SPS GRP

In the pursuance to establish the main
infrastructure industries with top of the line water

system production lines and technology, The
Saudi Pipe Systems Company has successfully
established its manufacturing plants in Phase 4,
Jeddah Industrial Zone, Jeddah, Saudi Arabia.

SPS is one of the leading manufacturer of all kinds
and sizes of Ductile Iron (D.I.) and Cast Iron (C.I.),
Epoxy Powder Coated Valves, Fittings, Fiber Glass
(GRP/FRP) Pipes, Pre-Insulated Pipes and Fittings
and HDPE Pipes as well. Valves include: Gate,
Butterfly, Check, Globe, Air Release, Float,
Pressure Reducing Valves and several other types
of valves, Fire Hydrants, Strainers, Flanges and
other industrial materials related to Water sector.

Beside D.I. Valves and Fittings, SPS manufactures
wide ranges of Fiber Glass (GRP/FRP) and Pre-
insulated Pipes and Fittings. The production
ranges from 100mm to 3000mm with pressure
rating from 6 Bars to 24 Bars. The annual
production capacity is 87,000 L/M.

Moreover, SPS has also established a most
advanced plant with fully automated extrusion
lines for the manufacture of High Density
Polyethylene (HDPE) Pipes with a minimum
capacity of 8,500 tons / year approximately,
covering the size ranges from 16mm 630mm
with pressure rating from 5 bars to 16 bars.

SPS has full technical support from leading
Companies namely: DUKER OVENTROP
(Germany), and CLA-VAL (Switzerland). All SPS
product are being tested at every stage of
production by its highly qualified, competent
and most experienced Quality Assurance
Engineers prior to dispatch within and outside
the Kingdom.

All SPS products are being tested at every stage
of production by its highly qualified, competent
and most experienced Quality Assurance
Engineers prior to dispatch within and outside
the kingdom.

SPS products are not only used by all renowned
customer of the Kingdom of Saudi Arabia, but
its products are being exported throughout the
GCC countries and many other countries like:
Egypt, Yemen, Sudan, etc.
Company Profile
1
P.O. BOX 34572 Jeddah 21478 Saudi Arabia, Tel (02) 608 1100 Fax (02) 636 5925
Email: spsvalve@sps.net.sa Website: www.saudivalve.com
Specializes in producing GRP Pipes and Fittings from small to big ranges with standard specifications,
through filament helical winding and continuous filament winding processes.

HDPE (HIGH DENSITY POLYETHELENE) PIPES FACTORY

2
FOUNDRY AND VALVES FACTORY

Specializes in the processing and production of all types of Valves, Pipes Fittings, Pipe Clamps, and
Flanges, which are essential for Water Sewage, Fire Fighting Systems, and Central Air Condition
Systems. The factory also produces engineered castings of variety of metals (Ferrous and Non-
Ferrous, e.g. Cast Iron, Ductile Iron, Aluminum, and Copper).

GRP ( FIBER GLASS POLYESTER ) PIPES AND FITTINGS

Specializes in producing HDPE Pipes through small to big sizes. The factory uses most advanced
Machinery and Equipment which are operated by well qualified engineers and technicians.
Saudi Pipe Systems Division
3
UNI9032 Pipes in glass-reinforced thermosetting resin (GRP)
UNI9033 and/or mortar pipes used in any application.
ASTM D 2996-88 Filament-Wound Reinforced Thermosetting Resin Pipe.
ASTM D3262-88 Reinforced Plastic Mortar Sewer Pipe
ASTM D3754-88
Fiberglass (Glass-Fiber-Reinforced Thermosetting-Resin Sewer and
Industrial Pressure Pipe
ASTM D3517-88
Fiberglass (Glass-Fiber-Reinforced Thermosetting-Resin Pressure Pipe
AWWA C950-95 Standard for Glass-Fiber-Reinforced Thermosetting-Resin Pressure Pipe.
BS 5480-90
Specification for Glass fiber reinforced plastics (GRP) pipes and fitting to
use for water supply or sewerage
ASTM D3262 Gravity Sewer
AWWA C950 Fiberglass Pressure Pipe
AWWA M45 Fiberglass Pipe Design Manual
SASO-1577 Gravity Sewer
SASO-1578 Pressure Sewer
ASTM D3839 and Appendix AWWA C950-95 in relation to the inspection standards buried
pipes.
GRP Pipe Characteristic
Unit of Measurement Filament Winding
Traction Resistance
Circ. direct
Kg/cm
2500-3000
Axial Direct 800-1300
Elasticity Young
Modules
Circumferential direct.
Kg/cm
240-3000
Axial direct. 105-125
Density Kg/cm 1.9
Barcol Hardness 35-45
Thermal Conductivity Kcal/mhC 0.22
Coefficient of Linear
Thermal Expansion
cm/cmC 1.6*10
Electrical Resistivity ohm/cm 10^14
Dielectric Constant F/cm 3-4
Three Base Materials Are Used For The Pipes Having Distinct Characteristic.
Polyster thermosetting resin being of three types : Isophtalic, Bisphenolic, and Vinylester
Continuous fiberglass roving.
Silica sand (optional)
Standards
The SPS pipes produced in our plant are manufactured in glass reinforced thermosetting resin (GRP) by
the Filament and Continuous Winding system. Reference is made to the following international
standards.

GRP Pipe Component
4

GRP PIPE PRESSURE Vs. DIAMETER CHART

RTRP (REINFORCED THERMOSETTING RESIN PIPE)

A fiberglass pipe without aggregate. Manufactured by the filament winding process up to 24 in.
nominal size.

RESIN USED IN SPS RTR PIPES
1.ISOPHTHALIC POLYESTER RESIN
Used for moderate corrosion resistance to water, acids, weak bases, and hydrocarbons such as
gasoline and oil.
2.VINYL ESTER RESIN
Offers maximum corrosion and temperature resistance to acid, alkalis, hypochlorite, and many
solvents. These products have been formulated for maximum performance with methyl ethyl ketone
peroxides. It is well documented that these catalysts provide optimal cure and thus maximum
corrosion resistance.

PRODUCT USAGE OF VINYL ESTER RESIN
1.Flame retardant / Heat resistance
2.Chemical resistance
3.Ultra Violet Rays
4.High strength to weight ratio
5.Electrical and thermal insulation.

Characteristic of Pipes
5
HYDROSTATIC LEAK TEST
PRESSURE REQUIREMENTS
PRESSURE
CLASS, Kpa
HYDROSTATIC
PRESSURE TEST, Kpa
345 689
689 1034
1034 1379
1379 2068
2068 1724
1724 3447
MINIMUM PIPE STIFFNESS REQUIREMENTS
FOR 5% DEFLECTION
DN
STIFFNESS CLASS
62 124 248 496
mm
MIN. PIPE STIFFNESS REQUIRED, Kpa
25-200
NR NR 36 72
250
NR 18 36 72
300-3600
9 18 36 72
DEFLECTION LEVEL
STIFFNESS CLASS (SN)
2500 5000 1000
A
15% 12% 9%
B 25% 20% 15%
HYDRAULIC FAILURE TEST
ASTM D1599
Every pipe must be tested to two times the
nominal pressure for two minutes or as long
as a specific standard requires. To reduce
the risk of making scrap, there should never
be more than 4 untested pipes.

HYDROSTATIC DESIGN BASIS HDB
ASTM D2992
Requires pipe to withstand a constant
pressure of 1.8 times the maximum operating
condition. Considering internal pressure and
external soil loads, Hydrostatic pressure
testing to failure (leakage) of pipe sample at
variety of very high constant pressure level is
applied.

