sabas grp liner spec v4 (1)

GRP Spec-V3-Apr 05

1.0 INTRODUCTION

This specification is constructed to cover the rehabilitation of large gravity sewers, pipelines and culvert structures through the use of glass reinforced plastic (GRP) pipe segments.

The document has been constructed to provide materials that comply with both performance requirements and prescriptive provisions of WIS 4-34-02. However, that well tried and tested document was published in 1986 and this specification is designed to update references contained within WIS 4-34-02, to provide for the use of ASTM and ISO standards where they are most appropriate, and to utilise tools available within the most current GRP standards in use within industry. The standard relies on the following primary source documents:

WIS 4-34-02: Water Industry Specification for glass reinforced plastic (GRP) sewer linings.

Sewer Rehabilitation Manual 4th Edition: Published by WRc PLC.

ASTM D3262-04: Glass-Fiber-Reinforced Thermosetting-Resin Sewer Pipe.

BS EN 13121-2:2003: GRP Tanks and vessels for use above ground. Composite Materials Chemical resistance.

prEN 13121-3:2003: GRP Tanks and vessels for use above ground. Design & workmanship.

2.0 GRP LINING MATERIAL SPECIFICATION

2.1. DEFINITIONS

For the purpose of this specification, the following definitions apply: -

C Glass Glass reinforced fibres formed from a low-soda borosilicate glass, regarded as chemical resistant, primarily used for overlay or surfacing mats.

E Glass Alumo-borosilicate glass with an alkali content of maximum one weight percent, when expressed as sodium oxide (Na2O)

Effective Length of unit

The distance between planes normal to the unit axis and passing through the real end points of the lining unit

Lining section A discrete length of circumferentially continuous sewer lining which may be either a single pipe lining unit or a combined pair of segmental linings units

Out of Squareness of unit end

The maximum distance between the real end surface and a plane normal to the unit axis and passing through the real end point (See Figure 2.1 – Section through nominally straight unit (Diagrammatic Only))

Out of Straightness

The maximum radial distance between the lining inner surface and any line parallel to the unit axis touching the lining inner surface (See Figure 2.1 – Section through nominally straight unit (Diagrammatic Only))

Pipe Lining Circular or non-circular sewer lining that has no longitudinal joints.

GRP SEWER AND CULVERT LININGS, MATERIAL SPECIFICATION, of 17

GRP Spec-V3-Apr 05

Polyester resin (Unsaturated)

A solution of polyester in a monomer (Usually styrene) which, when subjected to the appropriate conditions (catalyst and accelerator), will cure (polymerise by cross-linking) to form a solid)

Real Corner

Points

The two points at each end of a lining segment at which the real end surface meets the lines along which the inner surface of the lining is intended to be jointed longitudinally to the adjacent lining segment (See Figure 2.1 –Section through nominally straight unit (Diagrammatic Only))

Real End Point The extreme point on the real end surface (See Figure 2.1 – Sectionthrough nominally straight unit (Diagrammatic Only))

Real End Surface

A surface joining the points against which the inner surface of the lining is intended to be jointed to the next lining section (See Figure 2.1 – Sectionthrough nominally straight unit (Diagrammatic Only))

Segmental Lining

Circular or non-circular sewer lining that is made up from pairs of upper and lower segments, which are joined longitudinally at their springings.

Springings The highest point at each side of an installed lining where the tangent to the internal surface is vertical

Total major Axis length

The distance between the crown and the invert of a lining section

Type I design The renovated sewer is considered to be acting as a composite section, consisting of the old sewer wall, grout and lining. It is assumed in the design that these three components are bonded together and that the grout is stiff and strong enough to transfer stress to the lining.

Type II Design This procedure is applicable to the design of pipe linings forming no reliable bond to the grout or old sewer. The design assumption is that the lining eventually bears the full load from the ground and traffic. The lining system is designed to act as a flexible pipe with the old sewer, annulus grout and soil providing the necessary support to maintain stability to both circular and non circular linings.

