rpc pipe systems pty ltd
TRANSCRIPT
WSAA Product Appraisal No PA 1322 Issue 2 1
COPYRIGHT
RPC Pipe Systems Pty Ltd
PRODUCT APPRAISAL REPORT NO PA 1322 ISSUE 2
FLOWTITE™ Filament Wound Glass Reinforced Plastic Pipe System
Jacking Pipes for Non Pressure Sewerage Applications. DN 300 – DN 3000
ISO 25780 – Plastic piping systems for pressure and non-pressure water supply, irrigation, drainage or sewer - Glass-reinforced thermosetting plastics (GRP) systems based on unsaturated polyester (UP) resin – Pipe with flexible joints intended to be installed using jacking techniques
Publication Date: 9 September 2016
WSAA Product Appraisal No PA 1322 2
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Document History
The following information indicates the changes made to this document.
Date Version File Location
8/10/2015 Peer Review
U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2013\PA 1322 RPC Pipe Systems Pty Ltd Flowtite Jacking Pipe\RPC - Jacking Pipe Proposal Draft 8102015 MR markup.docx
6/11/2015 Publication
U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2013\PA 1322 RPC Pipe Systems Pty Ltd Flowtite Jacking Pipe\RPC - Jacking Pipe Final.docx
9/9/2016 Publication
U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2013\PA 1322 RPC Pipe Systems Pty Ltd Flowtite Jacking Pipe\RPC - Jacking Pipe Final.docx
Peer Reviewers
Name/Title Organisation Date
IPAM Network WSAA Infrastructure Products and Material Community of Practice
30/11/2015
Carl Radford, Program Manager Asset Creation WSAA 6/11/2015
Carl Radford, Program Manager Asset Creation WSAA 9/9/2016
Approvals
Name/Title Signature Date
Carl Radford, Program Manager Asset Creation Carl Radford 6/11/2015
Carl Radford, Program Manager Asset Creation WSAA 9/9/2016
WSAA Product Appraisal No PA 1322 Issue 2 3
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Overview of WSAA
The Water Services Association of Australia (WSAA) is the peak industry body that supports
the Australian Urban Water Industry. Its members and associate members provide water and
sewerage services to approximately 20 million Australians and many of Austra lia’s largest
industrial and commercial enterprises.
The Association facilitates collaboration, knowledge sharing, networking and cooperation
within the urban water industry. It is proud of the collegiate attitude of its members which
has led to industry-wide approaches to national water issues.
WSAA can demonstrate success in the standardisation of industry performance monitoring
and benchmarking, as well as many research outcomes of national significance. The WSAA
Executive retains strong links with policy makers and legislative bodies and their influences,
to monitor emerging issues of importance to the urban water industry. WSAA is regularly
consulted and its advice sought by decision makers when developing strategic directions for
the water industry.
WSAA was formed in 1995 as a non-profit organisation to foster the exchange of information
relating to the provision of urban water services between industry, government and the
community, and to promote sustainable water resource management.
The Association’s main activities focus on four areas:
1. Influencing national and state policies on the provision of urban water services and
sustainable water resource management;
2. Promoting debate on environmentally sustainable development and management of
water resources and the community health requirements of public water supplies;
3. Improving industry performance and establishing benchmarks and industry leading
practices for water service processes; and
4. Fostering the exchange of information on education, training, research, water and
wastewater management and treatment and other matters of common interest
Copyright
This document is copyrighted. Apart from any use as permitted under the Copyright Act
1968, no part of this document may be reproduced or transmitted in any form or by any
means, electronically or mechanical, for any purpose, without the express written permission
of Water Services Association of Australia Limited.
© Copyright 2015 by WATER SERVICES ASSOCIATION of Australia Limited All rights
reserved.
WSAA Product Appraisal No PA 1322 Issue 2 4
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CONTENTS
PRODUCT APPRAISAL REPORT NO PA 1322 .......................................................................................................................... 1
1 EXECUTIVE SUMMARY ............................................................................................................................................. 6
1.1 Recommendation .................................................................................................................................................. 6
2 THE APPLICANT ......................................................................................................................................................... 7
2.1 Manufacturing facilities .......................................................................................................................................... 7
3 THE PRODUCT ........................................................................................................................................................... 7
3.1 General.................................................................................................................................................................. 7
3.2 Manufacture of the Flowtite® GRP jacking pipes ................................................................................................... 7
3.2.1 Manufacturing Process ................................................................................................................................... 8
3.2.2 Joints .............................................................................................................................................................. 8
3.2.2.1 Stainless Steel Coupling for Jacking Pipes (Type SE) ............................................................................. 8
3.2.2.2 Filament Wound Couplings for Jacking Pipes (Type GR) ........................................................................ 8
3.2.2.3 Stainless Steel Sleeve Couplings for Jacking Pipes (Type SR) ............................................................... 9
3.2.2.4 Flowtite® Filament Wound Couplings for Pressure Jacking Pipes (Type FJ) ........................................... 9
3.2.3 Jacking Pipe Constituents ............................................................................................................................. 10
3.2.3.1 Reinforcement ........................................................................................................................................ 10
3.2.3.2 Resin ...................................................................................................................................................... 10
3.2.3.3 Aggregate and Fillers ............................................................................................................................. 11
3.2.4 Elastomers .................................................................................................................................................... 11
3.3 Nominal Sizes ..................................................................................................................................................... 11
3.4 Jacking Load and Nominal Stiffness ................................................................................................................... 11
3.5 Nominal Pressure ................................................................................................................................................ 11
3.6 Nominal Pipe lengths .......................................................................................................................................... 11
3.7 Flowtite® Joint Properties (couplings) ................................................................................................................. 12
3.8 Allowable Angular Deflection ............................................................................................................................... 12
3.9 Straightness ........................................................................................................................................................ 12
3.10 Pipe Fittings and Accessories ........................................................................................................................... 13
4 SCOPE OF THE APPRAISAL ................................................................................................................................... 13
5 APPRAISAL CRITERIA ............................................................................................................................................. 13
5.1 General................................................................................................................................................................ 13
5.2 Quality Assurance Requirements ........................................................................................................................ 13
5.3 Performance Requirements................................................................................................................................. 13
6 COMPLIANCE WITH APPRAISAL CRITERIA........................................................................................................... 14
6.1 Compliance with Quality Assurance Requirements ............................................................................................. 14
6.2 Compliance with Performance Requirements ..................................................................................................... 14
6.2.1 Production and type test requirements to ISO 25780:2011. ......................................................................... 15
6.2.2 Mechanical Characteristics ........................................................................................................................... 15
6.2.2.1 Initial specific ring stiffness - Batch release test ..................................................................................... 15
6.2.2.2 Long-term specific Creep Stiffness - Type test ...................................................................................... 15
6.2.2.3 Initial resistance to failure in a deflected condition - Batch release test .................................................. 15
6.2.3 Resistance of pressure pipes internal pressure - Type test .......................................................................... 16
6.2.4 Resistance to strain corrosion - Type test ..................................................................................................... 16
6.2.5 Joint performance - Type test ...................................................................................................................... 16
6.2.6 Longitudinal compressive strength ............................................................................................................... 16
