GRP

Glass-fiber Reinforced Plastic Pipe
(GRP PIPE)
Installation Manual of
GRP Pipe
Above ground Piping
grp@ggenc.com
www.gilgwang.co.kr
Tel : +82-31-354-4222
www.gilgwang.com
Fax : +82-31-354-3456
CONTENTS
1. Introduction .
2. Field Service Representative . 1

3. Fire Safety . 1
4. Inspecting pipe at the job site ... 1
1.5 Repairing Pipe . 2
6. Jointing Pipes
6.1 Overlay joints . 3

6.1.1 Alternative: overlay pack ..... 7
6.1.2 Branch Connection ...
6.1.3 Tools for butt joint . 12

6.1.4 Gel time
12
6.2 Flanged joints . 13

6.2.1 Bolt, Nut & Washer
6.2.2 Recommended Bolt Torque
14
. 15
6.2.3 Recommend Procedure for Flange Installation . 16

6.3 Other Jointing Method . 17
6.3.1 Flexible Steel Coupling
17
7. U.V. Resistance .. 18
8. Pipe Support 19
8.1. General Rules ...
19
8.2. Support ... 19

8.3 Anchor .
20
8.4 Guide .... 21

8.5 General Installation ..
23
9. Passing to the (concrete)Wall ... 25

10. Dimension Tolerances .... 26
11. Repair Manual .. 28
11.1 Cutting Edge ..
32
12. Field Hydrostatic Testing ... 33
ii
GILGWANG GREENTECH CO.,LTD.

Title
Re. Date
Installation Manual of GRP Pipe

Above Ground Piping
2006-03-02
Doc. No.
Page
1. Introduction
This section of the manual describes the requirements for installation of GILGWANG
GREENTECH (Hereinafter called as GGT) pipes above ground. In addition this
manual provides guidance how to avoid and solve problems during installation. GGT
Glass fiber Reinforced Pipe systems offer, by their specific nature, many applications
and advantages compared with other materials.
2. Field Service Representative

The supplier(GGT) can provide a field service representative(Supervisor). The field
service representative will advise the installer to help him achieve a satisfactory pipe
installation. The service will range from continuous to intermittent depending on the
job schedule, complexity and installation result.
3. Fire Safety
Glass Fiber Reinforced Plastic(GRP) pipe can burn, like virtually all plastic pipe made
with petrochemicals. Therefore it is not recommended for use in applications which
are exposed to intense heat of flames. During installation, care must be taken to
avoid exposure of the pipe to welders sparks, cutting torch flames or other heat
which could ignite the pipe material. This precaution is particularly important when
working with volatile chemicals in marking lay-up joints, repairing or modifying the
pipe in the field.
4. Inspecting pipe at the job site

All pipes should be inspected upon receipt at the job site to insure that no damage
has occurred in transit. Depending on length of storage, amount of job site handling
and other factors that may influence the pipes condition, it may be wise to re-inspect
the pipe just prior to installation. Inspect the shipment upon delivery is as follows:
c Make an overall inspection of the load. If the load is intact, ordinary inspection
while unloading will normally be sufficient to make sure the pipe has arrived
without damage.
d If the load has shifted or indicated rough treatment, carefully inspect each pipe
section for damage. Generally, an exterior inspection will be sufficient to detect
any damage. When pipe size permits, an interior inspection of the pipe at the
location of an exterior scrape may be helpful to determine if the pipe is damaged.

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Above Ground Piping
2006-03-02
Doc. No.
Page
e Check the quantity of each item against the bill of lading.

f If any imperfection or damage is found, immediately segregate the affected pipes
and contact the supplier.
Do not use pipe that appears damaged of defective.
If the Field Service Representative is present at the time of your inspection(s), he
will be glad to assist you.
5. Repairing Pipe
Normally, pipes with minor damage can be repaired quickly and easily at the job site by a
qualified individual. If in doubt about the condition of a pipe, do not use the pipe. The field
service representative can help you determine whether repair is required and whether it
is possible and practical. He can obtain the appropriate repair specification and arrange
for the required materials and a trained repair technician, if desired. Repair designs can
vary greatly due to pipe thickness, wall composition, application, and the type and extent
of the damage. Therefore, do not attempt to repair a damaged pipe without consulting
the supplier first. If you want to more information for repair of pipe, you can obtain in GGT
repair manual.

Title
Re. Date

Above Ground Piping
2006-03-02
Doc. No.
Page
6. Jointing Pipes
6.1 Overlay joints
GGT pipe sections are typically jointed to overlay method. Other jointing systems
such as flanges and thread joints may also be used for jointing GGT pipe. GGT
jointing system on pipe and overlay is all butt joint unless otherwise requirement
(Figure 1.1).
OVER-LAY JOINT
Figure 1.1 Overlay Joints

This joint is made from glass fiber reinforcement and polyester resin. It is typically
used where it is required to withstand axial forces from internal pressure. This
system provides a strong, leak-proof joint and can be applied either in the shop or in
the field. Joint reinforcing is supplied in varying widths and pre-cut for each
particular pressure and diameter. GGT strongly recommends that all GRP joints be
installed by trained personnel with experience. Final assembly joints should not be
installed until the system hangers, supports and anchors have been properly located
and fixed equipment connections have been made. Because of the high rate of
thermal expansion in GRP piping, all measuring, cutting, fitting and joining may be
performed at the same ambient temperature. Standard field joint kits include glass
reinforcing materials, resin putty, resin for laminating, surface coating material and
catalyst.
All butt welds are to be made in accordance with ASTM C582 or NBS Specification PS
15-69. The actual procedure will be performed as follows:

