Industrial

Fibreglass

Fabricators

Maskell Productions Ltd.

16th March 2010

Flowtite Pipe

• Introduction

• Features and Benefits

• Standards and Testing

• Manufacturing

• Quality Control

• Applications

• Conclusions

Topics

• One of Australasia’s largest and

most experienced industrial

fibreglass fabricators.

• Manufacture a wide range of

industrial fibreglass products

including piping systems, tanks,

air pollution systems and

associated equipment, all in

fibreglass (FRP/GRP).

• Completing projects in the

fibreglass field for over 40 years

(since 1968) and are experienced

throughout Australasia.

Introduction

Maskell Productions Ltd

• Distribute Flowtite pipes throughout Australasia.

Introduction

• Water transmission and distribution

(potable and raw water)

• Sanitary sewerage collection and

outfalls

• Storm sewers and drainage

• Sea water intake, outfalls and

cooling water lines

• Circulating water, make-up and

blowdown lines for power plants

• Penstock lines for mini-

hydroelectric power plants

• Industrial effluents

Flowtite pipes are used in

numerous applications:

Break down of GRP

Fibreglass

• Modern glass fibre was invented in 1938 by Russell Games-Slayter

of Owens-Corning

• Glass is kept molten in a large vat and then drawn through die’s to

produce fibres which are bundled into rovings.

• The fibreglass is then used as a reinforcement in plastic products.

Resin - GRP Resins are broadly classified into the following types:

• Polyester: Patented by DuPont in 1936 these are some of the oldest

and most common resins, they are economical and provide good

long term corrosion resistance.

• Vinyl Ester: a range of hybrid resins developed by Dow chemicals in

the 1970’s that have improved chemical and heat resistance. Mainly

used for industrial chemical industry for strong acids and oxidising

chemicals.

• Epoxy Resins: Initially developed in 1936 and licenced to Ciba now

Huntsman/Ashland Chemicals. Specifically for high strength

applications where adhesive strength is critical. Also used where

curing under water is required.

History of Industrial GRP

• The first GRP products were airplane parts developed by Owens-

Corning in 1942 as part of the war effort.

• In 1964 the first underground fuel storage tank was installed in

Chicago. It was uncovered in 1985 and test samples were sent

away for analysis and showed that the properties exceeded those

required for new tanks under UL standards. Tha tank is still in

service.

• The first GRP pipes were produced by a number of manufacturers

starting in the 1960’s. The first pipes were filament wound

(explanation to follow)

• In 1977 Veroc Technologies develops a continuous pipe

manufacturing process that allows pipe to be manufactured in large

diameters up to 4m at rates of 10m/hr

Advantages of GRP pipe

• GRP pipes are designed for a long

maintenance free life

- Minimum design life 50 years

- In aggressive conditions

• Projected life time for GRP is much

greater than for many “traditional

materials”.

• GRP pipes have been in successful

continuous use for at least 40 years

• GRP will not corrode like other

pipe materials.

Features & Benefits

• Economical

• Corrosion-resistant material

• Choice of jointing techniques both RIKA rubber seal

joint and permanent welded joint (butt and strap)

• Stringent performance standards

• Extremely smooth bore

• Long standard lengths

• Light weight

• High technology pipe manufacturing platform

Economical

• Pipe competitive with other commonly used materials

• No corrosion surveys required

• Low installation cost

• Low operating (pumping) costs

Features & Benefits

Corrosion-resistant material

• Long service life.

• No need for linings, coatings, cathodic protection or other forms

of corrosion protection.

• Low maintenance costs.

• Hydraulic characteristics essentially constant over time.

Features & Benefits

Long standard lengths (20 and 40 feet)

• Fewer joints reduces installation time

• Special lengths from 1 to 40 feet

Light weight (1/4 weight of ductile iron and 1/10 weight of concrete pipe)

• Low transport costs (nestable).

• Avoids need for expensive pipe handling equipment.

Extremely smooth bore

• Low friction loss means less pumping energy needed, lower operating cost.

• Allows flatter grades, less excavation for gravity flow.

• Minimal slime build-up can help lower cleaning costs.

Features & Benefits

Proven jointing system

The standard Flowtite joint makes use of the REKA elastomeric gasket, proven over more than 75 years.