INITIAL RING DEFLECTION
LEVEL A - No visual evidence of cracking.
LEVEL B - No structural damage to the pipe wall.
GRP pipes long term (50 year) Ring
deflection/bending (strain) capability when
exposed to an aqueous environment and under a
constant load must meet level A deflection level.
PARALLEL PLATE LOADING TEST
ASTM D2412-02
Parallel Plate Stiffness testing machine is
designed to determine the load deflection
characteristics of GRP pipe under parallel-
plate loading. The characteristics determined
by this method are pipe stiffness, stiffness
factor, and load at specific deflections
Long Term Material Properties Testing
6
UNI9032 Pipes in glass-reinforced thermosetting resin (GRP)
UNI9033 and/or mortar pipes used in any application.
ASTM D 2996-88 Filament-Wound Reinforced Thermosetting Resin Pipe.
ASTM D3262-88 Reinforced Plastic Mortar Sewer Pipe
ASTM D3754-88
Fiberglass (Glass-Fiber-Reinforced Thermosetting-Resin Sewer and
Industrial Pressure Pipe
ASTM D3517-88
Fiberglass (Glass-Fiber-Reinforced Thermosetting-Resin Pressure Pipe
AWWA C950-95 Standard for Glass-Fiber-Reinforced Thermosetting-Resin Pressure Pipe.
BS 5480-90
Specification for Glass fiber reinforced plastics (GRP) pipes and fitting to
use for water supply or sewerage
ASTM D3262 Gravity Sewer
AWWA C950 Fiberglass Pressure Pipe
AWWA M45 Fiberglass Pipe Design Manual
SASO-1577 Gravity Sewer
SASO-1578 Pressure Sewer
ASTM D3839 and Appendix AWWA C950-95 in relation to the inspection standards buried
pipes.
GRP Pipe Characteristic
Unit of Measurement Filament Winding
Traction Resistance
Circ. direct
Kg/cm
2500-3000
Axial Direct 800-1300
Elasticity Young
Modules
Circumferential direct.
Kg/cm
240-3000
Axial direct. 105-125
Density Kg/cm 1.9
Barcol Hardness 35-45
Thermal Conductivity Kcal/mhC 0.22
Coefficient of Linear
Thermal Expansion
cm/cmC 1.6*10
Electrical Resistivity ohm/cm 10^14
Dielectric Constant F/cm 3-4
Base Materials Used For The Pipes Having Distinct Characteristic.
Polyster thermosetting resin being of three types : Isophtalic, Bisphenolic, and Vinylester
Continuous fiberglass roving.
Silica sand (optional)
Standards
The SPS pipes produced in our plant are manufactured in glass reinforced thermosetting resin
(GRP) by the Filament and Continuous Winding system. Reference is made to the following
international standards.

GRP Pipe Component
7
STRAIN CORROSION TEST
Covers the procedure for determining the chemical - resistant properties of fiberglass pipe in a
deflected condition.

Quality Control
8
APPLICABLE PROCEDURES / DOCUMENTS INSPECTION / TESTING
ASTM D2563 Visual Inspection
ASTM D3567 Dimension Control
ASTM D2583-87 Barcol Hardness
ASTM D2105-90 Longitudinal (Axial) Tensile Strength
ASTM 2290-00 Hoop (Circumferential Tensile Strength
ASTM D1599 Hydrostatic Leak Test (Hydraulic)
ASTM D2412-02 Stiffness Test
ASTM D2584-68 Glass Reinforcement Content (Loss of Ignition)

QUALITY CONTROL ON PRODUCTS
The test, which the products undergo during the manufacturing stages and before dispatching ensures
that they fully comply with the international specifications and that they suitable for the usage which
they have been made for.

SPS STANDARD SPECIFICATION FOR FIBER GLASS PIPE
Quality Control
BASIN WITH
CORROSIVE
SOLUTION
DEFLECTED
PIPE
9

LABORATORY

SPS has made the effort to have state of the art laboratory
of testing department. This department supervise and issue
certificate on all test perform or according to project
consulting required.

TESTING
SPS-GRP PIPES undergo a series of tests to assure quality
standards, these tests are performed on each pipe/batch.
Testing starts on raw materials by making sure of
choosing the highest quality raw material we can assure top
quality final product.
By inspecting-dimensions and visual/weight throughout
production line.
Step by step: follow up checking of materials as they
advance throughout the production line. All the way to
finished products.
All raw materials undergo extensive testing to assure and
confirm that it meets technical specifications and standard
of products.

RESINS
Density at 25C ASTM D 792
Viscosity at 25C ASTM D2393-86
Gel Time at 25C ASTM D2471-94
Exothermic Peak ASTM D2471
Acid Number - ASTM D1639
H.D.T. ( 264 psi) ASTM D648
Color(Gardener Scale) ASTM D1544
Volumetric Shrinkage UNICHEM21969
GLASS
MASS PER UNIT AREA ISO 3374-2000
PERCENT HUMIDITY ISO 3344-1997
LOSS OF IGNITION ISO 1887-1995
TEST FOR THE APPROVAL OF RAW MATERIALS
Besides test based on workability and test based on
verification of the chemicals inertness for resins, for the
approval of new raw materials the tests listed in the former
paragraph shall be completed with the following tests.

RESIN
-Tensile Strength ASTM D 638 M 87 b
-Flexural Strength ASTM D 790 M 86
GLASS
-Split Disk ASTM D 2290 / 76

Quality Assurance and Testing
PROPERTIES OF SPS GRP PIPES

SERVICE LIFE OF 50 YEARS.
ENVIRONMENTALLY FRIENDLY.
CAN BE TRANSPORTED AS NESTED.
CORROSION RESISTANCE.
Resistant to corrosion in a wide
range of fluid handling applications.
STRENGTH TO WEIGHT
Pipe strength per unit weight
surpasses iron, carbon, and stainless
steels.
LIGHTWEIGHT
1/6

the weight of other steel with
similar properties and 1/10 the
weight of similar concrete product.
NON-CONDUCTIVE
not necessary to dissipate static
electricity build-up when
transporting certain fluids such as jet
fuel.
DIMENSIONAL STABILITY
meet the most stringent material
stiffness, dimensional tolerance,
weight and cost criteria.
LOW MAINTENANCE COST
Resistant to rust and require
minimal protection from the
environment.
RESIN
-Polyester resins based on bisphenol or bisphenol A.
-Polyester resins based on Isophthalic acid.
-Vinyl Ester resins based on urethane modified or epoxy
based. In all cases the resins are taken as a solution of 45 to
50% of styrene monomer.
MAT
-A fibrous material consisting of random-oriented, chopped,
or swirled filaments loosely held together with a binder.

SURFACING MAT
-A thin mat of fine fibers used primarily to produce a smooth
surface on a reinforced plastic.

HOOP DIRECT ROOVING
-A collection of parallel glass strand or filaments, coated with
a finished or coupling agent, to improve compatibility with
resins, gathered without mechanical twist. (Fig. 1)
WOVEN ROOVING
-A glass-fiber fabric reinforcing material made by the weaving
of glass-fiber roving.
CATALYST
-MEKP (Methyl Ethyl Ketone Peroxide) in phthalate plasticizer with 9% active oxygen and 33%
peroxide content used on an average of 1.5% in the resin.

PROMOTERS
-Cobalt octoate in phthalate plasticizer with 6% metal used on an average of 0.4% in the resin.

INHIBITORS
-Pera-t-butyl-catechol, 10%, in phthalate plasticizer used on an average of 0.1% in the resin.
SILICA SAND
-Siliceous sand conforming to ASTM C33, except that the requirements for gradation need not
apply.
Material Used In Production Process
10
HELICAL FILAMENT WINDING MACHINE
Pipes are manufactured using the Filament Winding process on computer controlled machines
(CAM), by adjusting the relative speed of mandrel rotation and glass distribution head movement,
helical reinforced layer with different angles can be wound. The inside diameter of the finished pipe is
defined by the mandrel outside diameter and the designed wall thickness is achieved by repeated
passes. Therefore the outside diameter of pipe (OD) is determined by the wall thickness. In order to
increase pipe stiffness, specially on large diameter pipe, silica sand can be added to parallel layers of
the mechanical wall.
MAIN CHARACTERISTIC OF FILAMENT WINDING PROCESS

Bell and Spigot ends are monolithic with the pipe wall.
Optimization of axial and hoop characteristic can be obtained by changing the winding angles.
Axial strength normally higher than pipe produced with other processes.
Pipe stiffness is not related to joint stiffness that is in any case higher than pipe stiffness.

Pipes are manufactured using the filament winding process are used either for above ground and
underground installation, with gravity flow, medium and high internal pressure.
GRP Manufacturing Method
MANDREL
RESIN BATH
TRANSLATE
ROTATION
11
PIPE WALL STRUCTURE
GRP pipe wall consist of three layers perfectly adherent one to the other and each having different
characteristic and properties in relation to their function.
LINER
Liner or chemically resistant layer is the internal layer of the pipe, it is in direct contact with the
conveyed fluid. This layer has the function to guarantee the resistance to the chemical corrosion and
the impermeability of the whole pipe. Liner has the internal surface namely the one in contact with the
conveyed fluid, particularly smooth.
This characteristic of smoothness reduces to minimum the fluid head losses and pumping heads and
opposes to the growth of mineral deposits and algae. Liner is made of two monolithic sub-layers (1)
Inner, in direct contact with the fluid, is reinforced with glass veil C 30 g/m
2
, with ratio resin content
in a range 80% - 90%by weight (2) Outer, reinforced with plies of glass mat E of 450 g/m
2
, with a
resin content in a range of 60% - 70% by weight.