6.2.7 Permissible Jacking Forces .......................................................................................................................... 17
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6.2.7.1 General .................................................................................................................................................. 17
6.2.7.2 Ulitmate Longitudinal Load ..................................................................................................................... 17
6.2.7.3 Designed Jacking Load and permissible eccentric jacking forces .......................................................... 17
6.2.8 Specific initial longitudinal compressive modulus. ........................................................................................ 17
6.2.9 Abrasion resistance ...................................................................................................................................... 18
6.2.10 Temperature and pressure re-rating ........................................................................................................... 18
6.2.11 Resistance to Ultraviolet degradation ......................................................................................................... 18
6.2.12 Other Technical Data .................................................................................................................................. 18
7 FITTING INSTRUCTIONS, TRAINING AND INSTALLATION ................................................................................... 18
8 REPAIR FOR NON-PRESSURE GRPJACKING PIPE FOR SEWERAGE APPLICATIONS ..................................... 18
9 PRODUCT MARKING ............................................................................................................................................... 18
10 PACKAGING AND TRANSPORTATION ................................................................................................................. 19
11 PRODUCT WARRANTY .......................................................................................................................................... 19
12 WATER AGENCY EXPERIENCE WITH THE PRODUCT OR FIELD TESTING REPORT ..................................... 19
13 DISCUSSION ........................................................................................................................................................... 20
14 LIFE EXPECTANCY ................................................................................................................................................ 20
15 FUTURE WORKS .................................................................................................................................................... 21
16 REPORT RECOMMENDATION .............................................................................................................................. 21
17 DISCLAIMER ........................................................................................................................................................... 22
17.1 Issue of Report .................................................................................................................................................. 22
17.2 Limits on Reliance on Information and Recommendations................................................................................ 22
17.2.1 Disclaimer of liability ................................................................................................................................... 22
17.2.2 Need for independent assessment ............................................................................................................. 22
17.3 No Updating ...................................................................................................................................................... 23
17.4 No Warranty ...................................................................................................................................................... 23
APPENDIX A – TECHNICAL MANUALS BROCHURES .............................................................................................. 24
AVAILABLE FROM RPC PIPE SYSTEMS OR THE FLOWTITE WEBSITE ................................................................. 24
APPENDIX B - QUALITY CERTIFICATIONS ............................................................................................................... 26
APPENDIX C – PRODUCT SCHEDULE ...................................................................................................................... 29
APPENDIX D – WSAA PRODUCT SPECIFICATIONS ................................................................................................ 34
APPENDIX E - SUPPLIER CONTACTS ....................................................................................................................... 36
APPENDIX F - NATA LABORATORY TEST RESULTS ............................................................................................... 37
TABLE F1 SUMMARY OF TYPE TESTS AND BATCH TEST RESULTS .................................................................... 38
APPENDIX G DOUBLE BELL REKA COUPLING QUALIFICATION TEST .................................................................. 43
APPENDIX H – EXAMPLE OF PIPE MARKING........................................................................................................... 46
APPENDIX I – FIELD TRIAL REPORT ......................................................................................................................... 47
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1 EXECUTIVE SUMMARY
This appraisal applies to Flowtite® Glass Fibre Reinforced Plastic (GRP) Jacking Pipes, for
non-pressure applications, joined using flexible non-end-load-bearing joints with elastomeric
seals and intended to be installed using various trenchless installation methods e.g. Slip
Lining, Micro Tunnelling and Pipe Jacking.
Issue 2 of this reports supersedes PA 1322 published in November 2015. PA 1322
amendments relate to increase in DN pipe range now available due to modification to
increase the load capacity of equipment at the RPC Pipe Systems’ factory in Lonsdale, SA.
We are getting some modifications made to increase the load capacity of our equipment so
will be able to handle this size.
RPC Pipe Systems is the exclusive Australian manufacturer of Flowtite® GRP Pipes for both
buried and trenchless applications. RPC Pipe Systems ’ factory in Lonsdale, SA, has the
capacity to manufacture pipes from DN 300 to DN 3000.
Flowtite® is a global brand manufactured in 22 plants in 16 countries. Flowtite® Jacking Pipe
has been developed to complement the original Flowtite® buried pipes for applications better
suited to trenchless applications. Flowtite® GRP pipe has been manufactured since 1971,
in Australia since 2006, with jacking pipe manufactured in Europe since 2006 and in Australia
since 2013.
The Flowtite® continuous wound GRP technology provides the flexibility for RPC Pipe
Systems to manufacture jacking pipe in a wide range of diameters and thicknesses to suit
individual applications. Jacking forces of up to 900 tonnes can be achieved for larger
diameter pipes.
Flowtite® GRP Jacking Pipes are manufactured with a nominal pressure class ranging from
PN 1 to 2.5 and stiffness rating ranging from SN 20,000 to 1,000,000.
Note Flowtite GRP pipes marked PN 1 are designated for non-pressure sewerage applications. For the
purposes of this appraisal Flowtite GRP pipes are manufactured with nominal pressure rating of PN 1 to PN
2.5 are typically used in non-pressure sewer applications.
GRP fittings used with Flowtite® GRP jacking pipe are fabricated from sections of straight
pipe, cut to length, joint wrapped externally and internally with additional fibre reinforcement
in accordance with AS3571.1 for sewerage systems. GRP fittings are supplied with spigot
ends suitable for connection to the Flowtite® jacking pipe stainless steel or GRP couplings.
Transition pieces can also be manufactured to connect Flowtite® GRP jacking pipe directly
to Flowtite® GRP buried pipe without the need for a manhole structure.
The Flowtite® GRP jacking pipe system is manufactured to comply with ISO 25780 – Plastic
piping systems for pressure and non-pressure, water supply, irrigation, drainage or sewer -
Glass-reinforced thermosetting plastics (GRP) systems based on unsaturated polyester (UP)
resin – Pipe with flexible joints intended to be installed using jacking techniques.
The declared external and internal diameters of the Flowtite® jacking pipes are provided in
the Flowtite® GRP Jacking Pipe Systems Product Guide.
Flowtite® GRP pipe for buried applications is the subject of a separate appraisal report PA
1211 Issue 2 published on the 6June 2013.
1.1 Recommendation
It is recommended that WSAA members and associates, subject to any specific requirements
of the member or associate, accept or authorise the Flowtite® GRP jacking pipe and fittings
as detailed in this report for use in non-pressure drainage or sewerage applications subject
to the design, installation and commissioning being in accordance with specifications
provided by RPC Pipe Systems and relevant WSAA Sewerage Code or WSAA Members or
Associated Members integrated WSAA Code editions.
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2 THE APPLICANT
RPC Pipe Systems was established in 2011 to acquire the business and assets of Fibrelogic
Pipe Systems Pty Ltd ('Fibrelogic'), Australia's leading manufacturer of continuously wound
glass reinforced plastic ('GRP') pipe and associated fittings.
It holds an exclusive Australian manufacturing and support licence for the Flowtite ® GRP
piping systems, technology and brand for Australia.
Flowtite® Technology is owned by the Amiantit piping group (AFIL), with 22 plants world-
wide. Flowtite® Piping Systems offer over 40 years of engineering experience in the
manufacture and design of GRP pipe systems.
RPC Pipe Systems Pty Ltd is located in Lonsdale, South Australia. RPC Pipe Systems has
supplied projects requiring GRP pipe and ducting installations for mining, power, sewer and
water companies throughout Australia.
RPC Pipe Systems Pty Ltd ('RPC Pipe Systems') is a South Australian company wholly
owned by RPC Technologies Pty Ltd that specialises in water surety solutions.
2.1 Manufacturing facilities
A purpose built factory in Lonsdale, South Australia, commenced operation during May 2006.
Two CW 3000 machines form the production equipment. The CW3000 machine has the
capability to produce pipe from DN 300 to DN 3000. RPC Pipe Systems also has fittings
fabrication facilities at the Lonsdale site and can manufacture fittings to match the pipe
product range.
All Flowtite® manufacturing plants are supplied with a complete working laboratory and all
production quality control test results are logged and recorded with full traceability.
3 THE PRODUCT
3.1 General
The Flowtite® GRP Jacking Pipe Systems Product Guide provides a complete description of
the products covered by this appraisal. Refer to Appendix A.
