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Large Industrial Fibreglass Pipe (FRP/GRP) Manufacturers

FRP/GRP Pipe... Exceptional Strength to Weight Ratio

Primarily because of its resistance to corrosive attack from virtually every kind of chemical or compound, FRP piping and components received early acceptance from the Chemical Process Industry.

Today, although corrosion resistance continues to be an important benefit, the other unique advantages of FRP have won the material an ever increasing acceptance in a constantly expanding range of applications where corrosion resistance is not necessarily a primary consideration.

This is especially true in applications requiring very large diameter pipe. One example of this is the 30 x 10m long 1,200mm diameter casings we provided for bridge building over rivers and estuaries where the pipe can be provided in the desired lengths as a former to pouring concrete pilings.

FRP pipe has an exceptional strength to weight ratio, because pound for pound fibreglass is stronger than steel. As a result the pipes have a high tensile strength as well as good shock and impact resistance. They also have excellent flow characteristics as a smooth glass-like finish reduces material build-up and improves fluid transmission.

Maskell Pipe is available in standard diameters from 50mm to 2m, with larger diameters available on request. These are also supplied with a range of fittings, such as flanges, elbow, tees to suit the installation.

FRP/GRP PIPE SYSTEMS PRODUCT CATALOGUE

Fibreglass (GRP/FRP) Pipe Systems
Maskell manufacture fibreglass filament wound (GRP/FRP) pipe for a wide range of industrial and process plant applications. Pipe systems range in size from DN50-DN3000 and include a full range of pipe fittings and various jointing systems. Pipe systems are designed for specific projects with consideration of pressure, stiffness and external load requirements. A range of resin systems and manufacturing processes are used to optimise the pipe system for the application, from mild water and wastewater pipe work to aggressive chemical pipe handling caustic or sulphuric acid systems and elevated temperature service.

Specification
Fibreglass pipe and tanks have been in use in buried service globally for over 40 years for storage and transport of potable water, wastewater and chemical process streams. Case histories and details of fibreglass pipe applications around the world are available upon request however we anticipate you will be familiar with the widespread use of GRP in countries including Australia, New Zealand, Europe and the United States. Fibreglass (GRP) pipework is to be designed in accordance with AWWA C950 for Fibreglass Pressure Pipe with pipe and fittings specified in Table 1 as follows:

Table 1: Fibreglass Pressure Pipe and Fittings Design Specification.
Pipework  Pipe diameters range from DN50 – DN3000, to a full range of pressure ratings and pipe stiffness classes.

DN50 DN75 DN100 DN150 DN200 DN200
DN300 DN350 DN400 DN450 DN500 DN600
DN750 DN900 DN1050 DN1200 DN1350 DN1500
DN1800 DN2000 DN2500 DN3000    
Fittings
• Bends Swept (DN1500) or Mitre Bend (Radius 1.5xD).
• Reducers Standard length: L=2.5xD(D2-D1).
• Flanges For attachment of valves, testing and measuring equipment. Standard flanges to British Standard BS10 or ANSI150 flanges are available.
• Blank Ends Domed end caps are available for all pipe diameters and are ellipsoidal end caps for installation and testing blanks. Bolted, flat end blanks are also available to fit full face flanges.
Internal &
External Finish
• Internal All pipework have a molded internal surface finish for maximum chemical resistance.
• External Finished with resin coat for longevity using the structural resin.
Joint Types 
• Butt & Strap
  Joint
A fibreglass bandage centred over the joint effectively bonds the two pipes together as one. Most secure.
• Coupling A flexible joint that slips over each end of the pipe and use a rubber ring to seal. GRP pipe couplings are available for jointing of the pipe.
Resin System To suit the required chemical resistance and longevity for the project, Pipes are manufactured from resin systems.(Isophthalic polyester and vinyl ester resin systems are used).

Fibreglass Pipe Features
Maskell has been bringing products to local market and international market that are low cost, long-term piping solutions to their customers. Below is a list of features and benefits that provides optimum installed and life cycle cost system.