MECHANICAL RESISTANT LAYER
Glass reinforced layers guarantee the mechanical resistance of the whole pipe against stresses due to
internal and/or external pressure, external load due to handling and installation, and thermal loads.
The layer is obtained by applying on the previous partly curved liner, continuous roving of glass wetted
with resin, under controlled tensioning. This layer can contain aggregates (inert granular material such
as silica) in order to increase the stiffness of the whole pipe. Thickness of mechanical resistant layer
depends on the design condition.

TOP COAT
Top coat or Gel coat is the outer layer of the pipe which consist of pure resin added with UV protectors
to protect the pipe from sun exposure. In case of severe exposure conditions, i.e. aggressive soils or
very corrosive environment, the gel coat can be reinforcement with a surfacing veil or added with
fillers or pigments.
MECHANICAL
RESISTANT
LAYER
TOP COAT
LINER
GRP Pipe Helical Filament Winding
12
NOMINAL DIAMETER INSIDE DIAMETER
mm in mm in
100 4 100 4
150 6 150 6
200 8 200 8
250 10 250 10
300 12 300 12
350 14 350 14
400 16 400 16
450 18 450 18
500 20 500 20
600 24 600 24
700 27 700 27
800 30 800 30
900 36 900 36
1000 39 1000 39
1100 42 1100 42
1200 48 1200 48
1300 51 1300 51
1400 54 1400 54
1500 60 1500 60
1700 66 1700 66
1800 72 1800 72
2000 78 2000 78
2200 84 2200 84
2300 90 2300 90
2400 96 2400 96
2600 102 2600 102
NOMINAL DIAMETER

ASTM D3567
INSIDE DIAMETER SERIES

SPS pipes manufactured in Helical Filament
Winding are ranging from diameters 100mm
to 2600mm. Nominal diameter coincides
with the internal diameter. Any nominal
diameter can be manufactured. Larger
diameters can be manufactured at site by
means of special equipment.
DIMENSION OF PIPE
DN
Dimension Control
13
GRP Pipe Continuous Filament Winding Machine
The Continuous Filament Winding Machine is
designed for the continuous production of
GRP pipes. Similar to Helical Filament Winding,
but continuous, this process allows to produce
only cylindrical parts like pipes, based on a
special continuous mandrel design. In this
process, both single-end roving and chop
(multi-end) roving are necessary. It is designed
for very high production capacity. It is ideal
choice when the GRP pipes are used for water
transmission and distribution, desalination
plants, cooling systems in power plants,
irrigation projects and sewage systems.
Using this technology and developed by
material specialist, a very dense laminate is
created that maximizes the contribution from
the three basic raw materials. Both the
continuous glass fiber roving and chop able
roving are incorporated for high hoop strength
and axial reinforcement. A sand as fortifier is
used to increased the stiffness with placement
near the neutral axis in the pipe wall core.

The basic machine for manufacturing (winder)
is composed of a continuous steel band
supported by beans which form a cylindrically
shaped mandrel. The beans rotate, friction
pulls the band around and roller bearings
allow the band to move longitudinally so that
the entire mandrel continuously moves in a
spiral path toward the end of the machine. As
the mandrel moves fine graded filler, glass
fibers and resins and surface materials are
metered on in precise amount under the
direction of a programmable logic controller
(PLC) and computer (PC). The PLC-PC modules
provide integrated process control based on
the recipes encoded. Only basic pipe such as
diameter pressure and stiffness class need to
be entered and the computer calculates the
settings.
14
GRP Pipe Wall Structure
The wall of the pipe manufactured on continuous filament winding machine is made of several layers.
OIOU
OUTER LINER
OUTER SKIN
MORTAR CORE
INTERNAL SKIN HOOP ROVING
AND CHOP REINFORCEMENT
ANTI-DIFFUSION BARRIER CHOP
MATERIAL REINFORCEMENT
INTERNAL LINER RESIN RICH
SURFACING VEIL REINFORCEMENT
T
O
T
A
L

T
H
I
C
K
N
E
S
S

INTERNAL LAYER
Layer directly contact with the internal fluid, and is resin rich (approx.90% by weight), reinforced with
a surfacing veil made of C glass (chemical resistant very light fiberglass mat), or polyester veil.
Thickness 0.2mm for 1 only surfacing veil, but can be doubled.

ANTI DIFFUSION BARRIER
Part of the internal layer, is resin rich (approx.70% by weight) and is reinforced with chopped roving
of E glass. The function is to stop the propagation of micro-cracks from the mechanical layer (inner
skin) to the internal layer. Thickness 0.8 mm to 2 mm or more according to project-specification.
The standard is 0.8 mm.

INNER HIGH STRENGTH SKIN
Forms the mechanical resistant layer together with the core and the outer skin. Reinforced with high
strength hoop wound fiberglass roving (50-60% by weight), and chopped roving (10-20% by weight).
The resin content is 25-30% by weight.

MORTAR CORE
To increase the thickness and the stiffness of the pipe without using a lot of valuable raw materials.
the main constituent of the mortar core is silica sand, with a few hoop and chop roving and as low as
possible resin.

OUTER HIGH STRENGTH SKIN
As the inner skin. Generally it has the same thickness of the inner skin, but can be different.

OUTER LINER
The outer liner can be simply pure resin, but can be also reinforced with a surfacing veil, in order to
increase the finishing and the chemical resistance to the environment.

15
Outside Diameter Series
SPS pipes manufactured in Continuous
Filament Winding are standardized on
the basis of the outside diameter in
order to use standard coupling.

Nominal Diameter (DN) and outside
Diameter (OD) are taken from the
International Standards, basically the
AWWA C-950.
DIMENSION OF PIPE FOR CONTINUOUS FILAMENT WINDING
z
DN
OUTSIDE DIAMETER SERIES OUTSIDE DIAMETER SERIES
NOMINAL DIAMETER OUTSIDE DIAMETER NOMINAL DIAMETER OUTSIDE DIAMETER
mm mm mm mm
300 310 1300 1332
350 361 1400 1434
400 412 1500 1536
450 463 1600 1638
500 514 1700 1740
600 616 1800 1842
700 718 1900 1944
800 820 2000 2046
900 924 2100 2148
1000 1026 2200 2250
1100 1128 2300 2351
1200 1229 2400 2453
2500 2556
16
DN PN1 PN6 PN10 PN16 PN20 PN25 PN32
80 N/A 89 178 238 269 N/A N/A
100 N/A 119 238 318 358 N/A N/A
150 N/A 178 357 477 538 N/A N/A
200 N/A 238 476 636 717 N/A N/A
250 N/A 297 595 795 896 N/A N/A
300 N/A 357 714 95 1076 N/A N/A
350 70 420 400 1120 1400 1750 2240
400 80 480 800 1280 1600 2000 2560
450 90 540 900 1440 1800 2250 2880
500 100 600 1000 1600 2000 2500 3200
600 120 720 1200 1920 2400 3000 3840
700 140 840 1400 2240 2800 3500 4480
800 160 960 1600 2560 3200 4000 5120
900 180 1080 1800 2880 3600 4500 5760
1000 200 1200 2000 3200 4000 5000 6400
1200 240 1440 2400 3840 4800 6000 7680
1400 280 1680 2800 4480 5600 7600 8960
1600 320 1920 3200 5120 N/A N/A N/A
1800 360 2160 3600 5760 N/A N/A N/A
2000 400 2400 4000 6400 N/A N/A N/A
2400 480 2880 4800 7680 N/A N/A N/A
2500 500 3000 5000 8000 N/A N/A N/A
LENGTH
The standard length of SPS Pipe is normally 12
meters for DN150 and above. DN100 are only
available in 9 meter standard lengths.
LOAD CAPACITY VALUES
The following values can be applied for axial tensile and hoop tensile for design objectives.

