The document outlines a training program on GRP (Glass Reinforced Plastics) pipe manufacturing, inspection, testing, and installation, aimed at enhancing participant knowledge and skills. It covers topics including types of GRP, manufacturing processes, inspection criteria, handling and storage, as well as safety precautions. The course is designed for all employees and includes practical insights into quality requirements and defect identification.

1. Prepared by : Anoop Manoharan
GRP Pipe Manufacturing, Inspection, Testing and Installation at site

2. Course Outline
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Objective :
To provide awareness on GRP pipe Manufacturing Processes, Inspection, Testing and installation at
site.
By the end of the programme, participants will be able to :
 Understand the manufacturing process
 Understand the minimum Inspection and Testing requirements at shop
 Understand the installation and testing requirements at site
Course intended for: All Employees
Duration: 30 minutes
Location: Microsoft Team
Training Provider: Anoop Manoharan & Basha Mujib (QA/QC Engineers)

3. Content
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1. Introduction about GRP
2. Characteristics and Advantages
3. References
4. Types of GRP
5. Material used in GRP
6. Manufacturing Process
7. Types of Joints
8. Classification of GRP
9. Shop Inspection and Testing
10. Common Defects
11. Marking & Identification
12. Packing, Handling , Storage & Transportation
13. HSE checks and controls at shop
14. Site receipt inspection and Preliminary Checks
15. Storage of GRP Pipes at site
16. Handling of Nested Pipes at site
17. Pipes laying in Trench
18. Pipes Jointing at site
19. Backfilling
20. Underground and above ground installations
21. Field Tests
22. Gel Coating
23. Quality Requirements
24. Safety Precautions
25. Conclusion
26. Q&A
Shop Activities Site Activities

4. Introduction
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What is GRP?
 GRP (Glass Reinforced Plastics) - Composite of Polymer matrix + reinforced with glass fibers.
 GRP belongs to the family of products known as FRP (Fibre Reinfornced Plastics )

5. Why GRP ?
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Characteristics and advantages :
 Long life; highly durable.
 Low maintenance cost.
 High Corrosion resistance.
 Low lifecycle cost.
 No need for cathodic protection.
 Less transportation and handling cost.
 Environmentally friendly.
 Economic when compared with DSS pipe

6. REFERENCES
CODES & STANDARDS
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International standards
 ASTM Standards - (ASTM D 2992, 2996, 2310, 3262, 3517, 3754, etc.,)
 AWWA - (AWWA C 950 & AWWA M 45)
 BS - (BS 5480, BS 7159, BS 4994, etc.,)
 UKOOA
 DIN.
Legal
 Local legislative documents and specific sections (As applicable)
Metito & Project specific
 Project Specification,
 Applicable Drawings and Data Sheets
 QA/QC Plan, ITP and Testing Procedures
 Method Statements and Risk Assessments
 Metito Standard checklist forms for Site Activities

7. Types of GRP
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Classification based on Raw material composition
Types Raw material used Application
GRUP: Glass reinforced
unsaturated polyester
Isophthalic resin /
Polyester resin + Fiber
Glass
• Temperature up to 60 º C.
• Irrigation, potable water, Sewerage,
Waster water, RO plants
GRV: Glass – fiber
reinforced vinyl ester.
Vinyl Ester Resin + Fiber
Glass
• Better mechanical and chemical
properties when compared to GRP
Pipes.
• Used for temperature up to 90 º C
GRE: Glass – fiber
reinforced epoxy.
Amine Cured Epoxy resin
+ Fiber Glass
• Temperature up to 110 º C
• Better properties than GRP/GRV
• Chemical resistance and anticorrosive
• Offshore application, Acid
transportation

8. Raw materials used
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Vinyl ester Resin Chopped strand Mat Woven Roving Mat
Direct Roving
Surface Tissue / Veil UV inhibitor

9. Pipe Wall Structure
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10. Manufacturing Process
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Manufacturing processes :
1. Discontinuous Filament Winding process (DFW)
2. Continuous Filament Winding process (CFW)
3. Centrifugal casting (CC)

11. Manufacturing Process
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1. Discontinuous Filament Winding process (DFW)
• Flexible, High Strength performance, High corrosion resistance, Good Pressure Withstanding
hydraulic performance
Helical winding Polar winding

12. Manufacturing Process
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2. Continuous Filament Winding process (CFW)
• Medium Mechanical performance
• Allows use of high percentages of fillers, siliceous aggregates and additives
• Application of the band in parallel direction (winding angle about 90 °) on a rotating collapsible
mold

13. Manufacturing Process
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3. Centrifugal casting Process (CC)
 Spraying of aggregates and reinforcing cut fibers inside a rotating drum.
 Used for Higher pipe thicknesses

14. Types of Joints
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Flanged Joint
Lamination Joint
Rubber seal lock Joint
Adhesive Joint

15. Types of Joints
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Bell and Spigot Joint Double Bell Coupling
Click here for more details regarding application of different joints

