SUPERLIT GRP INSTALLATION MANUAL
Contents
1. dicic 3 ameti Fra TT inar N C B 15 188 ONY SATA lod IE 331 TALI d 1 390 18 BHU ums d Buldno 440 9500 331 Buldnoo dae edi edid acid 4045 440 did Y 5 SUD dao 49018 3 0 div 0 1 8 0 JOBSITE SAFETY PROCEDURES 8 1 Pre installation stage a All site personnel should complete technical and safety trainings regarding jobsite activities including loading unloading storing and installation before accessing to the jobsite b Jobsite Safety Procedures booklet should be prepared and distributed to all jobsite personnel Warning labels and plates should be placed at appropriate places at jobsite c During safety trainings prior accidents and experiences should be presented by pictures and videos undesired outcomes of the accidents should be emphasized It 1s vital to persuade and convince job site personnel for the importance of jobsite safety to be able to enforce and apply the procedures strictly d A safety supervisor should be assigned Responsibilities duties and authority of the safety supervisor should be clearly identified and declared to all job site personnel e Safety equipment such as helmets safety shoes safety gloves etc should be provided and consigned to each site personnel with a signed receipt declaration f Site person2. 20 INSTALLATION OF PIPES AND FITTINGS ccccsssssssssssssscsscsssssscsscesccsccsceeoees 31 EENG 31 Lowenne 1 32 SANA AA A A 33 OA OOO 11 38 TAA OS Gl E 39 Hilin COMMS n 40 n D aaa as n e e 45 CONNECTION OF PIPES WITH RIGID STRUCTURES 47 Repair Pipeline closure pipes 49 SITE CONTROLS AFTER INSTALLATION s s eee sss s s i 50 CHECKING yertical delle clon 4 25 m repro ici idas 50 51 52 Filling the pipeline for hydrotesting sss 55 Alowa ICA d a aaa saad 56 Takime pipeline AMON 1x baa sas 56 JOBSITE SAFETY PROCEDURES asena 60 EE Eet 60 O 60 Wile entero non PIDE aula 61 Dita AAA as ada die l Storage of chemicals and raw materials sss s eene nnne 62 5 0 5 1 3 2 5 3 5 4 5 5 5 6 5 7 6 0 6 1 7 0 7 1 7 2 7 3 7 4 7 5 7 6 8 0 8 1 8 2 8 3 8 4 8 5 INTRODUCTION The purpose of this manual is to guide field teams to perform a proper installation of Superlit GRP pipes couplings and fittings While using this manual solid engineering practices and common sense should a
3. ve pel w Ehi n ee Y Se e EH an i 81 AA AAA Sij Sr seruis 8018 OL NOLEODONWOO ajppnd uy Buyjdnas E appnid 1805 20 73 ese eile MOUS dag adig guo EAA eren Cc ANSIA 6 1 Repair Pipeline closure pipes Repair and pipeline closure pipes are used under below conditions a Field hydrotesting 15 generally applied at certain pipeline lengths sections To install testing caps to the section ends gaps are left along the pipeline Pipeline closure pipes are used to close these gaps after field hydrotesting b For faster installation in some cases installation starts from both ends of the pipeline route At the junction point pipeline closure pipes are used to complete the pipeline c Defective sections of a pipeline can be detected during field hydrotesting In some cases these detected parts are needed to be replaced 11 there 1s no possibility to repair the crack with hand lamination In such cases repair closure pipes are used to close the pipeline Before placing the repair closure pipe it should be controlled whether or not both sides of the pipeline are at the same level and axis After cutting repair closure pipe at the required length mechanical couplings should be assembled on both ends When repair closure pipe is placed in the gap pipe should be alig
4. 1 ii geb r nsr gg 1 S508 poo by dana WWD unu a Tau EA 3 2 General information on trench excavation Following points should be considered during trench excavation a Take necessary safety precautions to ensure a safe working environment b Prevent water penetration into the trench c During excavation make sure that trench walls keep vertical position d For a flat bedding remove all obstacles and sharp edges such as rocks gravels concrete etc from the trench e Remove all organic items such as plants tree roots etc from trench ground f Ensure that trench ground is strong and stable g If the trench ground is not stable enough increase trench depth for stabilization works h Discharge water if there is any from the trench before bedding preparation 1 When the underground water level is high 1t might cause pipes to float To prevent floatation increase the trench depth to increase the height of backfilling J Ensure that trench width is sufficient enough for bedding and backfilling compaction works k Ensure that excavated materials are piled at a distance from the trench to avoid the possibility of rolling back into the trench 20 Bedding after ground stabilization 21 3 3 Sheet pile application during trench excavation Trench walls should be supported with sheet pil
5. Superlit recommends below values for the distance of pipes in the same trench 24 Diameter mm Minimum distance between pipes mm 200 600 mm 300 mm 700 1200 mm 600 mm 1300 2000 mm 1000 mm 2100 3000mm 1500 mm 3000 mm ve st 2000 mm Table 3 Minimum distance between pipes 3 7 Cross over of pipes In case of cross over of pipes one pipe crossing over the other pipe minimum distance between 2 pipes should be determined as per below illustration and formula fg 412 gt 70 RD Gravel or 90 SPD 5 send f should not be less than 300 mm Figure 9 Cross over of pipes There are some cases where a new pipeline route passes underneath an existing pipeline In such cases existing pipeline should be shut down if possible and excavation should start only after stabilization of the existing pipeline with supports The new pipes should be lowered into the trench without interacting with the supports and should be laid slowly underneath the existing pipeline 25 After placing new pipes backfill material should be applied to close the gap between the two pipes and should be compacted by hand It 1s also recommended to add a small amount of cement in the back fill material 3 8 Trench depth While determining the trench depth intended purpose of service design of the pipeline pipe characteristics trench soil characteristics static dynamic load combinations shoul
