rpc pipe systems pty ltd

WSAA Product Appraisal No PA 1322 Issue 2 1

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RPC Pipe Systems Pty Ltd

PRODUCT APPRAISAL REPORT NO PA 1322 ISSUE 2

FLOWTITE™ Filament Wound Glass Reinforced Plastic Pipe System

Jacking Pipes for Non Pressure Sewerage Applications. DN 300 – DN 3000

ISO 25780 – Plastic piping systems for pressure and non-pressure water supply, irrigation, drainage or sewer - Glass-reinforced thermosetting plastics (GRP) systems based on unsaturated polyester (UP) resin – Pipe with flexible joints intended to be installed using jacking techniques

Publication Date: 9 September 2016

WSAA Product Appraisal No PA 1322 2

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Document History

The following information indicates the changes made to this document.

Date Version File Location

8/10/2015 Peer Review

U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2013\PA 1322 RPC Pipe Systems Pty Ltd Flowtite Jacking Pipe\RPC - Jacking Pipe Proposal Draft 8102015 MR markup.docx

6/11/2015 Publication

U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2013\PA 1322 RPC Pipe Systems Pty Ltd Flowtite Jacking Pipe\RPC - Jacking Pipe Final.docx

9/9/2016 Publication

U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2013\PA 1322 RPC Pipe Systems Pty Ltd Flowtite Jacking Pipe\RPC - Jacking Pipe Final.docx

Peer Reviewers

Name/Title Organisation Date

IPAM Network WSAA Infrastructure Products and Material Community of Practice

30/11/2015

Carl Radford, Program Manager Asset Creation WSAA 6/11/2015


Approvals

Name/Title Signature Date

Carl Radford, Program Manager Asset Creation Carl Radford 6/11/2015



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Overview of WSAA

The Water Services Association of Australia (WSAA) is the peak industry body that supports

the Australian Urban Water Industry. Its members and associate members provide water and

sewerage services to approximately 20 million Australians and many of Austra lia’s largest

industrial and commercial enterprises.

The Association facilitates collaboration, knowledge sharing, networking and cooperation

within the urban water industry. It is proud of the collegiate attitude of its members which

has led to industry-wide approaches to national water issues.

WSAA can demonstrate success in the standardisation of industry performance monitoring

and benchmarking, as well as many research outcomes of national significance. The WSAA

Executive retains strong links with policy makers and legislative bodies and their influences,

to monitor emerging issues of importance to the urban water industry. WSAA is regularly

consulted and its advice sought by decision makers when developing strategic directions for

the water industry.

WSAA was formed in 1995 as a non-profit organisation to foster the exchange of information

relating to the provision of urban water services between industry, government and the

community, and to promote sustainable water resource management.

The Association’s main activities focus on four areas:

1. Influencing national and state policies on the provision of urban water services and

sustainable water resource management;

2. Promoting debate on environmentally sustainable development and management of

water resources and the community health requirements of public water supplies;

3. Improving industry performance and establishing benchmarks and industry leading

practices for water service processes; and

4. Fostering the exchange of information on education, training, research, water and

wastewater management and treatment and other matters of common interest

Copyright

This document is copyrighted. Apart from any use as permitted under the Copyright Act

1968, no part of this document may be reproduced or transmitted in any form or by any

means, electronically or mechanical, for any purpose, without the express written permission

of Water Services Association of Australia Limited.

© Copyright 2015 by WATER SERVICES ASSOCIATION of Australia Limited All rights

reserved.


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CONTENTS

PRODUCT APPRAISAL REPORT NO PA 1322 .......................................................................................................................... 1

1 EXECUTIVE SUMMARY ............................................................................................................................................. 6

1.1 Recommendation .................................................................................................................................................. 6

2 THE APPLICANT ......................................................................................................................................................... 7

2.1 Manufacturing facilities .......................................................................................................................................... 7

3 THE PRODUCT ........................................................................................................................................................... 7

3.1 General.................................................................................................................................................................. 7

3.2 Manufacture of the Flowtite® GRP jacking pipes ................................................................................................... 7

3.2.1 Manufacturing Process ................................................................................................................................... 8

3.2.2 Joints .............................................................................................................................................................. 8

