion.
The allowable buckling pressure is compared with the applied • Do not pass spreading equipment directly over the pipe until 4’
buckling loads as follows: of fill has been placed over the crown.
γw · hw + Rw · Wc + Pv ≤ qa • Groundwater should be redirected away from the buried pipe
using culverts or swales.
where,
• FRP piping is lightweight and, when empty, will float-out of its
γw = Specific weight of water = 0.0361 lb/in3
bedding if surface and ground water are not properly redirected.
Pv = Internal vacuum pressure, psi Once the piping has “floated” it must be reinstalled.
When live loads are present, this should be examined separately. • For severe traffic loads such as at railway crossings, the FRP
The simultaneous effect of live load and internal vacuum need not piping should be concrete encased.
typically be considered.
• Use a flexible gasket to protect the outside of the buried pipe
γw · hw + Rw · Wc + WL ≤ qa where it passes through a concrete wall.
Buried Pipe Installation • Watch for differential soil movement where buried pipe passes
As mentioned at the start of this section, the installation of buried through walls.
pipe is at least as important as the proper design of the piping. Below • If O-ring joints are used, concrete thrust blocks are required at
is a summary of some of the important points to consider when significant changes in direction.
installing buried FRP piping.
• For O-ring joints, remove material under the spigot to lessen the
• The initial excavation should encompass the pipe diameter plus chance of foreign material entering the bell during insertion.
6” to 12” below the pipe and at least 12” on either side. The side
• If butt and wrap joints are used, the area under the joint must be
walls should be adequately sloped or safely supported.
sufficiently excavated to allow the worker to apply and roll-out
The bedding should consist of at least 6” of well graded, granular the reinforcing material.
material (ex. sand or gravel) which will allow for drainage of ground
RPS is also experienced in the design of partially buried piping. This
and surface water under the piping. This material should be slightly
design and installation method can provide reduced wall thickness
shaped to accept the contour of the pipe and well compacted to at
compared to fully buried piping due to the reduction of soil loading.
least 98% Proctor Density. All large rocks should be removed and any
It is critical, however, that well compacted soil be placed around the
soft spots in the native soil should be excavated and re-filled.
piping sufficient to hold the piping in place and maintain roundness.
• The “haunches” of the pipe need to be well supported with
the above mentioned fill and the fill must be well compacted
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References
For more information on buried piping design and installation refer
to:
RPS Pipe & Fittings Installation Manual
American Water Works Association - “Fiberglass Pipe Design –
AWWA M45”
“Standard Practice for Underground Installation of Fiberglass Pipe –
ASTM D 3839” – ASTM Standard

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JOINING SYSTEMS • Adhesive formulated using the same resin as the pipe (bis-A
vinyl ester or epoxy novolac vinyl ester)
• Some limitations on fittings available (see RPS Dimensional
Catalogue for more information)
• Requires minimal training
• Requires specialized tool for field tapering (available to rent or
purchase).
• Pipe wall thickness and/or liner thickness may be limited;
however various options do exist (consult RPS directly for more
information)
Butt & Wrap Joint
RPS utilizes four (4) major types of joining systems on our products. The Butt and Wrap joint is an industry standard providing
The designer needs to carefully examine each system to determine simple assembly of an unlimited number of components. RPS
which best suits the particular application. A description of each offers both a “straight” and “tapered” butt joint with the details
joining system from a design standpoint is provided below: summarized below.
RPS Tapered Adhesive Joint Straight Butt & Wrap Joint

• Available in all sizes / laminate combinations

The RPS Tapered Adhesive joint utilizes a matching bell and spigot
system combined with a specially formulated adhesive to provide • Simple assembly procedure
quick and easy assembly of numerous combinations of pipe and • Provides good corrosion resistance
fittings.
• Ends can be “capped” (ex. 2 layers of Veil) to increase corrosion
• Available in 1”Ø to 12”Ø resistance
• Quick to assemble (about 3 times faster than butt and wrap • Inside lay-up recommended on larger diameters (> 20”) to
joint) improve chemical resistance.
• Self-aligning due to tapered fit • Provides same axial strength as pipe
• Provides excellent chemical resistance due to continuity of the • Has generally lowest burst strength of all bonded joint types
corrosion barrier and thin adhesive line.
• Has high bending strength
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 Design Manual

Tapered Butt & Wrap Joint Full Face Flange

• Available in all sizes / laminate combinations • Available in all sizes

• Offers improved chemical resistance over straight butt joint by • Allow for dismantling of components
providing continuous corrosion liner. Comparable to tapered
• Quick to assemble in field
adhesive joint.
• Most costly of all joint types
• Offers increased pressure strength over straight butt joint
• Experience has shown flanges offer the greatest potential for
• More time consuming to install than a straight butt joint.
leaks
• More costly than straight butt joint due to increased labour
• Requires bolting compatible with the process
component
• Requires gaskets compatible with the process although soft
• Requires more sanding in the field compared to straight butt
(60-70 durometer) EPDM are most common
joint.
• Cannot use “ring” gaskets
• Inside lay-up recommended on larger diameters (> 20”) to
improve chemical resistance. • Can be damaged by over-torqing
Flanged Joint • FRP flanges must be properly aligned to avoid overstressing
during installation, cannot be forced into place.
Flanged joints may be used to connect pipe and fittings, and
to connect to equipment. RPS offers full face style flanges and • Sealing rings on full face flanges provide sealing at lower
Lap Joint style flanges as summarized below. Standard drilling bolt torques
for flanges conforms to ANSI B16.5 Cl.150 for ≤ 24” Ø and ANSI
B16.47 Series A Cl.150 for > 24ӯ. Other drilling patterns are
available (eg. DIN 2501 PN10)

