FCPP -Fiberglass-coated Concrete

Pressure Pipes
Product Guide
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Amiantit Group of Companies
The Amiantit Group is a leading global industrial
organisation that manufactures high quality pipe
systems, researches, develops, owns and licenses
advanced pipe technologies and provides water
management services. The Group supports global
infrastructure development projects and delivers to
municipal, industrial, agricultural and energy markets
worldwide.
Amiantit has a presence in more than 70 countries,
including almost 30 wholly-owned or joint ventured
manufacturing facilities in the Middle East, Europe,
North America and Latin America, North Africa, The
Far East, Central Asia, the Indian Subcontinent and in
Africa. Amiantits manufacturing capabilities are sup-
ported by technology companies and sales offices
around the globe.
Other members of the Group are predominantly
limited liability companies owned by the Amiantit
Group in varying percentages and operating under
individual commercial registrations.
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Ameron Saudi Arabia, Ltd
Ameron Saudi Arabia Ltd. (ASAL) was established in
1978 in Dammam, Saudi Arabia, as a limited liability
company operating three manufacturing plants
located in Dammam and Jubail with total annual
production capacity of more than 1000 km. It is a joint
venture company between Saudi Arabian Amiantit
Co. (Joint Stock Co.) as majority share holder and
Ameron International (USA).
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Pipes constitute a major element item in all water tran-
sit projects. The service life of pipes installed below
or above ground is essential for the efficient use of in-
vested resources. The performance of pipes and their
operational costs, which form an important aspect of
the project costs in all water transit lines world-wide,
has become increasingly evident.
In 1982, due to highly aggressive environmental
conditions in the Arabian Gulf Region, Ameron Saudi
Arabia Ltd started using an extra protection system of
coal-tar epoxy to protect its concrete pipe products.
It also recommended the use of cathodic protection
(CP) on the pipe systems in order to make absolutely
sure of the integrity of the belowground pipeline and
protect it against natural chemical attacks from the
harsh soils in the area.
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In 1997 Ameron Saudi Arabia Ltd began their Fiberglass coated pipe appears to maintain its
research and development into how to improve the physical integrity without developing any crack or
coating of concrete pressure pipes. In 2002, to further physical degradation in all tests, clearly pointing to a
develop the coating system, the company contracted high-performance, durable product.
with the Engineering and Research center of the King
Fahad University of Petroleum and Minerals (KFUPM).
Based on both efforts, the outcome has revealed that
the use of a fiberglass layer as a protective coating
for concrete pipes is the most effective and efficient
protection system. This is due to its excellent durabil-
ity, chemical resistance, adhesion and its ability to
provide corrosion protection.

Concrete pressure pipe has demonstrated a consis-

tently long service-life when properly installed in most
natural environmental conditions. This is attributed to
the protection that Portland cement affords to embed-
ded steel. The hydrated cement is chemically basic,
having a pH of about 12.5. At this pH, an oxide film
forms on the embedded steel surfaces, which pas-
sivates the steel. The passivated steel will not corrode
unless a corrosion cell condition is created.
By applying a layer of Fiberglass coating on the
external surface, the concrete pressure pipe will be
more durable, more reliable, and cathodic protection
will not be required.

The results obtained indicate that a 2 - 3 mm layer of

fiberglass renders the concrete pressure pipe system
highly resistant to corrosion.
The following can also be concluded from the find-
ings:

Fiberglass coated concrete pressure pipe show a

much higher tensile strength and reduced shrink
age.
Performance of fiberglass coated pipes in mini
mum of six months of exposure cycles show no
adverse implication.
under thermal cycles, wet-dry cycles and U-V
exposure.
Chloride penetration in fiberglass coated con -
crete pressure pipe is negligible.
No adverse effect of continuous exposure to alka-
line solution over five months is observed.

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The core pipe is manufactured based on AWWA C303 4.2 Fabrication of joint rings
standard requirements with modifications to the
process of curing and the application of the cement- Bell and spigot rings, which form the O-ring sealed
mortar coating. The Fiberglass coating is applied at joint between adjacent pipes, are fabricated from flat
a later stage to the dry surface of the cement-mortar bars and special hot-rolled sections respectively. The
coated pipe. steel is accurately cut, rolled and welded into a ring
and then sized on a hydraulic press to an exacting
Fiberglass concrete pressure pipes (FCPP) consist of: circumferential length tolerance.
Welded steel cylinder.
Centrifugally cast concrete or cement-mortar
lining.
Steel reinforcing bar wrapped at a predetermined
stress around the cylinder.
A dense cement-mortar coating over the steel
cylinder and wrapped reinforcement.
Steel joint rings welded to the cylinder to form a
self-centring bell and spigot joint sealed by a com
pressed rubber gasket.