Unit Axis For a pipe lining section, the unit axis is a line passing through the centroids of the real end surfaces. For a segment, the unit axis is a line passing through the mid point of lines joining the real corner points at each end of the segment (See Figure 2.1 – Section through nominally straight unit (Diagrammatic Only))


GRP Spec-V3-Apr 05

Figure 2.1 – Section through nominally straight unit (Diagrammatic Only)

2.2. RAW MATERIALS

2.2.1 Surface tissue

Surface tissue, where used, shall be manufactured from C glass glassfibre or synthetic polyester fibres.

2.2.2 Glassfibre Reinforcement

All glassfibre reinforcement shall have a surface treatment compatible with the lining manufacturing process and the matrix resins. Glassfibre shall be E glass 90/10 unidirectional (UD) matting to ISO 2113 combined with stitch bonded chopped strand mat (CSM) to ISO 2559, whereby 1 layer of CSM shall separate layers of UD matting to maintain laminar shear strength in accordance with the requirements of prEN 13121-3:2001. The E type glass shall be orientated with the fabric Warp laid in the ‘hoop’ direction to derive maximum pipe stiffness and strength; the material shall be in accordance with the requirements of D4029-04. It shall contain no more than 0.2% moisture by weight as supplied; it shall be uncontaminated and protected to the point of use.

2.2.3 Aggregate

Aggregate when used as a part of the structural wall shall be clean, washed, high grade silica sand containing no less than 95% silica and a size range between 0.05mm and 5mm with an upper limit of 20% of the glass reinforced wall thickness. Aggregate shall contain no more than 0.2% moisture by weight when tested in accordance with the method described in ASTM C566-97(2004).

2.2.4 Filler

Any filler shall consist of clean inert material (e.g. silica) with a particle size below 0.05m and shall be used only as a resin extender. Fillers shall be free from contaminants such as sodium chloride, calcium chloride or potassium chloride and contain not more than 0.2% moisture by weight when tested in accordance with the method described in ASTM C566-97(2004) or BS 812-109:1990.


GRP Spec-V3-Apr 05

2.2.5 Resins

Isophthalic polyester resin complying with the requirements of Type B or C of BS 3532: 1990 or vinyl-ester resins shall be used. All resins shall be supplied pre-accelerated by the resin manufacturer with the catalysation process undertaken in accordance with the resin manufacturer’s instructions.

Cured resins, as cast singly without reinforcement, shall have an elongation at break greater than 2.5% when tested in accordance with ASTM D638-03 or BS 2782-3:Methods 320A to 320F:1976. Resins “flexibilised” by the addition of plasticisers shall not be used.

Uncatalysed liquid polyester resins shall have an acid value of 20 or below when tested in accordance with BS EN ISO 2114:2000, BS 2782-4:Method 432B:2000, or equivalence when tested in accordance with ASTM D2690-98. A hydroxyl value of less than 30 when tested in accordance with BS EN ISO 2554:1999, BS 2782-4:Method 432C:1997, or equivalence when tested in accordance with ASTM E222.

In addition to the requirements of BS 3532, the heat distortion temperature of the unreinforced fully cured resin, when determined in accordance with BS EN ISO 75-2:2004.

2.2.6 Dyes and pigments

Dyes and pigments shall not normally be included in the lining materials. Painting or any other obscuration of the surface shall be limited to any marking or other process required by this specification.

NOTE Coloration for the purposes of resin mix control may be permitted but only when approve by the resin supplier.

2.3. CONSTRUCTION

2.3.1 General

All sewer linings shall be manufactured with the following elements (See Figure 2.3.1 – Liner Construction):

I a single protective layer (SPL) consisting of either a veil layer (VL) or resin layer (RL),

II a barrier layer (BL)

III a glass reinforced wall comprised of two outer reinforcing layers with a central polymer mortar core

IV a rough backing to provide a bond between the lining and annulus grout (necessary for Type I composite designs only)

Note 1: An optional non-slip invert coating may be provided additional to the resin rich liner.


GRP Spec-V3-Apr 05

Figure 2.3.1 – Liner Construction

Note 2: Whereby the SPL and BL, jointly form the corrosion protection liner.

2.3.2 Corrosion Protection Liner (CPL)

The CPL (See Figure 2.3.1 – Liner Construction), comprised of the SPL and BL, shall contain no filler or aggregate and shall have a maximum thickness of 1.5mm.