Table 2: Features and Benifits of Fibreglass Pipe.
Features Benefits 
Filament wound pipe • For high strength and high pressure applications
• Consistent high product quality
• High hoop and axial strength
Corrosion-resistant
fibreglass materials
• Extended, effectual service life
• Low maintenance cost
• No necessity for linings, coating, cathodic
  protection, wraps or other forms of corrosion
  protection
• Constant hydraulic characteristic over time
Light weight
• 1/4 weight of ductile iron
• 1/10 weight of concrete
• Reduced transport costs
• Eliminates need for handling equipment
• Ease of installation
Long standard lengths • Fewer joints hence reduced installation time
• Lower delivery cost – more pipe per transport
Extremely smooth bore • Lower operating cost and low friction loss
• Minimum slime build-up can help lower cleaning costs
Range of joint types • Quick installation for rubber ring or welded joints
• Axial restraint for site welded pipe
• Site mitre of pipe simple to preform
Flexible manufacturing process • Custom diameters can be manufactured.
High technology pipe design • Lower wave celerity than other piping materials
  reduces surge pressures due to water hammer
  compared to iron/steel and concrete materials.

Product Performance
Table 3: Fibreglass Pipe Performance.
Features Benefits 
Flow Velocity Maximum recommended flow velocity is 3.0m/sec. Velocities of up to 4m/sec. can be used if the water is clean and contains no abrasive material.
UV Resistance There is no evidence to suggest that ultraviolet degradation is a factor that affects the long-term service life of Maskell pipes. The outermost surface will be affected with discolouring of the surface observed. If so desired, after 25-30 years the exterior surface of Maskell pipe may be recoated with two-part urethane paint compatible with GRP.
Thermal Coefficient The thermal coefficient of axial expansion and contraction for Maskell pipe is 24 to 30 x 10-6 m/m/ºC.
Mechanical Range of pipe pressure from full vacuum to 40 Bar.
Designable pipe stiffness for span or burial.

Hydraulic Characteristics of Maskell Pipe
Maskell produces FRP pipes by reproducible process. All these pipes are provided with resin rich interior layers, providing very smooth inner surfaces. These smooth interior surfaces result in very low fluid resistance.

Apart from above, the interior pipe surfaces typically remains smooth over time, in most fluid services. Therefore, fluid resistance will not increase with age. This has been demonstrated when several FRP pipes under operation over the decade were inspected and evaluated. Certificate from respective authorities is available upon request confirming no deterioration. Values for GRP pipe are:

Table 4: Roughness Parameters (Mean Values)
Cole Brook - White
E or K (mm)
Manning
M
Hazen - Williams Coeff.
C
0.029 105 150

Standards
Standards developed by AWWA, ISO, Australian Standards and British Standards are applied to a variety of Maskell fibre glass pipe application. The common international codes used by Maskell for design and manufacture are:
  1. American Water Works Association AWWA C950: Fibreglass Pressure Pipe.
  2. AWWA Design Manual M45 for Fibreglass Pressure.
  3. Australian Standard AS2556.1 (1998): Buried Flexible Pipelines.
  4. Australian Standard AS2634 (1983): Chemical Plant Equipment Made From Glass-Fibre Reinforced Plastics (GRP) Based on Thermosetting Resins.
  5. British Standard BS5480 (1990): Specification for GRP Pipe for use for Water Supply or Sewerage.
  6. British Standard BS7159 (1989): Design and Construction of GRP Piping Systems for Individual Plants.
  7. British Standard BS6464 (1984): Specification for Reinforced Plastics Pipes, Fittings and Joints for Process Plants.
  8. ISO 10639 (2004): Plastic Piping Systems for Pressure and Non-Pressure Water Supply.


Quality Control and Testing
The Maskell production facilities have been accredited to ISO9001. A summary of Maskell quality assurance system is available upon request, which details the QA procedures and principles used in the manufacture of GRP pipe and chemical plant equipment. A quality assurance ITP can be provided for the specific projects along with details of the level of quality assurance to be used.

Table 5: Quality Control and Testing of Maskell Products.
Raw Materials Raw materials delivered to Maskell contain vendor certification which demonstrates their compliance with Maskell quality requirement. In addition to this, all raw materials are sample tested prior to their use, ensuring pipe materials compliance with the stated specifications.
Finished Pipe All pipes undergo control checks in the following listed ways:
• Visual inspection
• Barcol hardness
• Wall thickness
• Section length
• Diameter
Physical Properties Routine checks are performed on manufactured pipe’s hoop and axial load capacities are verified. Pipe construction and composition are confirmed as well.

The following control checks are performed on a sampling basis:
• Pipe stiffness
• Deflection without damage or structural failure
• Axial and circumferential tensile load capacity
 
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