HOOP TENSILE LOAD CAPACITY
Minimum hoop or circumferential load, N per length (mm)
HOOP TENSILE LOAD CAPACITY
SPS Pipe Technical Data
17
DN PN1 PN6 PN10 PN16 PN20 PN25 PN32
80 N/A 89 178 238 269 N/A N/A
100 N/A 119 238 318 358 N/A N/A
150 N/A 178 357 477 538 N/A N/A
200 N/A 238 476 636 717 N/A N/A
250 N/A 297 595 795 896 N/A N/A
300 N/A 357 714 95 1076 N/A N/A
350 70 420 400 1120 1400 1750 2240
400 80 480 800 1280 1600 2000 2560
450 90 540 900 1440 1800 2250 2880
500 100 600 1000 1600 2000 2500 3200
600 120 720 1200 1920 2400 3000 3840
700 140 840 1400 2240 2800 3500 4480
800 160 960 1600 2560 3200 4000 5120
900 180 1080 1800 2880 3600 4500 5760
1000 200 1200 2000 3200 4000 5000 6400
1200 240 1440 2400 3840 4800 6000 7680
1400 280 1680 2800 4480 5600 7600 8960
1600 320 1920 3200 5120 N/A N/A N/A
1800 360 2160 3600 5760 N/A N/A N/A
2000 400 2400 4000 6400 N/A N/A N/A
2400 480 2880 4800 7680 N/A N/A N/A
2500 500 3000 5000 8000 N/A N/A N/A
Nominal Pressure (PN) Pressure Rating (Bar) Diameter Limit (mm)
1 1 3700
6 6 3700
10 10 2500
16 16 2000
20 20 1400
25 25 1400
32 32 1400
AXIAL TENSILE LOAD CAPACITY
Minimum axial or longitudinal load, N per circumference (mm)
PRESSURE
Nominal Pressure of SPS pipes are listed below. Some nominal pressures are not available in all
diameter and stiffnesss.
18
STIFFNESS CLASS N/ m
3

SN 2500 2500
SN 5000 5000
SN10000 10000
HYDROTESTING
Standard Factory Test Pressure 1.5 x PN
Maximum Field 1.5 x PN (Nominal Pressure)
Maximum Pressure 1.4 X PN (Nominal Pressure)
SURGE
STIFFNESS CLASS
GRP pipe can be supplied to the following stiffness
FLOW VELOCITY
The flow velocity for clean water and contains no abrasive material are up to 4m/sec. The
recommended maximum flow velocity is 3m/sec.
ULTRA VIOLET DEGRADATION EFFECT
Discoloration in the outermost of the SPS pipe may be occurred due to exposure from sunlight or by
ultra violet degradation. However, it cannot affect to the long term service of SPS pipe. Proper
maintenance is also required to make the service of the pipe longer.
POISONS RATIO
In any pipe constructions the Poisons ratio is required. The Poisons ratio of SPS pipe is slightly less
by using the following hoop tensile and axial loading ranging 0.22 to 0.29.
THERMAL COEFFICIENT
The SPS pipe thermal coefficient of axial expansion and contraction is between 24 to 30 x 10
4

cm/cm/C
19
Steel, Ductile and Iron pipes 50%
SPS Pipe surge pressure allowance 40% of Nominal Pressure
DN 350-400 450-800 900-2500
SN 2500 meter/sec
PN6 365 350 340
PN10
435
420 405
PN16
500
490 480
DN 350-400 450-800 900-2500
SN 10000 meter/sec
PN6 420 415 410
PN10
435
425 415
PN16 500 465 485
PN25 580 570 560
PN32 620 615 615
DN 80 100 150 200 250
SN 10000 meter/sec
PN6 580 560 540 520 500
PN10 590 570 560 50 520
PN16 640 620 610 600 590
DN 350-400 450-800 900-2500
SN 5000 meter/sec
PN6 405 380 370
PN10 435 420 410
PN16 505 95 480
PN25 575 570560
SURGE AND WATER HAMMER
WATER HAMMER
Water hammer or pressure surge is the sudden rise or fall in pressure caused by abrupt change in the
fluid velocity within the pipe system.
THE CAUSE OF WATER HAMMER PRESSURE IN THE PIPE:
1. Rapid closing or opening of valves.
2. Sudden starting or stopping of pumps such as during power failure.
3. Change in velocity of the fluid.
4. Rate of change of velocity (valve closing time).
5. Compressibility of the fluid
6. Stiffness of the pipe in the hoop direction and physical lay-out of pipe system.

SPS PIPE WATER HAMMER PRESSURE APPROXIMATION AND ALLOWANCE:

An approximate relationship for the maximum pressure variation at a given point in a straight
pipeline with negligible friction loss can be calculated from the formula:
H = (wv) / g
Where:
H = change in pressure (m) v = change in liquid velocity (m/s)
w = surge wave celerity (m/s) g = acceleration due to gravity (m/s)

SPS PIPE SURGE WAVE CELERITY
20
SPS -GRP Pipe Hydraulic Characteristics
21
Saudi Pipe Systems Co. (SPS) produces GRP pipes
by continuous filament winding machines, by
reproducible processes. All these pipes are
provided with rich interior layers, providing very
smooth inner surfaces. This smooth interior
surfaces results in very low fluid resistance.

For hydraulic analysis of the every piping system,
pipe roughness is the concern. One of the FAQ by
the Hydraulic Engineers / Consultants /
Contractors / Clients is what the value of GRP pipe
toughness is.

This roughness is being used in various forms in
various equations of hydraulic analysis. Find below
the summary of the mean value based on the
experimental studies.

These values are based on the experimental
studies carried out by Owens Corning and SINTEFF
from Norway. Complete report is available upon
request.

In fact AWWA C-950 also recommends for the
usage of similar values. This confirms that above
values are in good agreement even with the
international standards.

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

Roughness Parameters (Means Values)
Flow Rate Cole Brook-White Manning Hazen-Williams
(m
3
/hr) or K (mm) M (m
1/3
/s) C (10
-1.38
m
0.37
/s)
150
N/A
178 357
For any additional hydraulic requirements and
clarifications do not hesitate to approach SPS. We
are willing to assist you anytime.

ABRASION RESISTANCE
Abrasion resistance can be related to the effects
that sands or other similar material may have on
the interior surface of the pipe. While there is no
widely standardized testing procedure or ranking
method. SPS-GRP Pipe has been evaluated by
using the Darmstadt Rocker method.

Results will be highly influenced by the type of
abrasive material used in the test. Using gravel
which was obtained from the same source as that
used at Darmstadt University, the average
abrasion loss of SPS Pipe is 0.84mm at 100,000
cycles.


22
Head loss chart
The Engineering department of SPS can assist
the costumers in all stages of their projects
and is able to issue (but not limited to) the
following documentation:

STRESS ANALYSIS ON AERIAL / BURIED
GRP PIPING SYSTEM BY MEANS OF
CEASAR II PROGRAM

Calculation of buried pipes according to
AWWA M-45.
Calculation of aerial pipes, installed on
supports according to AWWA M-45.
Hydraulic calculations according to usual
formula.
Standards and Specifications.
Design Technical and shop drawings in
Autocad format.
Field assistance.

SPS EXPERTS ARE ABLE TO PROVIDE
ASSISTANCE DURING THE FOLLOWING FIELD
ACTIVITIES

Installation
Laminations
Hydro-Testing

GRP pipe installation needs special attention if
the contractor engaged in laying the pipes has
no knowledge or experience with this product.
In this case the SPS /GRP by means of its
technical team can offer assistance by sending a
qualified person to the customer who will train
and assist the contractor.

Engineering Services
FIELD OF APPLICATION

Water transmission and distribution on both civil
and industrial (Potable and Raw Water).

Sewer system on both urban and industrial.

Irrigation networks.

Water intakes for cooling water system.

Waste water outfalls to sea.

Sea lines and river crossings.

Process lines for industrial plants.

Corrosive fluids and verity gas tanks.

Wells casing and wells pump riser.

Penstock.

Flue gas desulphurization.

Gasoline handling and distribution networks.

Flue gas stacks.

Gravity & pressure sewer lines.

Storm sewers.

