QUALITY STANDARTS
The standards developed by ASTM, AWWA and ISO cover a series of glass reinforced pipe applications including water, domestic waste water and chemical agent conveying. The common point of all these standards is that all these standards are all performance-based. In other words, the performance tests required for GRP pipes are specified by these standards.
ASTM
Today various ASTM Product Standards are in use for different glass reinforced pipe applications. ALFEBOR GRP pipes are designed to meet all ASTM standards.
ASTM D 3262 Non-pressure wastewater pipe
ASTM D 3517 Pressure pipe for clean water
ASTM D 3754 Wastewater pressure pipe
AWWA
AWWA C950 is one of the most comprehensive and valid product standards related to the pipes reinforced with glass fiber. This standard covers extensive requirements focusing on quality control and prototype competence tests for pipes and fittings used in pressure water line applications.
ALFEBOR GRP Pipes are designed to meet the requirements of this standard.
AWWA C950 Glass fiber reinforced pressure pipes for clean water
AWWA M45 Fiberglass pipe design
ISO
This product standard is valid for GRP pipes with a diameter from 50 mm to 4000 mm used in water and wastewater applications. The standard covers competency tests for pipe and sleeves and all product tests. ALFEBOR GRP pipes meet the requirements of this standard.
ISO/DIS 0467.3 Wastewater and Drainage
ISO/DIS 0639.3 Clean Water for pressure or non-pressure pipes
OTHER STANDARDS
The other standardization organizations such as BS and DIN also published performance specifications for GRP pipes. ALFEBOR meets the performance requirements of these standards to the extent that they do not conflict with AWWA C950.
DIN 16869 Glass fiber reinforced polyester resin pipes and fittings
BS 5480 Pipe and coupling elements for water and wastewater applications.
It is a common subject requested by all the standards, from the pipe producer for proving by sampling, the compliance of the pipe with the minimum performance requirements. This minimum performance requirements for GRP pipe are both for short term and long term.
The most important ones are expressed in all the previously described standards as;
- JUNCTION
- INITIAL RING DEFLECTION
- LONG TERM PRESSURE RESISTANCE
- CORROSION STRAIN CAPACITY
Alfebor is carefully performing the all mentioned tests in order to control whether the requirements TS 4355, TS EN 1796, TS EN 14364, ASTM D 3262, ASTM D 3517, AWWA C950, DIN 16869, ISO 10467 and ISO 10639.
1- JUNCTION
Coupling Tests
This important performance test is realized in compliance with ISO 10639 Standard with coupling prototypes made with elastomeric gasket sealed sleeves. This is a standard which is valid for the entire pipe industry and which had determined the coupling performancerequirement of the pipes of all types of materials and for each pressure class and diameter.For the simulated laying conditions, flexible coupling is expected to resist against the hydrostatic pressure. The pressures applied in this test are 100kPA (1 bar) for non-pressure pipes and 1.5 times the operation pressure for the pressure pipes. Additional configurations are linear line, maximum angular turning and differential cutting loads. It also includes some fatigue pressure tests.
2- INITIAL RING DEFLECTION
2.1 Initial Ultimate Deflection in the pipes that are laid underground
The allowable deflection value is not specified in ISO Standard system, however, this value can be calculated from ISO TR 10465 – 3: 1999 Standard.
İNTAŞ SYRIA produces GRP pipes in a way to meet;
- SO/DIS 10639 – GRP Pipe System in Providing Water
- SO/DIS 10467 – GRP Pipe System in Drainage and Waste Water Applications
Standards and also the mechanical requirements of ANSI/AWWA C950 standard.
The design procedures in AWWA M-45 Glass Fiber Pipe Design Manual for Water Applications should be followed.
2.2 Minimum Axial Strength
ISO initial values are given as N/mm in unit circumference in relation with the pipe pressure class and diameter. Minimum axial strength values in AWWA are given as Ibf/inch in unit circumference correlated with the pipe pressure class and diameter.
2.3 Initial Failure (Burst) Pressure
Initial blasting pressure is based on long term safe blasting pressure and the regression factor is obtained from the long term static internal pressure. This test methods applied by using the static pressure are similar in ISO and AWWA, but long term safety factors are different.
3- LONG TERM PRESSURE RESISTANCE
3.1 Hydrostatic design base – HDB
Another important competency test is hydrostatic design base – HDB determination test. This test is realized incompliance with ASTM D2992 Procedure B or ISO and high constant hydrostatic pressure is applied on many pipe samples until they leak. The pressure on which the leaking occurs (or the ring strain resistance) and the time values are extrapolated to 50 years on the logarithmic basis.
Extrapolated damage pressure (strain) value or HDB, should be at least 1.6 times the pressure class of the concerned operation (strain for the related pressure class).
In other words, the design criteria, pressure value of the constant pressure pipe for being resistant for 50 years, should be minimum 1.6 times the maximum operation pressure. On the other hand, since the effect of the internal pressure and the external loads in the pipe design is taken as resultant, the safety of the pipe only against the internal pressure is bigger than 1.6 according to the above condition.
