Method Statement for FRP / GRP

Installation, Lamination and Backfilling

 TABLE OF CONTENTS

Section No. Title

1.0 General

1.1 Scope of work

2.0 Reference Documents

3.0 Manpower, Tools and Equipment’s

4.0 Work Execution

 Shipping, handling and storage
 Pipe Installation Procedure
 Pre- alignment and Joint preparation
 Lay-up process
 Backfilling Pipe and compaction

5.0 Quality Assurance / Quality Control

6.0 Health, Safety and Environment Control (HSE)
7.0 Attachment
7.1 HSE Risk Assessment
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1.0 General

This method statement is developed as a step by step sequential guideline for the
work to be carried out for the FRP/GRP works. All work activities shall adhere to SAS
/ Acciona and SWCC Safety rules and work permits will be observed.

1.1 Scope of work

The instructions cover pipe installation, butt & wrap jointing system of pipe
and backfilling. This procedure required to do lamination by skilled labour.

2.0 Reference Document

● Issued for Construction Drawings – based on plans to be executed

● Standard Construction Drawings

3.0 Manpower, Tools and Equipment’s

3.1 Manpower
3.1.1 Safety Supervisor
3.1.2 Civil Supervisor
3.1.3 QA / QC Engineer
3.1.4 Surveyor
3.1.5 Surveyor’s Helper
3.1.6 Foreman
3.1.7 Rigger, Crane Operator
3.1.8 Applicator
3.1.9 Skilled Laborer , Scaffolder

3.2 Tools and Equipment

3.2.1 Surveying Equipment ,
3.2.2 Rotary disc grinder with carborundum sanding disc.
3.2.3 Graduated measuring cylinder for measuring catalyst.
3.2.4 Paint rollers
3.2.5 Steel grooved rollers
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3.2.6 Mixing tongue/Sticks ,

3.2.7 Barcol hardness tester
3.2.8 Thermometer
3.2.9 Dewatering pump

3.2.10 One gallon polyethylene empty pots for mixing resin.

3.2.11 Styrene for cleaning tools and bubble out during lay-up

3.3 Safety requirements

3.3.1 Safety goggles
3.3.2 Safety shoes
3.3.3 Dusk masks
3.3.4 Safety helmet
3.3.5 Safety belts (in case of high elevation)

4.0 Work execution

Listed are the typical methods to be done during the installation of all elements.
Following is the outline of methods which will be discussed item by item.

 Shipping, handling and storage

 Pipe Installation Procedure
 Pre- alignment and Joint preparation
 Lay-up process
 Backfilling Pipe and compaction

4.1 Shipping, Handling and Storage

4.1.1 Inspecting Pipe

All pipes should be inspected upon receipt at the job site to insure that no
damage has occurred in transit. Depending on length of storage, amount of
job site handling and other factors that may influence the pipes condition, it is
recommended that the pipe be re-inspected just prior to installation. Inspect
the shipment upon delivery, as follows:
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 Make an overall inspection of the load. If the load is intact, ordinary

inspection while unloading will normally be sufficient to make sure the
pipe has arrived without damage.
 If the load has shifted or indicates rough treatment, carefully inspect
each pipe section for damage. Generally, an exterior inspection will be
sufficient to detect any damage. When pipe size permits, an interior
inspection of the pipe surface at the location of an exterior scrape may
be helpful to determine if the pipe is damaged.
 Check the quantity of each item against the bill.

4.1.2 Unloading and Handling Pipe

 Be sure to maintain control of the pipe during unloading. Guide ropes
attached to pipes or packages will enable easy manual control when
lifting and handling. Spreader bars may be used when multiple support
locations are necessary. Do not drop, impact, or bump the pipe,
particularly at pipe ends.
When handling single pipes, use pliable straps, slings or rope to lift. Do not use
steel cables or chains to lift or transport the pipe. Pipe sections can be lifted
with only one support point (Figure 2–1) although two support points placed as
in Figure 2–2 is the preferred method for safety reasons as it makes the pipe
easier to control. Do not lift pipes using hooks at pipe ends or by passing a
rope, chain or cable through the section end to end.

