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Form No.

PEM-6666-0
TITLE: SPECIFICATION NO. PE-TS-999-100-M042
STANDARD TECHNICAL SPECIFICATION REV.00 DATE: 24.10.2009
FOR VOLUME: II PART: B SECTION: D
GLASS REINFORCED PLASTIC (GRP) PIPES SHEET 1 OF 6

1.0 SCOPE

The GRP pipe shall confirm to all parameters as laid down in IS standards or relevant SASO or
ASTM, BS or any International standard as regards to materials, dimension, classification, testing and
type of joints of machine made pipes with glass fiber reinforced thermosetting resins with aggregate
filler having nominal diameter as specified

1.1 MANUFACTURING: The method of manufacturing of GRP pipe shall be such that the form and
diversions of the finished pipes are accurate within the limits specified in relevant clauses of IS
standards later and manufactured through continuous filament winding process using advancing
mandrel method. The GRP pipe shall conform to equivalent international standards.

1.2 WALL COMPOSITION: As per IS14402-96 or equivalent international standards like AWWA C950,
ASTM 2996 and BS5480 with applicable revision of codes.

1.3 DIMENSIONS: The tolerance limits as specified in IS 14402-96 or equivalent international standard
should be followed/adhered to for all dimensions.

2.0 MATERIALS:

2.1 RESIN: A thermosetting polyester resin to be used and quality parameter should as per IS14402-96
(latest) or equivalent international standards mentioned elsewhere in the tender. Pipe shall have to be
provided with UV stabilized resin coat as external layer.

2.2 GLASS FIBER REINFORCEMENT: Glass fiber reinforcement shall be of commercial grade Boron
free electrical and corrosion resistance glass type and shall conform to IS 11273-1992, IS11320-1985
or IS11551-1986 as appropriate or equivalent international standard like ASTM D2343. The same
shall be procured from renowned manufacturer. BS 5480 also to be referred.

2.3 REINFORCEMENT: E or ECR (preferable) glass fiber procured from renowned fiberglass
manufacturer shall be used for all dimensions.

2.4 OTHER MATERIALS:

 Aggregates: Siliceous and or a size range between 0.05 mm and 0.8mm may be incorporated
in the composite structure.
 Filler: Insert fillers (with particles size below 0.05mm) may be incorporated either own or with
aggregates.
 Additives: Additives may be incorporated for modifying the properties of the resin.

3.0 DIMENSION:

3.1 Pipes shall be supplied in nominal length of 6M/12M unless otherwise specified as per contract piping
layout drawing /layout requirements. The tolerances on nominal lengths shall be within ± 25mm as per
approved drawing by BHEL in line with shipping constraints. A max of 10% of pipe lengths shall be
supplied in short lengths as per IS 12709 clause 7.2.

3.2 WALL THICKNESS: The minimum wall thickness at any point shall not be less than the wall
thickness specified in the manufacturing data sheets current at the time of purchase. It shall be
ensured that the wall thickness meets the requirement of minimum thickness specified in IS code or
equivalent international code. The wall thickness and outside diameter shall be measured to an
accuracy of 0.1 mm with micrometer and pipe tape in accordance to specified approved drawing.

3.3 WALL COMPOSITION: The basic structural wall should consist of Thermo setting food grade
Polyester resin and as per Clause No. 2.3 glass fiber reinforcement. The inner surface of a GRP pipes
and fitting wall shall have a good grade resin rich corrosion barrier compatible for water with a
thickness of minimum 1.0mm Pipe shall have to be provided with UV stabilized resin coat as external
layer.
BHEL - PS-PEM: PPEI BUILDING, SEC. 16A, NOIDA - 201301
Form No. PEM-6666-0
TITLE: SPECIFICATION NO. PE-TS-999-100-M042
STANDARD TECHNICAL SPECIFICATION REV.00 DATE: 24.10.2009
FOR VOLUME: II PART: B SECTION: D
GLASS REINFORCED PLASTIC (GRP) PIPES SHEET 2 OF 6

3.4 JOINTS

3.4.1 The pipe shall have a join system that shall provide for fluid tightness for the intended service
condition as per approved drawings. Pipe joints shall be capable of withstanding internal pressure.

3.4.2 Coupling: To join GRP pipe to GRP pipe with rubber gasket and central register will be used for un-
restrained portion of the piping.

3.4.3 Butt strap joint (Lamination Joint): The Butt strap joints shall be used joining GRP piping in restraint
portion of the piping.