3.2.2.1 Stainless Steel Coupling for Jacking Pipes (Type SE) ............................................................................. 8

3.2.2.2 Filament Wound Couplings for Jacking Pipes (Type GR) ........................................................................ 8

3.2.2.3 Stainless Steel Sleeve Couplings for Jacking Pipes (Type SR) ............................................................... 9

3.2.2.4 Flowtite® Filament Wound Couplings for Pressure Jacking Pipes (Type FJ) ........................................... 9

3.2.3 Jacking Pipe Constituents ............................................................................................................................. 10

3.2.3.1 Reinforcement ........................................................................................................................................ 10

3.2.3.2 Resin ...................................................................................................................................................... 10

3.2.3.3 Aggregate and Fillers ............................................................................................................................. 11

3.2.4 Elastomers .................................................................................................................................................... 11

3.3 Nominal Sizes ..................................................................................................................................................... 11

3.4 Jacking Load and Nominal Stiffness ................................................................................................................... 11

3.5 Nominal Pressure ................................................................................................................................................ 11

3.6 Nominal Pipe lengths .......................................................................................................................................... 11

3.7 Flowtite® Joint Properties (couplings) ................................................................................................................. 12

3.8 Allowable Angular Deflection ............................................................................................................................... 12

3.9 Straightness ........................................................................................................................................................ 12

3.10 Pipe Fittings and Accessories ........................................................................................................................... 13

4 SCOPE OF THE APPRAISAL ................................................................................................................................... 13

5 APPRAISAL CRITERIA ............................................................................................................................................. 13

5.1 General................................................................................................................................................................ 13

5.2 Quality Assurance Requirements ........................................................................................................................ 13

5.3 Performance Requirements................................................................................................................................. 13

6 COMPLIANCE WITH APPRAISAL CRITERIA........................................................................................................... 14

6.1 Compliance with Quality Assurance Requirements ............................................................................................. 14

6.2 Compliance with Performance Requirements ..................................................................................................... 14

6.2.1 Production and type test requirements to ISO 25780:2011. ......................................................................... 15

6.2.2 Mechanical Characteristics ........................................................................................................................... 15

6.2.2.1 Initial specific ring stiffness - Batch release test ..................................................................................... 15

6.2.2.2 Long-term specific Creep Stiffness - Type test ...................................................................................... 15

6.2.2.3 Initial resistance to failure in a deflected condition - Batch release test .................................................. 15

6.2.3 Resistance of pressure pipes internal pressure - Type test .......................................................................... 16

6.2.4 Resistance to strain corrosion - Type test ..................................................................................................... 16

6.2.5 Joint performance - Type test ...................................................................................................................... 16

6.2.6 Longitudinal compressive strength ............................................................................................................... 16

6.2.7 Permissible Jacking Forces .......................................................................................................................... 17


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6.2.7.1 General .................................................................................................................................................. 17

6.2.7.2 Ulitmate Longitudinal Load ..................................................................................................................... 17

6.2.7.3 Designed Jacking Load and permissible eccentric jacking forces .......................................................... 17

6.2.8 Specific initial longitudinal compressive modulus. ........................................................................................ 17

6.2.9 Abrasion resistance ...................................................................................................................................... 18

6.2.10 Temperature and pressure re-rating ........................................................................................................... 18

6.2.11 Resistance to Ultraviolet degradation ......................................................................................................... 18

6.2.12 Other Technical Data .................................................................................................................................. 18

7 FITTING INSTRUCTIONS, TRAINING AND INSTALLATION ................................................................................... 18

8 REPAIR FOR NON-PRESSURE GRPJACKING PIPE FOR SEWERAGE APPLICATIONS ..................................... 18

9 PRODUCT MARKING ............................................................................................................................................... 18

10 PACKAGING AND TRANSPORTATION ................................................................................................................. 19

11 PRODUCT WARRANTY .......................................................................................................................................... 19

12 WATER AGENCY EXPERIENCE WITH THE PRODUCT OR FIELD TESTING REPORT ..................................... 19

13 DISCUSSION ........................................................................................................................................................... 20

14 LIFE EXPECTANCY ................................................................................................................................................ 20

15 FUTURE WORKS .................................................................................................................................................... 21

