4S-10.01 Simons FRP Structures.pdf

CONTENT OF DESIGN STANDARD 4S-10.01 SECTION

1.

SCOPE OF SPECIFICATION

2.

CODES, STANDARDS AND REFERENCES

3. 3.1 3.2 3.3

GENERAL REQUIREMENTS List of Materials Shop Drawing Performance Tests

4. 4.1 4.2 4.3 4.4 4.5

MATERIALS Resins Resin Additives Glass Fiber Reinforcing Materials Synthetic Surfacing Materials Resin Paste

5. 5.1 5.2 5.2.6 5.3 5.3.1 5.3.2 5.4 5.5 5.5.8 5.5.9 5.6

F.R.P. LAMINATE Construction Liner Resin for the Liner Structural La Laminates Hand Lay-up Construction Filament Wi Winding Co Construction Finishing of Ou Outside Su Surfaces Butt Joints Resin for Joints Material Su Supply fo for Fi Field Jo Joints Appearance, Wo Workmanship an and Sh Shop Co Condition

6.

DIMENSIONAL TOLERANCES

7. 7.1 7.2 7.3 7.3 7.4 7.5

PHYSICAL AND MECHANICAL TEST METHODS Hardness Glass Content Phys Physic ical al Prop Proper erti ties es for for Inne Innerr Lin Liner er and and Con Conta tact ct Molde olded d Lam Lamiinate nates s Properti rties of of Fi Filament Wo Would Str Stru uctu ctural ral La Laminates Hydrostatic Leak Tests

8.

REPAIR OF DAMAGED SECTIONS

9.

IDENTIFICATION MARKS

10.

INSPECTION

11.

SHIPPING, HANDLING AND STORAGE

12.

F.R.P. .P. FIE FIEL LD JO JOINT INTS - INS INSTALLATION ION SP SPECIFI IFICATION ION

MANUFACTURE MANUFACTURE AND INSTALLATION SPECIFICATION FOR FRP STRUCTURES DESIGN STANDARD ISSUED FOR PROJECT NO.

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Y:\PROYECTO\1800\documentos\Estandares\00 Y:\PROYECTO\1800\documentos\E standares\00 - STD.PROPAC\piping\4s\4S-10 STD.PROPAC\piping\4s\4S-10.01.DOC .01.DOC

4S-10.01

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SHEET 1 OF 27

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DATE OF ISSUE GENERIC APPR. DATE

22Feb2001

1.

SCOPE OF SPECIFICATION

1.1.

This specification governs the manufacture and installation of glass fiber reinforced polyester pipe and structures (further on referred to as FRP), manufactured by contact molding (hand lay-up and filament winding) processes.

1.2.

The purpose of this specification is to establish minimum acceptable standards for the fabrication and installation of FRP structures.

1.3.

If a fabricator takes exceptions to any requirement of this specification, he shall state so in his tender and make appropriate alternate proposals.

1.4.

Fabricating and installing product to this Standard may require the use of materials and equipment that could be hazardous. This document does not purport to address all the safety aspects associated with their use. Anyone using this Standard has the responsibility to consult with manufacturers of constituent materials and other appropriate authorities to establish appropriate health and safety practices in conjunction with any existing applicable regulatory requirements prior to its use.

2.

CODES, STANDARDS AND REFERENCES The following publications are applicable to this Standard.

2.1.

Local Codes

2.2.

ASTM methods for testing FRP lam inates and components: D635 D638 D648 D695

Flammability Tensile Properties Heat Distortion Compression Properties

D757 D790 D2583 D2584

Flammability Flexural Properties Barcol Hardness Ignition Loss (Glass Content)

2.3.

Definition of terms for Reinforced Plastics, as published in Section 3 of CAN/CGSB-41.22-93.

3.

GENERAL REQUIREMENTS

3.1.

Listing of Materials Fabricators shall submit, with their quotation, a list of all component materials which they intend to use for fabrication of the quoted order. This list shall include resins, catalysts, catalysts, and promoters; ultra-violet light inhibitors; thixotropic tinting and parting agents, agents, etc.; and all reinforcing materials. It shall state the manufacturer, and the product's name and identification marks.


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3.2.

Shop Drawing After receiving an order for fabrication of any FRP product (including pipes, flanges, and fittings), the fabricator shall submit a fabrication drawing (3 copies), and have it reviewed by the Engineer before commencing the work. After the drawing has been accepted accepted as satisfactory, one sepia shall be supplied. Fabrication drawings are required for all FRP products, and shall show dimensions, location of field joints, spool numbers, wall thickness, lam inate construction, and resin systems. Marked-up sepias of Engineer's drawings are acceptable.

3.3.

Performance Tests

3.3.1.

The Engineer may request mechanical or chemical tests to be performed by the fabricator, in order to verify the quality of FRP laminates or structures, and the compliance with the requirements of these specifications.

3.3.2.

Results of tests performed as part of routine quality control programs of either the fabricator or the resin manufacturer may be acceptable.

3.3.3.

The Engineer may select any item of an order for testing, during or after fabrication.

3.3.4.

Test procedures shall be specified by the Engineer, and shall be performed as per Section 7 or as per appropriate ASTM specifications. Other special tests may be agreed upon by the Engineer and the fabricator.

3.3.5.

If test results are within requirements of this specification, the fabricator will be paid the quoted hourly rates for labor, the quoted unit rates for FRP products, and cost for all auxiliary materials and equipment.

3.3.6.

If test results do not meet the requirements of this specification, all costs incurred and all costs for materials used shall be borne by the fabricator.

3.3.7.

If there is any failure of either pipe, flanges, fittings, or joints, the whole order covered by this test shall be rejected, and no part of it shall be shipped unless two additional tests on materials from that order, again selected by the Engineer, prove satisfactory. The two additional tests, including all materials, shall be at the fabricator's expense.

3.3.8.

Results of the glass content test described in Section 7.2 shall be submitted to the Engineer, if requested. Tests shall be made for each type of construction, hand lay-up, and filament winding.

3.3.9.

Tests by independent laboratories may be specified by the the Engineer at any time. Those costs will be paid for by the Purchaser directly.


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4.

MATERIALS

4.1.

Resins

4.1.1.

Type of resin or a particular resin shall conform to that specified on the Piping Classification Sheets or detail drawings.

4.1.2.

Cure systems (catalyst and promoters) shall be as specified or recommended by the resin manufacturer.

4.1.3.

When resin has been supplied by its manufacturer with an optimum monomer content for normal use, styrene or other monomer shall not be added, added, except for minor adjustments of viscosity. Such additions shall not normally be more than 5% by weight, and shall be consistent with the resin manufacturer's recommendations.


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4.1.4.