3.4.4 Flanged Joint: The flanged joints shall be used for connecting valves, pumps and other piping etc.
having EPDM gasket and hot galvanized IS bolting to IS1367 Class 4.6.

3.4.5 ASTM D4161(Standard specification for fiber glass [glass fiber reinforced Thermosetting Resin] pipe
joints using Flexible Elastomeric seals.) to be followed. Joint qualification test reports to be submitted
by supplier.

4.0 WORKMANSHIP:

4.1 The pipes shall be free from all defects including indentation, delaminating, bubbles, pinholes, cracks,
pits, blister, foreign inclusions and resin staved areas that due to their nature degree or to the extent
that detrimentally affects the strength and serviceability of the pipe. The pipe shall be as uniform as
commercially practicable in colour opacity, density and other physical properties as per ASTM 2563/
BS 5480/IS14402 or equivalent international standard.

4.2 The inside surface of each pipe shall be free of bulges, dents ridges and other defects that result in
a variation of inside diameter of more than 3.2mm from that obtained on adjacent unaffected portions
of the surface. No glass fiber reinforcement shall penetrate the interior surface of the pipe wall.

4.3 Joint sealing machined surface shall be free of dents, gouges and other surface irregularities that will
affect the integrity of the joints.

4.4 The inside surface of each pipe shall not have any visible defects such as bulges, dents ridges, foreign
inclusion, cracks, crazing, pin notes and bubble of nature degree, extend that determination affected
the performance of the pipe. No glass fiber reinforcement shall penetrate the interior surface of the
pipe wall.

5.0 STRUCTURAL PROPERTIES:

Each pipe length shall have sufficient strength to withstand the class AA loading in addition to the
overburden of backfill load up to the required depth. The minimum initial ring stiffness for withstanding
above load conditions with maximum 5% of long-term ring deflection shall be appropriately determined
by manufacturer for actual execution

6.0 BEAM STRENGTH:

The pipe shall meet the minimum longitudinal tensile strength as per relevant clauses of IS 14402-96
or equivalent international standard. Test shall be performed in accordance to the requirements in
AWWA C950 and ASTM D3517.

7.0 HOOP & AXIAL TENSILE STRENGTH:

The pipe shall meet the minimum hoop and axial tensile strength as per relevant clauses of IS 14402
or SASO 1578-99 or AWWA C950, ASTM D3517 or equivalent international standard.

BHEL - PS-PEM: PPEI BUILDING, SEC. 16A, NOIDA - 201301


Form No. PEM-6666-0
TITLE: SPECIFICATION NO. PE-TS-999-100-M042
STANDARD TECHNICAL SPECIFICATION REV.00 DATE: 24.10.2009
FOR VOLUME: II PART: B SECTION: D
GLASS REINFORCED PLASTIC (GRP) PIPES SHEET 3 OF 6

8.0 HYDRAULIC PROPERTIES:

A) Soundness: Each length of shall withstand without leakage (seepage) or cracking the internal
hydrostatic pressure as per relevant clauses of IS 14402-96 or equivalent international standard.

B) Other testing requirement and pipes will be tested as per IS 14402-96 or equivalent international
standard.

All ‘Type’ tests are to be carried out i.e. long-term ring bending strain (ASTM D5365) long-term
hydrostatic strength (ASTM D2992) etc.

9.0 MARKING:
The marking on pipe shall include the following:
 The manufacturer’s name of trademark
 The nominal pipe diameter
 Class of pipe (Pressure & Stiffness)
 Batch no. or date of manufacture
 Pipe should also be marked with certification no.

10.0 APPLICABLE STANDARDS:

1. IS 14402 GRP Pipes, Joints and Fittings for use in Potable Water
Supply
2. IS 5382 Rubber sealing rings for gas mains, water mains and sewers
3. IS 13916 Installation of GRP Piping system – code of practice
4. IS 6746 Unsaturated polyester resin systems for low-pressure fiber
reinforced plastic
5. IS 9845 Method of analysis for determination of and/or overall
migration of constitutes of plastic materials and articles
intended to come into contact with foodstuffs.
6. IS 11273 Woven rowing fabrics of ‘E’ glass fiber
7. IS 11320 Glass rowing for the reinforcement of Polyester and epoxies
resin system
8. IS 11551 Glass fiber chopped stand mat for the reinforcement of
polyester resin system
9. IS 1367 (Part 1 Technical supply conditions for threaded steel fasteners
to 20)
10. AWWA C950 For fiber glass pressure pipe
11. ASTM D2992 Standard practice for obtaining hydrostatic of pressure design
basis for “GRP Pipes and Fittings.”
12. ASTM D2563 Standard practice clarifying visual defects in glass reinforced
plastic laminated parts
13. ASTM D2583 Standard method for indentation hardness of rigid plastic by
means o bared compressor.
14. ASTM D5421 Standard specification for contact molded “Fiber glass”
flanges.
15. ASTM D3839 Standard practice for underground installation of GRP Pipes.
16. ASTM F477 EPDM Sealing Rubber Ring
17. BS 5480 GRP pipe joints and fittings for use for Water Supply of Sewerage
18. BS2429 Specification for Lamination joint design
19. SASO 2143-00 Test methods for fiber glass reinforced resin pipes.