6. be lowered closer to the previously installed pipe and should be carefully aligned 32 5 3 Pipe installation Superlit GRP pipes are delivered with a coupling installed on one end 11 not required otherwise Clean the pipe ends from dust and dirt Visually check pipe ends for delamination Delamination 1s partition of pipe layers Clean the rubber gasket and remove any stones gravel or dust from the grooves of the gasket Apply lubricants on the gasket with a piece of soft fabric Lubrication material should be organic Never use petroleum based lubricants Superlit advises soft soap or paraffin to be used as a lubricant under standard conditions Amount of lubricant can be determined from the below table Pine diameter Lubricant amount p Approximate for each connection 200 600 mm 700 1200 mm 1300 2000 mm 2000 mm and above Table 7 Lubricant amount For easier assembly of pipes a pit should be excavated for the coupling to settle After assembly of the pipe to the previous pipe coupling pit should be filled with backfill material and should be compacted Bell Hole fill after completing pipe joint Proper Bedding Support Improper Bedding support Figure 10 Coupling pit 33 Pipes and fittings can be assembled by using below techniques a With come along jack GRP Coupling come along jack rope plank on both sides to plank come along jack Insert soigot until end
7. couplings are not backfilled Safety precautions should be applied around the pipeline if possible tested section of the pipeline should be isolated from human access before starting hydrotest After completion of the hydrotest unfilled top sections of the couplings should immediately be filled with backfill material 52 53 Ev Lee NUCA An Sang a mag Mes 5 b adig dup ag OSEAN qui e dna pug LN su EN T zm si nv sg s m s a Yl p nai z WE ES PEE SOS 8 EA 9c m k 54 LA 1 or op ges Fann Lab ened CLES 078 A il LZ 0511 EW 290 Ld ng dvo ONS 79315 cir b l pesao en EUIS mei 001 E Fe lu r TEE EEE aale Toe peran jor me Fr Esto gt me a ee ore Bi CT beg ine i i e Note During hydrotesting of large diameter GRP pipes with nominal pressure 10 bars and above couplings might rotate For high pressure pipelines test pressure should not be increased 1f the coupling tops are left unfilled for visual inspection If a coupling rotation 1s detected test should be immediately stopped coupling should be aligned and test should be repeat
8. load Consult Superlit for lifting points and lifting method for nested pipes b Storing pipes as nested is a prefered application in many cases due to less storage cost and space However do not store nested pipe bundles as stacks and always store nested pipes as a single level c To prevent movement of inner pipes while transporting special packaging techniques are used for nested pipes Do not release original packaging of nested pipes until installation 12 d Before denesting inner pipes be sure to remove all packaging such as steel strips wooden wedges sand bags etc without damaging the pipes e The most common technique used for denesting pipes 1s using a forklift with a padded boom fixed on one of 1ts forks The padded boom installed on the fork 15 generally a steel tube covered with plastic Before denesting the pipes be sure that the forklift capacity 1s sufficient for this operation Denesting operation can be described as follows Forklift operator places the boom inside the most inner pipe without touching the pipe walls then starts lifting the boom very slowly The boom lifts the pipe slightly until the lifted pipe becomes completely loose inside the outer pipe By driving forklift backwards lifted pipe 15 taken out of the bundle After each denesting pipes should be visually controlled for damages To keep the pipe bundle stable 1t 15 recommended to perform denesting operation at a denesting station If weight le
9. of pipe reaches the center reaister Figure 11 Come along jack 34 b With Backhoe or Bulldozer While pushing the pipe with backhoe bucket or bulldozer blade a plywood should be used between the pipe end and the bucket or the blade to prevent structural damage on the pipe end pipe being installed installed pipe GRP Coupling Backhoe bucket Bulkhead 4 x 4 and Plywood GRP Coupling pipe being installed installed pipe Bulldozer Blade GRP Coupling 3ulldoz Ge Bulkhead 4 x 4 and Plywood GRP Coupling Figure 12 Installation with backhoe or buldozer c With pliable strap and excavator arm This method is widely used at jobsites Pliable strap 15 tied around the pipe and excavator arm pulls the strap and strap pulls the pipe towards the installation direction This method should only be applied by very experienced excavator operators 35 In all above mentioned methods pipe should be inserted into the coupling until pipe touches the stopper of the coupling For big diameter pipes field technicians can enter the pipe after the installation to control the alignment of the stopper and the pipe However for small diameter pipes a different technique should be used to ensure touching of the pipe and the stopper since there 15 no possibility to get into the pipe In such cases distance from the coupling outer end to the stopper 15 measured and marked on the pipe and pipe 15 pushed inside the coupling until marked se