TABLE FOR ACCEPTABLE RESIN APPLICATIONS Manufacturer

Trade Name

Type Resin

Description

Comment

Re Reichhold

ATLAC 382 382

B

Bisphenol Fumarates

■

ATLAC FLEX. BLEND 4010

F

Bisphenol Fumarates Flexilized Versions

ATLAC 580

V

Vinyl Esters

■

ATLAC 570

H

Various - Hi Heat Resistance

■

ATLAC 400

I

Isophthalic

□

ATLAC 711

FR

Fire Retardant

■

ATLAC 297

X

Speciality Resin

□

Dow Chemical

DERAKANE 411-45

V

Vinyl Esters

■

Co Company

DERAKANE 470-36

H

Various - Hi Heat Resistance

■

DERAKANE 510-A

FR FR

Fire Retardant

■

DERAKANE 510-N

H

Various - Heat Resistance

■

Ashlands Ashlands

HETRON 700

B

Bisphenol Fumarates

□

Chemical (Hooker)

HETRON 700C

F


HETRON 901

V

Vinyl Esters

□

HETRON 197

X

Specialty Resin

■

HETRON 92

X

Specialty Resin

□

Koppers

DION COR-RES 6694

B

Bisphenol Fumarates

■

Company Inc.

DION COR-RES 6695FR

FR

Fire Retardant

□

DION COR-RES 7000A

F


Uniroyal

VIBRIN 539

I

Isophthalic

■

Reichold

POLYLITE 33-402

I

Isophthalic

□

Legend:

■

□

□

■

=

Resins acceptable due to performance history

□

=

Resins conditionally acceptable due to chemical similarity and resin fabricators' case histories

Note: Other resins may be considered, if adequate performance can be documented by resin supplier.


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1.2.

Resin Additives

1.2.1.

The resin may contain thixotropic agents as required for viscosity control to a maximum of 3% by weight with prior agreement from the Owner or Engineer.

1.2.2.

Pigments, fire retardant agents, or other fillers which interfere with the visual inspection of the laminate may only be used where specif ically authorized in writing by the Engineer.

1.2.3.

Ultra-violet light inhibitors shall be used in accordance with the resin manufacturer's recommendations in all resins for laminates which will be exposed to direct sunlight.

1.3.

Glass Fiber Reinforcing Materials

1.3.1.

All glass fiber used as reinforcing materials, except surfacing veil, shall be a commercial Gr ade 'E' type glass. Glass fiber made from other types of glass are acceptable, if physical physical and chemical properties are equal to or better t han Grade 'E' type glass.

1.3.2.

Surfacing veil used on the surface exposed to chemical attack shall be a commercial Grade 'C' type glass, unless specified otherwise on Piping Piping Classification Sheets or detail drawings. drawings. (See Section 4.4 for synthetic surfacing materials.)

1.3.3.

All glass fibers shall have received a chemical surface treatment im mediately after they were formed. The sizing agent for this surface treatment shall be compatible with the resin to be used. The diameter of the glass fibers and the sizing agent shall be selected by the manufacturer of the fibers for imparting optimum properties to the FRP laminates.

1.3.4.

Fiberglass reinforcing materials fabricated from these glass fibers shall be designated by the glass fiber manufacturer as being suitable for the particular fabrication method selected by the FRP manufacturer, and shall produce laminates with minimum physical properties specified in Section 5.

1.3.5.

Continuous rovings shall be flat and untwisted ribbons of parallel untwisted strands of glass fibers, wound into suitable spools. The number of strands per roving and the yield, yield, expressed as yards of rovings per pound, may be selected by the FRP manufacturer to suit his application, subject to Clause 4.3.4.

1.3.6.

Woven rovings shall be a coarse and loosely woven fabric, produced from rovings of Clause 4.3.5. The warp and weft of this fabric shall consist of an equal equal number of equal rovings per unit length. length. The weight of the woven rovings fabric shall be 24 oz./sq.yd. 18 oz./sq.yd. woven woven rovings may be permitted under special circumstances, if extra drapeability is required. Approval by the Engineer is required before 18 oz. woven rovings may be used.

1.3.7.

Chopped strand mat shall be commercially available available grade of "High Solubility Mat". It shall consist of a 1 1/2 oz./sq.ft. of chopped strands of glass fiber, 1" to 2" long, arranged in a random pattern and held together with a resinous binder. binder. This binder shall dissolve quickly in the monomer of the resin and shall be compatible with the resin of the laminate. The binder shall not affect the glass to resin bond bond nor allow liquids to penetrate along fibers into the laminate. It shall not impair the chemical resistance of the resin. Chopped strands may be produced from either continuous rovings of Clause 4.3.5 or from spun rovings (single strand looped upon itself and held together with a slight twist).


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1.3.8.

Surfacing mat (veil) shall consist of continuous glass fibers arranged in a random swirl pattern. The fibers shall be held together with a resinous binder. The properties of this binder shall be as stated in Clause 4.3.7. The thickness of the surfacing mat shall be approximately 0.01".

1.3.9.

Glass reinforcing materials, not described in Clauses 4.3.5 to 4.3.8, or other weights of those materials shall not be used unless specified on detail drawings.

1.3.10.

Combination reinforcing materials, like woven rovings and chopped strand mat to be applied as one unit, may only be used with the written permission of the Engineer.

1.3.11.

Glass reinforcing materials shall be protected from moisture at all times. Material on which which moisture can be detected, or which are under suspicion of being damp, shall be rejected and may not be used for fabrication of FRP items. Once glass reinforcing material has been exposed to moisture and thereby becoming unusable, it cannot be restored by drying. To prevent condensation on glass reinforcing materials, they shall be stored in heated buildings or be heated in vapor-proof bags to ambient workroom temperature.

1.4.

Synthetic Surfacing Materials Surfacing material made from chemical resistant synthetic fibers (such as Dynel, Orlon, Dacron and Terylene) for use in specific environments may be approved or specified by the Engineer. These synthetic surfacing materials shall be designed by their producers as being suitable for use with polyester resins.

1.5.

Resin Paste

1.5.1.

Type A may be be quick setting paste of polyester polyester resin with a suitable filler. This paste may be a commercially available compound (Carpatch) or may be prepared by the fabricator. Resin paste Type A may only be used where not exposed to the corrosive environment, such as filling crevices in butt joints with inside overlay or rounding re-entrant corners on structures or fittings.

1.5.2.

Type B shall be used whenever whenever the paste is not sealed within a laminate. This paste shall be prepared from flexible resins as specified in Clause 5.2.6. This resin shall be filled with short glass fiber and silica flour to a consistency of a very soft paste. It shall remain sufficiently liquid for bonding to surfaces in contact with, but it shall not flow out of vertical or overhead crevices. A small amount of talc or similar material may be added to improve workability. workability.


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5.

FRP LAMINATES

5.1.

Construction All FRP laminates shall have a liner (see 5.2) on surfaces that are exposed to the corrosive environment and a structural laminate. The structural laminate may be constructed either by hand lay-up (see 5.3) or by filament winding (see 5.4).


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5.2.

Liner (See Fig. 1 and 2) The requirements of this Section 5.2 shall apply to liners of all FRP laminates, unless specifically modified on Piping Classification Sheets or detail drawings.