16. Classification of GRP Pipes
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GRP Pipes are mainly classified as,
1. Pressure class (PN): represents pipe’s design pressure in Bar
2. Stiffness class (SN): represents pipe's minimum initial specific
stiffness in N/m² (Pa)
NB : Other pressure class and stiffness class are also available

17. Inspection and Testing of GRP Pipes
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The most common testing used in GRP are,
1. Testing of Raw Materials
 Viscosity (cps or Pa-s) - the resistance to flow of a
liquid
 Specific Density (kg/m3) - the mass per unit volume
of a material
 Curing / Gel time (sec) - to determine the curing
characteristics / the time taken to gel on a surface at
a specified temperature
Gel Time test
Viscometer
Specific density test

18. Inspection and Testing of GRP Pipes
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2. Testing on samples for physical properties
 Stiffness Test (N/m2)- Resistance to
Deflection and Creep
 Axial Tensile Test (N/mm2) – Resistance to
axial tensile load.
 Burst Test (psi or bar)- to determine the
ultimate pressure resistance
 Loss on Ignition test (%) - determine the
ignition loss of a cured reinforced resin
sample
Stiffness Testing
Axial Tensile test
**Sample Lab test Report **Sample ITP
Burst Test
Loss on ignition test

19. Testing of GRP Pipes
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3. Testing on Finished products
 Visual Inspection
 Dimensional Inspection
 UT Thickness check (mm)
 Barcol Hardness Test (B) - measure the
degree of cure.
 Acetone Sensitivity Test- to determine
solubility or chemical resistance
 Hydrotest - to check pipe integrity
under pressure conditions
Hydrotest UT Thickness Check
Barcol Hardness Test Acetone sensitivity Test
** Sample Hydrotest report
Note: During hydrotest care must be taken to detect the seepage/
sweating through minute pores. Thorough visual inspection with
increased holding time (minimum 30 mins) shall be considered.
Dimensional check

20. Defects in GRP Pipes
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1. Visual Defects
Wrinkling Pinhole
Poor adhesion of the Gel Coat
Blister's
Star crazing / cracking
The most found visual defects on GRP pipes are,
** Refer Acceptance as per ASTM D 2563

21. Defects in GRP Pipes
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2. Defect observed during manufacturing
Seepage / sweating noticed on pipe surface through minute pores during
hydrotest
Root Cause: Uneven polymerization due to higher speed of production of pipe
Correction done: Defective pipes rejected and replaced with new ones
Corrective action:
• Calibration of machine done
• Speed chart is pasted near to machine for ready reference.
• Continuous Monitoring required by Production and QC Engineer

22. Handling, Transportation & Storage of GRP Pipes
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 Not only for protection of pipes but also for the safety of the personnel handling them.
 Avoid direct contact of Lifting accessories (Metal chains, Metallic slings, hooks) with GRP
items.
 Use Wide band webbed slings of polypropylene, nylon or similar material.
 Obtain Lifting permits (if required)
 Onload /Offload one pipe at a time
 Do not drop or drag or rolled on the ground
Handling:

23. Handling, Transportation & Storage of GRP Pipes
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 Use Flat bed Trailers.
 Use supports (free of sharp edges or projection)
 Evenly support over their full length
 Do not overhang the vehicle
Transportation:

24. Handling, Transportation & Storage of GRP Pipes
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 Only on flat even grounds
 Away from sharp projections
 Adequate space for movement of lifting equipment
 Protected from direct sunlight for long period of storage.
 Never place in contact with lubricating oil, gasoline and solvents.
 Away from exhaust outlet and other high temp. sources
Storage:

25. HSE Hazards and Controls at Manufacturer Shop
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Common Hazards
 Resins are highly flammable and explosive
 Irritation to skin, eyes, nose and throat
 Excessive inhalation may cause dizziness, drowsiness, loss of
consciousness, cardiac irregularities.
Control Measures
 Use Proper PPEs (dust / vapor mask, safety glass, rubber gloves,
long sleeved shirt, long pants, safety hat, shoes, etc..)
First Aid measures
 If inhaled take victim to fresh air
 Flush eye with flowing water
 Wash skin with soap
 Take medical aid in case of severity

26. Site Receipt Inspection & Preliminary Checks
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Site receipt Inspections
 Ensure no damages occurred during transit
 Check the quantity
 Verify the spool numbers against the Delivery Note.
 Verify inspection reports.
Preliminary Checks
 Approved documents are available (Piping and trench backfilling Material submittal, Method
Statement, Drawings & RA, EA, PQP, HSEP, ITP)
 Piping route is clear of obstructions, existing services (if any) are well protected.
 Approved subcontractor and competent Engineers, HSE team are available
 Obtain permit to work

27. Storage of GRP Pipes at Site
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The pipes shall be stored on an even surface. The stacking height depends on
the soil conditions as well as the loading and safety equipment on site as below table

28. Handling of Nested Pipes at Site
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GRP pipes may be delivered nested (i.e., one or more small pipes inside a larger pipe). Nested
pipes must always be lifted using at least two straps or slings. De-nesting is accomplished
by inserting a forklift/mobile crane boom. Proper padding is essential on the boom.