Circulating water for power plants.
23
24
Prior to unloading of pipes from trailer, all items shall be inspected for any visual transportation
damages.
Single pipe must be unloaded and handled separately (one at a time). Use pliable straps, slings or
ropes to lift single pipe.
Do not use steel cables or chains to lift or transport the pipe.
Care shall be taken to prevent pipes from rolling or falling from flat bed trailer and this shall be
attained by using proper supports.
HANDLING OF NESTED PIPES

We propose to nest various diameter pipes during transportation. Always lift nested bundles using at
least two pliable ropes. Always keep nested pipes on site in the original transportation package only.
Stacking of these pipes is not advisable. De-nesting of pipes should be done carefully at pre allocated
station. Inside pipe may be removed by lifting slightly with an inserted padded boom to suspend the
section and carefully move it out without damaging the outer pipe.
Transportation and Handling
25
AVAILABLE METHODS IN PIPE SYSTEM
INSTALLATION AND ADJUSTMENT OF
JOINT:

Double O-ring Bell and Spigot Joint
Double O-ring Bell and Spigot with locking key
joint.
Mechanical Coupling.
Butt and Strap Joint.
Flanged Joint.
Reka Coupling.

METHODS FOR INSTALLATION OF PIPE AND
FITTINGS

1.STANDARD COMPONENTS
Adjustment should be made in the field by means
of Butt and Strap joining system.
2.PRE-FABRICATED PIPES
For quick and easy mounting, narrow tolerances
less field joints, and lower installation cost.

CATEGORIES OF ABOVE GROUND
INSTALLATION

1. Lines which laid directly on the surface of the
ground.
2. Lines which are hung or supported as in typical
plant.
-Tensile Resistance Couplings should be used. In
well-supported pipelines for non-pressure
application, a non-tensile resistant system can be
used.
-- Horizontal pipe should be supported at
intervals suggested by support spacing data.
- For the supporting of pipes systems, several
types of pipe clips can be used. Between pipe
and steel collar, a PVC saddle or protective
rubber layer should be provided to minimize
abrasion.
Installation
GRP
OVERLAY
F
F
SUPPORT
S
U
P
P
O
R
T

UNDERGROUND INSTALLATION CLASSIFICATION OF NATIVE SOILS

The external loads (soil and traffic) above a GRP
buried pipe cause a decrease in the vertical
diameter and an increase in the horizontal
diameter (deflection), that is indicate of
stain(stress) levels in the pipe wall.
Native soils according to AWWA 950/95 are
classified in 4 soil stiffness category.
Native soil groups depend both on soil types
(classification) and soil density, which together
determine the soil modulus. The symbols GW,
GP,SW,SP,GM,SM,SC,ML,CL etc are in
accordance to ASTM-D2488.

SOIL STIFFNESS CATEGORY 1

Crushed Rock and Gravel with <15% Sand and
5% Fines
- Provide maximum pipe support for a given
density due to low contents of sand and fines.
-Can be installed at relatively high soil stiffness
over a wide range of moisture contents.


Course Grained Soils with Little or no Fines
-When compacted, provide a relatively high
level of pipe support. However, open-graded
groups may allow migration and sizes should be
checked for compatibility with adjacent
material.

Course Grained Soils with Fines
-Provide less support for a given density SC1 and
SC2 material.


Fine Grained Soils with Medium to no Plasticity
- The moisture content must be near optimum
to minimize compactness effort and achieve the
required density.
- Can provide reasonable levels of pipe support.
SOIL PIPE SYSTEM

The external loads (soil and traffic) above a
GRP buried pipe cause a decrease in the
vertical diameter and an increase in the
horizontal diameter (deflection), that is
indicative of strain (stress) levels in the pipe
wall.

The horizontal movement develops a passive
soil resistance that enhances pipe support.

The amount of deflection depends on soil
load, live load, native soil characteristics, pipe
backfill material, trench width, hunching and
pipe stiffness.

Buried fiberglass pipes generally
accommodate 4-5% long term deformation
without structural damage.
26
Installation
INSTALLATION TYPE 1
-Carefully constructed bed.
-Backfill 70% relative Density Gravel.
-Backfill compacted gravel to 300mm over pipe crown.

INSTALLATION TYPE 2
-Carefully constructed bed.
-Backfill 90% standard proctor Sand.
-Backfill compacted sand to 300mm over pipe crown.

INSTALLATION TYPE 3
-Backfill to 70% of pipe diameter with gravel or sand (primary
pipe zone)
-Backfill from 70% to pipe crown with compatible native
compacted to 90% standard Proctor.

INSTALLATION TYPE 4
-Prepare pipe bed and haunch with sand or gravel compacted to
90% standard Proctor or 70% Relative Density.
-Backfill from 30% of pipe diameter to pipe crown with
compactable native compacted to 90% standard Proctor.

INSTALLATION TYPE
GROUND LEVEL
NATIVE SOIL
I
N
I
T
I
A
L

B
A
C
K
F
I
L
L

BEDDING
-MIN. 150mm
F
I
N
A
L

B
A
C
K
F
I
L
L

3
0
0
m
m

EXCAVATED TRENCH WIDTH
F F
Where:

F = 200 for pipe DN300
to 500 mm.

F = 300 for pipe
DN600 to 900 mm.

F = 450 for pipe DN1000
to 1600 mm.

F = 600 for pipe above
DN1600 mm.

27
Installation

FABRICATION METHODS
Fitting are manufactured by the hand lay-up,
contact molding and spray-up process. In hand
lay-up and contact molding, previous veil and
alternate layers of mat and woven roving
saturated with resin are applied on the mold.
The operation is repeated to reach the required
thickness.
To fit the special needs of the costumers a
study and development can be performed for
making non-standards products. Before
supplying such products, SPS/GRP needs to be
sure that the product is made according the
relevant standards and that is tested and
proven as a good one.

WALL STRUCTURE
GRP fitting wall such as the pipe wall consist of
three layers perfectly adherent one to the other
in order to have monolithic structure, each
having different characteristics and properties
in relation to their function. Liner and top coat
are the same as the pipe. The difference
consists in the mechanical resistant layer due to
the type of reinforcement used.

Fittings
FITTINGS AND ACCESSORIES
Supply the following fittings such as Flanges, Elbows, Wyes, Tees, Couplings, and reducers.
Large Diameter Fittings are available upon request.

28
FLANGE
CALIBRATED END
FLANGE FLANGE
FLANGE
LAMINATION
JOINT END
CALIBRATED END
LAMINATION JOINT
L L L
FLANGES
29
Fittings
FL/CAL. END FL/FL FL/ LAM. JOINT END
100 105 340 170
150 120 470 235
200 125 540 270
250 135 620 310
300 160 720 360
350 170 800 400
400 195 910 455
450 210 1000 500
500 230 1100 550
600 270 1290 645
700 315 1500 750
800 360 1710 855
900 400 1900 950
1000 430 2060 1030
1100 480 2160 1080
1200 520 2240 1120
1300 550 2300 1150
1400 580 2360 1180
1500 620 2440 1220
DN
OVER-ALL LENGTH, L (mm)
DN
DRILLING
PN10 PN16
T OD PCD
HOLE
DIA.
No. OF
HOLES
T OD PCD
HOLE
DIA.
No. OF
HOLES
100 23 220 180 16 8 28 220 180 16 8
150 25 285 240 20 8 31 285 240 20 8
200 30 340 295 20 8 36 340 295 20 12
250 35 395 350 20 12 41 405 355 22 12
300 40 445 400 20 12 48 460 410 22 12
350 41 505 460 20 16 50 520 470 22 16
400 41 565 515 22 16 52 580 525 27 16
450 45 615 565 22 20 57 585 640 27 20
500 47 670 620 22 20 60 715 650 30 20
600 53 780 725 27 20 66 840 770 33 20
700 61 895 840 27 24 76 910 840 33 24
800 67 1015 950 30 24 85 1025 950 36 24
900 73 1115 1050 30 28 90 1125 1050 36 28
1000 85 1230 1160 33 28 105 1255 1170 39 28
1100 90 1340 1270 33 32 105 1355 1270 39 32
1200 90 1455 1380 36 32 105 1485 1390 45 32
1300 95 1575 1490 39 32 110 1585 1490 45 32
1400 95 1675 1590 39 36 110 1685 1590 45 36
1500 100 1785 1700 39 36 110 1820 1710 52 36
FLANGES

DXN
OD
PCD
T
30
Fittings
FLANGE COUPLING

REDUCER

CONCENTRIC REDUCER ECCENTRIC REDUCER

1. Length of A and B = Length of Lamination according to DN and pressure.
2.Length of L = ( D1 - D2 ) x 2.5
FLANGE CALIBRATED END
FLANGE-BELL END
FLANGE SPIGOT END
REKA COUPLING
A A L B L B
D
1