BHEL - PS-PEM: PPEI BUILDING, SEC. 16A, NOIDA - 201301


Form No. PEM-6666-0
TITLE: SPECIFICATION NO. PE-TS-999-100-M042
STANDARD TECHNICAL SPECIFICATION REV.00 DATE: 24.10.2009
FOR VOLUME: II PART: B SECTION: D
GLASS REINFORCED PLASTIC (GRP) PIPES SHEET 4 OF 6

SPECIFICATONS FOR GRP FITTINGS & SPECIALS

1.0 GENERAL

All GRP fittings, such as bend/elbows, ends, tees, flanges and reducers etc. shall be equal to
or superior in performance to pipe of the same classifications and shall be smoothly finished
internally.

All GRP fittings are to be manufactured in factory. Dimensions of all fittings should be as per
BS7159 and drawings to be submitted to BHEL/CUSTOMER for approval before
manufacturing.

2.0 FITTINGS MADE FROM STRAIGHT PIPE:

Fittings shall be fabricated from complete pipes or portions of straight pipe complying with
this standard as applicable for the pipe classifications. The fitting shall comply with the
declared design requirement and be suitably mitered. The miter shall be over wrapped
externally and internally with liner, woven roving and/or chopped strand mat to ensure the
longitudinal and circumferential tensile strength is at least equal by design to that of the pipe
with which the fittings is to be used. All fittings should have sufficient end length of pipe to
accommodate over wrapped length of fitting and pipe. All fittings should have internal,
external reinforcing dimensions as per BS7159.

GRP BENDS/WYES/PUDDLE FLANGE AND SPECIAL

The GRP bends, all type of flanges including puddle flanges are mitered from the pipe and
joined by hand laminations. Standard GRP bends are supplied factory made and if required
can be manufactured at site, Normally for segment 15 degree-20 degree change is
recommended for Elbow/Bend. Sufficient pipeline at the end of the fitting should be provided
for lamination. Stiffeners/webs shall be provided wherever required. BS7159 should be
followed for internally and externally reinforcement dimensions to fittings. Detailed
dimensions of fittings with reinforcement should be submitted to BHEL/CUSTOMER for
approval before manufacturing. For flange design, BS4994 should be referred.

GRP TEES & SCOURE ‘T’ CONNECTION

GRP tees with standard flanges matching PCD etc. should be provided for connection of
Butterfly valve, scour valve, air valves etc.
GRP flange in special cases where non standard flanges are to be used shall be designed as
per BS4994.

3.0 FITTINGS MADE BY MOULDING

Moulded GRP fittings shall be made by hand lay-up, contract moulding, hot or cold press
moulding or tape winding with internal liner.

4.0 TOLERANCES FOR GRP FITTINGS.

a) Except for flanged pipe work, which may require closer tolerances, the permissible
deviations from the stated value or the angle of change of direction of a fitting such as
a bend, tee or junction shall not exceed 1 degree.
b) Except for flanged pipe work, which may require closer tolerances the permissible
deviations on the manufacturer’s declared length of a fitting, exclusive of the socket
where applicable shall be ±25mm taken from the point of intersection to the end of the
fitting. Also tolerance of the angle of a bend and the angle between the main and leg
of a Wye of tee shall be ± 1 deg.