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Above Ground Piping
2006-03-02
Doc. No.
Procedure for Overlay (Butt Joint)

1. Cutting
Measure off length of GRP pipe required and
using a marker and straight edge, draw a line
completely around surface to be cut.
Cut pipe with a saber saw using a fine toothed
blade or a circular saw with an abrasive blade.
2. Puttying on the pipe

If necessary, before puttying, Installer can be
beveling about 15~ 30and pipes are
beveled only to structural layer or middle layer.
Pipe will be placed in the position in which they
are to be welded. A catalyzed thixotrophic
polyester paste will be applied to the joint seam.
Make certain work area and surfaces are as
clean as possible and dry.
3. Grinding
After filled and enough cured in bevel should be
grind until same level of the pipe outside.
4. Preparing fiberglass
Lay out fiberglass mat strips on work table.
Length of each strip(fiberglass) should be 50mm
longer than circumference of the pipe. The width
of strip(fiberglass) in accordance with GGT
manual (See table for length of overlay).
The width of the first layer shall be 50mm
minimum. The woven roving shall not be greater
in width than the layer of chopped strand mat.
Page

Above Ground Piping
Title
Re. Date
2006-03-02
Doc. No.
5. Laminating
Mix prescribed amount of catalyst with required
amount of resin in clean container. Resin will
harden in about 20-30 minutes. After mixing the
catalyst thoroughly, apply resin to fiberglass mat
by the brush or paint roller.
6. Overlaying
Before overlay on pipe installer shall be applied
resin on the pipe surface. Pick up the completed
weld fiberglass by one end and center it carefully
on the pipe. Apply the taper end first with the
narrowest fiberglass on the pipe weld.
7. Remove bubble
Be sure weld is centered, with care taken to
avoid wrinkles on the under or back side of the
weld. Finished joint should be built up in
successive layer uniformly and without air
bubble. Successive layers shall increase
uniformly to provide minimum total thickness of
overlay which meet the width of the last layer. Do
not move or disturb weld until it is thoroughly
cured.
8. U.V(ultraviolet) Coating
After overlaying finish, surface may be rough
grind by sand paper grinder. After surface
grinding, pipe shall be coated by acid resistant
and U.V protective gel coat resin. After ultraviolet
(U.V) coating, do not touch until it is thoroughly
dry on the pipe surface.
Page

Above Ground Piping
Title
Re. Date
2006-03-02
Doc. No.
Page
External reinforcing lamination
Putty
30 Bevel Angle
(If Required)
Inside lamination (100x2 mm)

(See Note 2)
(See Note 1)
Figure 1.2 Typical Overlay
Pipe Size
Overlay Length( L )mm
Pipe Size
Overlay Length( L )mm
(DN)mm
5 bar
7 bar
10 bar
(DN)mm
5 bar
7 bar
10 bar
150
100
100
130
700
270
380
550
200
100
120
160
800
310
440
620
250
100
140
200
900
350
490
700
300
120
170
240
1,000
390
540
780
350
140
200
280
1,100
430
600
860
400
160
220
310
1,200
460
650
930
450
180
250
350
1,400
540
760
1100
500
200
270
400
1,500
580
810
1200
600
240
330
470
1,800
700
1000
1400
Note 1:The recommended maximum tolerance of butt joint gap will not be over than
below dimensions;
Note 2: If necessary, over 650mm pipe may be structural laminate in pipe internal. (3mm)
Nominal Pipe Size
gap (mm)
For 15mm through 500mm
2.0
2.7
3.6
For Lager than 1000mm
4.5

Above Ground Piping
Title
Re. Date
2006-03-02
Doc. No.
Page
6.1.1 Alternative: overlay pack

The maximum thickness of each pack is approximately 5 mm, but never more than
of the total lamination thickness; each lamination shall be made with at least two
superimposed packs, and the joining area shall be staggered. The width of the overlay
shall be equal to the width of the whole wrapping.
The width of the wrapping can decrease at the outer part of the reinforcement, but
joints in the hoop direction are not allowed. When laying the fiberglass plies, it is
essential to create staggers between the strips, at least 25 mm wide, in order to have
an overlapping joint between packs.
Packs overlapping
Tissues staggering in each pack
25 mm
Tissues staggering in first pack

25 mm
Figure 1.3 Typical Method of Overlay

Each ply of glass reinforcement should be saturated with resin and the pack
prepared should be rolled vigorously so as to squeeze out all the air bubbles and to
ensure complete impregnation and compactness.
The pack saturated with resin should be peeled carefully from the work table and
then turned over and applied to the zone of the joint so that the last strip is placed
against the surface of the pipe.
When the pack is applied on the pipe/joint surface, make sure that it is not wrinkled.
The next operation is the elimination of the air bubbles.

Above Ground Piping
Title
Re. Date
2006-03-02
Doc. No.
Page
6.1.2 Branch Connection

Branch connections are in two types:
With integral sleeve reinforcement, surrounding all the main pipe;
With pad reinforcement.
Db
(TYPE 2)
Db
Dm
(TYPE 1)
Sleeve reinforcement
Pad reinforcement
Figure 1.4 Fabrication Method of TEE

The type with sleeve reinforcement is generally used for branch pipe diameter (Db)
equal or greater than of the main pipe diameter (Dm). The pad diameter is then
used for Db< Dm. The type to be used is in any case clearly shown in the standard
or job dimensional tables.
Execution With External Liner Restoration
Since it is not possible to work inside the pipe, the bevel shall be on the outer part and
with a long tapering (tapering angle 710), and reinforcements applied as per the
following drawings.
Two C glass veils and two CSM 380 or 480 E glass mats will be applied on the
tapered surfaces, as shown at section 6.1 for butt joint. In order to increase the
bending radius of the successive laminations, apply over the liner restoration putty or
E glass mat strips resin impregnated.
Warning The following drawings are not to the scale, in order to make more clear the
different parts of the joint. Actually the lamination has not an uniform thickness and it is
shown in the dimensional tables.