16 REPORT RECOMMENDATION .............................................................................................................................. 21

17 DISCLAIMER ........................................................................................................................................................... 22

17.1 Issue of Report .................................................................................................................................................. 22

17.2 Limits on Reliance on Information and Recommendations................................................................................ 22

17.2.1 Disclaimer of liability ................................................................................................................................... 22

17.2.2 Need for independent assessment ............................................................................................................. 22

17.3 No Updating ...................................................................................................................................................... 23

17.4 No Warranty ...................................................................................................................................................... 23

APPENDIX A – TECHNICAL MANUALS BROCHURES .............................................................................................. 24

AVAILABLE FROM RPC PIPE SYSTEMS OR THE FLOWTITE WEBSITE ................................................................. 24

APPENDIX B - QUALITY CERTIFICATIONS ............................................................................................................... 26

APPENDIX C – PRODUCT SCHEDULE ...................................................................................................................... 29

APPENDIX D – WSAA PRODUCT SPECIFICATIONS ................................................................................................ 34

APPENDIX E - SUPPLIER CONTACTS ....................................................................................................................... 36

APPENDIX F - NATA LABORATORY TEST RESULTS ............................................................................................... 37

TABLE F1 SUMMARY OF TYPE TESTS AND BATCH TEST RESULTS .................................................................... 38

APPENDIX G DOUBLE BELL REKA COUPLING QUALIFICATION TEST .................................................................. 43

APPENDIX H – EXAMPLE OF PIPE MARKING........................................................................................................... 46

APPENDIX I – FIELD TRIAL REPORT ......................................................................................................................... 47


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1 EXECUTIVE SUMMARY

This appraisal applies to Flowtite® Glass Fibre Reinforced Plastic (GRP) Jacking Pipes, for

non-pressure applications, joined using flexible non-end-load-bearing joints with elastomeric

seals and intended to be installed using various trenchless installation methods e.g. Slip

Lining, Micro Tunnelling and Pipe Jacking.

Issue 2 of this reports supersedes PA 1322 published in November 2015. PA 1322

amendments relate to increase in DN pipe range now available due to modification to

increase the load capacity of equipment at the RPC Pipe Systems’ factory in Lonsdale, SA.

We are getting some modifications made to increase the load capacity of our equipment so

will be able to handle this size.

RPC Pipe Systems is the exclusive Australian manufacturer of Flowtite® GRP Pipes for both

buried and trenchless applications. RPC Pipe Systems ’ factory in Lonsdale, SA, has the

capacity to manufacture pipes from DN 300 to DN 3000.

Flowtite® is a global brand manufactured in 22 plants in 16 countries. Flowtite® Jacking Pipe

has been developed to complement the original Flowtite® buried pipes for applications better

suited to trenchless applications. Flowtite® GRP pipe has been manufactured since 1971,

in Australia since 2006, with jacking pipe manufactured in Europe since 2006 and in Australia

since 2013.

The Flowtite® continuous wound GRP technology provides the flexibility for RPC Pipe

Systems to manufacture jacking pipe in a wide range of diameters and thicknesses to suit

individual applications. Jacking forces of up to 900 tonnes can be achieved for larger

diameter pipes.

Flowtite® GRP Jacking Pipes are manufactured with a nominal pressure class ranging from

PN 1 to 2.5 and stiffness rating ranging from SN 20,000 to 1,000,000.

Note Flowtite GRP pipes marked PN 1 are designated for non-pressure sewerage applications. For the

purposes of this appraisal Flowtite GRP pipes are manufactured with nominal pressure rating of PN 1 to PN

2.5 are typically used in non-pressure sewer applications.

GRP fittings used with Flowtite® GRP jacking pipe are fabricated from sections of straight

pipe, cut to length, joint wrapped externally and internally with additional fibre reinforcement

in accordance with AS3571.1 for sewerage systems. GRP fittings are supplied with spigot

ends suitable for connection to the Flowtite® jacking pipe stainless steel or GRP couplings.

Transition pieces can also be manufactured to connect Flowtite® GRP jacking pipe directly

to Flowtite® GRP buried pipe without the need for a manhole structure.