10. of the pipeline b At pressured pipelines ensure that distance between the air valves is around 500 750m Air valve diameters should be in accordance with d DN 1 10 or 1 15 whereas d represents air valve diameter d Ensure that all air is expelled from the pipeline e Do not use rapid closing vanes f To avoid sudden stopping and running of pumps which causes water hammer take necessary precautions g Avoid air penetration from water intake structure into the pipeline at gravity pressured pipelines h When pipeline is discharged partially or completely repeat the steps mentioned above while re filling the pipeline 56 57 ORTA dat Jdid duz adla LAOHS 340 ke v 22 Ev LAL eech LELE r svo LR ee ir mah n sana E a 33 11 8 dere TEL r 9 V l m Gb nara ge iai AT LS 11 Las HE Bi 51 TWIX AJ ui 62 Woy WOES dat Ty amp E aan GE M m 1 W daz Jald JHCHS 32018 SPAH 313344022 INO 87 1 58 67 17 oil B SAN Twelve M 50 9 HOY 832314 59 y y 5 aa 220 Sure LITHIA D 1
11. GLASS FIBER REINFORCED POLYESTER GRP PIPES amp FITTINGS INSTALLATION MANUAL PIPE INDUSTRIES INC INDEX Page rte 4 1 0 TRANSPORTATION UNLOADING 2 5 1 1 Transportation of pipes and fittings 66666666666666666666666 666666666666666 666660 nnne n 5 1 2 Loading l alasan 5 1 3 Loading and unloading of couplings and fittings 9 Ee 9 1 5 Unloading handling and storage of nested pipes 12 Lo Handle OT DA ANG O ba as n 14 1 rs ys 14 2 0 SCHEMATIC ILLUSTRATION OF PIPE INSTALLATION STEPS 15 3 0 TRENCH EXCAVATION AND PREPARATION FOR PIPE INSTALLATION 18 SW MEUSE OT OO EE 18 3 2 General information on trench excavation nnns 20 3 3 Sheet pile application during trench 6563 311010 6666666666666 6666 nennen 22 25 4 Preparation 000 23 77 1760007 RE o 24 3 6 Multiple pipe installation in a single trench 24 0710000 0100 001000 25 mo e liu li hs O ad ba 26 l NEE TEn h Ben EE 27 De OV OAE AI 28 4 0 BEDDING AND BACKFILLING MATERIAL CLASSIFICATION
12. at ideal materials for bedding and backfilling are properly compacted granular materials However to reduce field costs excavated trench soils are very often used as pipe zone backfill In such a case excavated trench soils should be analyzed to determine the suitability of usage as backfill material Superlit engineers always recommend compacted granular material for bedding and backfilling 18 19 UT 4 E M Wi X Tes gt 16 bie L E ie pilt g zin EU 3 i N XP F Djrious cw GALS Gu UD Ea ug n kqdtins ae siam yawa jy O 8 Wu 0001 0 2 Wo 000 lt 2 009 x 2 0 8 Uno 009 gt Terri y 35 Odi nee uy Lar SERT EX pupp AE mad TRR s ua oe el 0300000 Thee Tei Puta pon cia n z 03 a Fa 000 35 zu E 2 E e Bez de 8 3 7 Remo pasadas NOILOSS SSOHO HON3HL 3dld 440 METE dia ap Bu Sw ARN anang 31 Jdid E E a a M E xi Ns i H xbr nen anm EI ria uem miri pr ban ions Belin Ia H L k ED 1 EE iy aloe marin Si irq m ED TET TL Hr
13. care should be exercised to avoid any structural damage The following points should be considered during these operations a Identify proper lifting points and methods b Identify proper moving methods and vehicles c Visually control each moved item for damages or cracks d Compare and control total quantity of moved or transported items with the order quantity e Report any damage or a missing item Note Damaged goods should not be used unless inspected and repaired by Superlit personnel 1 2 Loading and unloading of pipes Loading and unloading operations are critical issues therefore techniques which will be used during these operations should be determined based on site conditions While loading or unloading and placing pipes on the ground prevent any impact with rigid objects to avoid structural damage Loading and unloading of pipes with DN gt 300mm should be exercised with an appropriate loading equipment or machine Based on pipe diameters lengths and weights as well as jobsite conditions crane lifting strap method or forklift can be used for these operations Loading and unloading with crane and lifting strap Pipes can be lifted either with one or two lifting straps however for an easier balancing control while lifting two lifting straps usage is recommended With one lifting strap the strap should be fastened at pipe s center of gravity With two lifting straps fastening points should be as per the below ill
14. ction meets the coupling end GRP Pipe stopper Figure 13 Pipe insertion to the coupling 36 37 1839p Su rdno did ay FT INST 5 4 Angular deflection Superlit GRP couplings are manufactured with full face EPDM gaskets When compared with similar couplings Superlit GRP couplings guarantee a complete leak tightness The biggest advantage of these couplings is their suitability for angular deflection Especially for longer pipelines it is possible to rotate the pipeline with angular deflections from the couplings without any necessity for additional elbows Below are the maximum allowable maximum deflection values 200 350 3 400 500 3 600 900 2 1000 1800 1 lt 0 0 5 Table 8 Allowable angular deflection values 38 Before applying an angular deflection pipe should be installed to the pipeline at a straight position then angular deflection should be performed Deflection angle Figure 15 Angular deflection 5 5 Flanged joints Flanged connections are used at several conditions such as Vane and pump connections At transitions between different types of pipes such as connection of a steel pipe with a GRP pipe At water tank or manhole connections While connecting two flanges alignment of bolts 15 a very important issue to avoid loading bending stress on bolts Flange thicknesses should be taken into consideration det
15. d 5 440 a TE er EV wa 28 r ay E un Eid ik L k arin 11 yr aq mana mens qua n men ani c Ren m aom 1 A ii ALL IM Tre med p perio y por ECH mu peg po UI o TUNER 107 ONY 53011 71 723 ei 3007 SAXA 33350155 rir 440 OdvONvIS MOST dac E uoi 23 110100 daz E S Jdid dati i aT 1 ZB LN w 0 3 1 4 lie ii A 002 a i 1 d F 4 3ald OHS dale 777 m 70678 INAH Ag 11910245 MOG die SSN 31 Wa vd H 8 9311 44 mao Didde dg da EE er 1 7 5 7 Trenching on slopes If the slope of the trench ground is 15 or higher GRP pipes should be manufactured with ribs In such trenches it 15 not suitable to use rounded gravels for bedding and backfilling since rounded gravels are subject to washout which leads to pipe support to reduce Advise of Superlit for bedding and backfilling material in sloped trenches is crushed rocks with internal friction angle 42 The most critical issue regarding sloped pipelines is the risk of backfilling and final back filling erosion Therefore erosion risk should b