5.2.1.

The surface of the liner exposed to the corrosive medium shall be resin rich and reinforced with a surfacing veil. Its minimum thickness shall be be .01".

5.2.2.

The liner behind the surface shall have a minimum thickness of 0.10", and shall be reinforced with not less than 20% and not more than 30% by weight weight of non-continuous glass fibers. Such reinforcement shall consist of nominal 3 oz./sq. ft. of chopped strands. Chopped strand mat shall conform to Section 4.3.7; Clause 5.3.1.2 shall also apply to liners. Other methods of incorporating the chopped strand reinforcement into the laminate may be accepted by the Engineer, if equivalent uniformity of fiber distribution can be ensured.

5.2.3.

The surface of liners to be in contact with the corrosive medium shall cure without being exposed to the oxygen of the air. They shall be constructed on suitable molds, whenever possible. possible.

5.2.4.

The exposed surface shall be free of cracks and crazing and shall have a smooth surface with an average of not more than 2 pits/sq.ft., provided the pits are less than 1/8" in diameter and 1/32" deep. Some wrinkles are permissible, provided their surface is smooth and free of pits. See also Clause 5.6.1.

5.2.5.

The liner shall be more resilient than the structural laminate, in order to increase impact resistance and to reduce the occurrence of stress cracks. It shall withstand the elongation of the structural laminate under five times design pressure, without incurring stress cracks or crazing of its surface.

5.2.6.

Resin for the Liner Unreinforced castings of resin for the liner shall have a minimum elongation of 4% before rupturing, a o minimum tensile strength of 9,000 psi, and a heat distortion point lower than 200 F. Agents used for increasing the flexibility of resin for making it acceptable for liners shall be approved by the resin manufacturer. The chemical resistance of the resin shall not be impaired.

5.2.7.

The initial cure of the liner shall be completed, and it shall have cooled off to below 100°F before the structural laminate may be applied. [Heat developed during during cure (exotherm) shall have dissipated.]

5.3.

Structural Laminates After completing the liner (see Section 5.2), the remainder of the wall thickness of FRP laminates shall be built up to provide sufficient strength to meet the mechanical requirements. This additional wall thickness may be constructed either by hand lay-up or by filament winding.


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5.3.1.

Hand Lay-up Construction

5.3.1.1.

For hand lay-up laminates, alternate layers of chopped str and mat and woven roving shall be added until the required number of layers have been applied or the required required wall thickness has been obtained. obtained. The exterior of all hand lay-up laminates shall consist of a chopped stand mat. Mat and woven rovings shall be lapped a minimum of 1". All overlaps shall be offset from those in previous layers. layers.

5.3.1.2.

Whenever possible, reinforcing materials shall be placed into a layer of liquid resin applied to the mold or to the laminate already on on the mold. The resin shall then be worked worked with suitable rollers through the material from below its surface.

5.3.1.3.

Glass content shall be between 30% and 50% by weight.

5.3.1.4.

Laminates shall meet the mechanical properties of Table A, based on total thickness of laminate, including liner. A factor of safety of 10 shall be applied for calculating allowable working stresses. (See Section 7 for test procedures.)

5.3.1.5.

Laminates over 3/8" total thick ness may be designed on the following basis: Assume an ultimate strength of 1500 lb./liner inch, in any direction for each layer, consisting of one mat and one roving. Calculate the required number of mats and rovings for resisting 10 times the design stress, add the inner liner (when applicable) applicable) and a mat on the outside. Inner liner and the cover mat are assumed not to contribute to the structural strength. The thickness of such laminate will vary, depending on the glass to resin ratio (see 5.3.1.3). Therefore, the ultimate tensile strength of these structural laminates will vary approximately 15,000 psi at 30% glass to approximately 25,000 psi at 50% glass content. Flexural strength and tangent modulus may be used as listed for 3/8" laminates, or as obtained through appropriate test. o

TABLE A - MECHANICAL PROPERTIES OF HAND LAY-UP LAMINATES AT 73 F ASTM TEST SPEC.

3/16"

1/4"

5/16"

3/8"

Over 3/8"

Ultimate tensile strength psi minimum

D638

9,000

12,000

13,500

15,000

See 5.3.1.5

Flexural strength psi

D790

16,000

19,000

20,000

22,000

See 5.3.1.5

Tangent m od odulus of el elasticity psi

D790

700,000

800,000

900,000

1,000,000

See 5.3.1.5

PROPERTY AT 73ºF


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5.3.2.

Filament Winding Construction

5.3.2.1.

Filament wound structural lam inates shall be constructed by saturating continuous rovings in a resin bath, and then winding these rovings in a controlled pattern on a suitable mold. The rovings shall be applied at an angle to the axis of of the mold. The winding angle shall shall be selected by the fabricator for obtaining the desired hoop and longitudinal longitudinal properties. It shall be uniform throughout the entire length and and thickness of the product. Each cover, or bi-directional layer, layer, shall consist of two complete layers of continuous continuous rovings. Rovings of each layer shall be placed parallel and close together together and should touch each other. Each layer shall be placed at an equal equal angle to the axis of the mold, but in opposite direction. The rovings of these two layers layers shall be interwoven with with each other at frequent and uniform uniform intervals. The interval shall be selected by the fabricator to suit the dimension of the product. Its maximum length shall be 6'. The winding pattern of each layer shall be closed when placing the last band of rovings of that layer. The winding pattern shall be regular and shall produce a dense laminate without unreinforced resin pockets. The continuous rovings, also called glass filaments, shall be placed at an equal equal and constant tension throughout the laminate. A maximum of 10% rovings in a band at the start are permitted to drop out during the winding process, provided Clauses 5.3.2.3 and 6.2 are satisfied.

5.3.2.2.

Filament wound structural laminates shall consist of not less than two covers of two layers of rovings.

5.3.2.3.

Glass content shall be between 60% and 70%, by weight.

5.3.2.4.

Winding angles shall not be less than 45 and not more than 70 off the horizontal axis.

5.3.2.5.

The thickness of a filament wound structural wall shall be designed by the fabricator within the limitations of Clauses 5.3.2.6 to 5.3.2.9. Fabricators may specify number of covers (bi-directional layers) layers) required in their design, after t hey established the thickness and glass content of t hese covers produced by their fabrication methods.

5.3.2.6.

Filament wound structural laminate is assumed to have a minimum ultimate hoop tensile strength of o 1,000 psi for each 1% of glass content, and zero psi longitudinal strength when winding angle ß = 90 . The strengths available in hoop and longitudinal direction at other winding angles shall be calculated by these formulas:

o

Hoop tensile strength, in psi Long Longit itud udin inal al tens tensile ile stren strengt gth, h, in psi psi

o

2

= 1 ,0 ,000 x % glass x sin ß 2 = 1,00 1,000 0 x % gla glass ss x cos cos ß

Where ß = the winding angle off the horizontal axis. A safety factor of 10 shall be applied to these calculated available strengths for obtaining allowable o working stresses in tension and compression. At operating temperature above 180 F, working stresses shall be lowered as required to maintain a safety factor of 10. 5.3.2.7.