HDB competency test guarantees the long term performance of the pipe for the pressure pipe applications.
3.2 Leak test
Leak test may be realized by two methods in ISO GRP pipe system: The first one is experimenting each pipe with a pressure which is 1.5 times of its pressure class. Here, the test period is not specified.
The second method is based on subjecting a sample to a test for 6 minutes under very high pressure. Test pressure is determined from the regression curved obtained from the long term static pressure test. This way, if the long term safety factor is equal to the value calculated from ISO DTR 104-65 – 3, then there will be a failure risk of 6.5%.
3.3 Long Term Ultimate Deflection
Although there is no requirement in AWWA C 950 related to long term deflection, it requires the producer company to determine the deflection value that is convenient for it and announce it. This value which is shown by Sb symbol is defined as strain (elongation % in breaking off).
In ISO, long term deflection is defined as % and it is as Level A deflection without the formation of pipe crack.Level B is the requested structural strength, values in parantheses are the requirement of AWWA C 950 (e.i. table 4)
The requirements are same on both methods.
The pipes laid underground should operate under nominal pressure.This means that the deflection of the laid pipe should also be taken into account.
This state is explained in ISO in ISO DTR 10465 – 3 Attachment G. The safety factors for the long term average minimum values are given in the following table. The values given above are determined according to 9% deviation coefficient.
For higher deviations, the safety factor should be increased. In AWWA, long term safety factor for aboveground and underground laying is constant and this value is 1.8. the calculation should be made in compliance with AWWA M-45 Article 5.7.4.
4- CORROSION STRAIN CAPACITY
This is the only and important pipe performance requirement test that is applied by subjecting the sample for the non-pressure pipes for sewage water, to deflection in chemicals and it is a special test performed for glass fiber pipes that transport chemical materials.
This test is performed by subjecting at least 18 ring samples taken from the pipe, to be deflected at various levels and by keeping them constant at this position according to ASTM D3681 and ISO 10952. The strained samples under the load are subjected to sulfuric acid of 1.0 N (5% by weight) from their internal bottom surfaces. This way, septic waste water medium is simulated. This state represents the Central Asia conditions where the worst septic waste water medium shown and where GRP applications are realized succesfully. By using the smallest squares analysis method, minimum corrosion strain value extrapolated for 50 years should be equal to the value shown for each stiffnes class. The value obtained this way shows the safe installing limitations during the design of GRP pipes to be used in these type of applications.
As ISO requirement, level A and level B values are used in order to form a regression formula. Calculations for 1.000, 3.000 and 10.000 hours are made from these deflection values. Test samples are kept at this deflection value and they are requested not to encounter any structural damage at the period calculated by the regression formula.
The environmental and axial load bearing capacities of the pipes produced are proved by routine tests. Additionally, pipe structure and composition are controlled by tests and approved.
Controls at the stage of production:
- Visual examination
- arcol hardness
- all thickness measurement
- Pipe length
- Diameter measurement
- Hydrostatic leak-proof test
The controls realized by taking sample:
- Pipe rigidity
- Deflection test performed without damage and
- structural damage
- Ring tensile strength
- Axial tensiIt is a common application required by all standards to take samples from pipe manufacturer to prove that the pipe meets minimum performance requirements. These performance requirements for GRP pipes are for short and long term.
The most important requirements are stated in all the mentioned standards as;
Joint
Initial Ring Deflection
Long Term Pressure Resistance
Corrosion Resistance Capacity
Alfebor carries out all of the mentioned performance test meticulously to check that the requirements of TS 4355, TS EN 1796, TS EN 14364, ASTM D 3262, ASTM D 3517, AWWA C950, DIN 16869, ISO 10467 and ISO 10639 are met.JOINTS
Coupling Tests
This important performance test is realized with coupling prototypes on branches that are made impermeable with elastomeric gasket in compliance with ISO 10639 Standard. This standard is valid for the entire pipe industry and stipulates the joint performance requirements of pipes of all diameter and pressure classes made from all kinds of materials.
A flexible coupling is expected resist against a hydrostatic pressure under simulated laying conditions. The pressure applied in this test is 100 kPA (1 bar) for non-pressure pipes and 1.5 times the operation pressure for the pressure pipes. Additional configurations are linear line, maximum angular turning and differential cutting loads. It also includes some fatigue pressure tests.
INITIAL RING DEFLECTION
Initial deflection in the pipes laid underground
The allowable deflection value is not specified in ISO Standard system; however, this value can be calculated according to ISO TR 10465 – 3: 1999 Standard.
ALFEBOR produces GRP pipes in a way to meet the requirements of the following standards;
ISO/DIS 10639 – GRP Pipe System in Providing Water
ISO/DIS 10467 – GRP Pipe System in Drainage and Waste Water Applications
In addition, the mechanical requirements of ANSI/AWWA C950 are met.
The design procedures in AWWA M-45 Glass Fiber Pipe Design Manual for Water Applications should also be followed.