16. d be taken into consideration Trench depth should be sufficient to prevent conveyed fluids to freeze Sufficient cover backfill and final backfill should be provided to prevent pipe flotation in potentially high ground water areas Generally accepted trench depths are as follows Pipe Stiffness Trench depth SN meter 2500 5000 10000 Table 4 Trench depth 26 Surface loads Live wheel load Min trench depth Kilo Newton bf meter AASHTO H20 C 72 16 000 1 0 BS 153 HA C 90 20 000 1 5 ATV LKW 12 C 40 9 000 1 0 ATV SKW 30 C 50 11 000 1 0 ATV SLW 60 C 100 22 000 1 5 Cooper E80 Railway 3 0 Table 5 Minimum trench depth 3 9 Unstable trench bottom If the trench bottom contains loose or montmorillonit type soils trench bottom is described as unstable bottom In such cases unstable trench bottom should be stabilized if possible loose soil should be removed If there is no possibility to remove the loose soil then penetration of underground water into the trench bottom should be prevented with drainage systems Trench bottom should also be supported and stabilized against collapse by forming bottom foundation layers Gravels or crushed rocks can be used to form bottom foundation layers Height of the foundation should be 20 cm minimum and can be increased based on trench bottom soil characteristics Standard bedding should be applied over the foundation layer To prevent loss of pipe support and
17. e taken into account while determining the backfill material and compaction level Erosion is a result of strong underground water flows rain wind and dust storms In any of these conditions granular backfilling material should be resistant to erosion In some cases methods such as rip rap big rock pieces placing claying asphalt application can be performed 45 46 Aul z LAU z H 2200 Sy OTS MEOR 4 3 1 1 ERARIO n ARO MES LIT a e d PR imm zu rin For jain r PA l Cap ETPEL T buy LEUR r gra rt Gm gu Punt FG ld mpm a Ls b irin m Tee ram az r ux bem zin Se Tei aren ia 5 E Amon Wn IOS PASE Joy sr perrogeur paq at jo Sue ucmaug yens usur 2 adm ur Jaye ew po SOSA p tmissy A Alfsuap pos patnis Mu y p SH te adid aroge pros yo Frag p ninssy QN OOF RE edid ul 3 pau isap are apppnd s unueno FILON Buippag aus pases ippeg jeg auos pausen open euid 6 0 CONNECTION OF PIPES WITH RIGID STRUCTURES The most critical issue regarding pipe and 11510 structure connection 15 the bending stress that may develop when there is a differential settlement move
18. ed and unloaded with maximum care In case fittings are delivered plain without external packaging determination of lifting points and unloading techniques are critical issues For unloading of fittings with packaging pipe unloading methods can be used In any case center of gravity and balanced distribution of mass factors should always be taken into account while lifting loading and unloading of fittings 1 4 Storage of pipes at job site a The storage area should be flat leveled and clear of objects such as rocks stones sharp edges etc b Pipes can be stored in piles to minimize the storage area within the allowed limits c While storing the pipes as piles wooden cradles should be placed between pipe levels The first level pipes should be supported with wooden wedges to prevent sliding d It is recommended to store pipes on flat timbers to facilitate placement and removal of lifting slings around the pipe as well as easy handling of pipes with a forklift e Flat timbers should be placed at a distance of 1 4 of pipe length from each pipe end f If couplings are delivered as bundles couplings should be stored at horizontal position to prevent radial deflection g The storage ground should be resistant to heavy loads and should not be exposed to strong winds Maximum piling height is around 2 5 meters It is not recommended to store pipes as piles for diameters bigger than DN 1200 mm Change of p
19. ed from the beginning 7 4 Filling the pipeline for hydrotesting Pipeline should be filled from the lowest point level and air should be to expelled from the highest point level of the pipeline through air valves Flow rate of filling should not exceed 5 10 of the pipeline nominal design flow rate If it is not possible to fill the pipeline from the lowest point additional air valves should be installed Below outlined method can be followed e Increase the pressure to 2 3 bar e Keep the pipeline under this pressure for 12 hours for stabilization e Shut off all air valves after ensuring that all air is expelled from the pipeline e After stabilization period increase the pressure by 2 bars every 30 minutes 55 e Continue to increase the pressure as explained above until the applied pressure 15 1 5 times of the nominal operation pressure of the pipeline Field hydrotest pressure is defined as the 1 5 times of the nominal operation pipeline pressure Measure the test pressure from the lowest point of the pipeline 7 5 Allowable leakage Most project specifications allow pressure loss or leakage on a pipeline up to a certain limit According to BS 8010 Part 2 5 1989 allowable leakage in 24 hours 15 0 02 liter mm 7 6 Taking pipeline into operation Following points should be considered while taking the pipeline into operation a Keep filling flow rate at 2 5 15 of the nominal operational flow rate