D
1

D
2

D
2

31
Fittings
ELBOW - MITERED
90 DEGREE 60 DEGREE 45 DEGREE 30 DEGREE
L

L

L

L

32
Fittings
90 60 45 30 90 60 45 30
100 223 160 142 113 283 220 202 173
150 345 250 223 180 415 320 293 250
200 446 320 284 227 536 410 374 317
250 548 390 346 273 658 500 456 383
300 640 449 397 310 770 579 527 440
350 736 514 453 352 886 664 603 502
400 798 544 474 359 968 714 644 529
450 884 599 520 390 1084 799 720 590
500 986 669 581 437 1216 899 811 667
600 1144 764 658 567 1404 1024 918 827
700 1302 859 736 534 1607 1164 1014 839
800 1466 958 818 587 1816 1308 1168 937
900 1624 1053 895 636 2014 1443 1285 1026
1000 1782 1148 972 684 2202 1568 1392 1104
1100 1940 1243 1050 732 2290 1593 1400 1082
1200 2103 1343 1132 930 2373 1613 1402 1200
1300 2262 1437 1209 834 2462 1637 1409 1034
1400 2420 1532 1286 883 2550 1662 1416 1013
1500 2578 1627 1364 931 2638 1687 1424 991
DN
L (PN10) L (PN16)
D1 D2
CALIBRATED
JOINT
LAMINATION
D1 D2
CALIBRATED
JOINT
LAMINATION
L H L H L H L H
100
100 240 120 370 185
700
100-300 1400 700 2270 1135
150
100-150 300 145 520 260 350-700 1400 780 2270 1215
200
100 380 210 690 355
800
100-350 1600 800 2590 1295
150-200 400 210 690 355 400-800 1600 900 2590 1395
250
100 470 260 840 440
900
100-400 1840 900 2900 1450
150-250 490 260 840 440 450-900 1840 1020 2900 1570
300
100-150 580 330 1000 530
1000
100-450 2000 1000 3200 1600
200-300 600 330 1000 530 500-1000 2000 1140 3200 1740
350
100-150 680 385 1150 615
1100
100-500 2200 1100 3400 1750
200-350 690 385 1150 615 550-1100 2200 1240 3400 1840
400
100-200 800 400 1320 660
1200
100-500 2400 1200 3600 1900
250-400 800 450 1320 710 600-1200 2400 1340 3600 1940
450
100-200 910 445 1470 735
1300
100-600 2600 1300 3800 1900
250-450 910 505 1470 795 700-1300 2600 1400 3800 2040
500
100-250 1000 500 1640 820
1400
100-600 2800 1400 4000 2100
300-500 1020 570 1640 890 700-1400 2800 1540 4000 2140
600
100-250 1200 600 1950 975
1500
100-700 3000 1500 4200 2200
300-600 1200 660 1950 1035 800-1500 3000 1640 4200 2240
TEE EQUAL AND UNEQUAL
D2
L
D
1

H

33
Fittings
The joint is a double O-ring bell and
spigot type with a locking device that
is inserted through a bell opening into
a hoop groove. Both metallic and
shear resistant plastic materials are
used for this device. This joint is a
non-destructive, separable joint.
Higher pressure can be supplied on
request.
The axial forces have to be sustained
by external devices.

SLEEVE COUPLING
DOUBLE O-RING BELL AND
SPIGOT WITH LOCKING KEY

GRP pipes manufactured by the continuous
filament winding machine and cross winding
machine are joined with sleeve coupling made
of lip-type elastomeric profile (REKA RRA-69)
inserted into the grooves of the GRP sleeve
and covering the pipe spigot ends.
the pressure of the conveyed fluid against
the profile lips
the compression of the elastomeric profile
between the pipe external surface.
Maximum Recommended Angular Deflection
of Bell and Spigot joint
DN Angular Deflection, Degree
< 500 3
>= 500 to < 900 2
>= 900 to < 1800 1
> 1800 0.5
Application

Diameters Pressure
25 - 500mm up to 30 Bar
600 - 1200mm up to 20 Bar
1300 and above up to 16 bar
BELL
END
SPIGOT
END
PRESSURE
TEST NIPPLE LOCKING KEY
DOUBLE
O-RING
REKA GASKET RUBBER
REKA COUPLING
PIPE 1 PIPE 2
Joints
34
PRESSURE
TEST NIPPLE
PIPE 1
PIPE 1
ANGLE
BELL SPIGOT JOINT

BUTT AND STRAP
This permanent joint consist of a hardening of impregnated glass, mats and tissues laminated
according to specified with and thickness. The laminated joint provides continuity in both hoop and
axial directions.
COUPLING AND EXPANSION JOINT
DN
PN10 PN16
T L T L
100 4 100 5 130
150 5 160 7 230
200 6 200 9 290
250 7 240 11 350
300 8.5 270 13 400
350 10 310 14.5 460
400 11 350 16 520
450 12 380 18 580
500 13 420 20 640
600 15 490 23.5 750
700 18 560 27 870
800 20 640 31 990
900 22 710 34.5 1100
1000 24.5 780 38 1220
1100 26 850 41.5 1220
1200 27.5 920 45 1300
1300 29 990 49 1300
1400 32 1060 52 1340
1500 35 1100 56 1340
DN
COUPLING EXPANSION JOINT
L NL BL
100 393 1172 672
150 467 1208 708
200 467 1208 708
250 467 1208 708
300 592 1208 756
350 592 1256 756
400 592 1256 756
450 704 1315 815
500 704 1315 815
600 704 1315 815
700 704 1315 815
800 704 1315 815
900 750 1336 836
L
T

D
N

NL
NL
N
L

L
N
L

COUPLING
EXPANSION JOINT
T = P ( ID+2T)/(2H-P)
L = P ( ID+2T)/2S
T = THICKNESS OF LAMINATION, Mpa
P = DESIGN PRESSURE, Mpa
ID = INSIDE DIA., mm
T = PIPE THICKNESS, mm
H = ALLOWABLE HOOP STRESS, Mpa
S = ALLOWABLE SHEAR STRESS, Mpa
The application field of butt and strap joint is related
to diameter and pressure classes of pipes to diameter
and pressure classes of pipes and fittings to be joint.
The dimensions of butt and strap joint are calculated
according to the following formulae :

35
Joints
36
SPS GRP pipe sections are typically joined using GRP double bell couplings or bell and spigot joints.
Pipe and couplings may be supplied separately or the pipe may be supplied with a coupling installed
on one end.
Other joining systems such as flanges, mechanical couplings and butt and strap lamination joints
may also be used with SPS GRP pipe.
JOINING PIPES
DOUBLE BELL COUPLING
Cleaning and Gasket Installation the following steps (1 to 4) apply to all double bell coupling-joining
procedures.
STEP 1: CLEAN COUPLING
Thoroughly clean double bell coupling grooves and rubber
gasket rings to make sure no dirt or oil is present.
STEP 2: INSTALL GASKETS
Insert the gasket into the grooves, leaving two or more
uniform loops of rubber (depending on diameter) extending
out of the groove. Do not put any lubricant in the grooves or
on the gasket at this stage. There should be a minimum of
one loop for each 450mm of gasket ring circumference.
With uniform pressure, push each loop of the rubber gasket
into the gasket groove.
When installed, pull carefully on the gasket in the radial
direction around the whole circumference to check for well-
distributed compression of the gasket.
Check also that both sides of the gasket protrude equally
above the top of the groove around the whole
circumference.
Tapping with a rubber hammer will be helpful to accomplish
the above.

STEP 1
STEP 2
STEP 3
STEP 3: LUBRICATE GASKETS
Next, using a clean cloth, apply a thin film of lubricant to the
rubber gaskets.

Pipe Joining
37
STEP 4: CLEAN AND LUBRICATE SPIGOTS
Thoroughly clean pipe spigots to remove any dirt, grit, grease,
etc. Using a clean cloth, apply a thin film if lubricant to the
spigots from the end of the pipe to the black positioning
stripe. After lubricating, take care to keep the coupling and
spigot clean.
Caution: It is very important to use only the correct lubricant
thin film of lubricants to the spigots from the end of the pipe
to the black positioning stripe. After lubricating, take care to
keep the coupling and spigot clean.
Caution: It is very important to use only the correct lubricant.
STEP 4
STEP 5: FIXING OF CLAMP
Clamp A is fixed anywhere on first pipe or left in position from previous joint. Fix clamp B on the pipe
to be connected in the correct position relative to the alignment stripe on the spigot-end (home line)
so as to act as a stopper.