Above Ground Piping
Title
Re. Date
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Doc. No.
Page
Base reinforcement lamination
Key Plan
B
C
Further external reinforcement
Pos. "A"
Db<Dm
Putty or "E" mat filling
Dm
Db=Dm
C
2 "C" veils + 2 "E" mats
Pos. "C"
Pos. "B"
Further reinforcement
Putty or "E" mat filling
Figure 1.5 Execution With External Liner Restoration of TEE
Execution With Internal Liner Restoration

The bevel is made in the inside part of the main and of the branch. The bevel angle is
approximately 30 ~ 45. The bevel will be filled with putty, as shown in the drawings.
The internal reinforcement shall terminate with two E glass mat and two C glass
veil in contact with the medium (internal liner restoration). The bevel and the putty
filling shall have a smooth fillet as shown in the drawings. For the lamination of the
internal and external overlays follow instruction at section 6.1.1.

Above Ground Piping
Title
Re. Date
2006-03-02
Doc. No.
B
Key Plan
Page
10
External Reinforcement
Pos. "A"
Putty
Db
Dm
Internal reinforcement
Db=Dm
C
C
Pos. "B"
Pos. "C"
Putty
Putty
Putty
Figure 1.6 Execution With Internal Liner Restoration of TEE

Above Ground Piping
Title
Re. Date
2006-03-02
Doc. No.
Page
11
Table 1.1 Standard Laminate Composition for Overlay
SEE NEXT PAGE
Notes :
1. Below(less than) 80mm pipe shall be laminate material to all Chopped Strand Mat
for overlay.
2. Symbol & Legend
S : Surface mat (# 30)
M : Chopped Strand Mat (# 450)
R : Roving Cloth (# 580)
The length of over lay (See page 6 of 30)
ATTACH DOCUMENT (Page 1 of 3)
STANDARD LAMINATE COMPOSITION OF BUTT JOINT

Thk.
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
9.5
10.0
10.5
11.0
11.5
12.0
12.5
13.0
13.5
14.0
14.5
15.0
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
M M
M R M
M R M M
M R M M
M R M R M
M R M R M
M R M R M M
M R M R M R M
M R M R M R M
M R M R M M R
M R M R M M R
M R M R M M R
M R M R M M R
M R M R M M R
M R M R M M R
M R M R M M R
M R M R M M R
M R M R M M R
M R M R M M R
M R M R M M R
M R M R M M R
PLY
Qty
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 M R
M
M
M M
M R M
M R M
M R M M
M R M R M
M R M R M
M R M R M
M R M R M
M R M R M
M R M R M
M
M
R M
M R
5
5
6
6
6
6
7
7
7
8
8
9
9
9
10
10
10
11
11
11
12
1
2
2
2
3
3
3
4
4
4
4
4
5
5
5
6
6
6
6
7
7

PLY
Qty

Thk.
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 M
15.5
16.0
16.5
17.0
17.5
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M M
M M
M M
M M
M M
R
R
R
R
R
M
M M
M R M
M R M
M R M M
12
13
13
13
14
7
7
8
8
8
18.0
18.5
19.0
19.5
20.0
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M M
M R M
M R M
M R M
M R M
M
M
R M
14 8
14 9
15 9
15 9
15 10
20.5
21.0
21.5
22.0
22.5
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
M
M
M
M
M
R
R
R
R
R
M
M
M M
M M
M R M
16
16
17
17
17
10
10
10
10
11
23.0
23.5
24.0
24.5
25.0
25.5
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
R
R
R
R
R
R
M
M
M
M
M
M
R
R
R
R
R
R
M
M
M
M
M
M
R
R
R
R
R
R
M
M
M
M
M
M
M
M
M
M
M
M
R
R
R
R
R
R
M
M
M
M
M
M
R
R
R
R
R
R
M
M
M
M
M
M
R
R
R
R
R
R
M
M
M
M
M
M
M
M
M
M
M
M
R
R
R
R
R
R
M
M
M
M
M
M
R
R
R
R
R
R
M
M
M
M
M
M
R
R
R
R
R
R
M
M
M
M
M
M
M
M
M
M
M
M
R
R
R
R
R
R
M
M
M
M
M
M
17
18
18
18
19
19
11
11
12
12
12
12
R
R
R
R
R
R
M
M
M
M
M
M
M
R
R
R
R
M
M
M M
M M