20. epair purposes below items should be taken into consideration a Entrance into a pipeline should only be done with Safety Supervisor s permission Safety Supervisor should evaluate all potential risks before permitting entrance Personnel having health problems and personnel who are not willing should not be allowed to enter into a pipeline b If there is a necessity to perform gas and oxygen level tests such tests should be performed by authorized and certified personnel c Ifthe oxygen level inside the pipeline is not sufficient entering personnel should be equipped with oxygen tubes d Personnel entering into a pipeline should be equipped with safety equipments and should always have a spare lighting e Communication between entering team and outside team should be clear and uninterrupted For any reason 11 communication is lost inside team should immediately get out of the pipeline 8 4 During repairs at job site a Safety procedures exercised during installation should also be applied while removing a pipe or a fitting from an installed pipeline b Repairing works should be performed at a repairing station Boundaries of the repairing station should be clearly marked c Any person other than authorized repair personnel should not enter to the repair station d Repairing equipment should be functional in good condition clean and clear of defects e Safety Supervisor should continuously inspect utilization of safety e
21. ermine the size of the bolts nuts and washers For tightening torques please consult Superlit engineering teams 39 5 6 Fitting connections One of the most important advantages of Superlit GRP pipe systems 15 the possibility of manufacturing project specific custom designed fittings However fittings are the most critical components of the pipelines due to the forces which occurs on fittings If not stated otherwise all Superlit fittings should be encased in concrete Casting of concrete should be performed step by step and by forming layers Fittings and pipes should be prevented from floating during concrete casting Amount of the concrete to be casted should be calculated according to the project specifications 40 41 Edid AWE Wao 2207 90079 18004 p 21000 uo DATNE ay 2 AAA Gg ali a 1 lt i m I lig v i A i e 0 ES 1 A e i 01 0913 9 3011 EECH m pS Hdl due 42 8008005 480 adia uous a rag hae 7 sou nm ba rini 3 d MOLTAS 5504 HONGaL MOST dc NOUDIS 55042 91 MOTH 440 DEE 43 200718 15 9 1 41342 no daz 4 4 30 Ti NT dac Jdi
22. es if the natural ground soil is loose or unstable underground water level is high or trench depth is higher than standard conditions However during removal of the sheet piles backfill compaction 15 subject to disruption which decreases the pipe support To overcome this problem removal of the sheet piles should be done step by step and after each sheet pile removal backfilling should be controlled and compacted until desired compaction level Crushed rock is recommended as backfilling material for trenches where sheet piles are used Since underground water level is generally high in these types of trenches crushed rock size should be big enough to resist water washout Superlit engineers advise trench width where sheet piles are used as DN 2m up to nominal pipe diameter DN 1000 and as 3xDN for nominal pipe diameter DN 1000 and above CUN 1 2h 5 m gt wad P p e E Ta e 1 a E Ae Ae A a Ga o E 3 d ei gt bab iR a R e aa R z e 4 Y 2 A T r n E 4 z 8 3 D r LI m TO 22 3 4 Preparation of trench bedding Trench bedding should be flattened leveled and compacted all along the trench Under unstable 5011 conditions trench depth and bedding thickness can be increased After trench excavat
23. ilar with minimum 12 passing No 200 sieve or Sandy or gravelly fine grained soils CL ML CL ML type soils with minimum 30 retained on a No 200 sieve Soil stiffness category SC4 Fine grained soils CL ML CL ML type soils with maximum 30 retained on a No 200 sieve Soil stiffness category SC5 Highly plastic and organic soils MH CH OL OH PT SCI type soils with low sand and fine containment provides maximum pipe support based on the compaction level Compaction of the material 15 easy and displays maximum support even under moisturized conditions SC2 type soils with a high compaction level displays a high pipe support SC3 type soils display lower pipe support compared to SC and SC2 category soils Compaction requires effort and high moisture conditions decrease the pipe support level 29 SC4 type soils require geotechnical evaluation before used for bedding or backfilling Compaction is difficult and is desired level of compaction is directly dependent on moisture conditions This type 15 of soil 15 not suitable for bedding or backfilling at high backfilling levels under traffic loads and if there is ground water in the trench SCS type soils are not suitable for bedding or backfilling Bedding material characteristics are very important for a proper support for the pipes Generally bedding and backfilling materials are preferred to have the same characteristics If the excavated material is preferred
24. ion bedding should be prepared to provide durable and stable support for pipe Pipe bedding should not be less than 15cm in height and should be prepared with compacted granular material at minimum 90 Standard Proctor Density or any other suitable bedding material at minimum 95 Standard Proctor Density Bedding depth should be increased 1f there are unstable loose or soft soil conditions If bedding material 1s sandy bedding material should be moisturized and should be compacted with vibrating compactors Bedding should always be flat and leveled with the trench bottom 23 y ke E SA 3 a 7 LT bu SL 3 5 Trench width Trench width should be wide enough to place fittings and connection parts and to allow a convenient working space for field teams for compaction For standard installations minimum trench width 1s advised as follows DN lt 600 Trench width DN 2 x 300mm DN gt 1000 Trench width DN 2 x 400mm DN 1000 Trench width DN 2 x 450mm If there are unstable loose or soft soil conditions based on the pipe stiffness and trench depth trench width can be increased 3 6 Multiple pipe installation in a single trench During installation of multiple pipes in a single trench distance between any of the 2 pipes is determined with the formula r r5 2 whereas T radius of the first pipe and T radius of the second pipe Complying with the formula
