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FCPP -Fiberglass-coated Concrete Pressure Pipes Product Guide
FCPP -Fiberglass-coated Concrete Pressure Pipes Product Guide

FCPP -Fiberglass-coated Concrete Pressure Pipes

Product Guide

FCPP -Fiberglass-coated Concrete Pressure Pipes Product Guide
FCPP -Fiberglass-coated Concrete Pressure Pipes Product Guide
FCPP -Fiberglass-coated Concrete Pressure Pipes Product Guide
FCPP -Fiberglass-coated Concrete Pressure Pipes Product Guide
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. Amiantit’s 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).

as majority share holder and Ameron International (USA). 2 Pipes constitute a major element item in

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as majority share holder and Ameron International (USA). 2 Pipes constitute a major element item in

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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3 In 1997 Ameron Saudi Arabia Ltd began their research and development into how to improve

In 1997 Ameron Saudi Arabia Ltd began their research and development into how to improve the coating of concrete pressure pipes. In 2002, to further develop the coating system, the company contracted 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.The following can also be concluded from the find- ings: Performance of fiberglass coated pipes in

Performance of fiberglass coated pipes in mini mum of six months of exposure cycles show no adverse implication.show a much higher tensile strength and reduced shrink age. under thermal cycles, wet-dry cycles and

under thermal cycles, wet-dry cycles and U-V exposure.six months of exposure cycles show no adverse implication. Chloride penetration in fiberglass coated con -

Chloride penetration in fiberglass coated con - crete pressure pipe is negligible.under thermal cycles, wet-dry cycles and U-V exposure. No adverse effect of continuous exposure to alka-

No adverse effect of continuous exposure to alka- line solution over five months is observed.fiberglass coated con - crete pressure pipe is negligible. Fiberglass coated pipe appears to maintain its

Fiberglass coated pipe appears to maintain its physical integrity without developing any crack or physical degradation in all tests, clearly pointing to a high-performance, durable product.

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4 The core pipe is manufactured based on AWWA C303 standard requirements with modifications to the

The core pipe is manufactured based on AWWA C303 standard requirements with modifications to the process of curing and the application of the cement-

mortar coating. The Fiberglass coating is applied at

a later stage to the dry surface of the cement-mortar coated pipe.

Fiberglass concrete pressure pipes (FCPP) consist of:

Welded steel cylinder.pipe. Fiberglass concrete pressure pipes (FCPP) consist of: Centrifugally cast concrete or cement-mortar lining. Steel

Centrifugally cast concrete or cement-mortar lining.pressure pipes (FCPP) consist of: Welded steel cylinder. Steel reinforcing bar wrapped at a predetermined stress

Steel reinforcing bar wrapped at a predetermined stress around the cylinder.Centrifugally cast concrete or cement-mortar lining. A dense cement-mortar coating over the steel cylinder and

A dense cement-mortar coating over the steel cylinder and wrapped reinforcement.bar wrapped at a predetermined stress around the cylinder. Steel joint rings welded to the cylinder

Steel joint rings welded to the cylinder to form a self-centring bell and spigot joint sealed by a com pressed rubber gasket.coating over the steel cylinder and wrapped reinforcement. The mortar for lining and coating consists of

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 mm 2 /m of pipe wall or numerically equal to 83.3 % of the pipe diameter in mm. Maximum 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.

4.1 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.

of cylinder required for the individual piece of pipe. Fabrication of steel cylinders 3 4.2 Fabrication

Fabrication of steel cylinders

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4.2 Fabrication of joint rings

Bell and spigot rings, which form the O-ring sealed joint between adjacent pipes, are fabricated from flat bars and special hot-rolled sections respectively. The steel is accurately cut, rolled and welded into a ring and then sized on a hydraulic press to an exacting circumferential length tolerance.

press to an exacting circumferential length tolerance. Fabrication of joint rings 4.3 Attachment of joint rings

Fabrication of joint rings

4.3 Attachment of joint rings

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.

length and to assure the ends are square. They are then welded to the cylinder. Attachment

Attachment of joint rings

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.

the water-tightness of the completed cylinder assembly. Hydrostatic testing of cylinders 4.5 Concrete or

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.

until the cement mortar is relatively dry to handle. Placement of concrete or cement-mortar lining. 4.6

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.

period of time under controlled temperature and humidity. Curing the lining. 4.7 Rod wrapping Upon completion

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.

cylinder immedi- ately ahead of the advancing rod wrap to fill all voids between the steel

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.

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.

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 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.

are braced internally with timber stulls until installation. S t o r a g e 5

Storage

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with timber stulls until installation. S t o r a g e 5 Application of cement-mortar

Application of cement-mortar coating

S t o r a g e 5 Application of cement-mortar coating Steam curing of cement-mortar

Steam curing of cement-mortar coating

of cement-mortar coating Steam curing of cement-mortar coating Fiberglass coating process Curing of Fiberglass coating

Fiberglass coating process

of cement-mortar coating Steam curing of cement-mortar coating Fiberglass coating process Curing of Fiberglass coating

Curing of Fiberglass coating

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5 Fiberglass-coated Concrete Pressure Pipe (FCPP) systems and accessories offers many advantages: Features Benefits

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 6.1 Pipes The Fiberglass coated concrete pressure pipe (FCPP) is offered in an extensive range

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.

on the pipe diameter. Short pipe, bevelled pipe, and a wide range of special pipe and
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6.2 Fittings and accessories:

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.

