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The right way is always the fastest way

Basic installation guidelines of Pacific GRP pipes.

This installation guide is intended as a basic guide to installation and it does notreplace more comprehensive guides and installation standards. GRP is an easyand fast pipe material to install but there are some basic rules to follow and anunderstanding of the pipe material and the design is required. These rules are notunique to GRP pipes but rather rules for the installation of flexible pipes in general.Please also refer to more comprehensive manuals, this document is not intendedto replace those, and always contact Pacific Pipe Systems site service departmentbefore the commencement of the installation.

The most important to remember is that the correct way is always the fastest andeasiest way to install GRP pipes. There are no time saving short cuts as all shortcuts will be very time consuming before the installation is completed and tested.With following the correct installation procedure, GRP pipes are by far the fastest

large diameter pipe material to install.

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esign considerations

n common with many other pipes materials like steel,E, PVC and even ductile iron, GRP is a flexible pipe.he soil is therefore a part of the pipeline design and for

e completed installation to perform as per design, thepes must be correctly installed.

RP is a pipe material that deflects under a line load.

When installed, the amount of deflection that takesace must be limited so that strains are not excessive.

When a GRP pipe is buried, it acts with the surroundingoil to form a composite structure.

s loads is applied from above, the pipe deflects.

s sides push into the soil surround.

assive soil pressure is mobilized to provide supportnd the pipe acts as an arch carrying carrying much ofe load in ring compression and only part in ringending.

he allowable deflections of pipes from DN300 andrger are 3% initial and 5% long term.

andling of pipes

When handling single pipe, use pliable straps, slings orope to lift. Do not use steel cables or chains to lift oransport the pipe.

ipe sections of larger diameters can be lifted withnly one support point, but two support points make thepe easier to control. Of safety reasons two supportshould always be recommended to minimize the risk

at the pipe section slides of the straps.

o not lift pipes by passing a rope through the sectionnd to end.

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RP pipes from Pacific Pipe Systems are highly engineered products and are

manufactured with precision using first class material and technology. The pipes

ave a long maintenance free service life with excellent flow properties.

nless the pipes are handled and installed correctly, the full benefits of the pipes

ill not be realized.



It is important to understand the factors that influence the amount of

deflection that takes place and how to control it.

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Surface Loads

Burial depth

Pipe stiffness

Live loads

Native soil type

Soil density

Backfill soil

Compaction %



Storing pipes.

Store pipe on flat timber.

When storing pipes directly on the ground, use aflat area free of rocks and other potentiallydamaging debris.

All pipes should be chocked to prevent rolling inhigh winds.

Maximum stacking height: 3 meters. Do not stackpipes larger than DN1400.

The pipeline designer considers:

Depth of burial. Traffic loading. Surface loading. Native soil type and density.

The pipeline designer specifies:

Pipe stiffness. Trench width. Bed, surround type and compaction.

The installer has the task of delivering thepipeline according to the specification.

Pipe laying and jointing.

The trench is excavated and the bed laid, leveled

and compacted.

Raking the center line of the bedding, to a depthof 25 mm will provide moire uniform support.

“Bell holes” should be provided at each couplingso the pipe is always in contact with the beddingand is not resting on the coupling.

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Joint preparation.

Normally pipes are delivered with thecoupling fitted to one end.

First the socket is cleaned.

And the gasket is fitted.

The gasket and the spigot are lightlylubricated.

Each coupling has two gaskets and acenter stop register.

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New

pipe Coupling

Gasket Installed

pipe



Pipes may be joined using:

Fabric slings or steel clamps with two

“come - along” jacks.

Careful use of the excavator bucketagainst a timber pad placed at the end ofthe pipe to be joined.

And it will come together like pictureshows.

It is very important to provide propersupport for the pipe and to ensure thatthere are no voids in the bedding and thatthe first lift of backfill at the “haunch” isfirmly compacted.

Use a tampering tool at the haunch toensure a good compaction.

Proper selection, placement andcompaction of pipe zone backfill areimportant for control l ing vert ical

deflection.

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Backfill.

Proper selection, placement andcompaction of pipe zone backfill areimportant for control l ing vert icaldeflection.

Pipes should be backfilled as soon asthey joined in the trench. Never leavelong stretches of pipes without backfill orunprotected in the trench.

Backfill should be placed and compactedin layers 75 - 300 mm depending uponthe type of backfill material andcompaction equipment being used.

Pipe deflection with full backfill is checkedperiodically to ensure it does not exceedthe allowed initial value. If the value iswithin the limit it indicates that the backfillprocedure is satisfactory.

Correcting over deflected pipes.

Pipes with an initial deflection between 4% and 8 % can be corrected. Pipes with adeflection exceeding 8 % should bereplaced.

For pipes deflected up to 8 % of

diameter:

Excavate to a level equal to approx.85 % of the pipe diameter.

Excavate just above and at the sidesof the pipe with hand tools to avoid impactwith heavy equipment.

Inspect pipe for damage. Damagedpipe should be repaired or replaced.

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Excavate to a level equal to approx.85 % of the pipe diameter.

Excavate just above and at the sides

of the pipe with hand tools to avoid impactwith heavy equipment.

Inspect pipe for damage. Damagedpipe should be repaired or replaced.

Re-compact haunch backfill withuncontaminated material.

Re-backfill the pipe zone in lifts withthe appropriate material, compacting

each layer to the required relativecompaction density.

Backfill to grade and check the pipedeflections to verify they do not exceedspecified values.

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Field pressure testing

Pressure pipelines will require a field pressure test prior to acceptance.

Pressure tests should be carried out regularly as installation proceeds.

Ideally, installation should never be more than 1 km ahead of testing.

Nowhere in the line should the pressure exceed 1.5 times the systemdesign pressure.

For more details, please refer to related manuals.



Pacific Pipe Systems Pvt Ltd

Plot 36 - 43 (P), 101 (P) Naranpura

Chandrasan, Sanand,

Ahmedabad, Gujarat 382170

Phone: +91 2717 273031

Fax: +91 2717 273032

Email: [email protected]

Pacific Website

Pacific GRP Pipe Systems

GRP pipes have a history spanning more than60 years and with well proven and tested

standards. The most commonly used areAWWA, ASTM and ISO standards and thoseare also the base for the Indian BISstandards. In the early days, due to the highercost of raw materials, GRP pipes had adisadvantage against metallic pipes but evenin this situation, GRP pipes were the fastestgrowing pipe material in the world in marketshare. It was supplied at a premium price dueto the benefits in corrosion resistance andlong term performance. Since then the raw

material cost ratio has changed to theadvantage of GRP pipes over metallic pipes.Now we supply a superior product at a morecompetitive price than traditional pipematerials.

pacific installation

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