GRP Pipe Manufacturing by CFW Process Flowchart

Mixing

Infrared curing
Resin
Fiberglass Hydro-testing
+
Cobalt Catalyst Reinforcements

Chamfering,
Shaving,
Calibration,
Cutting

Storage
In-line automatic spigot calibration & Chamfering
Dosing of cobalt – automatic
PLC controlled chemical dosing
Pipe Design Recipe
Feed the design parameters into the CFW machine
In-house Tests
Axial Tensile Strength Test
Stiffness Test
Flexure Test
Split Disc Testing Machine – for HOOP strength test
Beam Strength Test
Strain-Corrosion Test
Strain-Corrosion End-point
Strain-Corrosion Test Report
 Strain-Corrosion Test Report

Fig. 2. Plot of regression line,

HDB Test
HDB Test Report
 HDB Test Report

Fig. 2 – Graph of regression line, 95% Confidence and Prediction Limits.

Cell Classification System
Type 1 : Filament-Wound
Type 2 : Centrifugally Cast

Grade 1 : Glass Fiber Reinforced Epoxy (RTRP Epoxy)

Grade 2 : Glass Fiber Reinforced Polyester (RTRP Polyester)
Grade 3 : Glass Fiber Reinforced Epoxy Mortar (RPMP Epoxy)
Grade 4 : Glass Fiber Reinforced Polyester Mortar (RPMP Mortar)

Liner A : No Liner
Liner B : Thermoplastic Liner
Liner C : Reinforced Thermoset Liner
Liner D : Non-reinforced Thermoset Liner

Example : Type 1, Grade 2, Liner C (Filament-wound, RTRP Polyester, Reinforced Thermoset Liner)
 STIS
E’n
E’b

Backfill
Traffic Loads
Installations

Pipe Invert
Compaction

Native Soil
Pipe Crown
Vertical
deflection
Facts about GRP Pipe
AWWA M45
Trench Cross-Section Terminology
fig. 6-1
 Native Soil Group Classification

Appendix C

Native Blow E’n Description Friction Description Unc. Comp.

Soil Counts’ value3,4 Angle Str. (kPa)
Group (MPa) (degrees)
1 > 152 34.5 Compact 33 Very stiff 192 - 384
2 8 – 15 20.7 Slightly 30 Stiff 96 – 192
compact
3 4–8 10.3 Loose 29 Medium 48 – 96
4 2–4 4.8 Very loose 28 Soft 24 – 48
5 1–2 1.4 Very loose 27 Very soft 12 - 24
6 0-1 0.34 Very, very 26 Very, very 0 - 12
loose soft

1 Blows/foot from standard penetration test, ASTM D1586.

2 For higher blow counts, E'n values increase to 345 MPa for rock.
3 The use of geotextiles in the pipe zone will likely increase the values of E'n above those listed.
4 If permanent sheeting is used in the pipe zone, consider native E’n = E'b, Sc = 1
 Field testing to assist Classification of Native Soils

Table E1 Simple Field Test for Determining Soil Group1

Native Soil Measurable Characteristic

Group
1 Can be barely penetrated with thumb
2 Can be penetrated with thumb to 4mm
3 Can be penetrated by thumb to 10mm
4 Can be penetrated by thumb to 25mm
5 Can be penetrated by thumb to 50mm
6 Can be penetrated by fist to 25mm

1 Based on Peck, Hanson and Thornburn, "Foundation Engineering," 2nd Ed., John Wiley and Sons,
Inc., 1974 and ASTM D2488.
Ideal backfill material, but costly…
 Description of Backfill Soils

Appendix D1 Backfill Soil Type Classification

Backfill Description Unified Soil Classification

Type Designation, ASTM D2487
A Crushed stone and gravel, < 12% fines GW, GP, GW – GM, GP - GM
B Gravel with sand, sand, < 12% fines GW – GC, GP – GC, SW, SP
SW – SM, SP – SM, SW – SC, SP - SC
C Silty gravel and sand, 12 – 35% fines, LL < 40% GM, GC, GM – GC, SM, SC, SM - SC
D Silty, clayey sand, 35 – 50% fines, LL < 40% GM, GC, GM – GC, SM, SC, SM - SC
E Sandy clayey silt, 50 – 70% fines, LL < 40% CL, ML, CL - ML
F Low plasticity fine-grained soils,LL < 40% CL, ML, CL - ML
 Backfill Modulus of Passive
Resistance, E’b (MPa)

Appendix D2 Backfill Modulus of Passive Resistance (Non-Saturated)

Backfill E’b values (MPa) at Relative Compaction

Type
80% 85% 90% 95%
A 16 18 20 22
B 7 11 16 19
C 6 9 14 17
D 3 6 9 102
E 3 6 9 102
F 3 6 92 102