• Simple design allows rapid assembly and faster pipeline installation.

• Precision manufacture ensures a secure pipeline

• Angular deflection at joint accommodates differential settlement

• Angular deflection at joint can be used to eliminate small bends.

Fabricated fittings

• Almost any configuration possible.

• Fittings fabricated to meet exact project requirements

• Design not limited by standard fittings

• Fittings spooled together to eliminate joints and reduce installation time.

Standards and Testing

Qualification Testing

All standards call for manufacturer to demonstrate compliance

with minimum performance requirements. Most important:

• Long-term ring bending

• Long-term pressure

• Strain corrosion (sewer)

• Joint

Flowtite pipe has been rigorously tested to verify conformance to:

• AWWA C950 - Pressure Water Pipe

• ASTM D3517 - Pressure Pipe

• ASTM D3262 - Non-Pressure Sewer Pipe

• ASTM D3754 - Sewer & Industrial Pressure Pipe

Standards and Testing

Strain Corrosion

Strain corrosion testing for GRP pipe used in sewer applications

is carried out in accordance with ASTM D3681.

Standards and Testing

Strain Corrosion

• 10,000 hours minimum exposure.

• Requires a minimum of 18 ring samples of the pipe to be deflected to

various levels and held constant.

• To simulate a buried septic sewer condition, strained rings are

exposed at the invert of the interior surface to 1.0N (5% by weight)

sulfuric acid.

• Minimum Factor of Safety of 1.5 applied to 50-year value.

Design allowable

100 101 102 103 104 105 50 years

Extrapolation

Log Time

Test Results

Log Deflection

(strain)

ScvFactor of safety =

1.5

Standards and Testing

Strain Corrosion Test Results

Standards and Testing

Long-term sustained pressure

• Carried out in accordance with ASTM D2992

• 10,000 hours minimum

• Requires minimum of 18 failure samples evenly

distributed over three log cycles of time

• Minimum factor of safety of 1.8 applied to 50-year value

xx x

xx

xx

x xx x x

Log Pressure

(strain)

HDS

PN

Log time 50 years

Factor of safety = 1.8

Flowtite pipe has been tested and approved for the conveyance

of potable water, meeting many of the world’s leading

certification and testing institutes’ criteria, including:

• NSF (Standard No. 61) – United States

• TZW – Germany

• Lyonnaise des Eaux

• WRC – United Kingdom

Standards and Testing

Potable Water

These standards require the flexible joints to withstand

hydrostatic testing in configurations that simulate exaggerated

in-use conditions.

Standards and Testing

AWWA & ASTM Standards apply to GRP

pipe joint performance.

• 2 x PN at maximum allowable angular deflection

• 2 x PN with lateral withdrawal of spigot from joint

• 2 x PN with spigot shear loaded

• 12 psi vacuum

Weight

Standards and Testing

• Pipe deflected under constant load.

• Aqueous environment.

• Minimum factor of safety of 1.5 applied to 50-year value.

Long Term Ring Bending

Standards and Testing

Strain Corrosion

Effect of long-term acid exposure on pipe life

Quality Control

Precision manufacturing yields reliable performance

• All manufacturing plants all work to the same

specifications and high standards of quality.

• ISO 9002

• Flowtite pipe manufactured at 15 worldwide

facilities.

Quality Control

Maskell maintain an extensive in-house and on-site

quality assurance system which is:

• ISO9001 Accredited, externally audited, license

QEC6641.

• Project specific quality plans where required or in-

house QA system.

• Inspection and Test Plans (ITP’s) for projects

utilised.

• Work Method Statements and Process Manuals

for manufacturing in-house and on-site work.

Manufacture – Filament Wound Pipe

Provides the highest strength pipe

• A mandrel of fixed diameter and

length is used to form the pipe.

• Fibreglass is wound onto the

mandrel through a bath of resin at a

fixed angle.

• Pipe can be designed to withstand

both axial and hoop stress and the

diameter is infinitely variable.

• Process suited to short runs up to

500m

Manufacture – Continuous pipe

State-of-the-art manufacturing

• The most advanced process for

manufacturing large diameter GRP pipe

is Flowtite's continuously advancing

mandrel process.