Note: The mechanical installation clamp is to act both as a stop to position the coupling and as a
device on which to attach the pulling (come-along jacks) equipment. Clamp contact with the pipe.
Shall be padded or otherwise protected to prevent damage to the pipe and to have high friction
resistance with the pipe surface. If clamps are not available, nylon slings or rope may be used as in
Figure 3.6, but care must be taken in the alignment of the acting as a stopper. However, if not
available, insert the pipe spigots until the home-line (alignment stripe) aligns with the coupling edge.
STEP 6: PIPE PLACEMENT
The pipe to be connected is placed on the bed with sufficient distance from previously joined pipe to
allow lowering the coupling into position.
SPS GRP provides sufficient lubricant with each delivery of coupling. If for some reason you run out,
please contact SPS GRP for additional supply or advice on alternative lubricants. Never use a
petroleum based lubricant.
CLAMP B CLAMP A
STEPS 5 & 6
COME-ALONG JACK (one on each side)
PLANK ON BOTH SIDES
TO PREVENT PIPE
DAMAGE
NYLON OR
ROPE SWING
38
STEP 7: JOIN COUPLING
Come-along jacks are installed to connect the pipe clamps and two 10 cm x 10 cm timbers or similar
(large diameters require a bulkhead) are placed between the pipe previously connected and the
coupling. While these are held in position the new pipe is entered into the coupling until it rests
against the pipe is entered into the coupling until it rests against the pipe.

Note: Approximate joining force 1 kg/mm of diameter.
Note: For smaller diameter (100mm to 300mm) it might be possible to joint pipe and coupling
without the use of come-along jacks. The use of levers is common to join small diameters.
STEP 8: JOIN PIPES
Come-along jacks are loosened and timbers removed before re-tightening the jacks for entering the
coupling onto the previously connected pipe. Check the correct position of the edge of the coupling
to the alignment stripe.

Note: When step 8 has been completed, clamp-B is left in position while Clamp A is moved on to the
next pipe to be joined.
WOOD (10cm x 10cm)
STEP 7 A
WOOD (10cm X 10cm)
B
STEP 8
B
A
A
B
39
Maximum angular deflection (turn at each coupling joint must not exceed the amounts given in table. The
pipes should be joined in straight alignment and thereafter deflected angularly as required
Angular Deflection at Double Bell Coupling Joint
The bending radius depends on the section length of the pipe. In the above table it is shown for the
standard section length of 6m to 12 m, but it can be easily calculated since it is inverse relation to the
section length (for 3m section length will be half of the radius for 6m section length).
PIPE DIAMETER
PIPE TO PIPE ANGULAR
DEFLECTION
BENDING RADIUS
L = 6m L = 12m
300 DN 600 4.0 86 172
600 DN 750 3.5 98 196
750 DN 900 3.0 115 229
900 DN 1100 2.5 138 275
1100 DN 1400 2.0 172 344
1400 DN 1900 1.5 229 458
1900 DN 2800 1.0 344 688
2800 DN 3800 0.75 458 917
3800 DN 4000 0.5 688 1375
COUPLING
PIPE
RADIUS OF
CURVATURE
DEFLECTION OF ANGLE
OFFSET
Angular Deflection of Double Bell Couplings
40
FRP Flange Joining Procedure
GRP flanges with diameter 350mm and larger should be jointed according to the following
procedure:

1. Thoroughly clean the flange face and the O ring groove with any clean rags and avoid any oil
contact for both the groove and the O ring.
2. Ensure the O ring gasket is clean and undamaged. Do not use defective gasket.
3. Position the O ring in the groove and secure in position, if necessary, with small strips of adhesive
tape at intermittent locations.
4. Make sure that the two flanges or connecting flange with valve or expansion joint is well aligned
with GRP flanges. Any misalignment could lead to high stress at flange neck and could cause damage.
5. Insert bolts, washers and nuts. All hardware must be clean and lubricated to avoid incorrect
tightening. Washers must be used on all GRP flanges.

1. Using a torque wrench, tighten all bolts to 35 N-m torque, following standard flange bolt tightening
sequences shown in Fig. SPS-2.
2. Repeat this procedure, raising the bolt until the flanges almost touch at their inside edges with a
gap of 2-3mm or maximum bolt torque of 100 N-m. Do not exceed this torque without consulting
SPS for advice. If done so, this may cause permanent damage to the GRP flange.
3. Uniform pressure should be established over the flange face by tightening bolts in 7 N-m (5 lb-ft)
increment according to the sequence shown in Fig. SPS-2. For flanges with more than 20 bolts,
similar alternating bolt tightening sequences shall be used, ( As per ASTM D4024-00).
4. Check bolt torque one hour later and adjust as seen necessary to 100 N-m.
5. The maximum torque, in any case, should not be more than 110 to 130 N-m. Care should be
exercised while increasing the torque uniformly.
6. The above procedure is applicable for all diameters.

FIG. SPS-2
FIG. SPS-1
METAL
FLANGE
GRP FLANGE
O RING GASKET
41
Note: When connecting two GRP flanges, only
one flange should have a gasket groove in the
face.

OTHER JOINING METHODS

1. Flexible Steel Couplings:
(Straub, Tee Kay, etc See Fig. SPS-3)
These couplings can be used for joining as well
for repair. The coupling consist of a steel mantle
with an interior rubber-sealing sleeve.

Three grades are available:
Epoxy or PVC-coated steel mantle.
Stainless steel mantle.
Hot dip galvanized steel mantle.

Control of bolting torque with these couplings is
most important. After initial bolt up, the
coupling should be rapped with a rubber mallet
to help seat and flow the gasket. Bolt torque
should then be adjusted up to proper levels.
Depending on coupling size, this procedure may
need to be repeated several times. Do not over
torque as this may. Over stress the bolts. Follow
the manufacturers recommended assembly
instructions.

2. Mechanical Steel Couplings:
(Viking Johnson, Dresser etc. See Fig. SPS-4)
These couplings can be used for joining, typically
to other types of pipe or to rigid items.
Bolting torque must be controlled not to exceed
the manufacturers maximum recommended
values. Excess torque could damage the pipe.
FLANGE
SLEEVE
GASKET
FLANGE
FIG. SPS-4
FIG. SPS-3
42
Site Hydrotest GRP Piping
UNDER GROUND PIPING SYSTEM-
COUPLING JOINTS

Field hydrotest could be conducted in segments
or as a complete piping system.

SEGMENT HYDROTESTINGS
Certain lengths shall be chosen according to site
conditions to test the installed piping system in
segments. A clearance of 4 meters minimum
shall be maintained between the segments
which could be later installed as Make-up pipe
piece with double spigot calibration to facilitate
the jointing on existing piping segment.

FIXING TEST PLUGS:
There are more than one methods to close
temporarily the pipe ends for hydrotest
purposes:

1.USING BLIND END CAPS:
Blind end cap is FRP coupling with one end
lamination, while the other end is with groove
for rubber gasket to work as sealing the end.
Fix the end cap with the last pipe end to be
tested after placing the rubber gasket into end
cap groove.
Joint with the spigot pipe end through
pullers/come-along jacks.
Necessary openings could be provided to the
end caps for ventilation/pressure gauge. After
segment test, these end caps could be removed
through pullers & could be reused for other
segments after rubber gasket replacement.
Adequate concrete block supports shall be
provided to the end cap to prevent the pipe
movement during hydrotest.

2.FLANGED BLIND END:
Flanged blind end is a spool consist of flange
with pipe piece & blind through a blind flange
with bolts at one end while the other end is a
spigot calibrated pipe shall be joined with the
existing end coupling.

* Further details of above options is available
upon request.)
CHECK LIST
PRIOR TO PIPE ENDS BLIND:
To check each coupling joint is connected
correctly and the clearance between the pipe
end is uniform all around. (Field joints testing
equipment is available for pipe diameters
ranging from 700 mm to 2600 mm ). This test
ensures the rubber gaskets correct positioning
inside the double bell coupling groove. The test
shall be conducted prior to start backfill. For
details, contact SPS field representative.
Internal visual inspection shall be carried out for
accessible pipe diameters for any possible
damage during installation/backfilling.
In no case, shall a single person be allowed to get
inside of the piping for inspection.