2.3.3 Single Protection Layer (SPL)

The thickness shall be a minimum of 0.25 and a maximum of 0.6 mm. The SPL shall consist of a suitable RL comprised of a suitable flexible resin as per the raw material requirements of EN 13121-2:2003. In the case that a VL is used, the resin system shall be added up to 10% by weight of surface tissue.

2.3.4 Barrier Layer (BL)

The BL shall be manufactured from a suitable resin system reinforced with fibres of between 20-30% content by mass. Reinforcement shall be in the form of E or E type glass chopped fibres, chopped strand mat or synthetic fibres.

2.3.5 Glass reinforced wall

The structural wall shall be made up from resin impregnated layers of E type glassfibre separated by a polymer mortar core. The fibre reinforced skins shall include resin with a quantity of fine fillers; the core element shall be comprised of filler and aggregates bound by a resin matrix. The same resin, applied to the whole structural wall element in a single application, shall be employed in both the reinforcing and core layers.

2.3.6 Rough backing

If an additional application of material is required for ‘Type I’ linings to pass the shear bond strength requirements of clause 2.8, it shall consist of an inert material uniformly distributed over the external surface and bonded using a suitable compatible resin.


POLYMER MORTAR CORE Reinforced E-Glass Skins

Barrier Layer

SingleProtection Layer Non-slip invert (optional)

Rough Backing (Type I only)

Note 2

GRP Spec-V3-Apr 05

2.3.7 Non slip invert

If a non-slip invert coating is applied to the resin rich liner it shall be bonded to the cured lining unit using a suitable compatible resin.

NOTE Non slip inserts should be specified with care as they might compromise the durability or performance of the lining unit.

2.3.8 Edges and ends

At the edges and ends of all lining segments and sections the structural wall shall be sealed with a suitable compatible epoxy resin (with suitable hardening system). The resin shall be pigmented black to ensure that a visual check can be used to determine full resin coverage.

2.4. QUALITY ASSURANCE

In strict accord with the requirements of WIS 4-3402, all GRP lining materials shall be manufactured under a suitable 3rd Party ISO 2001:2000 Accredited quality assurance scheme acceptable to WRc.

As per WIS 4-34-02, Appendix H, this requirement enables lining materials to be suitably marked with the “4-34-02” nomenclature.

As part of the quality assurance procedures the manufacturer shall keep records of the following against the individual serial numbers of output product:

raw material batch details, including source, acceptance test records, purchase dates and shelf-life at time of use;

computerised mixing records; negative mould pressure at commencement of infusion; maximum pressure during the manufacturing process; and, confirmation of resin draw for each injection.

2.5. APPEARANCE AND SURFACE CONDITION

The surface of the lining material shall be free from tackiness and defects such as protruding fibres, air voids, crazes, cracks, blisters or foreign matter that might impair the performance in service. The internal surface of the lining shall be smooth.

NOTE Some rectification or repair is permitted under WIS 4-34-02, (See 10.7 and Table Appendix G of that Specification).

2.6. DIMENSIONS

2.6.1 Section length

Lining sections shall be manufactured to within a tolerance of ±10mm of the nominal overall or effective lengths specified by or agreed with the purchaser provided that the sum of the lining section required.

2.6.2 Effective length of segments

A pair of segments intended to fit together to form a lining section shall not differ in effective length by more than 3mm.


GRP Spec-V3-Apr 05

2.6.3 Cross section

a.) Pipe linings

The tolerance on internal height and width shall be ±(4+0.002D) mm, where D (mm) is the nominal major axis of non-circular linings specified by or agreed with the purchaser, or ± 0.5% D for circular linings as per the requirements of BS 5480: 1990, clause 5.2.3.

b.) Segments

The tolerance on the width between the longitudinal joints and the depth from the unit axis to the crown or invert of the lining shall be 1% or ± 5mm (whichever is the lesser) of the nominal value specified by or agreed with the purchaser.

c.) Wall thickness

The wall thickness of the lining, excluding the rough backing if applied, but including the resin rich liner (See Figure 2.3.1 – Liner Construction), shall be at least the minimum specified by or agreed with the purchaser. The maximum overall wall thickness shall be not greater than 20% or 3mm, whichever is the lesser, of the minimum specified thickness.