The Flowtite® GRP jacking pipe system is manufactured to comply with ISO 25780 – Plastic

piping systems for pressure and non-pressure, water supply, irrigation, drainage or sewer -

Glass-reinforced thermosetting plastics (GRP) systems based on unsaturated polyester (UP)

resin – Pipe with flexible joints intended to be installed using jacking techniques.

The declared external and internal diameters of the Flowtite® jacking pipes are provided in

the Flowtite® GRP Jacking Pipe Systems Product Guide.

Flowtite® GRP pipe for buried applications is the subject of a separate appraisal report PA

1211 Issue 2 published on the 6June 2013.

1.1 Recommendation

It is recommended that WSAA members and associates, subject to any specific requirements

of the member or associate, accept or authorise the Flowtite® GRP jacking pipe and fittings

as detailed in this report for use in non-pressure drainage or sewerage applications subject

to the design, installation and commissioning being in accordance with specifications

provided by RPC Pipe Systems and relevant WSAA Sewerage Code or WSAA Members or

Associated Members integrated WSAA Code editions.


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2 THE APPLICANT

RPC Pipe Systems was established in 2011 to acquire the business and assets of Fibrelogic

Pipe Systems Pty Ltd ('Fibrelogic'), Australia's leading manufacturer of continuously wound

glass reinforced plastic ('GRP') pipe and associated fittings.

It holds an exclusive Australian manufacturing and support licence for the Flowtite ® GRP

piping systems, technology and brand for Australia.

Flowtite® Technology is owned by the Amiantit piping group (AFIL), with 22 plants world-

wide. Flowtite® Piping Systems offer over 40 years of engineering experience in the

manufacture and design of GRP pipe systems.

RPC Pipe Systems Pty Ltd is located in Lonsdale, South Australia. RPC Pipe Systems has

supplied projects requiring GRP pipe and ducting installations for mining, power, sewer and

water companies throughout Australia.

RPC Pipe Systems Pty Ltd ('RPC Pipe Systems') is a South Australian company wholly

owned by RPC Technologies Pty Ltd that specialises in water surety solutions.

2.1 Manufacturing facilities

A purpose built factory in Lonsdale, South Australia, commenced operation during May 2006.

Two CW 3000 machines form the production equipment. The CW3000 machine has the

capability to produce pipe from DN 300 to DN 3000. RPC Pipe Systems also has fittings

fabrication facilities at the Lonsdale site and can manufacture fittings to match the pipe

product range.

All Flowtite® manufacturing plants are supplied with a complete working laboratory and all

production quality control test results are logged and recorded with full traceability.

3 THE PRODUCT

3.1 General

The Flowtite® GRP Jacking Pipe Systems Product Guide provides a complete description of

the products covered by this appraisal. Refer to Appendix A.

3.2 Manufacture of the Flowtite® GRP jacking pipes

RPC Pipe Systems can design GRP jacking pipes to meet the different needs of many non-

pressure applications (pressure applications omitted from appraisal scope), by varying resin

and glass proportions, orientation and configuration.

Flowtite® GRP jacking pipes are manufactured from a composite material designed to take

advantage of the corrosion-resistant properties of polyester resins and glass fibres (see

Figure 1). The “Flowtite GRP Jacking Pipe Systems” product guide is available from the

Australian distributor Iplex and provides a complete description of the product.


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FIGURE 1 FLOWTITE® COMPOSITE MATERIAL

3.2.1 Manufacturing Process

Flowtite GRP jacking pipes are produced using the Flowtite® continuous advancing mandrel

process.

The mechanical properties of Flowtite® GRP jacking pipes can be varied by adjusting the

quantity and proportions of the various raw materials in the pipe wall. The flexibility of this

system enables pipes to be designed to meet a wide range of applications. The types of

resin may also be varied in order to meet the many duties and environments to which the

pipes may be subjected to.

3.2.2 Joints

Ref: Clause 7.5 of ISO 25780:2011

RPC Pipe Systems has four joints available for Flowtite® GRP jacking pipes, each with a

coupling mounted onto one end of the pipe and an elastomeric seal which seals the pipe.

RPC Pipe Systems provide instructions for the selection of the available types of flexible

stainless steel or filament wound joint coupling for jacking pipe.