Vertical deflection measurements shall be taken
to observe the pipe behavior after the backfill.
(Refer to underground installation manual for
details).
Make sure that the pipes are backfilled to the
minimum cover depth requirements of
hydrotest.

For 100mm to 300 mm diameters
(Min. 600 mm cover over the pipe crown)

For 350mm diameters and above
(Min. 1000mm cover over the pipe crown)

Double bell coupling joints could be exposed in
case of the client requirements.

Make sure that the backfilling slope at the joints
location is maintained with minimum pipe
exposure.

PREPARATION PRIOR TO HYDROTEST:

Make sure that the test method statement is
available with full understanding of
implementation to the testing team.

Allowance for each branch/manhole to move
freely, within limits during the hydrotest.

Fixing ventilation at highest points, minimum
two pressure gauges and filling points with
valves.

43
The values and reading at the pressure shall be
calculated taking into account the static head
between the lowest pipe invert level along the
complete line and the level of the pressure
gauge.

All flanges are tightened to the specified torque
bolt sequence. Make sure that the values are
anchored and the above ground piping, if any is
supported as specified.

In no case, shall a single person be allowed to get
inside of the piping for inspection.

Upon verification of the inspection, when the
finding are all judged acceptable & recorded,
manhole covers shall be closed.
Prior to start water filling, temporarily piping &
blinds shall be installed checked & verified by
the
client/consultant/contractor/representatives.

WATER FILLING & PRESSURIZING THE
SYSTEM:
(It shall be confirmed that all vent points are
fully opened to atmosphere, prior to start water
filling).

Introduce water filling through temporary hosing
& pump at lowest point. Pump capacity shall be
chosen according to the pipe diameter and
segment/system linear length. (Pump having
100m
3
capacity/hour are generally used for large
diameter pipes).

The sign of complete water filling is when the
water starts coming through higher point
ventilation opened valves.

Stop water pumps at this stage & check the
flanges, valves and connected accessories for
any webpage/leakage while keeping the vents
open.

PRESSURIZING:

Start pressurizing the segment/system through
pump. Once the water starts coming out
through vent opening, close the valves at low
elevation. Later on the high elevation end the
vent valves shall be closed as well after water
starts coming.

The pressure increment shall be maintained
approximately as 0.5 bar/10minutes at this
stage. When the pressure reaches to 2 bar, the
pumps shall be stopped.

Keep this stoppage for 15-20 minutes. During
this time, following checks shall be made:

Pressure at each test gauge shall be checked &
recorded on inspection sheet.
Watch the pressure at the water feed point for
any decrease in pressure.
Walk through along with the underground
lines to observe any traces of wet soil. Check the
coupling joints if exposed.

The inspection sheet shall be maintained for the
observations & findings.

Anything unusual shall be immediately reported
to the team leader.

Unless there is no findings which prevent the
test from continuing, the segment/system shall
be further pressurized.

Connect the hose with the pressure pump and
start pressurizing the line. At this stage, slightly
open the vent. Valve should be fixed at a higher
elevation to ensure that no entrapped air is
present.

Upon confirmation of water coming out of the
vent, valve shall be closed. The system is now
totally closed and under pressure.
Continue the pressure pump until it reaches to
5.0 Bar. During this operation, the pump shall
be constantly attended for pressure control.

Stop the pressure pump once it reaches to 5.0
Bar and let it stabilize.

There could be a drop in pressure due to the
thermal expansion, which could be resolved by
restarting the pump or keep it as is & record it
on the inspection sheet.

Keep this stoppage for about 30 minutes. During
this period, repeat the same sequence of
inspection as described earlier. The findings &
observations shall be recorded on inspection
sheets.

Any unusual findings shall be reported
immediately to the team leader.
Unless there are no findings which prevent the
test from continuing, the segment/system shall
be further pressurized to the requirement.

The test pressure should not exceed 1.5 times
the maximum rated operating pressure. The test
pressure shall be maintained for a minimum
period of time.

(It is recommended to maintain the test hold
time to a maximum of 15 minutes after pressure
stabilization).

A thorough inspection shall be made as Final
Inspection.

Fill up the inspection sheets accordingly.

The test shall be considered as PASS if no signs
of leakage is observed.

The inspection sheets shall be signed by the
authorities.

POST HYDROTEST:
After completion the test, drain or flush out the
filled water from the pipe segment/system
through drain valves & vents shall be opened.
This pressure release shall be made slowly @ 2
bar/5 minutes.

1. Remove the end cap from the segment as per
procedure.

2. Prepare the pipe end to be ready for next
installation.

3. Exposed joints may be backfilled using the
specified backfill material.

4. Connect the adjacent segment ends with
closure pipe piece.

5. Continue the installation for the other
segments & conduct the hydrotest in the similar
manner as described earlier, keep connecting
the segments through closure spools.

6. Complete system hydrotest/Final hydrotest.

The purpose of this hydrotest is to test the pipe
closure spools joints.

Following arrangements shall be made:
All branch connections shall be kept free to
move.
Separate the line from all connections
equipments.
Exposure of joints at closure pipe piece shall be
done manually in order to prevent the pipe from
any damage.

The procedure described for the segment testing
is applicable to the final hydrotest.

For final hydrotest, it is recommended to
maintain the test hold pressure for minimum
period of time (one is enough to inspect the joint
/ fittings) and the pressure shall be equal to the
maximum rated operating pressure.
44
SPS - GRP Manholes are made of a chemical
resistant thermosetting isophthalic polyester resin
and fiberglass reinforcement with silica sand or
calcium carbonate additives. The standard
diameter (DN) of manholes are usually 1000 mm
or 1200 mm cylinder with a concentric reducer on
top of it to form a 600 mm man way. The
concentric reducer (cone) is manufactured
separately by hand lay - up process will then be
factory jointed with the manhole body to form one
piece manhole. GRP manholes conform to the
ASTM for GRP manhole Specification D 3753.
Ultimate Compressive strength in the
axial direction, when measured
according to ASTM D695 is 985 Kg/ cm.
Cylinder Stiffness ( ASTM D2412)

MANHOLE HEIGHT,
H(mm)
MINIMUM STIFFNESS,
KN/m
1000 1800
4.96
2000 - 3600
8.69
3800 - 7600
20.82
USE AND APPLICATION
The product is applicable to use in corrosive
environment such as sanitary sewers, storm
and sewers including cooling water lines with
a temperature from - 40 to 70 deg. C.
The ring and cover must rest on a course of
bricks or a concrete ring, not the fiberglass
support ledge. All surcharge load must be
applied to the ring and cover.
GRP manholes must be installed in
accordance with SPS installation instruction.
Holes or arches must be cut in the cylindrical
portion of the manhole using a circular
cutting diamant disc or similar equipment
with a masonry type blade. Axes, hammers,
chisels or similar tools are not advisable to
use to make cuts on the manhole.
Maximum single cutout hole diameter is 750
mm for the 1200 mm manhole and 600 mm
for the 1000 mm manhole. Sum of all
cutouts must not exceed 1900mm for the
1200 mm manhole and 1500 mm for the
1000 mm manhole.
DIMENSION TOLERANCE
DN 1200 1000 7
H 1000 ~ 7600 50
Wall
Thickness
10 10 min
PRODUCT REQUIREMENT AND TOLERANCES
Visual Standard
SPS-GRP Manhole is to be commercially
free from the following defects.
DEFECTS DEFINITION
Fuzz
Glass fibers loosely
adhering to the pipe which
are not wet out with resin
Protruding Fibers
Glass fibers sticking out
from pipe surface that are
not wet out with resin
Resin Runs
Runs of resin and sand on
surface of pipe
DN
H

Manhole
45
Main Office : Jeddah Industrial Zone Phase IV
P.O. Box 34572 Jeddah 21478
Kingdom of Saudi Arabia
Tel. +966 2 608 1100 / +966 2 637 0999
Fax +966 2 636 5925 / +966 2 637 9439
www.saudivalve.com / spsvalve@sps.net.sa

Sales Office : Takhasussi Street
P.O. Box 52408 Riyadh 11563
Kingdom of Saudi Arabia
Tel. +966 1 482 6006 Fax +966 1 482 8742

SPS GRP

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