3.2 Manufacture of the Flowtite® GRP jacking pipes
RPC Pipe Systems can design GRP jacking pipes to meet the different needs of many non-
pressure applications (pressure applications omitted from appraisal scope), by varying resin
and glass proportions, orientation and configuration.
Flowtite® GRP jacking pipes are manufactured from a composite material designed to take
advantage of the corrosion-resistant properties of polyester resins and glass fibres (see
Figure 1). The “Flowtite GRP Jacking Pipe Systems” product guide is available from the
Australian distributor Iplex and provides a complete description of the product.
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FIGURE 1 FLOWTITE® COMPOSITE MATERIAL
3.2.1 Manufacturing Process
Flowtite GRP jacking pipes are produced using the Flowtite® continuous advancing mandrel
process.
The mechanical properties of Flowtite® GRP jacking pipes can be varied by adjusting the
quantity and proportions of the various raw materials in the pipe wall. The flexibility of this
system enables pipes to be designed to meet a wide range of applications. The types of
resin may also be varied in order to meet the many duties and environments to which the
pipes may be subjected to.
3.2.2 Joints
Ref: Clause 7.5 of ISO 25780:2011
RPC Pipe Systems has four joints available for Flowtite® GRP jacking pipes, each with a
coupling mounted onto one end of the pipe and an elastomeric seal which seals the pipe.
RPC Pipe Systems provide instructions for the selection of the available types of flexible
stainless steel or filament wound joint coupling for jacking pipe.
Refer to Section 3.7, 3.8 and 6.2.5 for joint properties, allowable angular deflection and joint
type tests.
The scope of this appraisal covers couplings that are both stainless steel and GRP.
3.2.2.1 Stainless Steel Coupling for Jacking Pipes (Type SE)
These RPC Pipe Systems couplings have a stainless steel sleeve with an EPDM seal firmly
attached and are used for trenchless installations only. Refer to Figure 2A for a diagram of
the Stainless Steel Coupling (Type SE).
The couplings are manufactured by RITEC GmbH & Co, Bakum, Germany. RITEC are the
major European supplier of stainless steel jacking pipe couplings.
FIGURE 2A STAINLESS STEEL COUPLING (TYPE SE)
3.2.2.2 Filament Wound Couplings for Jacking Pipes (Type GR)
RPC Pipe Systems offer couplings with a glass fibre reinforced plastic sleeve that is flush
fitted and used for trenchless installations. Gaskets are fitted in grooves in the pipe spigot.
Refer to Figure 2B for a diagram of the Filament Wound Coupling (Type GR).
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FIGURE 2B FILAMENT WOUND COUPLING (TYPE GR)
3.2.2.3 Stainless Steel Sleeve Couplings for Jacking Pipes (Type SR)
RPC Pipe Systems offer couplings with a stainless steel sleeve that is flush fitted and used
for trenchless installations. Gaskets are fitted in grooves in the pipe spigot. Refer to Figure
2C for a diagram of the Stainless Steel Sleeve Coupling (Type SR).
FIGURE 2C STAINLESS STEEL SLEEVE COUPLING (TYPE SR)
3.2.2.4 Flowtite® Filament Wound Couplings for Pressure Jacking Pipes (Type FJ)
RPC Pipe Systems offers the Flowtite® GRP Pipe pressure coupling for pressure jacking
applications. The coupling is the same as used on Flowtite® GRP buried pipes and is only
for custom applications. Pressure jacking pipes are not being considered in this appraisal
and this joint is being shown for information purposes only. Refer to Figure 2D for a diagram
of the Flowtite® Filament Wound Pressure Coupling (Type FJ).
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FIGURE 2D FLOWTITE® FILAMENT WOUND PRESSURE COUPLING (TYPE FJ)
3.2.3 Jacking Pipe Constituents
The wall of Flowtite® GRP jacking pipes is built with several layers (see Figure 1):
interior surface layer and liner;
inner structural layer (skin);
core;
outer structural layer (skin); and
exterior surface layer.
The interior surface layer of the pipe is resin rich and depending on the pipeline application
may include glass or polyester veil. The liner is built with resin and chopped glass fib res.
The structural layers are comprised of the inner skin, core and outer skins. The skins contain
continuous hoop rovings, resin and chopped glass, while the core contains sand fillers.
The exterior surface layer, or outer layer, is resin rich and depending on the pipeline use
may contain glass or polyester veil.
3.2.3.1 Reinforcement
Ref: Clause 4.3.2 of ISO 25780:2011
The Lonsdale plant uses E or ECR-glass to manufacture pipes for water supply and
sewerage. ECR-Glass is a requirement for all sewer application whereas E or ECR glass
can be used for water applications. RPC Pipe Systems has provided technical data sheets
for the selected glass reinforcements that are approved by Amiantit for use in Flowtite® GRP
jacking pipes showing compliance with ISO 2078. Both chopped strand and continuous
rovings are used to provide both longitudinal and hoop strength.
3.2.3.2 Resin
Ref: Clause 4.3.3 of ISO 25780:2011
The Lonsdale plant manufactures Flowtite® GRP jacking pipes using orthophthalic polyester
resin EPS 1 supplied by Nuplex Industries of Australia to an Amiantit specification. The RPC
Pipe Systems Purchase Acceptance Standard (PAS) requires that the heat distortion
temperature of the cured resin, when tested in accordance with ISO 75-2, should be at least
75°C, which allows a maximum operating temperature of 55°C.
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Other resins are available for specialised applications.
3.2.3.3 Aggregate and Fillers
Ref: Clause 4.3.4 of ISO 25780:2011
Sand is used as filler in Flowtite® GRP jacking pipes. The RPC Pipe Systems PAS requires
that less than 3% of the sand have particles larger than 0.71 mm and no particles be larger
than 1 mm. The sand is sourced locally from a deposit in the Adelaide region. The locally
sourced sand results in an “almost white’ pipe unlike other GRP products common to the
Australian water industry.
3.2.4 Elastomers
Ref: Clause 4.3.5 of ISO 25780:2011
The Flowtite® pipe couplings for jacking application use EPDM rubber.
RPC Pipe Systems require elastomeric joint compliance with EN 681-1:1996 which is
equivalent to AS 681.1:2008.
3.3 Nominal Sizes
Ref: Clause 4.2.1 of ISO 25780:2011
Nominal sizes of Australian Flowtite® jacking products range from DN 300 to DN 3000:
Flowtite® jacking pipes can be manufactured as either an OD or ID series depending on the
requirements of the project.
Typical dimensions of Flowtite® jacking pipes appear in the Flowtite® GRP Jacking Pipe
Systems product guide in Appendix A.
3.4 Jacking Load and Nominal Stiffness
Ref: Clause 4.2.2 and 4.2.3 of ISO 25780:2011
Flowtite® GRP jacking pipes can be supplied in the following jacking loads and stiffness
classes.
TABLE 2 JACKING LOAD (TONNES) AND NOMINAL STIFFNESS (SN)
Jacking Load (Tonnes) Nominal Stiffness (N/m²)
From 50 to 900 ≥ 20,000
The nominal stiffness in Table 2 above, correspond to the minimum nominal stiffness value
specified in Clause 4.2.3 of ISO 25780.
Flowtite® GRP jacking pipe can be supplied with a nominal stiffness as low as SN 2,500
although ISO 25780 requires a minimum stiffness of SN 20,000 for jacking applications.
3.5 Nominal Pressure
Ref: Clause 4.2.4 of ISO 25780:2011
The Flowtite® GRP jacking pipe intended for use in non-pressure applications can be
supplied with a nominal pressure rating ranging from (PN) 1 to 2.5, which relates to
components pressure rating in bars.
3.6 Nominal Pipe lengths
Ref: Clause 5.1.3 of ISO 25780: 2011
Although the winders for Flowtite® GRP jacking pipe are capable of producing any pipe length
from 3 to 21 m, the nominal length is limited by factory layout and practical aspects, such as
transportation.