The longitudinal elongation of pressure vessels due to internal pressure shall not be more than 0.1% at design stresses.

5.3.2.8.

Tensile and flexural module must be obtained and substantiated through appropriate tests, if they are required for structural design.


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To estimate the behavior of pipe, a tensile modulus of 2,000,000 psi in hoop direction, and 1,000,000 in o longitudinal direction may be assumed for pipe with ß = 55 and 70% glass. 5.3.2.9.

For pipe and pressure vessels, the longitudinal working stress calculated with formulas of Clause 5.3.2.6 shall be equal to or greater than the required minimum longitudinal strength to be calculated by multiplying the hoop stress at the selected wall thickness and at design pressure with the appropriate factor in Table B. TABLE B -RATIO OF REQUIRED MINIMUM LONGITUDINAL STRENGTH TO HOOP STRESS AT DESIGN PRESSURE Underground and Above Ground Lines Supported Per Standard 4S-30.03 or 4D-20.10 NOM. PIPE DIAMETER

PRESSURE LINES

GRAVITY to 25 psi

50 psi

75 psi

100 psi

125 psi

150 psi

2"

0.5

2.0

1.3

1.0

0.9

0.8

0.8

3"

0.5

1.5

1.0

0.8

0.7

0.7

0.7

4" to 48"

0.5

1.2

0.9

0.7

0.7

0.7

0.6

5.3.2.10. If a fabricator proposes to deviate from these requirements for filament wound structures, he shall submit detail engineering data and appropriate test results to the Engineer for evaluation. 5.4.

Finishing of Outside Surfaces

5.4.1.

All laminate surfaces not in contact with molds shall be coated for pr evention of air-inhibition of the exposed resin surfaces.

5.4.2.

Pipe or other laminates to be used for further fabrication shall be cello-finished or shall receive a final coat of non air-inhibited resin.

5.4.3.

Pipe ends to be butt jointed in the field shall be cello-finished for a minimum of 12".

5.4.4.

All other laminates surfaces not included above may receive a final coat of waxed resin instead of finishes as per Clause 5.4.2. Wax shall be added to resin as per resin manufacturer's recommendation. This waxed resin coat shall be applied during the final stages of the laminating work or during the initial cure of the laminate, before the exotherm (heat of curing) develops. If a waxed resin coat is applied after the exotherms have dissipated, heat shall be applied in a suitable manner to cure this thin resin coat.

5.4.5.

Cut edges of laminates, including those to be butt-jointed in the field, shall be sealed with a brush-coat of non air-inhibited resin.

5.4.6.

All cut edges of laminates not to be shop or field-jointed shall be rounded off and then brush-coated with resin specified for inner liner, containing wax as per 5.4.4.


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5.5.

Butt Joints (Made by Shop Manufacturer) This type of joint shall be used for joining laminates of FRP structures, including pipe sections and fittings, unless specified otherwise on drawings or purchase documents.

5.5.1.

Laminate ends shall be fitted with a maximum gap of 1/2 the laminate thickness or 1/4", whichever is smaller.

5.5.2.

Surfaces to be overlaid shall be cleaned of parting agents, waxes, curing films, oil, grease, or other contaminants. Cleaned surfaces shall be ground with with suitable grinding equipment for removing surface resin and resin paste, until glass reinforcing is exposed. Surface shall be roughened, with glass fiber ends exposed. It shall not not appear polished.

5.5.3.

Gap between laminates to be joined joined shall be filled with resin paste (see Section 4.5). Resin paste shall not protrude on the inside. After the paste has cured, the joint area shall be cleaned again by grinding. All resin paste spread over the outside shall be removed.

5.5.4.

Differences in laminate thickness shall either be ground down to a 10:1 slope or be built up with chopped strand mat laminate. Resin paste shall not be used for filling of low spots when wall wall thicknesses differ.

5.5.5.

Structural joint laminates shall be constructed with alternate layers of chopped strand mat and woven roving, in accordance with Section 5.3.1. 5.3.1. They shall be be as strong as the laminates they join. Their minimum width and the minimum layers of glass reinforcements shall be as shown in Table C.


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TABLE C - MINIMUM DIMENSION FOR STRUCTURAL JOINT LAMINATES LAMINATE THICKNESS - T INCHES

mm

WIDTH - W IN INCHES UP TO 6"

8" TO 12"

Over 14"

NUMBER OF LAYERS OF GLASS REINFORCING JOINTS ON HAND LAY-UP PIPE

JOINTS ON FILAMENT WOUND PIPE

MAT MA

WR

MAT

WR

3/ 3/16

.188

5

6

6

8

3

1

4

2

1/ 1/4

.250

6

6

8

10

4

2

4

2

5/ 5/16

.313

8

6

8

12

4

2

5

3

3/ 3/8

.375

10

8

10

12

5

3

6

4

7/16

.438

11

8

10

14

5

3

7

5

1/ 1/2

.500

13

8

12

14

6

4

9

7

9/ 9/16

.563

14

-

12

16

7

5

10

8

5/ 5/8

.625

16

-

14

16

8

6

11

9

11/16

.688

17

-

14

16

9

7

12

10

3/ 3/4

.750

19

-

-

16

10

8

14

12

7/ 7/8

.875

22

-

-

16

11

9

-

-

1

1.000

25

-

-

16

12

10

-

-

Note: Note:

See Sectio Section n 12 for specia speciall requir requiremen ements ts of field field joints joints..

5.5.6.

All joint laminates shall start with two layers of 6" wide (minimum ) chopped strand mat, centered over the gap (6 joints shall have 4" wide mats). They shall be saturated with resin and thoroughly rolled out with grooved metal rollers, before proceeding with the remainder of the laminate. Successive layers shall shall increase in width to provide the minimum joint width specified in Table C. The additional layers may be of uniform width. If they are uniform, they shall be placed so as to produce a joint laminate of the required dimension. The minimum side and end lap of reinforcing layers layers shall be 4". 4". Laps shall be staggered. Only mat shall be in contact with cured laminates. All woven rovings rovings shall be separated by mat. The top layer shall be mat. If a joint laminate has to be constructed in two two or more stages, each stage shall begin and end with a layer of mat. At least one-half of the minimum joint width shall contain layers of woven woven roving specified. The balance of the width shall taper smoothly on both sides to a feathered edge. The center of the joint laminate shall be within 1" of the gap.

5.5.7.

Gaps of butt joints on all pipe and structures with a diameter of 24" or more shall be overlaid on the liner side with a laminate of the same construction as the liner (see Section 5.2). Gaps on a smaller pipe or structure shall be overlaid whenever whenever accessible. Minimum width of these overlays shall shall be 4".

5.5.8.

Resin for Joints Structural joint laminate on the outside of pipe or structures and made by the fabricator in his shop may be made with resins specified for the structural laminate, provided that joint has an inside overlay.