2.6.4 Out-of-Squareness

a.) Pipe lining units

The out-of-squareness at each end shall be compatible with the jointing system employed and shall be not more than 2mm + 0.005 or 10mm, whichever is the lesser, where is the average of the maximum and minimum internal diameters measured in mm.

b.) Segmental units

The out-of-squareness at each end shall be compatible with the jointing system involved and shall be not more than 2mm + 0.002W or 5mm, whichever is the lesser, where W is the average distance between the real end corner points at each end of the segment measured in mm.

c.) Out-of-straightness

The out-of-straightness of a unit shall be no more than the lesser of 0.3 % or 5mm of its effective length.

2.7. JOINTS

a.) Longitudinal joints Type I (where used)Longitudinal joints applied within a ‘Type I’ composite system shall be constructed and sealed so as to present the inclusion of grout during liner installation. The jointing system shall also be designed with the grouting system to provide sufficient rigidity to ensure that the deflection to span ratio experienced during the placement of grout is less than 3% as per the serviceability requirements of the SRM.

b.) Longitudinal joints Type II (where used)In the case that longitudinal joints are used within a ‘Type II’ system, the joints shall be fully moment transferring and shall exhibit both strength and stiffness characteristics in excess of the requirements of the lining system design. The longitudinal joints shall be fully watertight to a pressure of at least 1.5 bar.


GRP Spec-V3-Apr 05

The joint shall be a lap type joints reinforced with pre-formed strips (which shall conform to the shape of the lining body), manufactured from E-glass reinforcement and a compatible epoxy lining system, and bonded to the body of the lining units. The lining units shall be designed so that the reinforcing strips sit flush with the inside body of the lining unit and do not protrude nor extend beyond the inner surface of the lining body.

The joints shall be sealed with a fail-safe sealing process whereby a ‘sealing gap’ is formed through the provision of a longitudinal channel created at connecting edges of the joints; along the entire length of the longitudinal joint-section. The sealing gap shall be filled only after the provision, bonding and curing (to the extent of 90% of full peel strength determined in accordance with the resin suppliers guidelines) of the reinforcing strips. The sealing gap shall be filled with a flexible 1-part polyurethane resin system, resistant to the sewer environment for which they are intended. The sealing gap shall be injected from a single point with weep-holes provided at the extremities of the longitudinal joint to provide visual confirmation that the sealing gap is fully filled. Vacuum points may be provided, through the use of an air ejector and vacuum cup system, at the weep points to assist in the sealing process if required.

Joint compliance shall be demonstrated by the testing of off-cuts of the installed lining system. Joint sections shall be subjected to testing, in accordance with ASTM D790-00 or BS 2782-10:Method 1005:1977, EN 63:1977, to determine the flexural properties of the joint. The bending moment resistance of the joint and equivalent stiffness (considered against the thickness of the lining wall and not against the thickness of the joint section for calculation purposes), shall be in excess of that required under the design of the lining system.

c.) Circumferential joints

Circumferential joints between lining sections may be flexible or rigid. All joints shall be capable of taking up an angular displacement of 1 in the vertical plane, 2 in the horizontal plane up to 1000mm size, 1 above that, and mismatch of the lining sections due to manufacturing tolerances. The joint detail shall be fit for the purpose intended such that grout infiltration during installation is minimised.

d.) Sealing materials

Rings and stripsElastomeric sealing rings and strips shall be provided as jointed O’rings and shall not be jointed at site. Rings shall then be placed on the outside of the spigot section and greased with a suitable compound to allow pipe jointing. Care must be taken to protect the sealing rings prior to jointing and all rings should be thoroughly cleaned prior to jointing. All jointing rings shall be manufactured from a bio-deterioration resistant elastomer deemed fit for purpose under ASTM F4777 or BS EN 681:2000. Where the lining is to-be used to convey the deleterious trade effluents a bio-deterioration resistant elastomer suitable for use under those conditions shall be used.

NOTE See also Information and Guidance Note No. 4-40-01.

CompoundsRigid setting or flexible compounds used to caulk or seal the gap between lining units shall be resistant to the sewer environment for which they are intended, and shall be suitable for installation within a confined space taking safety aspects into consideration.

