SHOP INSPECTION AND TESTING PROCEDURE FOR

WAVISTRONG® ‐ RTR (GRE) PIPES & FITTINGS

PREPARED BY APPROVED BY

Khaleelullah Quadri M. Awad

QC Supervisor QC Manager

SITP - 0762022 ‐ GRE ‐ RFIP ‐ MRB ‐ SA ‐ Rev. 0

 Table of Contents

Section Activity Page No

A RAW MATERIAL INSPECTION
A1 Refractive Index 3
A2 Viscosity of Resin 3
A3 Reactivity of Resin (Gel Time, Cure Time and Peak Temperature) 3
A4 Glass Fiber (Moisture Content / Binder Content / Tex Properties) 4
A5 C – Glass Veil and W/R Mat (Moisture Content / Binder Content / Density) 4
B PRODUCT TESTING AND INSPECTION
B1 Pipe Stiffness & Deflection Test (Specific Tangential Initial Stiffness, STIS) 5
B2 Axial Tensile Strength (ATS) 5
B3 Hoop Tensile Strength (HTS) 6
B4 Laminate Composition – Loss on Ignition Test 7
B5 Water Absorption – Boil Resistance Test 7
B6 Degree of Curing (Tg value) 8
B7 Barcol Hardness Test 8
B8 Visual Inspection (Appearance) 8
B9 Hydrostatic Pressure Test 9
B10 Dimensional Control 9

SITP - 0762022 ‐ GRE ‐ RFIP ‐ MRB ‐ SA ‐ Rev. 0

A) RAW MATERIAL INSPECTION: -

A.1 Refractive Index: (ITP Act. No. 1.9.1)

Apparatus : Abbe’s Refractometer and cooling system.

Procedure : Refractive Index of resin is determined by the following procedure and

guidelines of ASTM D 1045 using a refractometer. After conditioning the resin
at 20° C, refractive index is determined.

Acceptance : Comply with the limits specified in WAVISTRONG® List of Approved Raw
criteria Materials

A.2 Viscosity of Resin: (ITP Act. No. 1.9.2)

Apparatus : Brookfield Viscometer and Thermometer.

Procedure : Viscosity of resin is determined by the following procedure and guidelines of

ASTM D 2196 using a Brookfield Viscometer. After conditioning the resin at 25° C,
viscosity is determined using a spindle of appropriate/ recommended size.

Acceptance : Comply with the limits specified in WAVISTRONG® List of Approved Raw
criteria Materials.

A.3 Reactivity of resin (Cure Time.): (ITP Act. No. 1.9.3)

Apparatus : Paper cup, digital thermometer with thermocouple probe, stopwatch, wax.

Procedure : The epoxy resin cure time is determined by following the procedure and
guidelines of ASTM D 2471-99. 100 g of resin is taken in a paper cup and
conditioned to 25°C, recommended quantities of Hardener is mixed well into
the resin. Timing device is started immediately on mixing the solution and a
waxed probe of the thermocouple is immersed into the resin. Temperature of
the resin mixture is measured using a thermocouple / thermometer. As the
curing reaction progresses, the resin cure time is determined.

Acceptance : Comply with the limits specified in WAVISTRONG® List of Approved Raw
criteria Materials.

SITP - 0762022 ‐ GRE ‐ RFIP ‐ MRB ‐ SA ‐ Rev. 0

 A.4 Glass Fibre: Moisture Content/ Binder content/ Tex Properties: (ITP Act. No. 1.9.4)

Apparatus : Crucibles, desiccator, electronic balance, oven and muffle furnace.

Procedure : Moisture content of the glass fibre is determined as the percentage weight loss
on heating a known amount of glass fibre sample at approximately 105° C for 3
hours. Binder content of the glass fibre is determined as the loss on ignition of
a known amount of dried glass fibre at approximately 600° C for 30 minutes.
The Tex (Linear density) of the glass fibre is determined by weighing 10 -20 m
of glass fibre roving. Tex is determined as the weight in grams of 1000 m of the
glass fibre roving.

Acceptance : Comply with the limits specified in WAVISTRONG® List of Approved Raw
criteria Materials.

A.5 C-Glass Veil and W/R Mat: Moisture content/ Binder content/ Density: (ITP Act. No. 1.9.5)

Apparatus : Crucibles, desiccator, electronic balance, oven and muffle furnace.

Procedure : Moisture content of the C-veil/ WR mat is determined as the percentage weight
loss on heating a known amount of glass sample at approximately 105° C for 3
hours. Binder content of the glass is determined as the loss on ignition of a
known amount of dried glass at approximately 600° C for 30 minutes. The grams
/ square meter (area density) of the glass is determined by weighing 0.1 - 0.5
square meter of glass. Gm / m² is determined as the weight in grams of 1 m2 of
the glass veil / WR mat.