BHEL - PS-PEM: PPEI BUILDING, SEC. 16A, NOIDA - 201301


Form No. PEM-6666-0
TITLE: SPECIFICATION NO. PE-TS-999-100-M042
STANDARD TECHNICAL SPECIFICATION REV.00 DATE: 24.10.2009
FOR VOLUME: II PART: B SECTION: D
GLASS REINFORCED PLASTIC (GRP) PIPES SHEET 5 OF 6

PACKING & TRANSPORTATION

1. Bidder to submit a write up for safe handling and stacking of pipes during transportation and at
site.

2. Pipes to be properly stacked on wooden saddles with stoppers covered with rubber stick and
nail to provide cushioning and shock absorption. Width, height and number of saddles to be
determined depending of diameter of the pipe. The pipes should be lifted by means of the
Nylon / Polyester Sling and lowered on to the runner whereby the entire length of the pipe is
getting support from the wooden runner. Depending on the diameter of the pipes, 1 – 4 no of
the pipes can be placed side by side on wooden runners and pipes should be strapped from
both ends of the wooden runner which will ensure that the pipes do not move. The number of
pipe layers to be decided based on pipe diameter & permissible height and 4Nos of wooden
runners should be placed for each layer. Whole package is to be strapped with polyester/Nylon
straps at two places before crimping with Aluminum seals. The entire load to be lifted and
placed in the container.

3. Rubber gaskets, centre registers, special fittings etc. should be wrapped in a Polyethylene
bubble Sheet / Bag and sealed. For smaller sizes, all such items should be packed in a
wooden box / crate and the inner surface of the wooden box should be lined with Bituminized
Water Proof Paper Craft.

4. Marking shall be provided on the boxes/crates indicating position of boxes for handling,
storage & nature of consignment. The ink used for this purpose as well as for marking dispatch
instruction shall be Non- Washable Marking Ink. The front and rear side of the
boxes/crates/pickings would carry the following details, duly stenciled in black paint.

 Name & address of the consignee


 Consignee P.O. reference no. and date
 Port of delivery
 Consigner name and address
 Country of origin
 Dimension of the box/crate/packing (mm)
 Net weight (Kg)
 Gross weight (Kg.)
 One copy of the packing list would be placed in a transparent polyethylene bag and nailed
to the inside of the box/crate/packing.
 Another copy of the packing list also wrapped in a transparent polyethylene bag would be
nailed to the external surface of the box/crate/packing.
 Each box/crate/packing will carry its separate identification no.

5. Smaller diameter pipes may be nested into bigger diameter pipes if the packages consist of
multiple diameter pipes. To avoid any kind of abrasion, thick rubber padding shall be used
between pipes strapped with nylon straps.

6. GRP pipes and fittings shall be prepared for shipment with the joining ends covered to protect
from damage. The protection can be made of Covers or U-shaped profiles in plastic material
wrapping with anti-shock and anti-abrasion plastic film or Wrapping with rubber tapes.

7. In case of transport by ship, packing shall be sea worthy so as to ensure safe delivery till site.

BHEL - PS-PEM: PPEI BUILDING, SEC. 16A, NOIDA - 201301


Form No. PEM-6666-0
TITLE: SPECIFICATION NO. PE-TS-999-100-M042
STANDARD TECHNICAL SPECIFICATION REV.00 DATE: 24.10.2009
FOR VOLUME: II PART: B SECTION: D
GLASS REINFORCED PLASTIC (GRP) PIPES SHEET 6 OF 6

DOCUMENTATION REQUIREMENTS AFTER AWARD OF CONTRACT:


Soft copies of Drawings / documents shall be exchanged during the approval process. However, final
documentation will be as below:

a. Quality Plan duly signed and stamped with bidder’s seal

b. Document for pipe thickness, stiffness/pressure class and other applicable calculations for all
sizes as per applicable standards, design parameters/conditions as specified in input data sheets
and contract piping layout drawings.

c. Drawings:
 Drawing of Pipe with marking details & Dimensions
 Drawing of Coupling with marking details & Dimensions
 Drawing of Rubber Gasket & Center Register Dimensions details
 Drawing of Pipe Trench details for Underground laying
 Drawing of Over ground Pipe supports
 Drawing of End Cap assembly for Field Hydro test
 Drawing for erection purpose indicating field joints and pipe/fittings based on approved
contract drawing
 Drawings of Fittings
 Drawings of Thrust Block along with calculations

d. Test Certificates/Test Reports

e. Method Statement for Underground Installation of GRP Pipe

f. Method Statement for Above ground Installation of GRP Pipe

g. Field Hydro test statement for Underground installation of GRP Pipe

h. Method for Butt Wrap Joining of GRP Pipes

i. Procedure for Long term tests, if applicable

BHEL - PS-PEM: PPEI BUILDING, SEC. 16A, NOIDA - 201301