• The output of an E1 winder at capacity is

approximately 24m/hr based on average

900mm diameter, 10 Bar pressure pipe.

Manufacture

Materials

Raw materials are delivered with

vendor certification demonstrating

their compliance with Flowtite

quality requirements.

• All raw materials are sample

tested prior to their use.

• Tests ensure that the pipe

materials comply with the

specifications as stated.

Manufacture

Joints and Couplings

The standard jointing system is a Flowtite

coupling which utilizes an elastomeric REKA

gasket for sealing. The REKA gasket sits in a

precision-machined groove in each end of the

coupling and seats and seals against a calibrated

spigot surface. The REKA gasket has been

proven in use for more than 75 years.

Couplings are produced with tightly controlled

dimensions. For this, Flowtite Technology has

developed a special machine that mills grooves in

coupling cylinders using diamond-tipped tools.

Manufacture

Quality Control

Batch sampling is performed for:

• Stiffness

• Deflection without damage to failure

• Composition (LOI)

• Circumferential and axial properties

- Strength: tensile and flexural

- Modulus

Tests on100% of all pipe produced:

• Hydrotest to 2xPN

• Visual inspection

• Cure - Barcol hardness

• Dimensional verification: Wall thickness, Outside diameter, Length

Trenchless Applications

Sleeving

GRP pipe can be manufactured to suit any

diameter of existing pipe.

Pipe can be supplied to site in any required

length.

GRP pipe can be designed to take

structural/earth loads if the host pipe is failing.

Trenchless Applications

Pipe Jointing

•Integrated coupling in large bore thick walled

pipe

•Using Stainless steel band type coupling over

O ring seals in pipe ends, flush with OD of pipe

•External coupling with slide lugs

•Butt and strap joints in fibreglass

Couplings for Potable Water Supply City of Leipzig

Relining DN 900 PN 10

Trenchless Applications

•Elasticity = reduced point loading and risk

of rupture

•High compressive strength

•Parallel pipe ends

•High dimensional accuracy

•Smooth even non absorbing surface

•Tested fatigue strength under cyclic load

•Approved installations under European,

Canadian and US railroad tracks

•High corrosion resistance

POLYCRETE and GRP Jacking

Pipe, Advantages:

Applications

32 Bar GRP pipe

The Pungwe-Mutare Water Supply Project in

Zimbabwe incorporates 71.4km of Flowtite pipe

and 7,896 couplings; all manufactured to strict

performance standards.

High-performance pipe

Projects such as this power plant in Argentina

call for long-lasting, high-performance pipe.

The excellent flow factor of Flowtite pipe will

allow the delivery of cooling water at high rates

for many years.

Applications

The ultimate test of corrosion resistance

Desalination plants at Al-Madinah, Yanbu, Al-Khobar

and several other locations in Saudi Arabia utilize

Flowtite pipe in an extremely corrosive environment.

Easy installation

One of the most important sanitary projects under

development in Argentina is the sanitary sewerage

collection system in the city of Santiago del Estero.

The main line of the sewer is 8000m in length, with

pipe diameters ranging from DN800 to DN1000.

Applications

Longest pipe sections

In Cottbus, Germany, a project to reclaim open-cast

mines, Flowtite pipe carries acidic water from coal

pits. At 21m per length, these corrosion-resistant

sections of DN800 Flowtite pipe were the longest

single lengths of pipe transported to site.

Easy installation

Lightness of Flowtite pipe was important for

the penstock project in Todtnau, Germany.

In nearly impassable rough wilderness,

transportation of the pipes and placing them

in the trench was greatly eased by the low

weight of the GRP material.

Applications

Weight savings translates to lower cost

For this water supply project in Norway, the

light weight of Flowtite pipe allowed the use

of less expensive equipment and made the

job move quickly.

Conclusion

• Flowtite filament wound GRP pipe is

manufactured to the highest standards and offers

a first class consistent and reliable pipe material

• Flowtite filament wound GRP pipe is the right

choice for the majority of civil engineering

pipeline projects

• Compared to other materials GRP has

- Longer life

- Lower maintenance

- Better performance

- More versatility

- Faster reliable installation