FCPP Tee

for butt-strap closures and steel bell and spigot ends for joints sealed with the standard round
for butt-strap closures and steel bell and spigot ends for joints sealed with the standard round
for butt-strap closures and steel bell and spigot ends for joints sealed with the standard round
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7 7.1 Pipes FCPP is designed and manufactured in accordance with the following standards and specifications:

7.1 Pipes

FCPP is designed and manufactured in accordance with the following standards and specifications:

AWWA C303 (AWWA Standard for Concrete Pres sure Pipe, Bar Wrapped, Steel-Cylinder Type).accordance with the following standards and specifications: AWWA M9 (Manual for Water Supply Practices – Concrete

AWWA M9 (Manual for Water Supply Practices – Concrete Pressure Pipe.Concrete Pres sure Pipe, Bar Wrapped, Steel-Cylinder Type). Saudi Arabian Standard Organization (SASO). Properties of

Saudi Arabian Standard Organization (SASO).for Water Supply Practices – Concrete Pressure Pipe. Properties of Fiberglass coating : Thickness 2.0 to

Properties of Fiberglass coating :

Thickness

2.0 to 3.0 mm

Pull strength

Average 5.5 N\mm²

Electrical resistive

Above 1.0 million Ohm ( )

External load carrying capacity

3 % more per linear meter

Water permeability

Zero mm

Chloride permeability

Zero coulombs

Resistance to UV and storage

No change in color

Above ground

Can be use without supplemental protection

Installation

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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Rubber O-ring

rubber gasket. Installation rates of 30 to 50 pipe sections per crew/day can be achieved. 13

Rubber O-ring

rubber gasket. Installation rates of 30 to 50 pipe sections per crew/day can be achieved. 13
rubber gasket. Installation rates of 30 to 50 pipe sections per crew/day can be achieved. 13

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
The table below illustrates the Deflections, Offsets,
Minimum Radii, and Laying Lengths of the standard
pipe.
Js
Jmax Jmin
Jmax
Jmin
L G
L
G
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Consistently high quality standards are an important feature of our Ameron® pipe systems produced throughout

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.quality control departments and laboratories, to ensure that production and services continually improve in quality.

production and services continually improve in quality.products are manufactured under the specified requirements. Ameron Saudi Arabia, Ltd has adopted and has been

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.pipeline. The quality control engineer is responsible for: For maintaining and implementing quality control standards

For maintaining and implementing quality control standards and procedures.is manufactured accord- ing to contract specification. For evaluating test results. For monitoring the

For evaluating test results.and implementing quality control standards and procedures. For monitoring the manufacturing process to main- tain

For monitoring the manufacturing process to main- tain compliance with the process standards.standards and procedures. For evaluating test results. Providing technical support to customers on quality matters.

Providing technical support to customers on quality matters.process to main- tain compliance with the process standards. Giving potential customers and vendor inspectors an

Giving potential customers and vendor inspectors an insight into the company’s quality program.Providing technical support to customers on quality matters. The quality control department has a highly experi-

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.

to relevant project specifications, drawings and standards. Ameron Saudi Arabia Ltd (ASAL) has produced a detailed
to relevant project specifications, drawings and standards. Ameron Saudi Arabia Ltd (ASAL) has produced a detailed

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.installation includes also pipe delivery and site storage. Pipes should be properly supported along the bottom

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.be taken into consideration in order not to damage the pipe. For pipe laying and embedding,

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 manufacturer’s tabular layout schedule.and embedding, please take the following into consideration Trenches must be excavated to provide a mini-

Trenches must be excavated to provide a mini- mum of 1 meter earth cover at the top of the pipe.by the manufacturer’s tabular layout schedule. Sub-grade should provide continuous, uniform support under

Sub-grade should provide continuous, uniform support under the haunches of the pipe after bedding and backfilling.a mini- mum of 1 meter earth cover at the top of the pipe. Trench should

Trench should be dewatered prior to pipe instal- lation.the haunches of the pipe after bedding and backfilling. As much as possible, pipes are laid

As much as possible, pipes are laid on the trench so that the bell end faces in the direction of laying.Trench should be dewatered prior to pipe instal- lation. Prior to assembling the joint, the inside

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.so that the bell end faces in the direction of laying. The spigot, the first 50

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.is to be plastered with a stiff mortar which should be finished flush with the adjacent

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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

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.the pipe trenches in lines, according to contract drawings. Backfill material above the pipe bedding, which

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.be free from rocks or clods larger than 75 mm in diameter. If densification of backfill

If densification of backfill is required, the material should be placed in horizontal layers and then compacted.as compaction of the pipe bedding material is completed. Hydrostatic testing of pipelines Each completed length

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.

installation guide, as well as parts and maintenance manuals specific to each product, are available upon
installation guide, as well as parts and maintenance manuals specific to each product, are available upon
installation guide, as well as parts and maintenance manuals specific to each product, are available upon
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Note :

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.

by Amian- tit and/or its subsidiaries before using them.     Ameron Saudi Arabia, Ltd P.O.
 
 
 
 

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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