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All other joint laminates shall be made with resins specified for the liner, unless specified otherwise on Piping Classification Sheets or detailed drawings. 5.5.9.

Material Supply for Field Joints Fabricators of FRP pipe structures shall supply materials for each butt joint to be made in the field. This material shall consist of:

5.5.10.

a)

Glass reinforcing materials, cut to length and width as in Tables A and B in Section 12 FRP Field Joint & Installation Specifications. Material for each joint shall be packed in a waterproof 6 mil (minimum) (minimum ) polyethylene bag, and be clearly labeled.

b)

Resin at the rate of 2 times the weight of glass reinforcing (see Clause 5.5.8).

c)

Bulk supply of promoters (in liquid form).

d)

Bulk supply of catalyst (in liquid form).

e)

Resin paste (see Section 4.5).

f)

Instructions for promoting and catalyzing the resin at the temperature ranges expected during the 3 field installation, expressed in cm (cubic centimeters) per gallon of resin.

g)

Priming agents when required (see Clause 5.5.10).

If new laminates have to be jointed to old laminates, the installation contractor shall make the appropriate bonding test before commencing with the work. If bonds are not satisfactory, appropriate priming agents shall be used to prepare the old laminates in accordance with recommendation of resin manufacturer.

5.6.

Appearance, Workm anship, and Shop Condition

5.6.1.

The laminate shall be as free as is commercially practicable from visual defects, such as dry spots, air bubbles, pin holes, the inclusion of foreign matter, or other signs which may affect the quality of the laminate. Sample laminates shall be used to establish establish acceptable limits, before placing an order for FRP products. Laminates with stress cracks or crazings will be rejected. See also Clause 5.2.4.

5.6.2.

Laminates cured with excessive exotherm (as indicated by opaque discoloration, signs of styrene evaporation, or brittleness) will be rejected.

5.6.3.

A Barcol hardness of at least 90% of the resin manuf acturer's minimum specified hardness for cured resin castings is required before FRP items may leave the fabricator's shop. This applies to liners, structural laminates, joints, and repair patches.

5.6.4.

Laminates shall be constructed at ambient temperatures of 60 F or above in dry and draft-free work areas. Laminates shall not be constructed in direct sunlight. After the outside surface has been been completed, as per Section 5.4, sunlight may assist curing laminates.

o


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6.

DIMENSIONAL TOLERANCES

6.1.

Dimensions of FRP structures shall be within ±1/8" or ±1/2%, or dimension given on fabrication drawings, whichever is greater. The inside diameter of pipe shall be within ± 1/8" or 1% of nominal diameter specified, whichever is greater. For larger diameter pipe, which may sag under its own weight, the external circumference shall be measured and shall be within ± 3% of the calculated nominal circumference.

6.2.

Wall thickness 'T' of laminates (see Fig. 1 & 2) shall not be less than the nominal thickness specified by the fabricator on fabrication drawings. Isolated spots may be accepted which are not less than 80% of this nominal wall thickness. The wall thickness 'T' may be larger than the specified nominal thickness, provided all reinforcing materials are placed as specified, and the glass/resin ratio is within the specified limit.

6.3.

Pipe and fittings shall be cut square with the axis of the pipe or fitting within ± 1/8" up to and including 24" diameter, and ± 3/16" for all larger diameters.

7.

PHYSICAL AND MECHANICAL TEST METHODS

7.1.

Hardness The Barcol Impressor (Model GYZJ 934-1) shall be used for determining hardness. Calibration of the Barcol instrument shall be verified by taking readings on a blank metal specimen of a known hardness. At least 10 readings on the clean resin rich surfaces of FRP laminates shall be made. After eliminating the two high and two low readings, the average of the remainder shall be the reported hardness reading.

7.2.

Glass Content

7.2.1.

Glass content shall be determ ined on a weight loss by ignition basis. Sample tested may be the full thickness of the laminate, approximately one (1) square inch in area. Low temperature pre-ignition prior to placing in a muffle furnace is recommended. The average results of three samples shall be considered the glass content.

7.2.2.

If liner and structural wall cannot be tested separately, the glass content of structural laminates may be calculated by using the result of tests as per 7.2.1 and assuming a glass content of 25% for the inner liner. This liner shall be assumed to be .11 inch thick for calculation purposes.

7.3.

Physical Properties for Inner Liner and Contact Molded Laminates

7.3.1.

Whenever possible, physical properties of contact molded laminates shall be tested on specimens taken at random from laminates of production line items, and ASTM test procedures shall be modified to suite the shape of these test specimens.


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7.3.2.

If required, specimens shall be taken from a laminate laid up on a straight surface. It shall have the same construction and thickness as the laminate whose physical physical properties are to be tested. The molded surfaces shall not be machined.

7.3.3.

The tensile, compressive, and flexural properties may be determined by using the appropriate ASTM test procedures.

7.4.

Properties of Filament Wound Structural Laminates

7.4.1.

The properties of the filament wound structural laminates shall be determined by performing a hydrostatic burst test on a section of the pipe in question. The length of this section shall be a minimum of five tim es the internal diameter. diameter. Test pressure shall be increased at a maximum rate of 50 psi/min. Hoop and longitudinal properties may then be calculated by applying the appropriate formulas: o

If ß is 55 or smaller, use: o

If ß is larger than 55 , use:

2

f = Pd/(2t sin ß) 2

f = Pd/(4t cos ß)

d

=

inside diameter

t

=

laminate thickness (without inner liner)

P

=

pressure at burst in psi

ß

=

winding angle off horizontal axis

f

=

stres ress in fil filamen ment wall in dire irection ion a winding ing angle ß at fai failure in psi. 'f' shall be equal to or greater than 1,000 psi x % glass content.

7.5.

Hydrostatic Leak Tests

7.5.1.

A true failure of a filam ent wound laminate is difficult to obtain, due to premature leaks. Therefore, a leak test may be substituted for a burst test. The leak test shall be performed on a section with a length of not less then five times the diameter. The pipe shall be fitted with suitable domed end closures.

7.5.2.

To be considered satisfactory, the leak test shall show that the pipe and fitting and joints (if applicable) will withstand at least five times the design pressure for a period of not less than one hour, without any leakage occurring. The test pressure shall be be increased at maximum rate of 50 psi/min.

7.5.3.

After completing a leak test successf ully, the pressure shall be relieved and after a 5 minute rest period, again be increased to failure or to the limit of the pumping equipment.

7.5.4.

Pipe subjected to this leak test shall not be used in the piping installation.

7.6.

Bonding Tests Bonding tests may be requested by the Engineer at any time when new laminate is added to existing laminates (secondary lay-ups), either in the fabrication shop or in the field.