25. ion pipe installation steps are described briefly with drawings to give a general overview At further sections installation steps mentioned hereby are explained in details Prepare trench bottom for bedding Sc E 1 55 2 Lower pipe into the trench using fabric strap 15 16 d vu B ckfil First pipe of installation 3 Fix the first pipe with backfill material Backfill 4 Lower the second pipe into the trench using fabric strap Align the pipe with the pipe line axis wi A 5 L 1 mere E ft p 1 0 Push pipe spigot into the coupling 17 3 0 TRENCH EXCAVATION AND PREPARATION FOR PIPE INSTALLATION Pipe installation methods for Superlit GRP pipes vary based on stiffness burial depth native soil characteristics and backfill material Initial and long term vertical deflection values should never exceed the values given on Table 1 regardless of the installation method and conditions Otherwise pipe performance might not meet the expectations 3 1 Basics of installation Superlit GRP pipes are designed to provide a continuous excellent performance for long years if the installation is performed correctly as per the instructions Therefore trenching bedding and backfilling specifications and methods should be evaluated very carefully Engineers have found out through considerable experience th
26. ipe s round form to oval form as a result of vertical loads 15 defined as vertical deflection and calculated as follows Deflection Figure 3 Vertical deflection Maximum allowed vertical deflection should not exceed below values while storing the pipes as piles stacks Stiffness Class Maximum Deflection SN diameter Table 1 Maximum vertical deflection Another way to describe storage height is to express the number of stacking layers Diameter DN Maximum number of stacking layers am SN 2500 200 450 4 500 700 3 700 900 2 1000 1200 2 gt 1500 1 Table 2 Maximum number of stacking layers 10 11 E n x Figure 5 Storage Of pipes as piles 2 1 5 Unloading handling and storage of nested pipes Pipes which will be shipped to far destinations can be shipped as nested smaller diameter pipe placed inside bigger diameter pipe to reduce transportation costs These pipes are packed in a special way and may require case specific procedures for unloading handling storing and transporting HR coe AA lt SOD E Mm UN 4 2 Ls gt EC TK x TV S e MN v de d General recommendations are as follows a Always use lifting slings while lifting nested pipes Since the weight of nested pipes will be much higher than the weight of a single pipe ensure that lifting slings are strong enough to handle the total
27. lways be taken into consideration and information provided on this manual should only be used as a guidance Specifications written for a particular project will always have a priority over the general guidelines mentioned herewith In case of a conflict or a contradiction please contact Superlit Project Design and Site Support Department Superlit recommends a whole study and evaluation of this manual before the start up of any jobsite activity In case of a need for further clarifications or practical trainings SUPERLIT ACADEMY is ready for your service To get information about Superlit Academy or to join Academy Programs please contact Superlit staff With the company s core principle of Sustainable Superior Quality in Production and Service Superlit Project Design and Site Support Department teams are always at your disposal whenever engineering support or supervision is needed for project design loading amp unloading handling transportation storage and installation of pipes Superlit Pipe s commitment on compliance with relevant standards and performance criteria is valid if the pipe installation is performed in line with this manual Superlit Pipe keeps the right to change any part of this document or as a whole without prior notification 1 0 TRANSPORTATION UNLOADING STORAGE 1 1 Transportation of pipes and fittings While transporting moving loading amp unloading pipes and fittings at jobsite maximum
28. ment between the pipe and the rigid structure To manage or at least to lower this bending stress short pipes should be used especially at connections with manholes vanes and pumps There are 2 general methods used a The coupling should be casted into the 11510 structure Coupling should be positioned inside the rigid structure model while casting the concrete b A short pipe wrapped with rubber sealing should be used at connections with the rigid structure to minimize the transition effect Rubber sealing should be placed before concrete casting with a recess of 25 mm Note While casting concrete ensure that the coupling keeps its original shape roundness Otherwise pipe might not slide into the coupling Use a high stiffness pipe at connections with rigid structures Ensure that pipe is not subject to high deflections Short pipe length can be determined as 2xDN with an upper limit of 2 meters or as 1xDN with an upper limit Of 1 meter Make sure that bedding and backfill of the short pipe 15 compacted properly Concrete Chamber or Manhole Rubber wrapped GRP Short Pipe around pipe GRP Coupling GRP Coupling Figure 21 Short pipe connection 4 48 T s R F y E xr lirin De ELD tp 2 mi irei di EEN E ei E EE 32200 ia E ER eee Er namg ls A I
