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RAW MATERIALS
The fundamental raw materials that go into the manufacturing of the Pipes and fittings are:
- Fiber glass: The fiber glass serve the purpose of the providing the mechanical strength to the pipe. The different types of fiber glass used are E-Glass, C-Glass and ECR-Glass. The fiber glass is used in different forms such as woven roving, chopped strand mat (CSM) and surface veil.
- Resins: The different types of resins used are Iso-phthalic, Vinyl Ester and Epoxy depending on the extent of chemical properties required for the final product.
- Auxiliary raw materials: Other raw materials like catalyst, accelerators, inhibitors, aggregates and pigments are used together with resin and glass reinforcements to achieve the desired properties of the fiber glass product. Catalyst is an organic compound which when added to resin in presence of an accelerator determines the polymerization reaction at ambient temperature. Accelerator is a chemical compound used together with a catalyst to shorten the polymerization time. Inhibitor is added to the resin to reduce its reactivity at ambient temperature. Sand is also used as filler during the winding process to increase wall thickness in certain cases.
Process:
Filament winding is the technique for manufacturing composite material structures. It is the process for fabricating a composite structure in which continuous fiber reinforcement (glass, boron, silicon carbide), either previously impregnated with a matrix material or impregnated during winding, are wound under tension over a rotating core. Once the material is wound it is heated in the oven to speed up the curing.
Dual Helical Winding: In this process the fiber glass woven roving wetted with resin is wound on the steel mandrel at pre-calculated winding angles. The dual helical winding pattern is responsible for providing the composite product with maximum mechanical durability. The resin used will decide the extent of its chemical and temperature resistance. The entire process is controlled via the software in which we determine the winding angles as well as the number of layers to be wound on to the product. More the winding angle, the greater the elasticity of the pipe.
The application of Mylar film helps in the extracting or de-molding process of the composite product.The inner line is mostly impregnated with Vinyl Ester resin (90%) and 10% glass veil to provide maximum chemical resistance. The structural wall is generally 70% roving and 30% glass providing it the optimum mechanical strength. The winding of the structural layer is usually done on a dry surface in case of GRP and wet liner surface in case of GRE. Use of ovens help in hastening the curing process and also makes sure the bonding takes place well. Once the pipes are extracted they are calibrated at the ends.
Pipes manufactured through this process can be from 25mm upto 2.0 mtr diameter based on the steel mandrels used.
Pipes are available in stiffness classes of 1250, 2500, 5000 and 10000 Pa. In nominal pressure classes, it is available in PN3, PN6, PN10, PN16 and PN20.
Continuous Filament Winding- Coming soon
GRP Pipes are made from the dual helical winding technology. The major raw materials used for this are fiber glass, Iso-phtahllic resin and sand (certain cases). Inner liner consists of surface tissue and Vinyl ester resin for maximum chemical resistance and to enhance abrasion. The structural layer consists of E- glass and Iso- pthallic resin. Outer Liner is a small layer with structure similar to the structural layer.
Diameters of pipe produced range from 25mm to 2800mm currently
GRVE Pipes are made from the dual helical winding technology. The major raw materials used for this are fiber glass, Vinyl Ester resin and sand (certain cases). Inner liner consists of surface tissue and Vinyl ester resin for maximum chemical resistance and to enhance abrasion. The structural layer consists of E- glass and Vinyl Ester resin. Outer Liner is a small layer with structure similar to the structural layer. GRVE Pipes are mechanically and chemically more strong when compared to GRP Pipes.
Diameters of pipe produced range from 25mm to 2800mm currently
GRE Pipes are made from the dual helical winding technology. The major raw materials used for this are fiber glass, Amine Cured Epoxy resin and sand (certain cases). Inner liner consists of surface tissue and Amine Cured Epoxy resin for maximum chemical resistance and to enhance abrasion. The structural layer consists of E- glass and Amine Cured Epoxy resin. Outer Liner is a small layer with structure similar to the structural layer.
Diameters of pipe produced range from 25mm to 2800mm currently
GRE pipes are much lighter and easier to handle and have a smoother internal surface GRE pipes also have minimal thermal conductivity giving it insulation properties. They are also much stronger mechanically and chemically than GRP and GRVE pipes are much more resistant to corrosion. These pipes are mainly used in the petrochemical industry’s processing lines and oil and gas lines (both onshore and offshore) as well.
- GRP TANKS AND CUSTOMIZED GRP PRODUCTS
- PREINSULATED PIPES & FITTINGS
- PRESSURE VESSELS & FITLERS
The standard fittings include Flanges, Couplings, Elbows, Tee’s, Reducers, Saddles, Crosses and End Caps.
Joints:
- PL/PL : Plain end/Plain End lamination joints
- SO/SP : Socket Spigot flexible joint / rigid joint
- FL/FL : Flange / Flange joint
- TSO/TSP: Tapered Spigot/Socket Joints
- CB/CS: Adhesive bonded Cement Bell/Socket Joints
- THSO/THSP: Threaded Spigot/Socket Joints
PRODUCT SPECIFICATIONS:
ASTM D 2996 :STANDARD SPECIFICATION FOR FILAMENT WOUND “FIBERGLASS” (GLASS REINFORCED THERMOSETTING RESIN) PIPE
ASTM D 3517 :STANDARD SPECIFICATION FOR “FIBERGLASS” (GLASS-FIBER REINFORCED THERMOSETTING-RESIN) PRESSURE PIPE
ASTM D 3262 :STANDARD SPECIFICATION FOR “FIBERGLASS” (GLASS-FIBER REINFORCED THERMOSETTING-RESIN) SEWER PIPE
ASTM D 4161: STANDARD SPECIFICATION FOR “FIBERGLASS” (GLASS-FIBER REINFORCED THERMOSETTING-RESIN) PIPE JOINTS USING FLEXIBLE ELASTOMETRIC SEALS
ASTM D 3754:STANDARD SPECIFICATION FOR “FIBERGLASS” (GLASS-FIBER REINFORCED THERMOSETTING-RESIN) SEWER AND INDUSTRIAL PIPE
API- 15LR :SPECIFICATION FOR LOW PRESSURE FIBERGLASS PIPE
API-15 HR : SPECIFICATION FOR HIGH PRESSURE FIBERGLASS PIPE
AWWA C 950 : STANDARD FOR FIBERGLASS PRESSURE PIPE
BS 5480: BRITISH STANDARD SPECIFICATION FOR GLASS REINFORCED PLASTICS (GRP) PIPES, JOINTS AND FITTINGS USED FOR SEWERAGE OR WATER SUPPLY
BS 7159: DESIGN AND CONSTRUCTION OF GLASS REINFORCED PLASTICS (GRP) PIPING SYSTEMS FOR INDIVIDUAL PLANTS OR SITES
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