The mortar for lining and coating consists of one part

cement to not more than three parts of fine aggregate
by weight. Steel cylinder thickness depends on the
pipe diameter with a minimum thickness of 1.5 mm
and a maximum thickness of 10 mm. Minimum
diameter of rod reinforcement is 6.0 mm with a
maximum diameter of 14 mm. Minimum area of rod
reinforcement is 493 mm2/m of pipe wall or numerically
equal to 83.3 % of the pipe diameter in mm. Maximum Fabrication of joint rings
area of rod reinforcement is 50% of the total steel
area. Maximum centre-to-centre spacing of rod
reinforcement does not exceed 50 mm. The bell and
spigot rings are fabricated from a mild steel strip and
a special hot-rolled shape respectively.

4.3 Attachment of joint rings

4.1 Fabrication of steel cylinders
An automatic helical weld machine forms a continu-
ous cylinder from coils of steel sheet. At the appropriate
point, a circumferential cutting operation separates
the exact length of cylinder required for the individual
piece of pipe.
The steel cylinders advance along the production line
to the joint ring attachment station.
A bell joint ring is placed over one end and a spigot
over the other end of each cylinder. The rings are
adjusted to give the pipe its exact overall length and
to assure the ends are square. They are then welded
to the cylinder.

Fabrication of steel cylinders Attachment of joint rings

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4.4 Hydrostatic testing of cylinders
A tensile stress of at least 75% of yield strength of
steel is hydrostatically induced into the cylinder steel
to check its strength and to confirm the
water-tightness of the completed cylinder assembly.
Hydrostatic testing of cylinders
4.5 Concrete or cement-mortar lining.
A measured quantity of cement-mortar, mixed under
controlled conditions, is placed uniformly throughout
the length of the tested cylinder while rotating in a
spinning machine. The lining is densified by increas-
ing the speed of the machine. High centrifugal forces
are maintained until the cement mortar is relatively
dry to handle.
Placement of concrete or cement-mortar lining.
4.6 Curing the lining
The lined cylinder is placed in a chamber where the
mortar cures for a specified period of time under
controlled temperature and humidity.
Curing the lining.
4.7 Rod wrapping
Upon completion of cure, the lined cylinder is
wrapped circumferentially with steel rod at controlled
tension and predetermined spacing. A slurry, rich in
Portland cement, is sprayed on the cylinder immedi-
ately ahead of the advancing rod wrap to fill all voids
between the steel and cylinder.
Rod wrapping
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4.8 Cement-mortar coating

The rod-wrapped cylinder is moved to the cement-

mortar coating machine where it is slowly rotated
while a stream of cement-mortar is impacted against
its surface to produce a dense, durable coating. A
second spray of Portland cement-rich grout precedes
the mortar to assure that the steel is coated. The mor-
tar is mixed under controlled conditions and applied
in a designed thickness and the surface is smoothed
in readiness for fiberglass application.

Application of cement-mortar coating

4.9 Steam curing of cement-mortar coating

The cement-mortar coated pipe is steam cured under

controlled conditions until the coating is of adequate
strength to permit handling. The joint rings are
cleaned and painted with a rust inhibitor.

4.10 Fiberglass coating process

The pipe is then moved to the fiberglass application

production line. It is rotated while Fiberglass chops
are applied together with resin. It is then pressed
and smoothed mechanically.
Steam curing of cement-mortar coating

4.11 Curing of fiberglass coating

The applied layer of fiberglass coating is further

cured by the application of heat before the pipe is
moved away from the machine.

4.12 Storage

The ends of the pipe are covered with tightly fittings

plastic caps which retain moisture in the mortar there-
by providing the environment for continued curing.
The completed pipe is stored on sand bags or sand
rows until it is loaded on the bolster-equipped truck
Fiberglass coating process
for delivery to the jobsite.
The number of layers of pipe in the storage stack and
on the truck is a function of the pipe diameter. Since
fiberglass coated concrete pressure pipe is designed
as a semi-flexible conduit, larger sizes are braced
internally with timber stulls until installation.

Storage Curing of Fiberglass coating

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Fiberglass-coated Concrete Pressure Pipe (FCPP)

systems and accessories offers many advantages:

Features Benefits

Corrosion-resistant Long, effective service-life.