29. ned to be on the same level and axis with both pipeline ends For a more effective connection repair closure pipe length is advised to be 20mm shorter than the pipeline gap After ensuring correct alignment both mechanical couplings should be pulled over to the pipeline During pulling over gasket of the coupling should not bend When coupling pull over and alignment is completed bolts of the mechanical couplings should be tightened with a torque wrench at the recommended torque value Flexible couping Figure 23 Application of repair closure pipes 49 7 0 SITE CONTROLS AFTER INSTALLATION 7 1 Checking vertical deflection Initial vertical deflection of the pipes should be kept under control to reach allowable long term vertical deflections Vertical deflection 15 defined as per the below formula 0 D D2 2 Figure 24 Vertical deflection Deflection 56 x 100 It 15 rather difficult to measure long term vertical deflections Long term deflections generally appear minimum 6 months after the completion of installation and in most cases it 1s not allowed to stop a pipeline in service to measure deflections Recommended method 15 to measure deflections 3 days after completion of backfilling Deflection controls should be performed parallel to the progress of pipe installation This way it will be easier to detect a deflection at an initial stage and to take immediate corrective actions Maximum allowable i
30. nel should strictly be controlled in terms of utilization of the safety equipment g Safety equipment supplied should be quality certified by independent accredited agencies h Periodic maintenance and controls on safety equipments should be performed Old torn out or non functional equipment should be replaced 1 Personnel who does not obey and apply Jobsite Safety Procedures should immediately be discharged from the jobsite area and pre determined penalties should be exercised 8 2 Installation stage a Safety supervisor should strictly control whether or not installation activities are performed as described during installation trainings If there is a case which needs application of a non standard installation procedures such a procedure should only be applied under the permission and supervision of the Safety Supervisor b Installation equipment should be free of damage and defects and should be completley functional 60 c Machines and vehicles such as excavator bulldozer grader etc should only be operated by certified and licensed operators without any exception d Make sure that communication system among jobsite personnel 15 clear correct uninterrupted and not subject to misunderstanding or misinterpretation For instance communication of a worker inside the trench with the crane operator lowering a pipe into the trench 8 3 While entering into a pipeline While entering into a pipeline for control or r
31. ngth of the pipes or the unloading equipment capacity do not allow above described denesting operation please consult Superlit Project Design and Site Support Department for special denesting procedures Figure 6 Denesting with a forklift 13 1 6 Handling of lubricants Lubricants used for pipe and coupling installation should always be stored in their original packaging During transportation make sure that the original packages are mounted tightly and not subject to any damage or leakage 1 7 Transportation of pipes Transportation vehicle should never be loaded over capacity while transporting pipes To prevent any structural damage due to the movement and vibration during transportation pipes should be detached from each other To keep the stability and to prevent movement pipes should be tightly packaged and supported with wooden wedges Maximum loading height for pipes 15 2 5m Pipe bundles should be fastened on the vehicle with pliable straps or ropes over the support points If steel strips or chains are used for fastening place fabric pads between the strips chains and the pipe to prevent abrasion Maximum deflection values during loading and transportation should not exceed the values given on Table 1 H H H B Ke E T F r Figure 7 Pipes loaded on truck 14 2 0 SCHEMATIC ILLUSTRATION OF PIPE INSTALLATION STEPS In this sect
32. nitial deflection Maximum allowable long term deflection Table 9 Allowable deflection 50 7 2 Detecting measuring deflection Whenever it is possible for a person to enter a pipeline which is generally valid for diameters 800mm and above vertical internal diameter can be measured with a laser meter device every 3 meters For smaller diameters pig method can be used Pig 15 a wooden disc with a height equal to the allowable deflected vertical internal diameter In this method pig 15 pulled through inside the pipeline If the pig gets in from one end and gets out from the other end without obstruction vertical deflection is accepted to be within the allowable limits min 30 cm x Figure 25 Pig application Superlit emphasizes the importance of performing deflection measurements parallel to the installation progress This way it will be easier to detect a deflection at an initial stage The cost as well as the time spent for corrective actions will be much economical Deflection values outside of the allowable limits are generally an outcome of improper backfilling If an initial deflection out of the allowable limits is detected backfilling should be excavated especially bottom sections of the pipe backfilling should be controlled and re compacted After ensuring that pipe bottom sections are well compacted backfilling operation should be repeated 51 After this corrective action deflection measurement
33. quipment during repairing 61 f Repair station environment should be clear of any possible fire risks g Repair station should be equipped with fire extinguishers If the repair should be performed inside the pipeline h Repairing personnel entering into the pipeline should wear isolated work suits and gas masks If the oxygen level is not sufficient personnel should be equipped with oxygen tubes Sufficient ventilation should be supplied to remove the dust from the pipeline 1 Ifthe repair inside the pipe should be done at 2m height or more suitable scaffolding should be provided 8 5 Storage of chemicals and raw materials a Chemicals and raw materials which will be used for repairs should be stored in a closed and locked storage room b Storage room should have natural ventilation and should not be subject to high temperatures c Storage room should be isolated from outer side conditions such as humidity rain snow etc d All chemicals and raw materials should be stored at their original packages e Storage room should be equipped with fire extinguishers 62