PLY
Qty

THE END
Continuous
Continuous
Continuous
Continuous
Continuous
S
S
S
S
S
20
20
20
21
21
12
13
13
13
14
R
R
R
R
R
Continuous
Continuous
Continuous
Continuous
Continuous
S
S
S
S
S
21
22
22
22
22
14
14
15
15
16
M
M
M
M
M
R
R
R
R
R
Continuous
Continuous
Continuous
Continuous
Continuous
S
S
S
S
S
22
23
23
24
25
16
16
17
17
17
M
M
M
M
M
M
R
R
R
R
R
R
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
S
S
S
S
S
S
25 17
Thk.
10 11 12 13 14 15
26.0
26.5
27.0
27.5
28.0
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
28.5
29.0
29.5
30.0
30.5
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
31.0
31.5
32.0
32.5
33.0
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
M
M
M
M
M
R
R
R
R
R
M
M
M
M
M
R
R
R
R
R
33.5
34.0
34.5
35.0
35.5
36.0
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
R
R
R
R
R
R
M
M
M
M
M
M
R
R
R
R
R
R
M
M
M
M
M
M
R
R
R
R
R
R
M
M
M
M
M
M
M
M
M
M
M
M
R
R
R
R
R
R
M
M
M
M
M
M
R
R
R
R
R
R

Above Ground Piping
Title
Re. Date
2006-03-02
Doc. No.
Page
12
6.1.3 Tools for butt joint

For butt and wrap joints the following is needed:
Measuring tape
Marker pen
Cleaning-rags
Grinder
Sanding disc
Gloves, brushes
hardener and glass reinforcement
A pair of scissors + knife
Steel rollers , Paint rollers
Dust masks
6.1.4 Gel time

Since many variables affect the cure of the resins, the catalyst system must be
adjusted for each individual application. The selection criteria for the catalyst
system are;
Gel time desired
Working Temperature
Effect of the mold as a heat sink
Table 1.2 Typical Gel Time for Resin with M.E.K.P
Mixing (%)
Temperature
( C)
Gel Time
(minutes)
Cobalt
F-2
M.E.K.P
15
30
0.5
1.3
25
30
0.3
0.2
1.0
35
30
0.3
0.7
1.0
15
60
0.3
1.0
25
60
0.3
0.7
1.0
35
60
0.3
1.2
1.0
F-2: Curing controller

M.E.K.P: Hardener (Methyl Ethyl Ketone Peroxide)

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6.2 Flanged joints

Flanged joints are used in piping
systems for easy of installation
and connection to equipment or
other material. All flanges are
designed for the requirement
pressures specified by the client. All
flanges manufactured by GGT are
continuous glass fiber reinforcing
from the hub into the flange face.
Manufacturing method for flanges
are hand lay-up and contact
molded with smooth radius.
Full Face Flange
Full Face Gasket
O-ring Flange
Washer
O-ring
Figure 1.7 Flanged joints

GGT standard is a bolting pattern which flanges are manufactured in accordance with
international codes. Bolting dimension system such as ANSI, AWWA, DIN, JIS can be
supplied. Flat face GRP flanges must be bolted to flat face companion flanges, with full
gaskets or O-ring. GGT flanges thickness design in accordance with ASME, ANSI
standards. (If you want to detail information see the our Manufacturing guide)
GRP flanges should be jointed according to the following procedure;
1. Thoroughly clean the flange face and O-ring groove.
2. Ensure the O-ring gasket is cleaned and undamaged. Do not use defective gaskets.
3. Position O-ring in groove and secure in position with small strips of adhesive tape.
4. Align flanges to be jointed.
5. Insert bolts, washers and nuts. All hardware must be cleaned and lubricated to avoid
incorrect tihtening. Washer must be used on the all GRP flanges.
6. Using the torque wrench, tighten all bolts to 40 N.m(4 kg.m) torque 20 N.m(2 kg.m) for
small diameter in accordance with standard flanges bolt tightening sequences. (See
Figure 1.8)

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7. Repeat this procedur,

increasing torque untile
the recommend value for
bolt torque. Do not
exceed this torque. To do
may cause permanent
damage to GRP flanges.
8. Check bolt torques one
hour later and adjust to
recommend bolt torque
for each size of flanges.
Figure 1.8 Procedure for Bolt Tightening
Connecting to RF Flange
If raised face flanged equipment is
connected to GRP flanges, a hard
plastic or metal filler ring must be
added to provide a flat connection
surface, in figure 1.9. The best
material for filler ring may be the
same as the full face gasket material
or the hardness shall be more than
full face gasket (EX: PE, PVC).
Filler ring
Valve or Equipment
GRP Flange
Figure 1.9 Insert of Filler Ring
6.2.1 Bolt, Nut & Washer

All nuts, bolts and washers will be in accordance with piping material specifications.
Dimensional requirement for bolts and nut will comply with ANSI standard (inch or
metric Thread) and the length of bolts will be in accordance with ANSI B16.5. When
jointing GGT fiberglass products flanges to flanges of other material or manufactures,
bolt length will be calculated.

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6.2.2 Recommended Bolt Torque

Based on Full Face Flat Gaskets 15mm through 250mm and O-ring Gaskets 300mm
through 2500mm diameter experience has shown these values to work. However,
these values may be increased 50% safely. Call GGT before exceeding 100% of
these values. Bolt torque must be uniform within a 10% range of recommended values.
Note: Uniformity of bolt torque is critical.
Table 1.3 Bolt Torque Depend on Pressure
Unit : kg m
Flange
Diameter
2 bar
4 bar
6 bar
8 bar
10 bar
12 bar
50
80
100
150
200
10
10
10
10
10
10
300
17
17
17
17
17
17
350
12
14
400
10
12
14
500
14
14
16
600
10
14
17
20
700
10
14
17
20
900
14
17
24
28
1000
10
14
18
28
32
1200
10
1400
10
1600
1800
2000
2200
2400

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6.2.3 Recommend Procedure for Flange Installation