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 Design Manual

Lap Joint Style Flange O-Ring Joint

• Available in all sizes

Generally used with large diameter buried pipe to provide quick
• Allows some rotation adjustment
installation.
• Seals at lower torque compared to full face flange
• Available in most sizes
• Similar cost to full face in large diameters, more costly in small
• Allows for quick installation
diameters
• Available in high pressure ratings
• Also requires proper alignment to prevent overstressing at
installation • Does not provide axial restraint, therefore thrust blocks required
at significant changes in direction.
• Loose ring (generally mild steel). Coating should be compatible
with the service conditions • Provides approximately 1° of angular adjustment
• Bolts and rings must be compatible to avoid corrosion • Has good chemical resistance, but for more severe applications,
o-ring material must be chosen to suit service conditions.
• Sealing rings on lap joint flanges provide sealing at lower bolt
torques • A “double o-ring” allows for testing prior to service
• Not recommended for slurry applications
General Comments on Joining Systems
Whenever possible, RPS recommends the use of our Tapered
Adhesive joining system to provide high chemical resistance and a
low installed cost. For sizes 14ӯ and larger, choose the Straight
Butt & Wrap system, if possible, to minimize sanding in the field
and improve installation time. For severe corrosion environments
(≥ 14”Ø), choose the Tapered Butt & Wrap system, or choose
edge-capping and the straight butt and wrap system. Avoid flanged
joints to minimize cost and reduce the risk of leaks. Where flanged
joints are necessary, consider Lap Joint flanges on larger diameters
(≥14”) to offer adjustment and provide superior sealing capability.

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QUALITY ASSURANCE and RESEARCH & Seismic & Wind Design

DEVELOPMENT “Minimum Design Loads for Buildings and Other Structures (ASCE
RPS Composites is certified to ISO 9001 through NSF ISR. Our quality 7)” – American Society of Civil Engineers
assurance program includes written procedures and work instruc-
Stress Intensification Factors (SIF’s)
tions covering all aspects of the Company’s operation, including
design and document & data control. All calculations and drawings “Design and construction of glass reinforced plastics (GRP) piping
affecting the fit, form or function of our products are reviewed by our systems for individual plants or sites – BS 7159” – British Standards
engineers to ensure compliance to the required specifications and Institute
standards. In addition, our R&D department is continuously testing
Regulatory Codes Applicable to FRP Piping
our existing product line as well as exploring new possibilities to
improve existing products or create new products. “Process Piping – ASME B31.3” – American Society of Mechanical
Engineers

REFERENCES “Power Piping – ASME B31.1” – American Society of Mechanical

Engineers
The following is a list of references that contain useful information
relating to the design of FRP piping and fittings. The references are Pipe Support and Pipe Stress Analysis
categorized by various subjects; however, some of the references “Piping and Pipe Support Systems” – Paul R. Smith / Thomas J.
may contain information beyond the main subject. Van Laan
General Information on FRP Design Testing and Research
“Fiberglass Pipe Handbook” – The Composites Institute of the Society “Standard Test Method for Tensile Properties of Plastics – ASTM D
of Plastics Industry 638” – ASTM Standard
“Corrosion Resistant Plastic Composites in Chemical Plant Design” – “Standard Test Method for Flexural Properties – ASTM D 790” –
John H. Mallinson ASTM Standard
“Custom Contact Molded Reinforced Polyester Chemical Resistant “Standard Test Method for Short-Time Hydraulic Failure Pressure of
Process Equipment PS 15-69” – National Bureau of Standards Plastic Pipe, Tubing and Fittings – ASTM D 1599” – ASTM Standard
“Structural Plastics Design Manual” – American Society of Civil “Standard Test Method for Longitudinal Tensile Properties of
Engineers Fiberglass Pipe and Tube – ASTM D 2105” – ASTM Standard
“Fiberglass Pipe Design – AWWA M45” - American Water Works “Standard Method for Indentation Hardness of Rigid Plastics by
Association Means of a Barcol Impressor – ASTM D 2583” – ASTM Standard
“Reinforced plastic pipes, fittings and joints for process plants – BS “Standard Practice for Obtaining Hydrostatic or Pressure Design Basis
6464” – British Standards Institute for Fiberglass Pipe and Fittings – ASTM D 2992” – ASTM Standard
“Design and construction of glass reinforced plastics (GRP) “Standard Specification for Filament Wound Fiberglass Pipe – ASTM
piping systems for individual plants or sites – BS 7159” – British D 2996” – ASTM Standard
Standards Institute
“Standard Specification for Machine Made Fiberglass Flanges – ASTM
D 4024” – ASTM Standard
“Standard Specification for Contact Molded Fiberglass Flanges –
ASTM D 5421” – ASTM Standard

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RPS Composites Inc.

740 Main Street
P.O. Box 299
Mahone Bay, Nova Scotia
Canada B0J 2E0
Tel: (902) 624.8383 | (800) 343.9355
Fax: (902) 624.6395
www.rpscomposites.com

RPS Design Manual - Dec 2016 29