(Fig 2-1) Figure 2–2 Lifting pipe at two support points

(0.2xL lifting support from each end)

4.1.3 Site Pipe Storage

 Store pipe on flat timber to facilitate placement and removal of lifting slings around the pipe.
 When storing pipe directly on the ground, be sure that the area is relatively flat and free of
rocks and other potentially damaging debris. Placing the pipe on mounds of backfill material
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has been found to be an effective way of site storing the pipe. All pipes should be chocked to
prevent rolling in high winds.

4.1.4 Pipe installation procedure.

 The native material must adequately confine the pipe zone backfill to achieve proper pipe
support.

 The bedding should be placed over a firm, stable trench bottom so as to provide proper
support. The finished bed must provide a firm, stable and uniform support for the pipe barrel
and any protruding feature of its joint. Provide 100 - 150 mm of bedding.

 Temporary backfilling shall be provided after installing pipe

Backfilling material shall be provided as follows.
o No soil clumps greater than two times the maximum particle size.
o No frozen material.
o No organic material.
o No debris (tires, bottles, metals, etc.)

4.1.4 Rigging and Scaffolding for pipe support .

 Rigging plan shall be approved by client and Sufficient scaffolding support shall be
provided , safety measure shall be taken to work inside pipe for wrapping.

4.2 Pre- alignment and Joint preparation

The pipe ends to be joined shall fit with as little gap as possible. The gap shall
under no circumstances exceed 13 mm. Gaps in excess of 3mm shall be filled
with a high adhesion filler.
The pipe ends shall be joined without misalignment. If adjusting the alignment
cannot eliminate an offset, step by step, then it should be equalized around the
circumference of the pipe. Any steps between the ends to be overwrapped that
exceed the larger of 1.00 mm or 1.0 % of the nominal diameter to the maximum
of 3.00mm, shall be filled with chop strand mat laminate wetted with the resin. The
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filling laminate shall be tapered 1/10

For laminate fills consisting of more than one ply of mat the widest ply shall be laid
first towards the end followed by successively narrower plies.

Resin preparation is an important part of the hand lay-up process. The amount of
catalyst has major impact on the laminate end properties. Use special catalyst for
hand lay-up.
The normal catalyst amount for hand lay-up resin is 1-3% when producing very
thin laminates 1-2.5% is an appropriate range.
The catalyst level should always be in the 1-3% range. Remember that the gel
time of the resin changes with catalyst levels. The ambient temperature will also
influence the gel time – higher temperatures give shorter gel times. Typical gel
time range 15-25 minutes at 25 degree Celsius.
The resin should be stirred for 1 minute before use to have good mixing before
laminate layup. Resin used for hand lay-ups can normally be delivered pre-
accelerated and if non–accelerated resin is used the recommended action is to
add 1% of a 1% cobalt solution to the mixture.

4.2 lay-Up process

4.2.1 Clean tools

When laminating it is of utmost importance that all tools are clean and without
pollution. There should be no cured resin on the roller surfaces. This will reduce
the effects of the tool and may also fail into laminate resulting in reduced strength
and possible air entraptions.

4.2.2 Application of layers

The pipe ends to be joined shall fit with as little as gap as possible. The gap shall
under no circumstances exceed 13mm. Gaps in excess of 3mm shall be filled with
a high adhesion filler and if offset at ends it should be minimized and prepare joint
ends as mentioned in section 4.
Thoroughly clean the pipe ends that are to be jointed.
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Check the plies width to be applied on the pipe joint. Extend 50mm extra at each
end to cover the roll out expansion margin during lamination.
Mark on each pipe end a distance ½ the total lay-up width. This marked at each
end to cover the roll out expansion margin during lamination.
For internal lamination, ensure that the safe access is available to work from
inside.
The same procedure and same number of pies shall be applied from inside as for
outside.
An internal lamination shall include groove at the lamination ends. This grooving
shall absorb the laminated plies edges into it. These grooves facilitate the product
flow without reducing the flow momentum.
The grinding procedure shall be repeated if the prepared surface is contaminated
prior to start the lamination work or it is more than 8 hours of grinding.
Wipe the ground areas with clean dry cloth to remove the collected dust and any
surface moisture.
Before applying the first layer of mat, the surface is wet out with resin to improve
the adhesion between the original laminate and the first lay-up layer. The resin will
also blind any particles or minor dusts that are left on the ground surface.(see
attachment for ND 1900 Dia pipe )