In overlay(butt joint) the flange to the GRP pipe, first ensure that the bolt holes are
aligned with those on the mating flange. Do not joint the pipe to pipe or fitting before
flange connection. The use of flat washers on all nuts and bolts must be required. The
maximum allowable torque is indicated on each flange and is also shown in Table 1.3.
Full face gasket materials, 3.0mm thick, with a Shore A hardness of 60 to 70
durometer are recommended for GGT fiberglass products flanges.
The following procedure is our recommendation
Assembling No.1 Assembling No.2
GOOD
STEP 2
STEP 1
Butt Wrap Joint
WRONG
Figure 1.10 Installation procedure for flanges

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6.3 Other Jointing Method

6.3.1 Flexible Steel Coupling
When connecting GGT GRP pipe to pipe, fitting
and other pipe materials with different diameter,
flexible steel coupling are one of the preferred
jointing methods. These couplings consist of a
steel mantle with an interior rubber sealing sleeve.
They may also be used to join GGT GRP pipe
sections together, for example in a repair or for
closure.
Figure 1.11 Flexible Steel Coupling
Two grades are commonly available;
1. Stainless steel mantle
2. Hot dip galvanized steel mantle
Regardless of the corrosion protection applied to the steel mantle, the balance of the
coupling needs to be corrosion protection as well.
Control of the bolting torque value of flexible steel coupling is most important. Do not
over torque as this may over stress the bolt or the pipe. Follow the coupling
manufactures recommended assembly instructions, but GGT will be recommended for
bolt torque limits.

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7. U.V. Resistance
There is no evidence to suggest that ultraviolet degradation is a factor that affects the
long-term service life of GGT pipes. But, the outermost surface will be affected with
discoloring of the surface observed. So, this layer offers sufficient protection against
U.V. radiation. The exterior layer (topcoat) consists of pure resin, equal to the type used
for the structural wall underneath, and will be exempted of pigments and fillers. The
thickness of the topcoat will be 0.3 mm.
Painting procedure of U.V layer is as follows:
c Clean the outside surface with thinner.

d In plastic vessel, the resin must be inserted M.E.K.P or Cobalt with injection after
measuring. (See note to resin mix table)
e They must be mixed with wood or plastic bar.

f With wool roller, pipes outsides grinding parts glass fiber must be painted well
without seeing exposure.
g Until curing, dust, other material must be taken care so that it may not inserted.
Table 1.4 For mixed top coating
RESIN
100
Provided by gel coat manufacture

10%
D.M.A
COBALT
PARAFFIN
6%
0.2%
1.5%
Mixing at the field

M.E.K.P
POT LIFE
(25C)
1.5%
5 ~ 10 minutes
z M.E.K.P should be mixed at the field with top coating material of provided by gel coat
manufacture.

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8. Pipe Support
OVERVIEW
SUPPORT
ANCHOR
Pipe anchors secure the

pipe
against
applied
forces. GGT fiberglass
pipe recommends anchor
Pipe supports prevent to
restrain
thermal
deflection of the pipe due expansion if the expansion
to the weight of the pipe cannot be handled the
and fluid.
directional change.
GUIDE
If anchors are used to
handle thermal expansion,
guides are required to
prevent lateral movement
of
the
pipe.
Lateral
movement may cause a
pipe to buckle when axial
compressive load exist in a
pipe.
8.1 General Rules

Unless otherwise the support types are shown below support detail drawings. Supports
must be installed at the precise position marked the drawing and considering site
conditions support must be installed the position needed. In case of pipe supports
affected by vibration, supports shall be installed firmly. There are six basic rules to
follow when designing and positioning supports, anchors, guides.
c Avoid point loads.

d Meet minimum support dimensions.
e Protect against abrasion.
f Support valve and other heavy equipment independently of the pipe in both vertical
and horizontal installations.
g Avoid excessive bending.

h Avoid excessive loading in vertical runs.
8.2 Support
To prevent excessive pipe deflection due to the weight of the pipe and the fluid,
horizontal pipe should be supported at intervals recommended in the support spacing
Table 1.5 with adjustments for temperature and specific gravity.

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Figure 1.12 Typical Type of Support

8.3 Anchor
An anchor must restrain the movement of the pipe against all applied forces. The low
modulus and light weight of GRP cause these pipes to move more easily under
water hammer conditions. If the movement causes excessive bending stresses, it
must be controlled by anchoring at change in direction. In some case, pumps,
tanks, and other similar equipment function as anchor. Anchors are required where
pipe size change and where GGT product pipe is jointed to pipe made of another
material or by another manufacture.
Additional anchors usually occur at valve locations, changes in direction of piping runs,
and at major branch connections. Operating experience with piping systems indicated
that it is good practice to anchor long, straight runs of aboveground piping at
approximately 90 meter(300 feet) intervals. These anchors prevent pipe movement
due to vibration or water hammering. Side of clamp laminate thickness must equal or
exceed the clamp thickness. Below figure shows a typical anchor.