2.8. PERFORMANCE REQUIREMENTS


GRP Spec-V3-Apr 05

The lining shall meet the minimum requirements of either the lesser of the requirements of WIS 4-34-02, or those stipulated under the system design, given in Figure 2.1 – Section through nominally straight unit (Diagrammatic Only) when tested in accordance with those clauses indicated. These parameters will be used for the structural design of the lining system.

Table 1.8.1 - Lining Performance Requirements

Property Minimum requirementsWIS 4-34-02

Clause covering test

Short term flexural (bending) modulus*

As agreed with purchaser and not less than 5,000 Nmm-2

9.2

Long term flexural (bending) modulus*

As agreed with purchaser and not less than 2,500 Nmm-2

9.3

Long term permissible flexural (bending) strain*

Greater than or equal to 0.5% where a test fluid of water is used or greater than or equal to 0.3% where a test fluid of acid is used

9.4

Long term tensile strength*

As agreed with purchaser but not less than 12.0 Nmm-2

9.5

Shear bond strength 1.0 Nmm-2 9.6

*Property measured in the hoop direction.


GRP Spec-V3-Apr 05

2.9. TYPE TESTS

2.9.1 Short term flexural (bending) modulus

The lining unit shall meet the requirements of Table 1.8.1 - Lining PerformanceRequirements when tested in the appropriate manner as follows:

The short term flexural modulus shall be determined in accordance with the procedures described in ASTM D790-00 or BS 2782-10:Method 1005:1977, EN 63:1977 from coupons cut from the hoop (bending) direction and having a radius of curvature greater than 250mm (near the springings) and using a testing speed of 10 mm/min.

NOTE when comparing lining units of a particular size but of different moduli and thickness, the value of E, time’s t can be a useful guide to relative stiffness.

2.9.2 Long term flexural (bending) modulus

Determine the long-term flexural modulus, (which is equal to the creep modulus at 50 years) in accordance with the requirements of WIS 4-34-02 Appendix C using coupons cut from the hoop direction and having a radius of curvature greater than 250mm.

2.9.3 Chemical Corrosion

The lining system shall have demonstrated chemical corrosion resistance, as required by the control test provisions of ASTM D3262-04, tested in accordance with the procedures or ASTM D3681.

2.9.4 Beam Strength

The lining materials shall achieve the minimum beam strength requirements of ASTM D3262-04. For testing and calculation purposes, in the case of non-circular linings, the maximum dimension, either width or height, shall be taken as an equivalent diameter for the purposes of ASTM D3262-04 Table 7.

2.9.5 Long term tensile strength

Tensile testing of the SABAS laminate presents specific problems due to the tensile strength of the material on what are predominately thick laminates (t>10 mm). As noted in the SABAS design manual, and from experience, it has been found that in normal sewer applications the design is limited by the shear bond strength and not tensile strength of the liner. Notwithstanding this, the long-term tensile strength shall be determined in accordance with the methodologies of prEN 13121-3:2001, whereby:

Each layer of the composite, comprising the two outer GRP skins and inner core, shall be analysed to determine their tensile strength. No contribution to this property should be considered from the surface and barrier layers.

The design factor, K, shall be determined in accordance with clause 7.8.4 of pr EN 13121-3:2001 as follows:

K = 2 x A1 x A2 x A3 x A4 x A5

Where, the factors of safety for the GRP liner design are based upon the methodology prescribed prEN 13121-3:2001, clause 7.8.4.1. Under this arrangement the following factors are to be used:


GRP Spec-V3-Apr 05

A1 Effect of manufacturing and quality control level, a value of 1 shall be taken when the maximum allowable load is determined by testing actual samples of the individual layers within the structural liner.

A2 The derivation of partial design factor relating to the chemical environment, a value of 1.1 used as a resin rich barrier layer is used to provide corrosion resistance to the laminate.

A3 The derivation of partial design factor relating to design temperature, shall be as follows:

A3 = 1 + 0.4[(TD-20)/(HDT-40)]

Where, TD design temperature.

Because of the generally low operating temperatures of sewers, compared to other industrial applications, typical values of A3 will be between 1.4-1.7.

A4 The derivation of partial design factor of 1 relating to the none dynamic nature of the loading. For liners with a depth of cover of less than 0.5m this factor will require further investigation.