Minimum Axial Strength
ISO initial values are provided in terms of N/mm in unit circumference with respect to the pipe pressure class and diameter. Minimum axial strength values in AWWA are provided in terms of Ibf/inch in unit circumference with respect to the pipe pressure class and diameter.
Initial Failure (Burst) Pressure
Initial burst pressure is dependent on long term safe burst pressure and the regression factor is derived from the long term static internal pressure. These test methods are similar to each other as they are applied by using the static pressure both in ISO and AWWA, however long-term safety factors are different from each other.LONG TERM PRESSURE RESISTANCE
Hydrostatic design basis – HDB
Another important competency test is hydrostatic design basis – HDB determination test. This test is carried out in compliance with ASTM D2992 Procedure B or ISO, and continuous high hydrostatic pressure is applied on many pipe samples until they start leaking. The pressure, where the leakage occurs (or the ring strain resistance) and the time values are extrapolated over a period of 50 years on the logarithmic basis.
Extrapolated failure pressure (stress) value or HDB should be at least 1.6 times the pressure class of the related operation (related pressure test stress).
In other words, the design criteria i.e. the pressure value of continuous pressure pipe that is resistant for 50 years, should be at least 1.6 times the maximum operation pressure. On the other hand, since the effects of the internal pressure and the external loads on the pipe design are taken as results, the safety of the pipe is based on the condition that the internal pressure is bigger than 1.6 as suggested above.
HDB competency test guarantees the long-term performance of the pipe for the pressure pipe applications.
Leakage test
Leakage test may be carried out by means of two methods as per the ISO GRP pipe system: In the first method each pipe is tested with a pressure 1.5 times its pressure class. Here, the test method is not specified.
The second method is subjecting a sample pipe to a very high pressure for 6 minutes. The test pressure is determined with a regression curve derived from the long-term static pressure test. This way, if the long-term safety factor is equal to the value calculated as per ISO DTR 104-65 – 3, the failure risk will be 6.5%.
Long term ultimate deflection
Although there is no requirement in AWWA C 950 related to long-term deflection, the manufacturer company is required to determine and notify the deflection value appropriate for the pipe. This value is indicated by Sb symbol and defined as stress (elongation % in breaking).
In ISO, long-term deflection is defined as % and it is accepted as Level A deflection if deflection occurs on the pipe without any crack. Level B is a value provided in brackets as required by AWWA C 950 standard and indicates the desired structural strength (See table 4).
The requirements are same on both methods. The pipes laid underground should operate under nominal pressure. This means that the deflection of the laid pipe should also be taken into account.
This case is explained in ISO DTR 10465 – 3 Annex G in ISO standard. The safety factors for the long-term average minimum values are given in the following table. The values given above are determined according to 9% deviation coefficient.
For higher deviations, the safety factor should be increased. In AWWA, long term safety factors for aboveground and underground pipe laying are constant and this is 1.8. The calculation should be made in compliance with AWWA M-45 Article 5.7.4.CORROSION RESISTANCE TEST
This is the only and important pipe performance test that is applied by subjecting the sample to the deflection in chemicals for the sewage water used for non-pressure pipes.
This test is carried out by subjecting at least 18 ring samples taken from the pipe to various levels of deflection and holding them fixed at this position according to ASTM D3681 and ISO 10952 standards. The samples stressed under the load are subjected to sulfuric acid of 1.0 N (5% by weight) from their internal bottom surfaces. Thus, septic waste water medium is animated. This case represents the Central Asia conditions, where the worst septic waste water medium exist, and GRP applications are realized successfully. The minimum corrosion stress value extrapolated for a period of 50 years by using the least square method should be equal to the value shown for each stiffness class. The value, obtained this way, shows the safe installing limitations during the design of GRP pipes to be used in these types of applications.
As ISO requirement, level A and B values are used in order to form a regression formula. Calculations for 1.000, 3.000 and 10.000 hours are derived from these deflection values. Test samples are kept at this deflection value and required not to sustain any structural damage over the period calculated by the regression formula.
The peripheral and axial load bearing capacities of the manufactured pipes are proven by routine tests. In addition, pipe structure and composition are checked and approved by tests.Controls at the stage of production:
Visual examination
Barcol hardness
Wall thickness measurement
Pipe length
Diameter measurement
Hydrostatic impermeability testThe controls over samples:
Pipe stiffness
Deflection test performed without damage and structural damage
Ring tensile strength
Axial tensile strength
As ALFEBOR TEST LABORATORY, we UNDERTAKE;
– To protect the confidentiality of our customers’ test results, reports and information
– To act in observance of Reliability, Honesty, Impartiality and Independency in all our activities,
– To stick to ethical values
– To carry out the tests in accordance with the legal requirements, requirements of national and international standards and to keep our service quality at the top level
– To continuously improve our laboratory management system with the contribution of our staff
– To follow technological developments in cooperation with scientific institutions
– To continuously increase customer satisfaction by acting in line with customer demands, and
– To provide all the resources necessary to achieve all of these by complying with TS EN ISO / IEC 17025 standard, local and international standards and legal requirements in all our activities.
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