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OVERLAY
OVERLAY
RUBBER PAD
DOUBLE CLAMP
Figure 1.13 Typical Type of Anchor

8.4 Guide
The guide mechanism must loose so as to allow free axial movement of the pipe.
However, the guides must be rigidly attached to supporting structure so that the pipe
moves only in the axial direction. All guides also act as supports and must meet the
minimum requirements for supports as set forth in Section 8.1, General Rules.
CAUTION: When thermal cycles frequent or vibration exists, the pipe must be
protected at points of contact. This is accomplished by bonding a wear saddle of steel
or one-half of a section of the same pipe to the pipe wall(See figure 1.15).
Figure 1.14 Typical Type of Guide
Figure 1.15 Protective Sleeve

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Table 1.5 Support Spacing

Pipe
Max. Spacing for Pipe Pressure Rating (bar)
(mm)
5
7
10
15
15
1.5
1.5
1.5
1.5
20
1.5
1.5
1.5
1.5
25
1.7
1.7
1.7
1.7
32
1.8
1.8
1.8
1.8
40
2.0
2.0
2.0
2.0
50
2.1
2.1
2.1
2.1
65
2.2
2.2
2.2
2.2
80
2.4
2.4
2.4
2.4
100
2.5
2.5
2.5
2.5
125
2.7
2.7
2.7
2.7
150
3.0
3.0
3.0
3.0
200
3.2
3.2
3.2
3.2
250
3.7
3.7
3.7
3.9
300
3.9
3.9
4.1
4.2
350
4.1
4.1
4.4
4.6
400
4.2
4.4
4.7
4.9
450
4.4
4.6
5.0
5.2
500
4.6
4.9
5.3
5.5
600
5.0
5.3
5.8
6.0
650
5.2
5.5
6.0
6.3
700
5.4
5.8
6.3
6.5
750
5.6
6.0
6.5
6.7
800
5.8
6.2
6.7
6.9
850
5.8
6.2
6.7
7.0
900
6.0
6.4
6.9
7.2
950
6.1
6.5
7.1
7.4
1,000
6.3
6.7
7.3
7.6
1,050
6.5
6.9
7.5
7.7
1,100
6.6
7.0
7.7
7.9
1,150
6.8
7.2
7.8
8.1
1,200
6.9
7.3
8.0
8.3
1,250
7.0
7.5
8.2
8.5
1,300
7.2
7.6
8.3
8.6
1,350
7.3
7.8
8.5
8.8
1,400
7.5
7.9
8.6
8.9
1,500
7.7
8.2
8.9
9.3
1,600
8.0
8.5
9.2
9.6
1,700
8.2
8.7
9.5
9.9
1,800
8.3
8.9
9.6
10.0
Note : The above table values are based on uninsulated pipe containing liquid
having specific gravity and at a maximum temperature of 80C

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8.5 General Installation

There are six basic rules to follow when designing and positioning supports, anchors,
guides.
1. Avoid point loads.
Use protective sleeves to eliminate points loads when necessary. (See Figure 1.15
for detail)
2. Meet minimum support dimensions.
Pipe support spacing must be installed in accordance with Table 1.5. Table 1.5 show
the support spacing for various piping system for liquids with a specific gravity of 1.0
and for gases. The data is presented on a basis of continuous spans. Continuous
spans are those which contain three or more spans in a straight section with all
interior spans equally spaced and load. Support saddle width must be minimum
120 for contact area(See Figure 1.15). The length of this saddle with respect to the
wide of the support must be 50mm longer than the calculated displacement of the
pipe. The saddle length(L) itself must be at least 100mm.
Saddle made from fiberglass pipe will be bonded to pipe with a paste made from
pipe spec resin or the adhesive. All bonded pipes and saddle surfaces may first be
rough grinded.
Table 1.6 Support Spacing vs. Specific Gravity
Specific Gravity of Liquid
Adjustment
Factor
0.75
0.90
1.00
1.10
1.25
1.50
1.05
1.02
1.00
0.98
0.95
0.91
3. Protect against abrasion.

Assure that adequate protection is provided where possible mechanical damage
could occur(See Figure 1.11, 1.14, 1.15). The inside of steel cradle should be
covered with a rubber or cork-rubber layer in order to minimize abrasion, causing by
pipe vibrations or movements(See Figure 1.13).

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4. Support valve and other heavy equipment independently of the pipe in both
vertical and horizontal installations.
To avoid GGT pipes being over stressed by bending, valves, butterfly valves or other
heavy accessories must be supported separately. This can be done by direct
support of the valve or indirectly by means of the flange bolts. So, valve, and other
heavy equipment shall be supported independently in both horizontal and vertical
direction(Figure 1.16). But, it is not necessary for light weight of each equipment.
HEAVY EQUIPMENT
HEAVY EQUIPMENT
HEAVY EQUIPMENT
Figure 1.16 Heavy Equipment Supporting

5. Avoid excessive bending.
When pipe lines are laid directly on the surface, take care to ensure that there
are no excessive bends that would impose undue stress on the pipe. (Refer to
Table 1.7 for minimum bending radius), (See Figure 1.17)
WRONG
RIGHT
Figure 1.17 Bending
OVERLAY
Figure 1.18 Vertical Support

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6. Avoid excessive loading in vertical runs.

Vertical pipe runs should be supported as in Figure 1.18. Figure 1.18 illustrates the
preferred method. Install guide collars at the same spacing as supports for the
horizontal piping.
9. Passing to the (concrete)Wall

When a pipe has to pass through a wall, the outside of the pipe must be protected by a
flexible material (a rubber layer, with a minimum thickness of 5mm) protruding some
100mm outside the wall at each side(See Figure 1.19).
Rubber Band
GRP Pipe
Min. 100mm
Concrete Wall
Figure 1.19 Pipe Passing through Concrete Wall (For Above Ground)
Steel Sleeve
Flexible Filler(50mm min.)
GRP Pipe
The Ground
Concrete Wall
Figure 1.20 Pipe Passing through Concrete Wall (For Underground)