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Bonding may be verified on full size normal production work like joint lay-ups on piping or other secondary laminates, or with bond-test laminates. The minimum dimensions of a bond-test laminate shall be 6" x 6" x 3/8". Such laminates shall be applied near the joint to be verified, at the same time and with the same batch of resin used for the first lay-up. After the test laminate did cure, it shall be r emoved with hammer, chisels and wedges. If the bonding of a test laminate is unsatisfactory, then the bond of the production laminate shall also be tested. For field joints, refer to Section 12.5.16. 8.

REPAIR OF DAMAGED SECTIONS

8.1.

Mechanical damage to FRP pipe or structures with fabrication blemishes may be repaired, if permitted by the Engineer.

8.2.

All repair work shall be perform ed under dry conditions, with ambient temperature above 60°F. At lower ambient temperatures, suitable heaters shall be used.

8.3.

Repair to Inner Liner Air bubbles, dry spots, stress cracks or any other imperfection of the inner liner shall be overlaid with a laminate identical to the liner. Stress cracks shall be completely removed by grinding. All other imperfections may be overlaid after grinding the surface only. only. Repair patches shall be at at least 2" larger all around than the imperfection, and cello-finish must always be done. In case of major damage, that section of pipe shall be replaced using two butt & strap joints. Repair of damages to other FRP structures shall be discussed with the Engineer.

8.4.

Repair to Structural Laminate Only very minor damage to structural laminates may be patched. Mechanical damages to the structural laminate of pipe or fittings shall be repaired with an overlay all all around the pipe. Similar as specified for butt joints in Section 5.5.

9.

IDENTIFICATION MARKS

9.1.

All FRP items shall have visible and durable identification tags. This tag shall be overlaid with one (1) layer of chopped strand mat.

9.2.

Identification tags shall show the following information: a)

Fabricator's name

b)

Name of resin or resins used

c)

Design pressure rating

d)

Line number and spool number for fabricated piping systems, or equipment number


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10.

INSPECTION

10.1.

Access The fabricator shall allow the Engineer or his Agent free access to the work involving any phase of the manufacture of the pipe, structures, or their components for the purpose of assuring compliance with this specification and/or conditions contained in the Purchase Order for which the pipe or components are manufactured.

10.2.

The Engineer or his Agent shall be permitted to take any FRP laminates, component materials, or spool pieces from the fabricator's premises for testing in outside outside laboratories. Payment shall be in accordance with Section 3.3.

10.3.

Notification The fabricator shall notify the Engineer 7 days in advance or a proposed shipment of an FRP order, or part of it. No FRP order or part of it shall be shipped without having been cleared for shipment by the Engineer.

10.4.

Acceptance A clearance for shipment shall not be construed as an unconditional acceptance for the FRP order. The fabricator's performance guarantees as to quality of materials and workmanship, and dimensional conformity with drawings shall not be affected.

11.

SHIPPING, HANDLING AND STORAGE

11.1.

FRP structures shall be suitably protected from damage in storage, during shipping, and when handling.

11.2.

Spooled section of pipe shall have flange f aces suitably protected.

11.3.

When nesting pipes of varying diameters for shipping, the liner of the receiving pipe shall be protected. Scratch marks on the inner liner are not permissible. When nesting pipes, the pipes which are placed placed inside other pipes must first be wrapped with 12" long bands of 1/4" thick foam plastic, taped in place, at 6' intervals. Large diameter pipes, tanks, etc. shall be internally braced with spiders (at least 6 spokes). All spider spokes shall rest against pieces of plywood which shall rest against pieces of plywood which, in turn, rest on styrene foam or equal. Frequency of spider placement depends depends on the wall thickness of the laminate laminate and shall be determined by the Engineer. The method of strapping on the truck shall be such that no point loading will occur. Use proper dunnage.

11.4.

FRP pipe and structures shall be off-loaded off-loaded with suitable lifting equipment. Rolling or dumping off trucks shall not be permitted.


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11.5.

Pipe, fittings, or structures which arrive in the field with apparent damage shall not be installed, unless instructed by the Engineer. Engineer. Damages shall be repaired as specified in Section Section 12.7.

11.6.

Fabricator shall be liable for any shipping damage.

12.

FRP FIELD JOINTS - INSTALLATION SPECIFICATION

12.1.

Scope This specification covers the installation of FRP butt and strap joints, and other FRP laminates made in the field during installation of FRP piping and structures. It is not applicable to FRP laminates made by fabricators in their shops. (For shop joints, see Section 5.5.)

12.2.

Codes and Standards Local safety codes and standards having jurisdiction over any part of the work shall apply.

12.3.

Protection of Working Area The curing of FRP laminates and their bond to existing laminates is affected by temperature and humidity. Polyester resins are are poor adhesives. New resins do not react with cured resins of the old laminates. New resins do bond to the millions of treated glass fibers of the old laminate, which are exposed by proper proper grinding. However, glass fibers are hydrophillic. hydrophillic. They absorb water from humid air. Resins will not bond to damp glass. To ensure good bonding of field joints, the working area shall be protected or improved as specified. Colder temperatures make field jointing more difficult. Refer to Clause 12.3.6.

12.3.1.

Whenever possible, field joints shall be made in heated and ventilated building.

12.3.2.

If field joints have to be made outside, they shall be made under suitable covers to provide shade during sunny periods, and to protect the work against possible rain showers.

12.3.3.

When the relative humidity is 70% or higher, field joints shall be be made inside a protective enclosure. This enclosure shall be heated until the relative humidity has decreased to 60% or less. FRP field jointing is not permitted when the relative humidity in the working area is 70% or over. However, under special circumstances, the Engineer may specify additional requirements for working in humid environment and ask the contractor to proceed with the work.

12.3.4.

Excavations for field joints on underground pipelines pipelines shall be kept free of standing water. If evaporating moisture raises the relative humidity in the excavation above 70%, the bottom of the excavation inside the protective enclosure shall be covered with polyethylene polyethylene sheets and Clause 12.3.3 shall apply.

12.3.5.

When the air temperature is less than 5 F above the dew point, Clause 12.3.3 shall apply.

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12.3.6.

o

Field jointing in temperatures below 60 F is permitted, provided Clauses 12.3.3 and 12.3.5 are adhered to, and provided the contractor has adequate curing chemicals on hand f or promoting and catalyzing the resin as specified by the resin supplier for cold weather work. In addition, the contractor must have adequate and suitable heating equipment available. See also Clause 12.3.8. Note: Note:

This viscosi viscosity ty of resin resin increases increases in cold cold weather. weather. More viscous viscous resins tend to make joint laminates too resin rich. Resin rich laminates tend to sag off the pipe when the resin heats up due to the curing process.

12.3.7.

Glass reinforcing material shall be protected from moisture at all times. They shall be kept in their polyethylene polyethylene bags until used for lay-ups. The temperature of glass reinforcing kits shall be equal to or warmer than the air temperature in the work ing area, before polyethylene bags may be opened.

12.3.8.

Electric resistance heaters, and especially infra-red heat lamps, have proven to be the most suitable source of heat for FRP field jointing. Combustion type heaters (Salamanders) are permitted, provided all exhaust gasses are vented to the outside of the protective enclosure.