1 100% relative compaction defined as maximum Standard Proctor Density at optimum

moisture content.
2 Values typically difficult to achieve, included as reference.
 Backfill Modulus of Passive
Resistance, E’b (MPa)
Appendix D3 Backfill Modulus of Passive Resistance (Saturated)

Backfill E’b values (MPa) at Relative Compaction

Type
80% 85% 90% 95%
A 13 13 14 15
B 5 7 10 12
C 2 3 14 4
D 1.7 2.4 9 3.12
E NA3 1.7 9 2.42
F NA3 1.4 1.72 2.12

1. 100% relative compaction defined as maximum Standard Proctor Density at optimum

moisture content.
2. Values typically difficult to achieve, included as reference,
3. Not recommended for use.
Standard Trench Installation, Type 1 Without Traffic
Burial depth, m corresponding to values of E’b

E’b Native Soil Group

MPa 1 2 3 4 5 6

2500 STIS
20.7 23.0m 18.0m 11.0m 7.0m 2.8m NA
13.8 18.0m 15.0m 10.0m 6.0m 2.6m NA
10.3 15.0m 13.0m 9.0m 5.5m 2.6m NA
6.9 11.0m 10.0m 7.5m 5.0m 2.4m NA
4.8 8.5m 7.5m 6.0m 4.0m 2.0m NA
3.4 6.0m 5.5 5.0m 3.8m 1.8m NA
2.1 4.0m 3.5m 3.5m 2.8m 1.6m NA
1.4 2.6m 2.6m 2.6m 2.2m 1.4m NA
Standard Trench Installation, Type 1 Without Traffic
Burial depth, m

E’b Native Soil Group

MPa 1 2 3 4 5 6

5000 STIS
20.7 23.0m 18.0m 12.0m 7.0m 2.8m 1.2m
13.8 18.0m 15.0m 10.0m 6.5m 3.0m 1.2m
10.3 15.0m 13.0m 9.0m 6.0m 2.8m 1.2m
6.9 11.0m 10.0m 8.0m 5.0m 2.6m 1.2m
4.8 9.0m 7.5m 6.5m 4.5m 2.2m NA
3.4 6.0m 6.0m 5.0m 4.0m 2.0m NA
2.1 4.0m 4.0m 3.5m 3.0m 1.8m NA
1.4 3.0m 3.0m 3.0m 2.6m 1.6m NA
Standard Trench Installation, Type 1 Without Traffic
Burial depth, m

E’b Native Soil Group

MPa 1 2 3 4 5 6

10000 STIS
20.7 24.0m 19.0m 12.0m 8.0m 3.6m 1.8m
13.8 19.0m 16.0m 11.0m 7.0m 3.6m 1.8m
10.3 15.0m 13.0m 10.0m 6.5m 3.4m 1.6m
6.9 12.0m 10.0m 8.5m 5.5m 3.2m 1.6m
4.8 9.0m 8.5m 7.0m 5.0m 2.8m 1.6m
3.4 7.0m 6.5m 5.5m 4.5m 2.6m 1.6m
2.1 4.5m 4.5m 4.0m 3.5m 2.4m 1.6m
1.4 3.5m 3.5m 3.4m 3.0m 2.2m 1.6m
Standard Trench Installation, Type 1 With Traffic
Burial depth, m

E’b Native Soil Group

MPa 1 2 3 4 5 6

2500 STIS
20.7 23.0m 18.0m 11.0m 7.0m NA NA
13.8 18.0m 15.0m 10.0m 6.0m NA NA
10.3 15.0m 13.0m 9.0m 5.5m NA NA
6.9 11.0m 10.0m 7.5m 5.0m NA NA
4.8 8.5m 7.5m 6.0m 4.0m NA NA
3.4 6.0m 5.5m 5.0m 3.8m NA NA
2.1 3.5m 3.5m 3.0m NA NA NA
1.4 NA NA NA NA NA NA
Standard Trench Installation, Type 1 With Traffic
Burial depth, m

E’b Native Soil Group

MPa 1 2 3 4 5 6

5000 STIS
20.7 23.0m 18.0m 12.0m 7.0m 3.0m NA
13.8 18.0m 15.0m 10.0m 6.5m 2.4m NA
10.3 15.0m 13.0m 9.0m 6.0m 2.4m NA
6.9 11.0m 10.0m 8.0m 5.0m NA NA
4.8 8.5m 7.5m 6.5m 4.5m NA NA
3.4 6.0m 6.0m 5.0m 4.0m NA NA

2.1 4.0m 4.0m 3.5m 3.5m NA NA

1.4 2.4m 2.4m 2.2m NA NA NA
Standard Trench Installation, Type 1 With Traffic
Burial depth, m