A5 The derivation of partial design factor of 1.75 based upon the data provided in Figure 7.8.4.5 for the conservative laminate construction assumed.

Therefore,

K = 2 x 1 x 1.1 x A3 x 1 x 1.75

As per Table 3 of prEN 13121-3:2001, the tensile strength contribution from the GRP structural wall skins, TSs, shall be (confirmed by testing to derive partial design factor A1):

TSs = 500 x 60 x Nmm-2 per kg/m2 (per mm unit width)

where = ration of mass in the Warp direction (0.9 for standard SABAS reinforcement)

Therefore,

TSs = 500 x 60 x 0.9 Nmm-2 per kg/m2


GRP Spec-V3-Apr 05

The core component tensile strength contribution, TSc, shall be calculated in accordance with the following formula:

TSc = TSr x tc x {(rr/Sgr)/[((1- rr)/Sga))+(rr/Sgr)]} Nmm-2 (per mm unit width)

Where, TSr = Tensile Strength of unreinforced resin

tc = Thickness of core in mm

rr = Core resin ratio (weight of resin/weight aggregate & fillers)

Sgr = Specific gravity of resin (take 1.1)

Sga = Specific gravity of aggregate particles (take 2.7)

The combined unit tensile strength shall be calculated as follows:

TS = K x (TSs.mr+TSc)/t Nmm-2

Where, t = lining wall thickness excluding the surface and barrier layersmr = weight of reinforcing per m2.

2.9.6 Shear bond strength (Type I only)

The lining unit shall be tested in accordance with the method described in WIS 4-34-02 Appendix D and shall attain the minimum requirement given in Table 1.8.1 - LiningPerformance Requirements.

A sample panel having a rough-backing representative of those tested shall be retained for quality control comparisons.

2.9.7 Analysis of construction

A minimum of five samples from the full design wall thickness of each lining test unit (excluding any rough backing or non slip coating) shall be fully analysed in accordance with Appendix E of WIS 4-34-02 and the results declared. The values shall form the control values for quality control purposes.

2.10. QUALITY CONTROL TESTS

2.10.1 General

The following test requirements are necessary in order to demonstrate a continuing satisfactory level of production quality in day to day production. The manufacturer shall establish a quality system to meet the requirements of ISO 9001:2000.

The required sampling frequency for quality control tests is given in WIS 4-34-02 Appendix F. Where destructive tests are specified the remaining useful portion of a complying unit (trimmed square) may be offered for sale, appropriately marked "undersize".

2.10.2 Dimensions

The overall length, effective length, cross section, out-of-squareness and out-of-straightness of each test sample, where specified, shall be determined using a method of measurement accurate to the nearest millimetre and shall comply with the requirements of WIS 4-34-02 clause 2.6.


GRP Spec-V3-Apr 05

Wall thickness and resin rich liner thickness shall be determined at a minimum of five locations in each test sample using a method of measurement accurate to the nearest 0.l mm, by measuring cut surfaces through the lining wall. The cut surfaces shall be smoothed sufficiently for the different layers to be delineated. The resin rich liner thickness shall be measured using a suitable optical (magnifying) technique. Each measurement shall comply with the requirements of clause 2.6. Generally the locations of cores shall include:

(i) a point of minimum internal surface curvature,

(ii) a point towards the centre of the test sample,

(iii) Points near each end of the test sample, but not at a joint.

NOTE Where the process does not produce distinct layer boundaries a relaxation in precision will be considered.

2.10.3 Resin cure

The surfaces shall not be tacky to the touch. Each test specimen shall be tested in accordance with the method described in ASTM2583 or BS 2782-10:Method 1001:1977, EN 59:1977, at a minimum of five points, away from the invert, and shall have a hardness not less than the minimum declared by the manufacturer at the time of confirmation of the order, for the resin system used.

2.10.4 Shear bond strength

In the absence of a suitable objective test method each test unit shall be compared visually with a panel retained from the type tests. If it is equivalent in respect of particle shape, size and surface distribution (or other bonding key) it shall be deemed to have adequate shear bond strength. If it differs appreciably it shall be rejected.

2.10.5 Short term bending modulus

Samples shall be tested by the method prescribed above shall comply with the requirements of Table 1.8.1 - Lining Performance Requirements.