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The standard nominal length of Flowtite® GRP jacking pipe manufactured at Lonsdale is 3 m.
Lengths of 2 m and 2.4 m are also available. Flowtite® GRP jacking pipe can also be supplied
in shorter lengths for special orders.
The total length of each pipe is equal to the nominal length with a tolerance of ±25 mm.
3.7 Flowtite® Joint Properties (couplings)
Ref: Clause 4.7.2 of ISO 25780: 2011
The standard jacking pipe jointing systems are either Type SE or Type GR (refer 3.2.2).
Plain ended GRP pipes are machined to accommodate the sleeve couplings. The couplings
are factory fitted to one pipe end. Deflections permitted at joints vary in accordance with
Table 3 in Section 3.8.
3.8 Allowable Angular Deflection
Ref: Clause 4.7.3.1 of ISO 25780: 2011
In accordance with ISO 25780 RPC Pipe Systems has declared:
(a) the maximum allowable deflection between adjacent pipes in the installed condition.
(b) the maximum allowable deflection at which each joint is designed to operate when
subjected to either internal or external pressure and the
(c) maximum angular deflection permitted during pipe jacking operations
(d) For parts (a) and (b) the values shall not be less than the values required by ISO 25780
Table 3 for sizes < DN 1000 and as calculated for sizes > DN 1000.
(e) Table 3 below specifies the maximum allowable angular deflection, at which each joint
is designed to operate when subjected to either internal or external pressure, including
the maximum allowable angular deflection permitted during pipe jacking operations.
TABLE 3 MAXIMUM ALLOWABLE INSTALLED DEFLECTION FOR PIPE JOINTS
ISO 25780 Requirements Flowtite® Specifications
External
Diameter
dOD
mm
Maximum allowable
installed deflection
a
mm/m
Maximum allowable
installed deflection
𝜹
degrees
Maximum allowable
installed deflection
a
mm/m
Maximum allowable
installed deflection
𝜹
degrees
200<dOD≤500 15 0.8594 15 0.8594
200<dOD≤500 10 0.5729 10 0.5729
1000<dOD a=10 x 1000/dOD Derive from value a a=10 x 1000/dOD Derive from value a
3.9 Straightness
Ref: Clause 5.1.5 of ISO 25780: 2011
The maximum permissible deviation from straightness of a surface line shall not exceed the
values given in Table 3 in ISO 25780, based on a 6m length. Flowtite® conforms to the
requirements of Table 3 in ISO 25780.
For proper sealing of the Flowtite® coupling, a smooth, dimensionally accurate outside spigot
surface is needed on each end of the pipe. Flowtite® manufacturing equipment chamfers the
edge of the pipe to avoid damage to the rubber gaskets, while simultaneously milling the
external surface. This equipment rotates the pipe and mills both ends using water-cooled
diamond-tipped tools.
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3.10 Pipe Fittings and Accessories
Flowtite® pipe fittings are moulded or fabricated using the same materials that are used to
produce the Flowtite® pipe. Fittings are supplied with spigot ends to suit the Flowtite® jacking
pipe couplings.
The standard range of fittings includes:
Double bell or socketed couplings.
Bends, 11¼º, 22½º, 45º, and 90º with spigoted or flanged ends.
Tees, either equal or reduced with spigoted or flanged ends. Eccentric tees and flanged nozzles can be manufactured to order.
Reducers, concentric or eccentric with spigoted or flanged ends.
End caps are available in all Flowtite® pipe sizes.
Y’s and other fittings can be manufactured to order.
Manhole couplings connectors with or without puddle flanges.
Transition pieces between standard Flowtite® pipe and Flowtite® jacking pipe.
See also the Flowtite® GRP Pipe and Fittings Engineering Design and Installation Guide.
4 SCOPE OF THE APPRAISAL
The scope of this product appraisal applies to the Flowtite® GRP jacking pipe as specified in
Section 3, for non-pressure applications using various trenchless installation methods such
as Slip Lining, Micro Tunnelling and Pipe Jacking.
5 APPRAISAL CRITERIA
5.1 General
Appraisal criteria is determined by the WSAA Infrastructure Products and Materials (IPAM)
Network and regularly reviewed to ensure that the criteria reflect the requirements of WSAA
members.
5.2 Quality Assurance Requirements
The WSAA product appraisal network accepts GRP pipes and fittings manufactured under
cover of a third party certified management system complying with ISO 9001 and having ISO
Type 5 product certification in accordance with ISO 25780 by a JAS-ANZ accredited
Certification Assessment Body (CAB) or by a CAB accredited by international accreditation
system recognised by JAS-ANZ.
5.3 Performance Requirements
Flowtite® GRP jacking pipes have successfully completed all long term testing for appraisal
for compliance with the requirements of ISO 25780 – Plastic piping systems for pressure
and non-pressure drainage and sewerage - Glass-reinforced thermosetting plastics (GRP)
systems based on unsaturated polyester (UP) resin Pipes with flexible joints intended to be
installed using jacking techniques.
The following Product Specifications are also relevant to this application:
WSA PS – 205J Centrifugally Cast Glass Reinforced Plastics (CC-GRP) Pipes for Pressure
and Non-Pressure Applications – Water Supply and Sewerage – Installed Using Trenchless
Installation Methods.
A copy of the above Product Specification can be found in Appendix D or downloaded from
the WSAA website.
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6 COMPLIANCE WITH APPRAISAL CRITERIA
6.1 Compliance with Quality Assurance Requirements
RPC Pipe Systems complies with the requirements of ISO 9001:2008 and is independently
certified with certificate number QEC23699.
Many Amiantit Group of Companies and licensees of Flowtite Technology have certification
that addresses the manufacture of GRP pipes and fittings. Given that the Lonsdale plant was
the thirteenth plant designed, constructed, equipped and commissioned under license to the
Amiantit Group and given that all procedures and documentation relevant to the production
and testing of pipes and fittings are supplied by the licensee, there is reasonable expectation
that RPC Pipe Systems will achieve certification of their products.
RPC Pipe Systems has provided assurance that internationally, Flowtite® pipe is
manufactured, as appropriate, in compliance with the requirements of the following
international standards:
ASTM
ASTM D3262
Standard Specification for “Fiberglass” (Glass-Fiber-Reinforced
Thermosetting-Resin) Sewer Pipe
ASTM D3517 Standard Specification for Fiberglass (Glass-Fiber-Reinforced
Thermosetting-Resin) Pressure Pipe
ASTM D3754 Standard Specification for Fiberglass (Glass-Fiber-Reinforced
Thermosetting-Resin) Sewer and Industrial Pressure Pipe
AWWA
AWWA C950 Fiberglass Pressure Pipe
AWWA M-45 Fiberglass Pipe Design Manual
ISO
ISO 10467
Plastics piping systems for pressure and non-pressure drainage and sewerage
-- Glass-reinforced thermosetting plastics (GRP) systems based on
unsaturated polyester (UP) resin
ISO 10639
Plastics piping systems for pressure and non-pressure water supply -- Glass-
reinforced thermosetting plastics (GRP) systems based on unsaturated
polyester (UP) resin
Other Standards
DIN 16868
Wound and filled glass fibre reinforced polyester resin pipes - Dimensions
BS 5480 Specification for glass reinforced plastics (GRP) pipes, joints and fittings for
use for water supply or sewerage
6.2 Compliance with Performance Requirements
RPC Pipe Systems has submitted the Flowtite® GRP jacking pipe systems for appraisal by
the Australian Water Industry as a fully tested, quality assured product, with documented
case histories (both local and international) and certified engineering standards.