E’b Native Soil Group

MPa 1 2 3 4 5 6

10000 STIS
20.7 24.0m 19.0m 12.0m 8.0m 3.5m NA
13.8 19.0m 16.0m 11.0m 7.0m 3.5m NA
10.3 15.0m 13.0m 10.0m 6.5m 3.0m NA
6.9 12.0m 10.0m 8.5m 5.5m 3.0m NA
4.8 9.5m 8.5m 7.0m 5.0m 2.5m NA
3.4 7.0m 6.5m 5.5m 4.5m NA NA
2.1 4.5m 4.5m 4.0m 3.5m NA NA
1.4 3.0m 3.0m 3.0m 2.8m NA NA
 Compaction of Backfill
Helpful tips for compacting the various types of backfill:

1. As a means of "calibrating" an installation method with a given backfill type, we

recommend that specific attention be given to compaction techniques and relative
compaction results during the installation of the initial sections of pipe used at a given
installation site.
2. When these initial pipes are installed, testing should be conducted frequently to
assure relative compaction and pipe deflection criteria are being achieved.
3. For backfill placement and compaction in the haunch areas, start compacting under
the pipe and work away from the pipe.

4. For side fill, compaction usually progresses best when the backfill is compacted at the
trench wall first and compaction progresses toward the pipe.

5. Usually the number of "passes" or repeated applications of the compaction equipment

(at a constant rate of movement) will increase the relative compaction.

6. Pipe zone backfill materials should be placed and compacted in uniform lifts on both
sides of the pipe.

7. Compaction over the top of the pipe must assure that there is sufficient material to not
impact the pipe. At least 150 mm cover should be sufficient when using a hand operated
plate vibrator compactor; however, 300 mm is recommended when using a hand
operated impact compactor. A relative compaction of no more than 85% SPD can
realistically be achieved when compacting the first 300mm lift over the pipe.

A measurement of the increase in the vertical diameter of the pipe is a reasonable

measure of compaction effort used during the installation and another good
"calibration" measurement.
 Spangler Equation developed in 1941, now evolved
into IOWA formula thru extensive field studies
conducted by Howard.

This condition can be

simulated in the lab thru
strain-corrosion testing.
FIELD SERVICE ENGINEER

Field Service Representative

WATANI can assign a Field Service Representative. He will provide

assistance to the installer so as the latter may attain a satisfactory pipe
installation. This “on-the-job” field service will be provided early in the
installation and may be carried on periodically throughout the
execution of the project. The service will range from continuous (full
time) to intermittent depending on the job schedule, difficulty, and
installation results.
Screen Shot of “Butt-Joint Overlay Calculation Software”
Joint Laminate Calculation Software
Screen Shot of “CEASAR II Software”
UNDERGROUND PIPELINE DESIGN

ANSI/AWWA Standard C950-95 and AWWA Manual M45 are the basic references of this guideline
to select the appropriate GRP pipe for underground installation. AWWA Manual M45 (First
Edition 1996) gives the design requirements and criteria for buried fiberglass pressure pipe.
Fiberglass pipes are flexible and can sustain large deformation without any difficulties for the
material.
Vertical loads (covering soil, traffic and water table) determine a deflection depending on soil
compaction around the pipe and on ring stiffness of the pipe cross-section.
AWWA Manual M45 recognizes that the pipe design can follow two different procedures based on
the stress or on the strain. Watani follows the strain procedure.
The design procedure involves the following steps:
1. Check the working pressure, Pw
2. Check the surge pressure, Ps
The maximum pressure shall not exceed 1.4 the pressure class of the pipe Pw + Ps ≤ 1.4Pc
3. Check ring bending, Sb
and, so on…
Buried Pipe Design Calculation Program
based on AWWA M45 guideline
Solutions to some worksite
problems….
Taking the exact measurement of Pipe O.D.
Accurately taking the Pipe O.D. using Pi Tape
Specially-made GRP connector for Ductile Pipe
GRP-To-Ductile Iron Connection Fitting
GRP-To-Ductile Connection, pressurized to 10 bar
In-situ building-up of GRP spigot
to the measured O.D
Large diameter GRP flanges up to 2600mm
Large diameter “Y” branch
Spools
Following are photo shots of GRP duct system for
Ardiya and Sulaibiya Waste Water Treatment
Plants…
GRP Ducts & Ducting Components, Sulaibiya & Ardiya Projects
GRP Pipe [Arabi Enertech] DN400
We provided help in in-situ jointing
Jointing by “butt-and-wrap” method
A completed in-situ “butt-and-wrap” joint
 Thank you very much for your time….

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