No need for additional linings, coating, cathodic protec-

tion, polyethylene wraps or other forms of protection.

Low maintenance costs.

Pipe performance prediction can be monitored at any

time during service-life due to electrical conductivity of
the steel element of the pipe

Hydraulic characteristics Smooth surface.

Concrete thrust blocks can be eliminated by welding

some number of joints near to the fitting.

Hydraulic capacity remains unchanged.

Flexible Conditions Can be used in high cover depths with different soils.

Additional surge pressure up to 50% of the design

pressure without the need to increase the pipe pressure
rating.

High external load carrying capacity (depth)

Can absorb structural settlements.

Minimal trench bedding material

Requirements

Carrying capacity The smooth surface of the cement-mortar lining pro-

vides a Hazen-Williams coefficient, C, of 145 for water
service. Because cement mortar does not corrode, the
carrying capacity does not decrease with age.

Impact resistant Better impact resistance for aboveground application than

other pipes materials.

Environmentally Friendly No hazardous health effects

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6.1 Pipes

The Fiberglass coated concrete pressure pipe

(FCPP) is offered in an extensive range of pipe diam-
eters and is completed by an outstanding range of
fittings and special pipe.

Our range of standard diameters in mm:

300 - 400 - 450 - 500 - 600 - 700 - 800

900 - 1000 - 1100 - 1200 - 1300 - 1400
1500 - 1600 - 1700 - 1700 - 1800

FCPP can be designed up to pressure class 27.6

bars (400 psi), with custom design up to 40 bar with
max diameter of 800mm, and for external loads as
required. The laying lengths vary from 10m to 12.5m,
depending on the pipe diameter. Short pipe, bevelled
pipe, and a wide range of special pipe and fittings
are also available.

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6.2 Fittings and accessories: FCPP Tee

A full range of special pipes and fittings and

accessories is available to satisfy project require-
ments. They are custom fabricated to suite the proj-
ect requirements at the pipe manufacturing facility
and delivered with the pipe to the construction site in
the proper sequence for installation in the pipeline.
Special pipes and fittings of all sizes can be supplied
with various end configurations including flanged
ends for flanged joints, steel plate plain ends for
mechanical coupling joints or for butt-strap closures
and steel bell and spigot ends for joints sealed with
the standard round rubber ring.

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7.1 Pipes

FCPP is designed and manufactured in accordance

with the following standards and specifications:

AWWA C303 (AWWA Standard for Concrete Pres Rubber O-ring

sure Pipe, Bar Wrapped, Steel-Cylinder Type).

AWWA M9 (Manual for Water Supply Practices
Concrete Pressure Pipe.
Saudi Arabian Standard Organization (SASO).

Properties of Fiberglass coating :

Thickness 2.0 to 3.0 mm

Pull strength Average 5.5 N\mm

Electrical resistive Above 1.0 million Ohm

()
Rubber O-ring
External load carrying 3 % more per linear
capacity meter
Water permeability Zero mm

Chloride permeability Zero coulombs

Resistance to UV and No change in color

storage

Above ground Can be use without

Installation supplemental
protection

7.2 Pipe joints

All FCPP pipe systems have a proven jointing system

that ensures the system works through its whole es-
timated service-life. The system also offers solutions
for transitions to other materials, such as connection
to valves or other accessories.

FCPP sections are rapidly assembled with a self-cen-

tring steel bell and spigot joint sealed with a confined
round rubber gasket. Installation rates of 30 to 50
pipe sections per crew/day can be achieved.

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Joint angular deflection and bevels
Maximum angular deflection (turn) at each joint, mea-
sured as the change in adjacent pipe centre lines,
must not exceed the amounts given in table below.
sured as the change in adjacent pipe centre lines,
must not exceed the amounts given in table below.

The table below illustrates the Deflections, Offsets,

Minimum Radii, and Laying Lengths of the standard
pipe.