RPC Pipe Systems is currently in the process of finalising ISO Type 5 Certification of Flowtite
GRP pipe. All long term testing required by ISO 25780 has been completed successfully.
Short term testing to verify the compressive strength of Flowtite® GRP pipe has been
conducted by the University of Adelaide. A copy of the test reports appears in Appendix B.
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6.2.1 Production and type test requirements to ISO 25780:2011.
Quality Control is a key function of the company’s manufacturing processes and the Quality
Control system extends from the acquisition of raw materials and continues through the
automated pipe production until the final despatch of the products. The jointing, external load
capacity, and environmental protection aspects of the pipes are continuously tested for full
reliability. The finished products are subjected to all of the rigorous testing requirements
prescribed by the relevant International Standards before being delivered to customers.
6.2.2 Mechanical Characteristics
6.2.2.1 Initial specific ring stiffness - Batch release test
Ref: Clause 5.2.1 of ISO 25780: 2011
The initial stiffness of Flowtite® GRP jacking pipes is designed to be above the nominal
values in all cases. Initial stiffness is part of daily quality control in all Flowtite ® factories. If
during quality control the stiffness is measured to be less than nominal the product is rejected
and downgraded to the next lower stiffness class.
Testing of pipes produced during ongoing manufacture has indicated that initial specific ring
stiffness meets the requirements of the ISO product standards.
6.2.2.2 Long-term specific Creep Stiffness - Type test
Ref: Clause 5.2.2 of ISO 25780:2011
The long-term specific ring stiffness of Flowtite® GRP pipe was performed using the long-
term creep stiffness method in accordance with ISO 25780:2011.
The tests were conducted in the Flowtite laboratory in Sandefjord, Norway on pipe
manufactured in Lonsdale. A type test report for a section of DN600, PN10, SN5000 Flowtite
FP2.1 design pipe, confirms that the pipe fulfils the requirements of the ISO standard.
The long-term specific ring stiffness of Flowtite® pipe has been measured in creep according
to ISO 10468 and reported by Flowtite® (nominated Test report T-2012-201) as shown in
Table 4:
TABLE 4 RESULTS OF LONG-TERM SPECIFIC RING STIFFNESS OF FLOWTITE® GRP
Sample Initial stiffness Stiffness at 12000 h Creep ratio at 50 yr
1523A-33-1 6349 5205 0.76
1523A-33-2 6233 5026 0.74
The test specimen was considered having a wall structure that is the same as the pipe
intended to be used in jacking installations.
6.2.2.3 Initial resistance to failure in a deflected condition - Batch release test
Ref: Clause 5.2.3 of ISO 25780:2011
The initial resistance to failure in a deflected condition is part of daily quality control in all
Flowtite® factories. The test procedure is Flowtite® Test method P 202, which is based on
ISO 10466 as nominated in ISO 10467 and ISO 10639. The criteria from Clause 5.2.3 of ISO
10467 and ISO 10639 are shown in Table 5:
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TABLE 5 RESULTS OF INITIAL RESISTANCE TO FAILURE IN A DEFLECTED
CONDITION
Stiffness class
SN
Deflection, %
Level A - No surface cracks Level B - No failure
2500 15 25
5000 12 20
10000 9 15
Testing of pipes produced during ongoing manufacture has indicated that initial resistance
to failure meets the requirements of the ISO product standards.
6.2.3 Resistance of pressure pipes internal pressure - Type test
Ref: Clause 5.7 of ISO 25780:2011 - (Specifies ISO 15306 test procedure within ISO 10467 and ISO 10639)
Flowtite® jacking pipes, for the purpose of this appraisal, are only considered for non-
pressure applications.
6.2.4 Resistance to strain corrosion - Type test
Ref: Clause 5.3 of ISO 25780:2011 - Specifies ISO 10467 test procedure
The published strain corrosion resistance of Flowtite® pipes is 0.66% (see Flowtite® test
report T-2011-205 at www.flowtite.com). Using the equation in Clause 10.6 of ISO 10952 as
specified in ISO 10467 Clause 5.4.2.1, this value can be converted to deflection and
compared with the requirement. By using the thickest of the pipes in each stiffness class the
following deflections are obtained. Refer to Table 6:
TABLE 6 RESISTANCE TO STRAIN CORROSION – TYPE TEST RESULTS
Stiffness SN 2500 SN 5000 SN 10000
Deflection, % 14.3 11.3 9.0
Comparing these values with the requirements in Table 17 of ISO 10467 shows that these
requirements are met.
Type testing of product manufactured in Lonsdale by RPC Pipe Systems (report T-2012-198)
shows a long term strain after 50 years is extrapolated to be 0.9% strain.
6.2.5 Joint performance - Type test
Ref: Clause 7.5 of ISO 25780:2011
Flowtite® Jacking pipes are joined using flexible non-end-load bearing joints with elastomeric
seals.
Type GR joints have been tested in accordance with the requirements of ISO 25780 Clause
7.5 as demonstrated in test report T-2014-233.
Type SE couplings are proprietary couplings as supplied to RPC Pipe Systems by Ritec
GmbH & Co. Type SE joints have been tested in accordance with the requirements of ISO
25780 Clause 7.5 as demonstrated in test report 2013-244 R1.
6.2.6 Longitudinal compressive strength
Ref: Clause 5.4 of ISO 25780:2011
Longitudinal compressive test was performed to determine the longitudinal compressive
stress at break for sample DN 478 GRP jacking pipe by the University of Adelaide (Report
C150711-RP-01). For a DN 478 jacking GRP pipe sample the minimum compressive stress
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at break is 90 N/mm2. Results obtained were 93.9 N/mm2 which is higher than the minimum
proving the sample fulfils the requirements of ISO 25780.
6.2.7 Permissible Jacking Forces
Ref: Clause 5.5 ISO 25780:2011
6.2.7.1 General
Permissible jacking forces are calculated to determine the force that can be applied to a pipe
during the jacking operation. Therefore the declared jacking load, ultimate longitudinal load,
the theoretical jacking load (concentric) and the eccentric jacking loads are to be determined.
Flowtite® used a DN478, SN320,000 Jacking Pipe for these results.
Material safety factors () of 1.75 and 3.5 have been used for assessment.
6.2.7.2 Ulitmate Longitudinal Load
The ultimate longitudinal load is the calculated value of the concentric longitudinal load that
the pipe withstands just before it breaks. This calculated value is used to determine the
permissible jacking forces of a jacking pipe.
Flowtite® tested a DN 478, SN320,000 jacking pipe and calculated its ultimate longitudinal
load to be Fult =3520kN.
Therefore the jacking pipe sample tested can withstand a concentric longitudinal load of
1428kN just before the pipe will break.
6.2.7.3 Designed Jacking Load and permissible eccentric jacking forces
RPC Pipe Systems has calculated that the theoretical design jacking load as;
• Fj,calc = 793 kN, which gives a Safety Factor of >3.5
RPC Pipe Systems have calculated the permissible eccentric jacking force on the pipe using
the estimated maximum angular deflection to still achieve a closed joint.
RPC Pipe Systems have declared the permissible eccentric longitudinal force the system
can withstand during a jacking operation is 793kN, taking into account the material safety
coefficient ( 1.75) and the estimated angular deflection.
Permissible jacking forces were calculated using the methods described in Annex C of ISO
25780 using minimum compressive strength at break as 85 N/mm2.
6.2.8 Specific initial longitudinal compressive modulus.
Clause 5.6 ISO 25780:2011
RPC Pipe Systems used a DN478, SN32,000 jacking pipe for these results.
The specific initial longitudinal compressive modulus expressed as Ec,m is the ratio of the
applied stress to the resulting strain below the elastic limit, both measured concurrently
during a short term compression test.
The specific initial longitudinal compressive modulus, Ec,m, is determined by selecting any
point from the performed quality control test data and using strain gauge at the tested
specimens.