29. Pipe Laying Trench Requirements
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Standard Trench
 The trench preparation must comply to approved drawing.
 Foundation & Bedding (soil/gravel or any other forms) as per project specification.
 Side support must provide with shoring or trench box in case excavated soil is not intact but loose.
Multiple Pipes
 Pipes must be laid in the same bottom level.
 The clear spacing between adjacent pipes must be as per below given table.

30. Pipe Laying Trench Requirements
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Trench Excavation Below Water Table
Dewatering process must be carried out to
ensure trench is dry prior laying the pipeline.
Trench supported with Trench Box
Side support must provide with shoring or
trench box in case excavated soil is not intact
but loose.

31. Various Underground Installations-Road Crossings
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Pipe Laying
Trench preparation

32. Various Underground Installations
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33. Pipes Joining at Site
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Coupling Cleaning Gasket Installation &
Lubricating
Spigots Cleaning and Lubrication
Fixing of Clamps Coupling Joining Pipe Misalignment

34. Pipes Joining at Site-Lamination Method
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Grinding & Sanding Alignment Resin+Woven Ring application After curing

35. Pipes Joining at Site
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Fast Curing of Pipe joints using Heating Blanket @1300C or as per specs

36. Pipes & Fittings Joining at Site-Flanged Joints
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GRP Fixed Flange. Flat Face
Bolting:
 Flange tightening sequence as per pic.1
 Torquing depends on Bolt standard or manufacturer recommendation
 Don’t overdo it to damage base material as well as gaskets
Pic.1

37. Backfilling
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 Backfilling shall be performed as per client
specification
 Degree of compaction and FDT Tests shall carryout
as per client specification
 Ensure warning tape installed during backfilling

38. Various Aboveground Installations-Wall Embedded
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39. Various Aboveground Installations-Skids
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 As per approved Isometric, PID or GA
 supports and clamps are checked for location,
type and span
 GRE flange mounted against a steel valve flange;
the support is preferably fixed to the steel flange.
 All MEICA Items are installed as per PID
 Pipes shall be identified, tagged, color banded,
flow direction marked (if any)

40. Installation of aboveground pipe systems
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Valve supports Bellow supports

41. Field Tests after jointing
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Barcol Hardness Test -ASTM D2583
 To determine the hardness of site laminated
joints.
 Degree of hardness depends on the resin
used or by manufacturer recommendation.

42. Field Tests-Pipe Deflection Test
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**Deflection test sample report

43. Field Hydrotest
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Piping Hydrotest Test pre-checks
 Pipeline system inside shall be clear of foreign particles, debris, grease etc.,
 All joining procedures and client inspections shall be completed.
 Trenches should be sufficiently backfilled, and joints should be left exposed.
 All supports, guides, and (temporary) anchors shall be in place
 Flange bolts shall be made up to the correct torque.
 Calibrated PG; media filling and disposal area must be agreed from client
 ITP, Method statement including test packs must be approved
 HSE requirements shall be respected.

44. Field Tests-Leak Test
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Piping Leak Tightness Test Piping Hydrotest Test

45. Gel Coating
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GRP Gel coated to improve UV and chemical resistance, for color coding of piping and vessels, or for
aesthetics.

46. Tolerance Chart
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 Tolerance chart for dimension control these
might vary project wise.
 Ensure only competent workers executing
the FRP works
 Ensure only latest approved drawings are
used
 Check for resins shelf life prior to application

47. Safety precautions
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 Obtain Permit to work
 Work must be carried out strictly under the supervision of
HSE
 Toolbox talks must be carried out at site.
 Proper ventilation must be provided to avoid irritation of
the respiratory system
 Safety precautions must be followed during hydrotest
 GRP material must be protected from hot works
 Comply to confined space requirements and always check
gas detector
 When cutting or grinding GRE materials proper personal
protection is necessary to protect eyes and skin
• A dust mask covering nose and mouth.
• A pair of safety goggles, Gloves and overall.
• Overall sleeves to keep the dust out.
• Protective clothing to protect the body.

48. SUMMARY
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BE Aware of GRP manufacturing process, inspection and tests involved
BE Ahead of manufacturer’s knowledge
BE Able to identify the defects
KNOW the specification and standards
KNOW drawing and design requirements
KNOW the controls and check points
DO Follow Method Statement and Risk Assessment
DO not take short cut – Short cut causes rework
DO not work hard – WORK SMART
In Summary BE…KNOW…DO!

49. CONCLUSION
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In this training – if this is followed what can we expect to see from attendees?
1. Activities involved in Manufacturing and installation of GRP pipes.
2. Understands HSE Risks involved and control measures to be implemented
3. Monitor and carryout Inspections and Tests

50. QUESTIONS & ANSWERS
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51. Design and Build Utilities Chemicals