12.3.9.

When working inside buildings, the contractor shall avoid spreading the grinding dust onto equipment or into other working areas.

12.4.

Preparation of Pipe Ends

12.4.1.

Pipe ends shall be fitted to each each other with a maximum gap of 1/4". After fitting, exposed glass on the edges shall be brush coated with hot r esin (see Clause 12.5.11).

12.4.2.

Thin wall pipe, 20" or lar ger, shall be aligned with each other and f ixed in place by inserting a suitable expandable device. This alignment device shall hold the inside diameters concentric and provide a backing for the gap between the pipe ends all around the circumference. The device shall be removed after the joint is completed.

12.4.3.

Pipe 18" or smaller, and pipe of adequate stiffness to retain its shape, may be held in place by external means or may be secured with hot hot patches (see Clause 12.5.11). The inside diameters shall be concentric.

12.4.4.

Pipe ends shall be cleaned by grinding with a coarse disc (#16 grit) in a power grinder for the width of the joint lay-up plus 4", equally spaced spaced on either side of the gap. This grinding operation shall remove all contamination and unreinforced resin from the surface, and shall expose the glass reinforcing of the pipe laminate. High edges caused by by differences in wall thickness shall be ground off to 8:1 slope (see also Clause 12.4.7). Ensure grinding discs remain clean. clean. Discs contaminated with uncured resin, wax wax and others shall be replaced. Note:

12.4.5.

Oil or grease on pipe ends shall be removed by washing washing with solvent or detergent. detergent. Wet pipe ends shall be thoroughly dried before grinding may commence. Dried soil (mud) and wax coating may be removed by grinding.

Pipe ends may be ground in advance of f itting and installing the pipes, provided the ends can be kept dry. During storage, all pre-ground pipe ends shall be covered with plastic bags secured with m asking tape. The maximum permissible interval between pre-grinding and lay-up of the field joint depends on the prevailing weather conditions. It should not exceed 24 hours unless permitted by the Engineer.


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12.4.6.

When pipes are cleaned and secured in place, the gap between ends shall be cleaned of grinding dust with a clean dry brush. Do not use compressed air. The clean gap shall be filled with with resin paste (putty). Resin paste Type A may be used, if an inside lay-up lay-up will be made. All gaps on joints without an inside lay-up shall be filled with resin paste T ype B.

12.4.7.

Resin paste shall not be used as filler when wall thicknesses differ. All fillers between pipe and joint shall consist of laminates, reinforced with chopped strand mat. The only resin paste permitted permitted between old and new laminate is an 1/2" 1/2" maximum radius filler in the root of three-way fittings. Filler laminates shall have cured and the exotherms shall have dissipated, before the joint laminate may be applied.

12.5.

Lay-Up of Field Joint

12.5.1.

After the resin paste is cured and imm ediately before commencing the lay-up of the joint laminate, the pipe ends shall be cleaned again by lightly grinding the entire area under the first lay-up. This grinding shall remove all resin smears, finger marks, soil stains, or other contaminates from the pipe pipe walls. This touch-up grinding shall also remove glass fibers which may have absorbed water from the air since the major grinding of Clause 12.4.4. Clean glass fibers exposed by grinding with a coarse and clean disc is the best assurance for a good bond. bond. Wiping with acetone or any other other liquid is not permitted.

12.5.2.

The grinding dust shall be brushed off with a clean dry brush. brush. Do not blow dust off off with compressed air. The grinding dust shall be completely dry and fall off the brush while while brushing. If a damp pipe surface or high humidity causes the dust to cake and to cling to the bristles, then the joint lay-up work shall be terminated. (See Clauses 12.3.3., 12.3.4, and 12.3.5.)

12.5.3.

The cleaned joint area shall be brush-coated with a thin layer of resin for 6" either side of the gap, and the first lay-up of the joint shall then be applied.

12.5.4.

Joint laminates shall be started by applying 2 chopped strand mats centered over the gap between the pipe ends. These mats shall be well wetted out with resin and thoroughly rolled out with grooved steel rollers. When all air bubbles within the mats and between between pipe and mats have been been removed, the balance of the laminate shall be applied in alternate layers of woven roving and m at, ending with a layer of mat. Woven roving shall never be in contact with pipe or cured laminates. laminates. The technique of applying applying the laminates depends on the preference of the contractor, provided the resulting joint is of acceptable quality. However, if a joint consists of a single lay-up only, all rovings shall be applied to the pipe in full length and one layer at a time. Ends shall be staggered. One mat may be applied together with with each roving.

12.5.5.

The joint laminate shall be uniformly wetted out without dry spots or or resin rich areas. It shall be shaped smoothly, and of uniform thickness; and contain 30% to 50% glass reinforcing, and 70% to 50% resin, by weight. Air bubbles within the laminate or between between pipe and laminate are not permitted. Joints in the woven roving reinforcing shall overlap a minimum of 4" and shall be staggered.


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amount of glass glass in a field field joint joint is fixed by Tables Tables D and and E. Note: Note: The amount When the glass content is 50%, then the weight or resin is equal to the weight of glass. When the MEASURED glass content is low, then the am ount of glass shall still be as specified by Tables D and E; but, the laminate contains more resin than required. If the measured glass content is 30%, then the laminate contains resin 2.33 times the weight of the glass. Laminates with 30% glass are significantly thicker than laminates with 50% glass content. 12.5.6.

Each lay-up shall consist of a minimum of 4 mats and 3 woven rovings. The maximum thickness per layup shall be 7 mats and 4 rovings. The first lay-up shall have a minimum of 5 mats and 3 rovings. The total number of mats and rovings to be used for various pipe sizes and pressure rating are listed below in Tables D and E. Field joint kits supplied by FRP fabricators shall be checked and adjusted to comply with this tabulation, if necessary. Note: Note: Glass reinforcemen reinforcements ts are supplied supplied in lengths lengths equal to the the circumference circumference of the pipe, plus plus overlap. overlap. Reinforcing for larger pipes are are rather long. To facilitate installation, reinforcing for pipe 24" and larger may be cut into two equal lengths, provided the cut sections overlap a minimum of 3" each. Cutting reinforcing into more than two sections is not permitted.

12.5.7.

After the first lay-up has cured and the exotherms (heat produced while resin is curing) have dissipated, the other lay-ups shall be completed in a similar manner as the first one. Before each new lay-up, lay-up, the old laminate under the increased width of the next lay-up shall be prepared as noted in Clause 12.5.1. Unreinforced resin smears and other contaminates shall be removed by touch-up grinding. Grinding of the first lay-up is not required, if its surface is clean and smooth, well cured and the second lay-up is started with one hour after the first one is cured. Grinding dust shall be be brushed off. All ground surfaces of pipe and previous lay-up lay-up shall be brush coated with with resin. The joint shall then be completed in the sequences and to the dimensions shown on T able E.

12.5.8.