A test piece taken from the pipe wall is compressed, at a uniform rate of strain in the direction
parallel to the longitudinal axis of the pipe, until failure occurs.
The ratio of the applied stress to the resulting strain below the elastic limit was calculated to
be 9900 MPa and declared as 8000-10000 MPa.
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6.2.9 Abrasion resistance
RPC Pipe Systems has supplied a copy of the Flowtite® Test Report No. T-97-113-B,
Abrasion Resistance Test. This test report describes an abrasion resistance test program
using the Darmstadt rocker test procedure (Ref DIN 19565) performed on DN 600, PN 10,
SN 5000 Flowtite® pipes. The average abrasion loss was found to be 0.34 mm / at 100,000
cycles (See page 10 in the Flowtite® GRP Pipe and Fittings Engineering Design and
Installation Guide.
The abrasion resistance of an individual pipeline material is difficult to determine because
test methods do not duplicate the varied abrasion conditions in sewers. Many comparative
Darmstadt rocker tests have resulted in a performance rating for plastics pipe materials that
exceeds other harder pipe materials. The test results indicate minimal wear and a calculated
life expectancy well beyond the requirements of most water agencies.
6.2.10 Temperature and pressure re-rating
Temperature and pressure re-rating is described in the Flowtite® GRP Pipe and Fittings
Engineering Design and Installation Guide and nominates 35ºC and below as requiring no
pressure re-rating. Re-rating is required for temperatures 36ºC to 50ºC and further re-rating
for temperatures 51ºC to 70ºC.
6.2.11 Resistance to Ultraviolet degradation
Flowtite® technical data states that there is no evidence to suggest that ultraviolet
degradation is a factor that affects the long term service life of Flowtite ® pipes. The exposed
outermost surface will be affected by discoloration and in the longer term glass fibres will be
exposed. If desired, the external surface of the Flowtite® pipe may be painted with two part
urethane paint compatible with GRP. However this will become an item requiring ongoing
maintenance.
6.2.12 Other Technical Data
For additional information refer to Flowtite® GRP Jacking Pipe Systems product guide in
Appendix A.
7 FITTING INSTRUCTIONS, TRAINING AND INSTALLATION
The Australasian Society Trenchless Technology has developed Trenchless Guidelines,
Standards and Specifications to assist industry users in Australia and New Zealand in
utilising these technologies. These documents are not intended to replace any existing
relevant manuals or standards. It remains the users responsibility to ensure that all relevant
laws, standards and specifications are adhered to during the course of a Works with use of
these trenchless technologies.
These Guidelines, Standards and Technical specifications are available from the
Australasian Society Trenchless Technology (ASTT) website. (http://astt.com.au).
8 REPAIR FOR NON-PRESSURE GRPJACKING PIPE FOR SEWERAGE
APPLICATIONS
The Flowtite® Installation Guide for Buried provides information on GRP repair procedures
and methods.
9 PRODUCT MARKING
Ref: Clause 6 in ISO 25780:2011
Flowtite® pipes are labelled in accordance with Clause 6 of ISO 25780: 2011 and includes:
Number of the applicable standard(s)
Manufacturers declared pipe external diameter
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Stiffness rating, (SN)
Pressure rating, (PN)
Permissible jacking load
The code letter “C” for the conveyance of surface water or sewage
The number of the standard (as above);
The nominal size (DN)
The stiffness rating, SN;
The pressure rating, PN;
The manufacturers name or identification; and
The date of manufacture in text or code.
Refer to Appendix H for an example of the pipe marking.
10 PACKAGING AND TRANSPORTATION
RPC Pipe Systems has advised that all products will be transported to site in timber cradles
and storage on site by the purchaser should be as per the manuals provided.
The Flowtite® Installation Guide for Buried Pipes has a Section titled ‘Shipping Handling and
Storage’. That Section provides comprehensive information and instruction complete with
diagrams and has Clauses titled:
Inspecting Pipe.
Repairing Pipe.
Unloading and Handling Pipe.
Site Pipe Storage
Storing Gaskets and Lubricant.
Transporting Pipe.
Handling Nested Pipes.
11 PRODUCT WARRANTY
The products are covered by the normal commercial and legal requirements of the
Competition and Consumer Act 2010, which covers manufacture to the relevant standard.
Additional warranties may be negotiated on a project specific basis.
12 WATER AGENCY EXPERIENCE WITH THE PRODUCT OR FIELD TESTING
REPORT
Table 7 lists a number of significant projects supplied to Australian water authorities.
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TABLE 7 AUSTRALIAN WATER AUTHORITIES - PROJECTS
Year Project Authority Description
2014 Ryan Rd Yarra Valley Water 622m OD530 SN90,000
767m OD447
SN100,000
2014 Alphington Sewer Project Melbourne Water 97m OD1335 SN32,000
63m OD820 SN120,000
2014 Canada Bay Canada Bay Council 336m OD1300
SN20,000
552m OD1400
SN20,000
2014 Cooper Street Yarra Valley Water 45m OD363 SN100,000
2015 Ellenbrook Water Corporation 512m OD478 SN32,000
2015 Darlington to Peachy Trunk Main City of Gold Coast 153m OD447
SN100,000
475m OD530
SN100,000
13 DISCUSSION
The RPC Pipe Systems Lonsdale plant was the 13th in a series of standard ‘turn -key’
manufacturing plants that have been successfully constructed and commissioned throughout
the world. There are now 22 plants constructed around the world. There is reasonable
justification for being confident that the Lonsdale plant is capable of producing non-pressure
jacking pipes and fittings to meet ISO standards in sizes suitable for the Australian and New
Zealand water industries.
As a licensed Australian manufacturer of an international product, RPC Pipe Systems has
been able to present considerable information on Flowtite® GRP pipe and fittings to
demonstrate a mature, widely used, tested and proven product range. The technical data
presented, available on the Flowtite® web site and included throughout this report is
extensive. The rapid responses to all technical and other questions raised, demonstrates a
willingness to cooperate and a ready availability of expertise from RPC Pipe Systems and
Amiantit / Flowtite®.
Amiantit provides technical expertise from Flowtite Technology AS located in Sandefjord,
Norway and they were responsible for commissioning the Lonsdale plant and providing RPC
Pipe Systems with technical support and oversight of the Australian Flowtite® pipe and
fittings production. Flowtite Technology AS will also be responsible for verification testing of
the Lonsdale pipe to meet Amiantit and ISO Standard requirements, particularly the long -
term hydrostatic pressure tests and resistance to strain corrosion.
The RPC Pipe Systems manufacturing plant for Flowtite® pipe has been equipped with a
complete QC laboratory and automatic hydrostatic testing machines for all diameter pipes
and associated couplings. Every pipe and coupling will be tested during manufacture and all
test results logged and recorded. More detailed information is available in the AFIL
catalogues available from RPC Pipe Systems.
14 LIFE EXPECTANCY
Based on the product information provided, the international reputation of the product and
subject to design, installation and commissioning in compliance with the manufacturer’s
instructions and relevant WSAA Water Supply and Sewerage Codes, Flowtite® GRP jacking
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pipe and fittings (FS and FP) could be expected to achieve an ‘A’ rating – Life expectancy in
excess of 100 years before major rehabilitation. This rating would be conditional on the future
work items being completed and should only be considered a general guide to life
expectancy and may increase or decrease as a result of the quality of installation, system
operating conditions, operating environment and other geographical and site specific factors.
15 FUTURE WORKS
RPC Pipe Systems is required to achieve ‘Product Certification’ to ISO 25780 for their
Australian manufacture of Flowtite™ GRP jacking pipes and couplings by 1 July 2016.