2.10.6 Analysis of construction

When tested by the method prescribed in 2.9.7 the disposition of the laminates or zones and the constituents within them shall correspond to those of the type tested liners. The percentage by mass of the constituents and the masses of glass per unit surface area shall not deviate from the declared control values by more than 10% (of each numerical value).

2.10.7 Appearance

The internal and external surfaces of each lining unit shall be examined visually for freedom from defects. Where practicable this shall occur prior to application of any rough backing or non-slip surface coating. Types of defect and final allowable limits are given in WIS 4-34-02, Table 2, Appendix G.


GRP Spec-V3-Apr 05

2.10.8 Chemical corrosion resistance

Where lining units are intended for use in a septic or aggressive sewer environment, where a non slip invert is applied or where the lining is intended for use in particular environments or with high temperature effluents, the lining system shall have demonstrated chemical corrosion resistance, as required by the control test provisions of ASTM D3262-04, tested in accordance with the procedures or ASTM D3681.

2.11. CONTROL OF TEST CONDITIONS

2.11.1 Test conditions

Unless otherwise required by this specification the test measurements shall be conducted at a temperature of 15 10C.

2.11.2 Specimen conditioning

For type testing in air (or in any cases of disagreement) specimens shall be kept in air 15 10C for not less than 88 hours prior to testing.

For quality control testing specimens shall be kept in air at 15 10C for not less than 12 hours after they are considered to be cured.

NOTE The preferred temperature for conditioning and testing plastics materials is 23 2C.

2.11.3 Test specimen preparation

In cases of disagreement mechanical test specimens shall be machined following the recommendations of BS EN ISO 2818:1997, BS 2782-9:Method 930A:1996.

2.12. WORKMANSHIP, INSPECTION AND CERTIFICATION

2.12.1 Manufacturing Process

GRP Liners shall be manufactured in a closed mould injection system to ensure the production of high quality components and repeatability of physical properties.

All structural layers of the GRP liner shall be produced in a single-injection process whereby structural core elements and reinforcing layers are formed in a singular resin infusion step.

An injection of a resinous polymer mortar mixture, into a cavity created between dry reinforcing fabric layers, shall form the structural core element. Resin shall be drawn from the polymer mortar mixture into the dry reinforcing layers. The directionally biased reinforcement is used, care shall be taken to ensure that the high strength direction is correctly aligned to give the designed balance of hoop and longitudinal strength The use of a single resin system providing both the polymer matrix for the polymer mortar core and the polymer matrix within the fibre reinforced skins shall be required to ensure that maximum shear strength and compatibility is achieved between the composite layers.

Resin system and polymer mortar mixing shall be controlled by automated batching plant. Hand application of corrosion protective layers shall be carried out strictly in accordance with the provisions of EN 13121-2:2003.


GRP Spec-V3-Apr 05

All raw materials shall be tested at a frequency sufficient to ensure consistency and compliance with this specification. The manufacturer shall adequately supervise all stages of production and keep records of the raw material batches used and products made each work shift or day. Manufacture shall be under environmental conditions compatible with producing satisfactory linings and raw materials shall be stored and used in compliance with the recommendations of their manufacturers.

Reinforcement materials shall be stored in dry conditions. The lining manufacturer shall be familiar with the changes in viscosity, gel times, etc., which may occur during storage of the resin, and make appropriate allowances in the lining manufacturing process. Resin stored in original unopened containers shall not be used after the resin manufacturer's stated limiting date in accordance with BS 3532: 1990.

The guidance of the resin manufacturer shall be sought on the useful life of resin delivered by tanker. Tanks used for bulk storage of polyester resin must be inspected regularly and checked for contaminants Materials and temperatures in the working environment shall not be less than 15C. All laminating work shall be discontinued if the air temperature falls below 15C or if the dew point is reached (condensation occurs), whichever is the higher.

NOTE A relaxation to 10C (or the dew point) may be permitted if final cure is effected application of heat.

2.12.2 Inspection

In addition to the manufacturer's own inspection and supervision, the purchaser or his appointed inspecting authority shall have access at all reasonable times to those parts of the manufacturer's works purchaser and to all relevant test records.