If it seems likely that the next lay-up of a joint cannot be started within the next 2 hours, the fresh laminate may be wrapped tightly with cellophane or similar material to prevent contam ination and air inhibition of the surface resin. Before commencing the next lay-up, lay-up, the surface gloss, gross irregularities, and unreinforced resin smears on each side of the laminates shall be removed by grinding.

12.5.9.

Field joints and all ground areas near the joints shall be brush coated with waxed resins during the initial cure of the last lay-up.

12.5.10.

The pot life of resin for field joints shall be between 25 25 and 35 minutes. Pot life is the time the resin remains usable after adding the catalyst. catalyst. The pot life shall be adjusted by varying the ratio of resin and and curing chemicals as required by prevailing temperatures in accordance with recommendations by the resin manufacturer. The recommended minimum ratio of catalyst catalyst shall be maintained at all times. If the pot life is still too short at the minimum catalyst ratio, the contractor shall obtain advice from the fabricator of the FRP pipe or from the Engineer.

12.5.11.

Resin for brush coating cut edges or for hot patches shall have a pot life of 5 to 10 minutes.

12.5.12.

Laminates which cannot be completed and pr operly rolled out with grooved steel rollers befor e the resin commences gelling, shall be removed from the pipe while the resin is still soft. The pipe shall then be cleaned and prepared again as noted in Clause 12.4.4, and a new lay-up lay-up shall be made. Lay-ups with less than the number of glass reinforcing specified shall not be permitted.


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12.5.13.

If resin in a laminate does not gel within 60 minutes, or its cure is not substantially complete within 2 hours of adding the catalyst, catalyst, the contractor shall apply heat. The laminate shall be kept heated until until its cure is completed. Laminates not cured satisfactorily after 24 hours shall be removed from the pipe and redone.

12.5.14.

Laminates cured with excessive exotherms and which show evidence of brittleness or pinholes shall be removed and redone.

12.5.15.

The cost of remedial work noted under Clauses12.5.12, 12.5.13, and 12.5.14, including the cost of new materials, shall be to the contractor's account.

12.5.16.

The Engineer may, at any time, ask the contractor to remove a completed or partially completed field joint from the pipe. If the bond between pipe pipe and joint is satisfactory, and if the joint laminate is of an acceptable quality, the contractor will get reimbursed for the cost of removing the joint and replacing it. If either the bond or the quality of the laminate is not acceptable, the contractor shall remove additional joints as instructed by the Engineer. The cost of removal and of all r emedial work shall then be to the contractor's account.

12.6.

Inside Lay-Ups Field joints on piping made as specified in this Section 12 do NOT require inside joint lay-ups. Inside joints shall not be made unless specified on drawings by the Engineer. All laminating work inside pipes or other confined spaces shall be subject to Clause 12.7.2.

12.7.

Repair of Damaged FRP Structures

12.7.1.

The intent of these instructions is to prevent crews with inadequate training or without appropriate equipment from working in confined spaces with potentially harmful materials.

12.7.2.

All repairs inside the vessels and repairs inside of pipes more than 30' from the open end shall be performed by trained crews from an experienced fabricator and with appropriate safety precautions.

12.7.3.

Repair of Structural Wall

12.7.3.1. Minor damage may be repaired with outside overlays equal in thickness and reinforcing as s pecified for field joints. The overlay shall extend extend a minimum of 6" all around the damaged areas. 12.7.3.2. Major damage and damage with cracked liner shall be cut out and replaced with a section of pipe and two field joints. If the damage is 3" or less in length, a patch of 3RW+5M over the damage, a minimum of 6" all around, plus a standard field joint are the minimum repair. 12.7.4.

Repair of Corrosion Liner of Pipe

12.7.4.1. Prior to installation and while both ends of the pipe section are st ill open, damaged liners in lar ge pieces shall be repaired with an inside overlay at least equal to the liner.


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12.7.4.2. 12.7.4.2. After pipe pipe is in the trench trench and jointed jointed to other other pipe length lengths, s, Clause Clause 12.7.2 shall shall apply apply.. When trained crews are not available, repair damaged liners from the outside as specified in Clause 12.7.3.2.


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TABLE D - TYPE OF LAY-UPS FOR DIAMETER AND PRESSURE RATING See Table E for lay-up details PRESSURE RATING DIA.

GRAVITY

50 psi

100 psi

150 psi

2"

50 mm

TYPE 1

TYPE 1

TYPE 1

TYPE 1

3"

75

TYPE 1

TYPE 1

TYPE 1

TYPE 1

4"

100

TYPE 1

TYPE 1

TYPE 1

TYPE 1

6"

150

TYPE 1

TYPE 1

TYPE 1 + 2

TYPE 1 + 2

8"

200

TYPE 2

TYPE 1 + 2

TYPE 1 + 2

TYPE 1 + 2

10"

250

TYPE 2

TYPE 1 + 2

TYPE 2 + 3

TYPE 2 + 3

12"

300

TYPE 2

TYPE 2 + 3

TYPE 2 + 3

TYPE 2 + 3

14"

350

TYPE 2 + 3

TYPE 2 + 3

TYPE 2 + 3

TYPE 2 + 3

16"

400

TYPE 2 + 3

TYPE 2 + 3

TYPE 2 + 3

TYPE 1 + 2 + 3

18"

450

TYPE 2 + 3

TYPE 2 + 3

TYPE 2 + 3

TYPE 1 + 2 + 3

20"

500

TYPE 2 + 3

TYPE 2 + 3

TYPE 2 + 3

TYPE 1 + 2 + 3

22"

550

TYPE 2 + 3

TYPE 2 + 3

TYPE 1 + 2 + 3

TYPE 1 + 2 + 3

24"

600

TYPE 2 + 3

TYPE 2 + 3

TYPE 1 + 2 + 3

TYPE 1 + 2 + 3

30"

750

TYPE 2 + 3

TYPE 2 + 3

TYPE 1 + 2 + 3

TYPE 1 + 2 + 3*

36"

900

TYPE 2 + 3

TYPE 2 + 3

TYPE 1 + 2 + 3

T 1 + 2 + 3 + 4*

42"

1050

TYPE 2 + 3

TYPE 2 + 3

TYPE 2 + 3 + 4*

T 2 + 3 + 3 + 4*

48"

1200

TYPE 2 + 3

TYPE 1+2+3

TYPE 2 + 3 + 4*

T 2 + 3 + 3 + 3 + 4*

Note:

Joints marked thus *, shall be designed by the fabricator to suit the particular installation. Joint design shall be approved by the Engineer. If expert guidance is not available, then the combinations marked thus * are the minimum requirements.


PROPAC

PROJ. APPR.

P.Healy

DEPT. APPR.

K.Serenius


4S-10.01

0

SHEET 26 OF 27

Rev.


22Feb2001


PROPAC

PROJ. APPR.

P.Healy

DEPT. APPR.

K.Serenius


4S-10.01

0

SHEET 27 OF 27

Rev.


22Feb2001

4S-10.01 Simons FRP Structures.pdf

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