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10. Dimensional Tolerances

GGT general pipe fabricating
tolerances for pre-fabricated GRP
piping assemblies through 2500mm
diameter are as follows:
Linear Tolerance
The
tolerances
on
linear
dimensions (intermediate or overall)
apply to the face to face, face to
end, and to end measurements of
fabricated
straight
pipe
and
headers; center to end or center to
face
of
nozzles
or
other
attachments.
Linear tolerances on A are

3.0mm for sizes 250mm and
smaller, 5.0mm for sizes 300mm
through 600mm. Linear tolerances
on A for sizes over 600mm are
subject to tolerances of 5.0mm,

increasing by 1.0mm for each
300mm in diameter over 600mm.
Note : Tolerance on dimensions
which do not include pipe
segments are to be base
on ANSI specification for
fitting.
SECTION X-X
Figure 1.21 dimensional tolerance

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Squareness Tolerance
Squareness of end cuts. B shall not deviate more than 3.0mm up to and including
600mm diameter and 5.0mm for diameters up to 1200mm.
Table 1.7 Summary of dimension tolerance
Nominal
Nominal
A
B
Dia.
Dia.
(mm)
(mm)
(mm)
(mm)
15 to 250
300 to 900
3.2
4.8
15 to 600
Over 600
Nominal
Dia.
(mm)
C
(mm)
D
(mm)
All Size
1.0mm
per
25cm
2.0
3.2
4.8
Table 1.8 Tolerance of Manufacturing - made fittings
Nominal Dia.
(mm)
15 to 200
A
(mm)
1.5
R
(mm)
1.5
L
(mm)
1.5
250 to 600
2.3
2.3
2.3
650 to 750
3.1
3.1
4.8
800 to 1200
4.8
4.8
4.8
For
angularlty
tolerance
Nominal Dia.
(mm)
15 to 100
Q
(mm)
0.8
125 to 200
1.5
250 to 400
2.3
450 to 600
3.1
650 to 1200
4.8

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11. Repair Manual

If at any time during handling or installation of the pipe, any damage such as a gouge,
crack or fracture occurs, the pipe should be repaired before the section is installed.
Typically, damaged pipe can be repaired quickly and easily by qualified personnel at a
job site. The repair design depends on the wall thickness, wall composition, application,
and the type and extent of damage. Do not attempt to repair damaged or defective pipe
without consulting the pipe GGT. Scrapes and gouges on the pipe exterior that are less
than 10 percent the pipe wall thickness generally require no repair, while deeper scrapes
generally require repair. Repair for damage to the inner layer depends on the damage
depth. Scratches, scrapes, and abrasion that do not penetrate through the entire liner
layer generally require no repair.
This GGT repair manual describes two methods for the eventual repair of GGT glass
fiber reinforced pipe systems. Procedure 1 is applied when a small damage or large
diameter on pipe and fittings. Procedure 2 is applied for severe damage or small
diameter on pipe and fittings. GGT recommend that repair of pipe as following;
Damage
Area
Grinding
Pipe Thk.
Repair procedure 1. (Applied for a small damage on pipe) 600mm through larger.
1. Damage of pipe
2. Grinding
Before installation of the straight pipe

and fitting section the installer should
inspect if any damage has occurred
due to transport or storage. If damage
on pipe and fitting installer should be
repaired in the field.
Damage
area
caused
during
transportation and installation shall be
grinded by grinder up to inner face. The
width of grind should be enough in order
to overlay on damage location.

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Fill up
Putty
Doc. No.
Pipe Thk.
Page
Grinding
29
Pipe Thk.
Title
3. Fill up with Putty
4. Grinding
After grinding, fill up with putty at first.

Hollow space must be filled by high
speed acid resistant resin and
Chopped Strand Mat.
After filled in hollow should be grind until

same level of the pipe outside.
5. Preparing and Cutting of Fiberglass

Lay out fiberglass mat strips on work table.
The overlay length and width depends on the extent and nature of the damage. Our
recommend for Length and width of each strip(fiberglass) will be longer than10 time
of wall thickness at damage end(See Figure 1.22).
6. Apply resin on fiberglass

Mix prescribed amount of catalyst with required amount of resin in a separate clean
container. Resin will harden in about 20-30 minutes. After mixing the catalyst
thoroughly, apply resin to fiberglass mat by the brush or paint roller.
7. Overlay on pipe
Pick up the completed weld fiberglass by one end and
center it carefully on the pipe. Apply the taper end first
with the narrowest fiberglass on the pipe weld.
8. Remove bubble
Be sure weld is centered, with care taken to avoid
wrinkles on the under or back side of the weld.
Finished joint should be built up in successive layer
uniformly and without air bubble. Successive layers
shall increase uniformly to provide minimum total width
of overlay which meet the width of the last layer. Do not
move or disturb weld until it is thoroughly cured.
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Overlay
(Lamination)
Page
30
Pipe Thk.
Title
Figure 1.22 Overlay Width

9. After overlaying finish, surface should be rough grind by sand paper grinder. After
surface grinding, pipe shall be coated by acid resistant or U.V protective gel coat
resin. For top coating reference is made to the GGT U.V coating instructions.
(See welding procedure on overlay manual). Ensure that the complete laminate
length L is observed on both sides of the damage location. The total length of
the laminate is larger than 10 times of the pipe wall thickness.
Repair procedure 2. (Applied for severe damage on pipe) 15mm through 500mm.
Over-Lay
Figure 1.23 Parch
Figure 1.24 Cutout and Replace