16 REPORT RECOMMENDATION
It is recommended that WSAA members and associates, subject to any specific requirements
of the member or associate, accept or authorise the Flowtite® GRP jacking pipes and
couplings as detailed in this report for use in non-pressure sewerage applications subject to
the design, installation and commissioning in accordance with specifications provided by
RPC Pipe Systems and relevant WSAA Sewerage Code or WSAA Members or Associated
Members integrated WSAA Code editions.
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17 DISCLAIMER
This Product Appraisal Report (Report) is issued by the Water Services Association of
Australia Limited on the understanding that:
This Report applies to the product(s) as submitted. Any changes to the product(s) either
minor or major shall void this Report.
To maintain the recommendations of this Report any such changes shall be detailed and
notified to the Product Appraisal Manager for consideration and review of the Report and
appropriate action. Appraisals and their recommendations will be the subject of continuous
review dependent upon the satisfactory performance of products.
WSAA reserves the right to undertake random audits of product manufacture and installation.
Where products fail to maintain appraised performance requirements the appraisal and its
recommendations may be modified and reissued. Appraisal reports will be reviewed and
reissued at regular intervals not exceeding five (5) years.
The following information explains a number of very important limits on your ability to rely on
the information in this Report. Please read it carefully and take it into account when
considering the contents of this Report.
Any enquiries regarding this report should be directed to the Program Manager, Carl
Radford, Phone: 03 8605 7601 email [email protected].
17.1 Issue of Report
This Report has been published and/or prepared by the Water Services Association of
Australia Limited and nominated Project Manager and peer group of technical specialists
(the Publishers).
The Report has been prepared for use within Australia only by technical specialists that have
expertise in the function of products such as those appraised in the Report (the Recipients).
By accepting this Report, the Recipient acknowledges and represents to the Publisher(s)
and each person involved in the preparation of the Report that the Recipient has understood
and accepted the terms of this Disclaimer.
17.2 Limits on Reliance on Information and Recommendations
17.2.1 Disclaimer of liability
Neither the Publisher(s) nor any person involved in the preparation of the Report accept(s)
any liability for any loss or damage suffered by any person however caused (including
negligence or the omission by any person to do anything) relating in any way to the Report
or the product appraisal criteria underlying it. This includes (without limitation) any liability
for any recommendation or information in the Report or any errors or omissions.
17.2.2 Need for independent assessment
The information and any recommendation contained (expressly or by implication) in this
Report are provided in good faith. However, you should treat the information as indicative
only. You should not rely on that information or any such recommendation except to the
extent that you reach an agreement to the contrary with the Publisher(s).
This Report does not contain all information that a person might require for the purposes of
assessing any product discussed or appraised within it (Product). The product appraisal
criteria used in preparing this Report may not address all relevant aspects of the Product.
Recipients should seek independent evidence of any matter which is material to their
decisions in connection with an assessment of the Product and consult their own advisers
for any technical information required. Any decision to use the Product should take into
account the reliability of that independent evidence obtained by the Recipient regarding the
Product.
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Recipients should also independently verify and assess the appropriateness of any
recommendation in the Report, especially given that any recommendation will not take into
account a Recipient’s particular needs or circumstances.
WSAA has not evaluated the extent of the product liability and professional indemnify
insurance that the provider of the product maintains. Recipients should ensure that they
evaluate the allocation of liability for product defects and any professional advice obtained
in relation to the product or its specification including the requirements for product liability
and professional indemnity insurance.
17.3 No Updating
Neither the Publisher(s) nor any person involved in the preparation of this Report [has] [have]
any obligation to notify you of any change in the information contained in this Report or of
any new information concerning the Publisher(s) or the Product or any other matter.
17.4 No Warranty
The Publisher(s) do[es] not, in any way, warrant that steps have been taken to verify or audit
the accuracy or completeness of the information in this Report, or the accuracy,
completeness or reasonableness of any recommendation in this Report.
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APPENDIX A – TECHNICAL MANUALS BROCHURES
AVAILABLE FROM RPC PIPE SYSTEMS OR THE FLOWTITE WEBSITE
Technical Manuals Brochures Manuals Documents Referenced
To obtain a copy of the FLOWTITE® GRP Jacking
Pipe Systems or FLOWTITE® Design Guide
please send an email with your details to
[email protected]. The FLOWTITE®
Design Guide is available in hard copy and CD
format.
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To obtain a copy of the FLOWTITE® Installation
Guide for Buried Pipes please send an email to
[email protected]. The Installation
Guide is available as a PDF file.
A copy of the Project Quality Plan- Jacking Pipe Inspection and Test Plan is available for the WSAA Members Only
website.
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APPENDIX B - QUALITY CERTIFICATIONS
Copies of the following Quality Certification Certificates are available for downloading from
the WSAA ‘Members Only’ IPAM Portal Website.
TABLE B1 RPC PIPE SYSTEMS PTY LTD – MANAGEMENT SYSTEMS
Applicants Business
(Attach all QA system certificates in full including schedules and last audit report)
Quality Systems Standard AS 9001:2008
Certification licence no. QEC23699
Certifying agency SAI Global
First date of certification 16 May 2007
Current date of certification* 4 April 2013
Expiry date of certification** 16 May 2016
TABLE B2 FLOWTITE TECHNOLOGY AS R&D LAB– MANAGEMENT SYSTEMS
Applicants Business
Østre Kullerød 3, 3241 Sandefjord
Quality Systems Standard1 AS 9001:2008
Certification licence no. 752-01
Certifying agency Intertek
First date of certification 27 March 1996
Date of Issue 7 June 2014
Expiry date of certification 16 June 2017
Note 1 Scope of Certification is Design of machinery and processes for production and testing of GRP/GRE pipe
products. Training, testing, research and development of GRP/GRE products.
TABLE B3– OTHER CERTIFICATES
Test Laboratory Certification
Flowtite Technology Sandefjord - Norway
Test Laboratory Accreditation Document No
Test 190 Norwegian Accreditation
Test Equipment Calibration Certification (Refer to Schedule)
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APPENDIX E - SUPPLIER CONTACTS
RPC Pipe Systems PTY. LTD 11 Christie Road,
LONSDALE SA 5160
Phone: (08) 8329 1111
Fax: (08) 8329 1122
Web site: www.rpcpipesystems.com & www.flowtite.com
Iplex Pipelines - Contact points Phone Fax
Technical Sales Managers:
Mr Michael Lancuba
7-15 Radford Rd
Reservoir, Vic 3073
(03) 9469 0320
(03) 9462 1540
Customer Services Department 13 18 40 13 18 60
Reservoir Victoria
PO Box 312
Reservoir Victoria 3073
03 9460 7000 03 6326 5277
Chipping Norton NSW
35 Alfred Road
Chipping Norton NSW 2170
02 9755 8243 02 9755 4480
Elizabeth South Australia
PO Box 133
Elizabeth South Australia 5112
08 8256 2000 08 8252 4858
Launceston Tasmania
PO Box 42 Invermay Tasmania 7248
03 6326 8031 03 6326 5277
Osborne Park Western Australia
PO Box 1194
Osborne Park Western Australia 6017
08 9340 4888 08 9340 4899
Strathpine Queensland
PO Box 5160
Brendale Queensland 4500
07 3881 9222 07 3881 1127
Winnellie Northern Territory
PO Box 39429
Winnellie Northern Territory 0821
08 8947 0466 08 8947 0347
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APPENDIX F - NATA LABORATORY TEST RESULTS
Test Reports have been made available for the purposes of preparing this product appraisal
report. The information is considered to be commercial in confidence and has not therefore
been made public. Should you require such information, please contact the manufacturer
(Appendix E).
The type testing and ongoing production testing (batch testing) confirm the Flowtite GRP
jacking pipes meet the requirements of ISO 25780:2011. Batch release testing is done in-
house on appropriate specialist testing equipment.