Refer to Section 3.7, 3.8 and 6.2.5 for joint properties, allowable angular deflection and joint

type tests.

The scope of this appraisal covers couplings that are both stainless steel and GRP.

3.2.2.1 Stainless Steel Coupling for Jacking Pipes (Type SE)

These RPC Pipe Systems couplings have a stainless steel sleeve with an EPDM seal firmly

attached and are used for trenchless installations only. Refer to Figure 2A for a diagram of

the Stainless Steel Coupling (Type SE).

The couplings are manufactured by RITEC GmbH & Co, Bakum, Germany. RITEC are the

major European supplier of stainless steel jacking pipe couplings.

FIGURE 2A STAINLESS STEEL COUPLING (TYPE SE)

3.2.2.2 Filament Wound Couplings for Jacking Pipes (Type GR)

RPC Pipe Systems offer couplings with a glass fibre reinforced plastic sleeve that is flush

fitted and used for trenchless installations. Gaskets are fitted in grooves in the pipe spigot.

Refer to Figure 2B for a diagram of the Filament Wound Coupling (Type GR).


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FIGURE 2B FILAMENT WOUND COUPLING (TYPE GR)

3.2.2.3 Stainless Steel Sleeve Couplings for Jacking Pipes (Type SR)

RPC Pipe Systems offer couplings with a stainless steel sleeve that is flush fitted and used

for trenchless installations. Gaskets are fitted in grooves in the pipe spigot. Refer to Figure

2C for a diagram of the Stainless Steel Sleeve Coupling (Type SR).

FIGURE 2C STAINLESS STEEL SLEEVE COUPLING (TYPE SR)

3.2.2.4 Flowtite® Filament Wound Couplings for Pressure Jacking Pipes (Type FJ)

RPC Pipe Systems offers the Flowtite® GRP Pipe pressure coupling for pressure jacking

applications. The coupling is the same as used on Flowtite® GRP buried pipes and is only

for custom applications. Pressure jacking pipes are not being considered in this appraisal

and this joint is being shown for information purposes only. Refer to Figure 2D for a diagram

of the Flowtite® Filament Wound Pressure Coupling (Type FJ).


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FIGURE 2D FLOWTITE® FILAMENT WOUND PRESSURE COUPLING (TYPE FJ)

3.2.3 Jacking Pipe Constituents

The wall of Flowtite® GRP jacking pipes is built with several layers (see Figure 1):

interior surface layer and liner;

inner structural layer (skin);

core;

outer structural layer (skin); and

exterior surface layer.

The interior surface layer of the pipe is resin rich and depending on the pipeline application

may include glass or polyester veil. The liner is built with resin and chopped glass fib res.

The structural layers are comprised of the inner skin, core and outer skins. The skins contain

continuous hoop rovings, resin and chopped glass, while the core contains sand fillers.

The exterior surface layer, or outer layer, is resin rich and depending on the pipeline use

may contain glass or polyester veil.

3.2.3.1 Reinforcement

Ref: Clause 4.3.2 of ISO 25780:2011

The Lonsdale plant uses E or ECR-glass to manufacture pipes for water supply and

sewerage. ECR-Glass is a requirement for all sewer application whereas E or ECR glass

can be used for water applications. RPC Pipe Systems has provided technical data sheets

for the selected glass reinforcements that are approved by Amiantit for use in Flowtite® GRP

jacking pipes showing compliance with ISO 2078. Both chopped strand and continuous

rovings are used to provide both longitudinal and hoop strength.

3.2.3.2 Resin


The Lonsdale plant manufactures Flowtite® GRP jacking pipes using orthophthalic polyester

resin EPS 1 supplied by Nuplex Industries of Australia to an Amiantit specification. The RPC

Pipe Systems Purchase Acceptance Standard (PAS) requires that the heat distortion

temperature of the cured resin, when tested in accordance with ISO 75-2, should be at least

75°C, which allows a maximum operating temperature of 55°C.


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Other resins are available for specialised applications.

3.2.3.3 Aggregate and Fillers


Sand is used as filler in Flowtite® GRP jacking pipes. The RPC Pipe Systems PAS requires

that less than 3% of the sand have particles larger than 0.71 mm and no particles be larger

than 1 mm. The sand is sourced locally from a deposit in the Adelaide region. The locally

sourced sand results in an “almost white’ pipe unlike other GRP products common to the

Australian water industry.