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1. Should severe or larger damage have occurred to existing pipelines, there is a risk
of the damaged section should be removed from the pipeline network. The length
of cutting on pipe shall be lager than damage area. The length depends on the
extent and nature of the damage. A diagram of the repair is shown below;
Diagram showing the repair:
W
Figure 1.25 Severe damage on the pipe
Figure 1.26 Cutting
2. The principle behind this method is that the pipe section containing the leak is cut
out the existing pipeline. Cutting piece of a length W shall be over 50mm on both
sides of the damage end line.
1.27 Replacing

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Figure 1.28 Assembly
Doc. No.
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32
Figure 1.29 Laminating
3. A new joint is trimmed to length W and installed in the existing pipeline using two
laminate joints, as described in the GGT Field Laminate Instructions (See welding
procedure on overlay manual).
11.1 Cutting Edge
The maximum gap between the pipe sections to be joined as following;.
Max. Gap
Connect to Pipe or Fitting

Figure 1.30 Maximum gap
Table 1.9 Maximum gap for Repair Pieces
Application size (mm)
Maximum gap (mm)
For 15 through 350
3.0
For 400 through 700
4.5
For 750 through 1400
8.0
For Lager than 1400
10.0

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12. Field Hydrostatic Testing

Testing with air or gas is not recommended because of the safety hazards involved. The
light weight, flexibility, and elasticity of fiberglass pipe create different conditions than are
present with steel pipe. If a catastrophic failure occurs in a fiberglass system, the system
would be subject to considerable whipping and other shock-induced conditions due to
the sudden release of stored energy. The recommended procedure is to conduct a
hydrostatic pressure test. If a field hydrotest is specified, it must be done regularly as
installation proceeds. In additional to routine care, normal precautions and typical
procedures used in this work, the following suggestions should be noted;
1. Preparation prior to test
Inspect the completed installation to assure that all work has been finished properly. Of
critical importance are;
Joints assembled correctly
System restraints (i.e,. Thrust block, other anchor) in place and properly cured.
Flange bolting torque for instruction.
Supporting for valve or other equipment
2. Filling the Pipeline with Water
Open valve and vent, so that all air is expelled from the pipeline during filling, and
avoid pressure surges.
3. Pressurize the pipeline slowly in accordance with GGT procedure. Considerable
energy is stored in a pipeline under pressure, and this power should be respected.
4. Insure the gauge location will read the highest line pressure or adjust accordingly.
Locations lower in the line will have higher pressure due to additional head.
5. Insure the maximum test pressure is not exceeded (See table 1.10). This may be
dangerous and result in damage to the pipe system.

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Table 1.10 Maximum Field Test Pressure

Pressure Class or
Design Pressure
Maximum Test Pressure
1.0 bar (14 psi)
1.5 bar (22 psi)
3.0 bar (44 psi)
4.5 bar (65 psi)
6.0 bar (87 psi)
9.0 bar (131 psi)
10.0 bar (145 psi)
15.0 bar (218 psi)
16.0 bar (232 psi)
24.0 bar (348 psi)
6. If the pipe is determined to be leaking and the location is not readily apparent, the
following methods may aid discovery of the problem source;
Check flange and valve area.
Check line tap area (If any).
Test the line in smaller segments to isolate the leak.

GRP

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Glass-fiber Reinforced Plastic Pipe

2. Field Service Representative . 1

6.1 Overlay joints . 3

6.1.3 Tools for butt joint . 12

6.2 Flanged joints . 13

6.2.3 Recommend Procedure for Flange Installation . 16

6.3.1 Flexible Steel Coupling

8.2. Support ... 19

8.4 Guide .... 21

9. Passing to the (concrete)Wall ... 25

12. Field Hydrostatic Testing ... 33

GILGWANG GREENTECH CO.,LTD.

Installation Manual of GRP Pipe

2. Field Service Representative

4. Inspecting pipe at the job site

GILGWANG GREENTECH CO.,LTD.

Installation Manual of GRP Pipe

e Check the quantity of each item against the bill of lading.

GILGWANG GREENTECH CO.,LTD.

Installation Manual of GRP Pipe

Figure 1.1 Overlay Joints

GILGWANG GREENTECH CO.,LTD.

Installation Manual of GRP Pipe

Procedure for Overlay (Butt Joint)

2. Puttying on the pipe

GILGWANG GREENTECH CO.,LTD.

GILGWANG GREENTECH CO.,LTD.

External reinforcing lamination

Inside lamination (100x2 mm)

Figure 1.2 Typical Overlay

Overlay Length( L )mm

Overlay Length( L )mm

For 600mm through 700mm

For 750mm through 950mm

For Lager than 1000mm

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6.1.1 Alternative: overlay pack

Tissues staggering in first pack

Figure 1.3 Typical Method of Overlay

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6.1.2 Branch Connection

Figure 1.4 Fabrication Method of TEE

GILGWANG GREENTECH CO.,LTD.

GILGWANG GREENTECH CO.,LTD.

Base reinforcement lamination

Further external reinforcement

Putty or "E" mat filling

Base reinforcement lamination

Base reinforcement lamination

2 "C" veils + 2 "E" mats

2 "C" veils + 2 "E" mats

Putty or "E" mat filling

Figure 1.5 Execution With External Liner Restoration of TEE

Execution With Internal Liner Restoration

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Figure 1.6 Execution With Internal Liner Restoration of TEE

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Table 1.1 Standard Laminate Composition for Overlay

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STANDARD LAMINATE COMPOSITION OF BUTT JOINT

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STANDARD LAMINATE COMPOSITION OF BUTT JOINT