2.12.3 Certification

The manufacturer shall, on request, furnish the purchaser or purchaser's representative, with copies of a signed certificate for each size and classification of lining units stating that the construction and testing of lining units supplied comply with the requirements of this specification and giving details of minimum performance parameters agreed with the purchaser.

If required by the purchaser, the quality control test, results or a suitable summary shall be provided with the certificate. A typical certificate is shown in Appendix H of WIS 4-34-02.

2.13. MARKING

All lining units shall be indelibly marked at each end on the inside face. No method of marking shall prejudice the performance of the lining in service. The marking shall give the following information:

a.) the manufacturer's name, initials or identification mark,

b.) the number WIS 4-34-02. The marking of the number 4-34-02 on products produced to this specification may only be applied by manufacturers covered by a third party certification scheme acceptable to WRc,

c.) Identification of the shift, productions line and date of manufacture. Coding of this information is permitted provided that the meaning of the code is available on request,


GRP Spec-V3-Apr 05

d.) the words "GRP TYPE IC SEWER LINING" or "GRP TYPE IIC SEWER LINING", as appropriate.

2.14. PROTECTION OF LINING UNITS

Lining units shall be handled, stored and transported in such a way as to prevent damage before receipt by the purchaser.

2.15. REFERENCES

This specification makes reference to the latest edition of the following publications (except where otherwise indicated), including all addenda and revisions: Sewerage Rehabilitation Manual published by the Water Research Centre.

BS2782-3320A/320F 1976

Methods of testing plastics. Mechanical properties. Tensile strength, elongation and elastic modulus

BS 812-109:1990 Testing aggregates. Methods for determination of moisture content.

BS-EN 681:2000 Elastomeric seals. Material requirements for pipe joint seals used in water and drainage applications. Thermoplastic elastomers

BS EN ISO 2114:2000 BS2782-4:Method 432B:2000

Plastics (polyester resins) and paints and varnishes (binders). Determination of partial acid value and total acid value

BS EN ISO 2554:1999, BS 2782-4:Method 432C:1997

Plastics. Unsaturated polyester resins. Determination of hydroxyl value

BS 3532:1990 Method of specifying unsaturated polyester resin systems

BS EN ISO 75-2:2004 Plastics. Determination of temperature of deflection under load. Plastics, ebonite and long-fibre-reinforced composites

BS 2782-10:Method 1005:1977, EN 63:1977

Methods of testing plastics. Glass reinforced plastics. Determination of flexural properties. Three point method

BS EN ISO 2818:1997, BS 2782-9:Method 930A:1996

Plastics. Preparation of test specimens by machining

BS 5480 Specifications for glass reinforced plastics (GRP) pipes and fittings for use for water supply or sewerage Part 1 Dimensions, materials and classification. Part2 Design and performance requirements.

BS 6000 Guide to the use of BS 6001. Sampling procedures and tables for inspection by attributes.

BS 6001 Sampling procedures and tables for inspection by attributes


GRP Spec-V3-Apr 05

BS ISO 2113 Reinforcement fibres. Woven fabrics. Basis for a specificationBS ISO 2559:2000 Textile glass. Mats (made from chopped or continuous strands).

Designation and basis for specificationsBS EN ISO 9001:2000

Quality management systems. Requirements

ASTM D 4029-04 Standard Specification for Finished Woven Glass Fabrics

ASTM C566-97 Standard Test Method for Total Evaporable Moisture Content of Aggregate by Drying

ASTM D638-03 Standard Test Method for Tensile Properties of Plastics

ASTM D2690-98 Standard Test Method for Isophthalic Acid in Alkyd and Polyester Resins

ASTM E222-00(2005)e1

Standard Test Methods for Hydroxyl Groups Using Acetic Anhydride Acetylation

ASTM D790-00 Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials

ASTM F477-02e1 Standard Specification for ELASTOMERIC Seals (Gaskets) for Joining Plastic Pipe

ASTM D3262-04 Standard Specification for Fiberglass (Glass-Fiber-Reinforced Thermosetting-Resin) Sewer Pipe

ASTM D3681 Standard Test Method for Chemical Resistance of Fiberglass (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe in a Deflected Condition


sabas grp liner spec v4 (1)

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