Jmax
D q

Js Jmin

q G

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Consistently high quality standards are an important
feature of our Ameron pipe systems produced
throughout the world. Our manufacturing sites are
continually checked by third parties and have official
approval under ISO 9001 and other standards.
All Ameron Saudi Arabia Ltd companies have their
own quality control departments and laboratories, to
ensure that
all products are manufactured under the specified
requirements.
production and services continually improve in
quality.
Ameron Saudi Arabia, Ltd has adopted and has been
implementing well-established quality control proce-
dures for all its products to comply with international
standard requirements, as well as customer specifi-
cations, with the aim of supplying its customers with
reliable products of consistent quality that will provide
maintenance-free service for the intended lifecycle of
the pipeline.
The quality control engineer is responsible for:
Ensuring that the product is manufactured accord-
ing to contract specification.
For maintaining and implementing quality control
standards and procedures.
For evaluating test results.
For monitoring the manufacturing process to main-
tain compliance with the process standards.
Providing technical support to customers on
quality matters.
Giving potential customers and vendor inspectors
an insight into the companys quality program.
The quality control department has a highly experi-
enced staff of quality control inspectors and labora-
tory technicians who perform inspections and tests
to assure that finished products comply to relevant
project specifications, drawings and standards.
Ameron Saudi Arabia Ltd (ASAL) has produced a
detailed installation guide for the field installation of
its products.
The company provides after-sales services to its cus-
tomers and sends its field engineers on regular site
visits to ongoing project jobsites in order to provide
quality control and liaise between the customer and
the company.
They assist the customer in becoming familiar with
the proper installation practices of ASAL products
and check whether the customer is installing the
products in accordance with the project specification
and design assumptions, as well as prescribed ASAL
installation practices. Field service personnel are
also responsible for the supervision of ASAL employ-
ees performing field works at the jobsite.
In general and for all products, installation includes
also pipe delivery and site storage.
Proper loading, transport and unloading practices
should be taken into consideration in order not to
damage the pipe.
Pipes should be properly supported along the
bottom and blocked to prevent accidental rolling,
whether pipes are strung along the trench side or
in a temporary storage yard.
For pipe laying and embedding, please take the
following into consideration
Trenches must be excavated to the line and grade
shown on the project drawing, except as amended
and supplemented by the manufacturers tabular
layout schedule.
Trenches must be excavated to provide a mini-
mum of 1 meter earth cover at the top of the pipe.
Sub-grade should provide continuous, uniform
support under the haunches of the pipe after
bedding and backfilling.
Trench should be dewatered prior to pipe instal-
lation.
As much as possible, pipes are laid on the trench
so that the bell end faces in the direction of laying.
Prior to assembling the joint, the inside shoulder of
the bell is to be plastered with a stiff mortar which
should be finished flush with the adjacent pipe
surfaces after joining.
The spigot, the first 50 mm of the bell, and the
rubber rings need to be lubricated with vegetable
soap. The pipes are then joined together with a
considerable force to engage the spigot and bell.
Once the pipe sections are in place, a joint band
is secured around the joint recess which is then
filled with mortar, which in turn must fill the annular
space between the ends of the pipe.
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 Bedding and the backfill-bedding material needs
to be backfilled in the pipe trenches in lines,
according to contract drawings.
Bedding and backfill material should not be
dropped directly on the pipe and all materials
placed within the pipe zone must be free from
rocks or clods larger than 75 mm in diameter.
Backfill material above the pipe bedding, which
should be a minimum depth of one meter above
the top of the pipe, may be placed as soon as
compaction of the pipe bedding material is
completed.
If densification of backfill is required, the material
should be placed in horizontal layers and then
compacted.

Hydrostatic testing of pipelines

Each completed length of the pipeline required to be
sectionalised for testing should be bulk-headed and
filled with water as soon as practicable; but until the
final field hydrostatic test is made, the pipe will not be
required to be subjected to greater water pressure
than that necessary to keep it filled. Prior to testing,
the section of the pipeline to be tested should be
placed under a slight pressure for at least 48 hours.

The pipeline should then be brought up to the test

pressure which must be maintained on that section
for a period of not less than 4 hours.
After the pipe has successfully met all of the test
requirements, the entire pipeline should be filled with
water and so maintained until the completion of the
contract.
A detailed installation guide, as well as parts and
maintenance manuals specific to each product, are
available upon request.

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 Utmost Care has been
taken to ensure that all the
contents of this brochure
are accurate. However,
Amiantit and its subsidiar-
ies do not accept respon-
sibility for any problems
which may arise as a result
of errors in this publica-
tion. Therefore customers
should make inquiries into
the potential product sup-
plier and convince them-
selves of the suitability of
any products supplied or
manufactured by Amian-
tit and/or its subsidiaries
before using them.

Ameron Saudi Arabia, Ltd

P.O. Box 589 Dammam
31421
Kingdom of Saudi Arabia
Phone: +966 3 847 15 00
Fax: +966 3 847 21 33
Info@amiantit.com
www.amiantit.com
www.ameronsal.com
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