4.2.3 Lay-up

Lay-up materials can either be placed directly on the surface before resin
application or wet out on a separate table prior to lay-up. The off line pre-wetting
of the mats can reduce the risk of air entraptions in the laminate and simplify the
lay-up and roll out process.
Apply the layers in the sequence as supplied in the packet of each kit.
Particular care should be taken with first applied layer. Use sufficient resin and
perform a through wet-out to insure good adhesion between the first applied ply
and the grinded pipe surface. Proper wet-out will also assure that the mat drapes
after the surface. After the first layer is thoroughly rolled out, usually two and two
mats can be applied before rollout.
When removing out air the recommended practice is to start from the centre of the
lay-ups and roll towards the edges. The applied pressure has to be controlled to
avoid mat movement and to ensure uniform glass content throughout the laminate.
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The final chop strand mat ply will though have to be wider than the underlying plies
in order to totally seal the wrap.

The construction of butt-wrap joints is shown in attachment. Number type and

widths of the different plies for the butt-wrap laminates are listed in the table.

4.2.3.1 Curing of sections

The number of lay-ups that can be applied before the laminate has to cure will
vary with surface characteristics.
On large plain areas, up to 10 layers can be applied before curing. Too many
layers will not allow proper heat dissipation when the resin is under curing process
and could cause blistering.
Apply the new lay-up ply, when the first layer is not sticky. Usually it is not
necessary to grind cured surfaces before continuing the lamination unless the
laminate is more than 24 hours old or has glossy surface. Always remove dust
and restart lamination on clean surface.

4.2.3.2 Finish of lay-Up process

The final mat glass ply should be rolled separately. The excess resin in the
laminate is usually enough to wet-out this mat.
When the desired thickness of the laminate is reached, it is recommended to wait
a while (15-20 minutes). This gives the laminate time to settle and be fully
impregnated of resin before performing the last operation.
After the last rollout the laminate is finished with mat layer. The mat should cover
the entire laminated area but not exceed the ground surface of the original
material.
The mat should be wet-out properly to ensure a smooth surface after the
exothermic reaction is complete, when the laminate is not sticky to touch a layer
of resin shall be applied.

4.2.3.3 Final inspection for alignment

Final inspection shall be conducted with client to check alignment and hardness
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Of the laminated joint using Barcol hardness tester.

4.3 Backfilling Pipe and compaction

installation requires the 300 mm over the pipe cover to be compacted. Trench
backfill under areas subjected to traffic load is often compacted to minimize road
surface settlement. Layer by layer compaction for 95% of modified proctor shall
be achieved with plate compactor or vibratory roller.

5.0 Quality Assurance / Quality Control

During execution of works, SAS shall assign quality control engineers that will
Monitor every step of the work to make sure that requirements of the Project are
followed.

6.0 Health, Safety and Environment Control (HSE)

For every aspect of work, safety awareness shall be strictly implemented.

The following are the minimum safety awareness to be implemented. Please refer
also to the attached Risk Assessment for additional Safety measures.
Work Premises – All work areas shall be maintained with respect to the tidiness
With all materials, tools & requirements stacked in appropriate locations to
prevent possible disturbance or even worst an accident.

o Safety of Crew – Toolbox meeting shall be done every start of work for all
areas to identify the hazards and how to prevent them. All personnel shall
have complete safety protective gears. .
o Equipment operators should be certified.

7.0 Attachment
7.1 HSE Risk Assessment
 FIELD JOINT LAMINATION
(Process Sheet - Balance Lay-up)
For ND1900-PN10-SN5000

Process Department Confidential

Amiantit FIBERGLASS Ind. Ltd. Rev.0 17-Dec.-18