Acceptance : Comply with the limits specified in WAVISTRONG® List of Approved Raw
criteria Materials.

SITP - 0762022 ‐ GRE ‐ RFIP ‐ MRB ‐ SA ‐ Rev. 0

B) PRODUCT TESTING & INSPECTION: -

B.1 Pipe Stiffness & Deflection Test (Specific Tangential Initial Stiffness, STIS): (ITP Act. No. 2.1)

Purpose : To determine the pipe stiffness (STIS)

Apparatus : Parallel plate loading machine (Stiffness testing machine), micrometer.

Procedure : Pipe stiffness (STIS) of the specimen is determined by following the procedure
and guidelines of ASTM D 2412.

Test : A ring specimen of 300 mm length shall be cut from the pipe to be tested and
Specimen the ends of the specimen shall be cut square and shall be free from damage.

Test : 1. Measure the thickness of the specimen at 8 places and calculate the
Method average thickness.
2. Measure the inside diameter of the sample at 4 places and determine
the average.
3. Measure the length of the specimen at 4 places and calculate the
average.
4. Place the specimen between the two parallel plates ensuring that the
minimum thickness is at the top.
5. Measure the unloaded vertical inside diameter to determine the
specimen self-deflection.
6. Bring the upper plate into contact with the specimen with only load
needed to hold it. And set the load and deflection indicator to zero.
7. Adjust the travelling speed of the upper plate to reach the required
deflection in about 3 minutes and compress the sample to deflection
level of 5%.
8. Repeat the steps from 5 to 8 by rotating the specimen by 35° and 70°
with respect to initial deflection.
9. From the average load obtained for 5% deflection, the specific
tangential initial stiffness is determined.

Acceptance : Dia 50mm : Min. 248 kPa (5000 N/m²)

Criteria Dia 350 – 450mm : Min. 148 kPa (2500 N/m²)

B.2 Axial Tensile Strength (ATS): (ITP Act. No. 2.2)

Purpose : To determine the axial tensile strength.

Apparatus : Universal Testing Machine (UTM), Vernier Calliper.

Procedure : The Axial Tensile Strength (ATS) of the specimen is determined by following
the procedure and guidelines o ASTM D 638.

SITP - 0762022 ‐ GRE ‐ RFIP ‐ MRB ‐ SA ‐ Rev. 0

 Test : Five parallel sides strip specimens of 200 – 300 mm length are cut from the pipe
Specimen in the axial direction.

Test : 1. Measure the minimum width and thickness of the test specimen and
Method record the values.
2. Subject the test specimens to tension on a UTM in the axial direction
up to failure.
3. Axial tensile strength per unit width is calculated by dividing the load
at failure with the width of the specimen. Axial tensile strength per
unit area is determined by dividing the load at failure with the width
and thickness of the specimen.
4. Repeat steps of 1 to 3 for the other specimens and take the average.

Acceptance : ATS value should be >= to the minimum value specified in the table 11.B of
Criteria AWWA C 950

B.3 Hoop Tensile Strength (HTS): (ITP Act. No. 2.3)

Purpose : To determine the hoop tensile strength.

Apparatus : Split Disc Machine / Universal Testing Machine, Vernier Calliper.

Procedure : The hoop tensile strength of the specimen is determined by following the
procedure and guidelines of ASTM D 2290.

Test : Three ring specimens of 5 – 15 mm width are cut from the pipe in the
Specimen circumferential direction.

Test : 1. Measure the minimum width and thickness of the test specimen at
Method two diametrically opposite position and record the values.
2. Mount the test specimen on the outside margin of the split disc test
fixture and subject the test specimens to stress in the hoop direction
up to failure.
3. Hoop tensile strength per unit width is calculated by dividing the load
at failure with the twice the width of the specimen. Hoop tensile
strength per unit area is determined by dividing the load at failure with
twice the width and one thickness of the specimen.
4. Repeat steps of 1 to 3 for the other specimens and take the average.

Acceptance : HTS value should be >= to the minimum value specified in the table 10.B of
Criteria AWWA C 950.

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 B.4 Laminate Composition – Loss on Ignition Test: (ITP Act. No. 2.4)

Purpose : To determine the laminate composition of the pipe sample.

Apparatus : Crucibles, desiccator, electronic balance, sieve - mesh and muffle furnace.

Procedure : The composition of the pipe material is determined by loss on ignition of the
test specimen following the procedure and guidelines of ASTM D 2584.

Test : Three test specimens of ≈ 15 x 50 mm dimension from the pipe.

Specimen

Test : 1. Weigh each specimen separately in porcelain crucible and record the
Method weight. Record the weight of the empty crucible.
2. Ignite the specimens in the muffle furnace at approximately 600° C for
30 minutes.
3- Weigh the burnt specimens after cooling back to ambient
temperature.
4- Weigh each crucible with residue and determined the resin % is as
percentage loss of weight of the specimen on ignition, the glass %
from the retained glass residue after the ignition of the sample and
the sand % from the retained sand residue after ignition of the sample.