34. s should be repeated monthly After 3 or 4 additional controls 1f the vertical deflection stays lower than 5 corrective action can be considered as successful If vertical deflection 15 measured as more than 5 in any of these additional controls corrective action should be repeated right from the beginning 7 3 Field hydrotesting Just like all other types of pipes GRP pipelines should also be tested before taking the pipeline into operation Field tests can be performed with water for pressured or non pressured pipelines The purpose of field hydrotesting is to detect any leakage points through the pipeline If the pipeline is tested as a whole 1 15 rather difficult to detect exact locations of leakages 1t 1s also difficult and costly to 1111 unfill the whole pipeline Therefore recommended test lengths are 250 1000m based on the pipeline conditions Below points should be checked before field hydrotesting a Make sure that all truss blocks and rigid structures made of concrete are completed at least 7 days before the hydrotest Ensure that concrete of the structures has completed curing and structures are rock solid b Ensure that all testing equipment are functional and in good condition c Close and seal the ends of the pipeline section subject to testing with end caps d Ensure that end caps are supported with anchors to resist test pressure For visual inspection of the couplings during hydrotesting 1 3 of top of the
35. to be used as backfilling material characteristics of the excavated soil should be analyzed for suitability Another critical point to be taken into consideration is the possibility of experiencing different soil characteristics along the pipeline Nominal Diameter Maximum particle size DN mm DN lt 450 450 lt DN lt 600 600 lt DN lt 900 900 lt DN lt 1200 1200 lt DN Tabel 6 Maximum particle size 30 5 0 INSTALLATION OF PIPES AND FITTINGS 5 1 Pre installation stage After completion of trench excavation and bedding installation can start in line with the project Pipes and fittings should be stored along the pipeline next to the trench according to the daily installation program for a faster and easier installation Stored goods should not block the working path of the construction machines such as crane excavator bulldozer etc 31 5 2 Lowering pipes onto the trench bed Lifting straps should be tied around the pipe from the appropriate lifting points While lifting fittings special lifting and alignment requirements should be taken into consideration For instance the arm angle of the Tee part Lifting can be performed with a crane or with the excavator arm and pipe should be lowered onto the bedding slowly During lifting and lowering inside the trench field teams instruct directions to the excavator operator to make sure that pipe will be placed at the right location Pipe should
36. to strengthen foundation filter cloth or geotextile can be laid onto foundation In addition pipe lengths should not exceed 6m at unstable trench bottom conditions 2j 3 10 Overflowing trench If the ground water level 15 rising onto the trench bottom this case is described as overflowing trench Under this condition ground water level should be decreased at least 20cm below the trench bottom before bedding preparation Gravel or crushed rock should be used for bedding and backfill in such trenches However crushed rock size should be big enough not to be dragged with the water flow Pipes are subject to floatation in overflowing trenches Therefore backfill amp final backfill height and Standard Proctor Density should be increased In some cases placement of additional weights onto the final backfill might be needed to prevent floating of pipes 28 4 0 BEDDING AND BACKFILLING MATERIAL CLASSIFICATION Bedding and backfilling materials are classified as follows according to AWWA M45 Fiberglass Pipe Design Manual of Water Supply Practices Soil stiffness category SC1 Crushed rock containing less than 15 of sand maximum 25 passing through 9 5 mm sieve and maximum 3 passing through No 200 sieve Soil stiffness category SC2 Clean coarse grained 50115 SW SP GW GP and similar soil with maximum 12 passing No 200 sieve Soil stiffness category SC3 Clean coarse grained soils SW SP GW GP and sim
37. ustration Both methods should be exercised very carefully fastening points should be controlled and secured To prevent any possible accidents ensure that there is nobody under the pipe while lifting Guide ropes tied around the pipe can be used to have manual control over the pipe while it is in the air This method is strongly advised particularly in high winds Pipe direction control with guide ropes should be performed at a distance should not be done from underneath the pipe Control Rope Figure 1 One lifting strap method with a guide rope 9 T Control Rape 1 4xL Figure 2 Two lifting straps method with a guide rope Loading and unloading with forklift This method 15 generally used for factory loadings or for wagon loadings of railway transportation However since there 15 generally no need for a forklift at infrastructure jobsites unloading at jobsites is performed with crane lifting strap method Ensure that forklift is operated by a licensed forklift operator Pipes should be placed on wooden cradles and forklift should lift the pipe with the cradle as shown on below picture 1 3 Loading and unloading of couplings and fittings Superlit GRP pipes are generally delivered with a coupling installed on one end If there is a special requirement or if additional couplings are required couplings can be delivered separately as bundles Regardless of 1ts dimensions every fitting should be carri
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