ISO 25780: 2011 calls up a range of performance tests which include the following:
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TABLE F1 SUMMARY OF TYPE TESTS AND BATCH TEST RESULTS
Characteristic Standard Clause Requirement Frequency Test
Result Standard
Result Pipe Size Doc ID
PIPES
Pipe Type Tests
Longitudinal Compressive
Strength
ISO 25780 5.4.2
Determine the specific initial longitudinal compressive stress at break
UN
SPEC
IFIE
D
PASS - αb,s 93.9 N/mm2 where αb,s,min = 90 N/mm2 for DN478
SN320,000 PASS DN478
C150711-RP-01
ISO 25780 5.4.4
Determine the specific initial longitudinal compressive stress at break on both rebated and unrebated test pieces
PASS Unrebated: αb,s 123 N/mm2 where αb,s,min = 90 N/mm2 for DN478 Rebated: αb,s 120 N/mm2 where αb,s,min = 90 N/mm2 for DN478
PASS DN478 C150711-RP-01
ISO 25780 5.4.6.1
The specific initial longitudinal compressive stress at break shall be higher than the declared minimum specific initial longitudinal compressive stress at break
PASS - αb,s 93.9 N/mm2 where αb,s,min = 90 N/mm2 for DN478
PASS DN478 C150711-RP-01
Specific initial longitudinal compressive
modulus
ISO 25780 5.6 Determine the specific initial longitudinal
Ec,m,Avg = 9900 MPa PASS DN478 C150711-RP-01
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Characteristic Standard Clause Requirement Frequency Test
Result Standard
Result Pipe Size Doc ID
compressive modulus
Pipe Batch Release Tests
Longitudinal Compressive
Strength
ISO 25780 5.4.4
Determine the specific initial longitudinal compressive stress at break on both rebated and unrebated test pieces
AS
PER
QU
ALI
TY P
LAN
PASS Unrebated: αb,s 123 N/mm2 where αb,s,min = 90 N/mm2 for DN478 Rebated: αb,s 120 N/mm2 where αb,s,min = 90 N/mm2 for DN478
PASS DN478 C150711-RP-01
ISO 25780 5.4.5.2 Calculate derated compressive stress of the spigot
Unrebated (Spigot): αb,s 123 N/mm2 where αb,s,min = 90 N/mm2 for DN478
PASS DN478 C150711-RP-01
ISO 25780 5.4.5.3 Calculate derated compressive stress of the barrel
Unrebated (Barrel): αb,s 123 N/mm2 where αb,s,min = 90 N/mm2 for DN478
PASS DN478 C150711-RP-01
ISO 25780 5.4.6.2
Both derated initial longitudinal compressive stresses at break for spigot and barrel of all quality control tests shall be higher than the minimum initial longitudinal compressive stresses at break
PASS Unrebated (Barrel): αb,s 123 N/mm2 where αb,s,min = 90 N/mm2 for DN478 Rebated (Barrel): αb,s 120 N/mm2 where αb,s,min = 90 N/mm2 for DN478 Unrebated (Spigot): αb,s 123 N/mm2 where αb,s,min = 85 N/mm2 for DN478
PASS DN478 C150711-RP-01
Specific initial longitudinal
ISO 25780 5.6 Determine the specific initial longitudinal
Ec,m,Avg = 9900 MPa PASS DN478 C150711-RP-01
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Characteristic Standard Clause Requirement Frequency Test
Result Standard
Result Pipe Size Doc ID
compressive modulus
compressive modulus
SE COUPLINGS
Coupling Type Tests
Performance
ISO 25780 7.5.2
Leak Tightness when subjected to an extenal pressure differential
AS
PER
QU
ALI
TY P
LAN
No damage, leakage or weeping
No signs of damage to components or change in pressure
greater than
0.08bar/h
DN600 PN1
2013-244 R1
ISO 25780 7.5.3
Leak Tightness when subjected to internal positive pressure following assembly
No damage, leakage or weeping
Withstand without
leakage an internal
pressure of 1.5 x PN for
15mins
DN600 PN1
2013-244 R1
ISO 25780 7.5.4
Leak Tightness when simultaneously subjected to angular deflection and draw
No damage, leakage or weeping
No signs of damage to components nor leak
DN600 PN1
2013-244 R1
ISO 25780 7.5.5
Leak Tightness when simultaneously subjected to misalignment and draw under static pressure
No damage, leakage or weeping
No signs of damage to components nor leak
DN600 PN1
2013-244 R1
ISO 25780 7.5.6 Leak Tightness when simultaneously
No damage, leakage or weeping No signs of damage to
DN600 PN1
2013-244 R1
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Characteristic Standard Clause Requirement Frequency Test
Result Standard
Result Pipe Size Doc ID
subjected to misalignment and draw under a positive cyclic pressure
components nor leak
Material / Joint
Properties
ISO 10467 AND ISO
25780 4.8 / 4.7.5
Effect on potable water
AS/NZS 4020 - Exposed to areas to volume ratio's up to 15,000
mm2/L Not Tested
ISO 25780 4.7 Joint Properties No damage, leakage or weeping PASS DN600 PN1
2013-244 R1
GR COUPLINGS
Coupling Type Tests
Performance
ISO 25780 7.5.2
Leak Tightness when subjected to an extenal pressure differential
AS
PER
QU
ALI
TY P
LAN
No damage, leakage or weeping
No signs of damage to components or change in pressure
greater than
0.08bar/h
DN820 PN1
T-2014-233
ISO 25780 7.5.3
Leak Tightness when subjected to internal positive pressure following assembly
No damage, leakage or weeping
Withstand without
leakage an internal
pressure of 1.5 x PN for
15mins
DN820 PN1
T-2014-233
ISO 25780 7.5.4
Leak Tightness when simultaneously subjected to angular deflection and draw
No damage, leakage or weeping
No signs of damage to components nor leak
DN820 PN1
T-2014-233
WSAA Product Appraisal No PA 1322 Issue 2 42
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Characteristic Standard Clause Requirement Frequency Test
Result Standard
Result Pipe Size Doc ID
ISO 25780 7.5.5
Leak Tightness when simultaneously subjected to misalignment and draw under static pressure
No damage, leakage or weeping
No signs of damage to components nor leak
DN820 PN1
T-2014-233
ISO 25780 7.5.6
Leak Tightness when simultaneously subjected to misalignment and draw under a positive cyclic pressure
No damage, leakage or weeping
No signs of damage to components nor leak
DN820 PN1
T-2014-233
Material / Joint
Properties
ISO 10467 AND ISO
25780 4.8 / 4.7.5
Effect on potable water
PASS PASS DN80 Equiv.
AWQ 27579 AWQ 27042 AWQ 64287 4007/92.1664
ISO 25780 4.7 Joint Properties No damage, leakage or weeping PASS DN820 PN1
T-2014-233
WSAA Product Appraisal No PA 1322 43
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APPENDIX G DOUBLE BELL REKA COUPLING QUALIFICATION TEST
WSAA Product Appraisal No PA 1322 Issue 2 46
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APPENDIX H – EXAMPLE OF PIPE MARKING
The label below appears on each pipe and designates the class of the pipe as well as
identifies the individual pipe with a serial number (in this case 180690096). Jacking load is
stencilled on the pipe as required by the customer.
WSAA Product Appraisal No PA 1322 Issue 2 59
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Melbourne Office
Level 8, Suite 8.02
401 Docklands Drive Docklands VIC 3008
Phone: (03) 8605 7601
Fax: (03) 8605 7612
Sydney Office
Level 11, 39 Martin Place
Sydney NSW 2000
GPO Box 915
Sydney NSW 2001
Phone: (02) 9221 5966
Fax: (02 9221 5977
www.wsaa.asn.au