Acceptance : Minimum Glass percentage should be 65

Criteria

B.5 Water Absorption (Boil Resistance). (ITP Act. No. 2.5)

Purpose : To determine the water absorption of the pipe specimens.

Apparatus : Water Container, balance with an accuracy of 0.1 mg.

Procedure : The water absorption of the pipe specimen is determined by following the
procedure & guidelines of ASTM D 570. Specimens are conditioned by keeping
at 75°C for one hour & weighed. Specimens are immersed in distilled water for
24 hrs. and weighed immediately after removing from the water. Water
absorption is determined as the percentage change in weight of the test
specimens.

Test : Three test specimens of ≈ 15x150mm dimension are cut from the pipe.
Specimen

Acceptance : Maximum allowed water absorption 1%

Criteria

SITP - 0762022 ‐ GRE ‐ RFIP ‐ MRB ‐ SA ‐ Rev. 0

 B.6 Degree of Curing (Tg value) (ITP Act. No. 2.6,2.7)

Purpose : To determine the glass transition temperature (Tg-value) of the internal liner
of the pipe & fittings.

Apparatus : Differential Scanning Calorimeter (DSC).

Procedure : The degree of curing/glass transition temperature (Tg-value) of the pipes and
fittings is determined by Differential Scanning Calorimeter (DSC) following the
procedure and guidelines of ASTM D3418. A small piece of Pipe/Fitting
specimen weighing about 4 – 6 mg is put in an aluminium crucible and placed
in the DSC instrument. The specimen is scanned from 60 to 210° C and the
thermal cycle data is analysed to get the Tg value.

Acceptance : Minimum Tg Value 125 °C

Criteria

B.7 Barcol Hardness: (ITP Act. No. 2.8 & 3.3)

Purpose : To determine the hardness of glass reinforced specimens

Apparatus : Barber, Barcol impresser.

Procedure : Barcol hardness of the specimen is tested by using a Barcol impresser following
the procedure and guidelines of ASTM D 2583.

Test : Test conducted on complete pipe/fitting/ flange sections.

Specimen
Test : 1. Set the point sleeve on the surface to be tested and hold the impresser
Method firmly between the instrument legs and point sleeve.
2. Apply quick thrust by hand against the specimen surface until the dial
reading reaches a maximum value.
3. Average value is determined from at least five readings.

Acceptance : Minimum Barcol 35.

Criteria

B.8 Visual Inspection (Appearance): (ITP Act. No. 2.9)

Purpose : To characterize visual defects and control them within the acceptance limit.

Procedure : The interior and exterior of the item is thoroughly checked for any visual defect
by following the procedure and guidelines of ASTM D2563.

Acceptance : Visual appearance shall be in accordance with:

Criteria A) ASTM D 2563 B) 01‐SAMSS‐034 Clause 5.1.2.9

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 B.9 Hydrostatic Pressure test: (ITP Act. No. 2.11)

Purpose : To check the soundness of the pipes & testable fittings (flanged).

Apparatus : Hydrostatic apparatus, pressurising system, calibrated pressure gauge,

stopwatch, specimen end closure and suitable support.

Procedure : Place the test specimen on the hydro-test apparatus and attach the end
closures. Fill the pipe with water ensuring that no air is entrapped. Pressurize
the specimen to the required test pressure (2X Pdesign) and examine the system
for 1 minute for leakage and weeping.

Acceptance : As per 01‐SAMSS‐034 Sec 5.1.2.1 / FPI standard, there should not be leakage,
Criteria weeping or drop in a pressure when the pipes & testable fittings (flanged)
tested at the required test (2 X Pdesign) pressure during the test period. The test
pressure shall be maintained for at least 30 Seconds and not exceeding to 1
minute.

Note : On completion of Hydro test, proper dry-out and flushing of water from the
component before final inspection.

B.10 Dimensional Control: (ITP Act. No. 3.1, 3.2, 3.4 & 3.5)

Purpose : To determine the dimensions of the items.

Apparatus : Dial gauge, Vernier Callipers, micrometer, circumferential wrap, Pi Tape, Steel
Tape, a plain horizontal surface, a string, and a metal ruler.

Procedure : Dimension (Diameter, Length & Thickness) of the GRE item is determined by
using suitable measuring devices and following the procedure and guidelines of
01‐SAMSS‐034 Sec 4.5.4, ASTM D3567 & AWWA C950. The average of
dimensional parameters is determined from the measured individual values.

Acceptance : Dimensions shall be in accordance with the pipe data sheet / product drawing.
Criteria

SITP - 0762022 ‐ GRE ‐ RFIP ‐ MRB ‐ SA ‐ Rev. 0