3.2.4 Elastomers


The Flowtite® pipe couplings for jacking application use EPDM rubber.

RPC Pipe Systems require elastomeric joint compliance with EN 681-1:1996 which is

equivalent to AS 681.1:2008.

3.3 Nominal Sizes


Nominal sizes of Australian Flowtite® jacking products range from DN 300 to DN 3000:

Flowtite® jacking pipes can be manufactured as either an OD or ID series depending on the

requirements of the project.

Typical dimensions of Flowtite® jacking pipes appear in the Flowtite® GRP Jacking Pipe

Systems product guide in Appendix A.

3.4 Jacking Load and Nominal Stiffness

Ref: Clause 4.2.2 and 4.2.3 of ISO 25780:2011

Flowtite® GRP jacking pipes can be supplied in the following jacking loads and stiffness

classes.

TABLE 2 JACKING LOAD (TONNES) AND NOMINAL STIFFNESS (SN)

Jacking Load (Tonnes) Nominal Stiffness (N/m²)

From 50 to 900 ≥ 20,000

The nominal stiffness in Table 2 above, correspond to the minimum nominal stiffness value

specified in Clause 4.2.3 of ISO 25780.

Flowtite® GRP jacking pipe can be supplied with a nominal stiffness as low as SN 2,500

although ISO 25780 requires a minimum stiffness of SN 20,000 for jacking applications.

3.5 Nominal Pressure


The Flowtite® GRP jacking pipe intended for use in non-pressure applications can be

supplied with a nominal pressure rating ranging from (PN) 1 to 2.5, which relates to

components pressure rating in bars.

3.6 Nominal Pipe lengths

Ref: Clause 5.1.3 of ISO 25780: 2011

Although the winders for Flowtite® GRP jacking pipe are capable of producing any pipe length

from 3 to 21 m, the nominal length is limited by factory layout and practical aspects, such as

transportation.


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The standard nominal length of Flowtite® GRP jacking pipe manufactured at Lonsdale is 3 m.

Lengths of 2 m and 2.4 m are also available. Flowtite® GRP jacking pipe can also be supplied

in shorter lengths for special orders.

The total length of each pipe is equal to the nominal length with a tolerance of ±25 mm.

3.7 Flowtite® Joint Properties (couplings)

Ref: Clause 4.7.2 of ISO 25780: 2011

The standard jacking pipe jointing systems are either Type SE or Type GR (refer 3.2.2).

Plain ended GRP pipes are machined to accommodate the sleeve couplings. The couplings

are factory fitted to one pipe end. Deflections permitted at joints vary in accordance with

Table 3 in Section 3.8.

3.8 Allowable Angular Deflection

Ref: Clause 4.7.3.1 of ISO 25780: 2011

In accordance with ISO 25780 RPC Pipe Systems has declared:

(a) the maximum allowable deflection between adjacent pipes in the installed condition.

(b) the maximum allowable deflection at which each joint is designed to operate when

subjected to either internal or external pressure and the

(c) maximum angular deflection permitted during pipe jacking operations

(d) For parts (a) and (b) the values shall not be less than the values required by ISO 25780

Table 3 for sizes < DN 1000 and as calculated for sizes > DN 1000.

(e) Table 3 below specifies the maximum allowable angular deflection, at which each joint

is designed to operate when subjected to either internal or external pressure, including

the maximum allowable angular deflection permitted during pipe jacking operations.

TABLE 3 MAXIMUM ALLOWABLE INSTALLED DEFLECTION FOR PIPE JOINTS

ISO 25780 Requirements Flowtite® Specifications

External

Diameter

dOD

mm

Maximum allowable

installed deflection

a

mm/m

Maximum allowable


𝜹

degrees

Maximum allowable


a

mm/m

Maximum allowable


𝜹

degrees

200<dOD≤500 15 0.8594 15 0.8594

200<dOD≤500 10 0.5729 10 0.5729

1000<dOD a=10 x 1000/dOD Derive from value a a=10 x 1000/dOD Derive from value a

3.9 Straightness

Ref: Clause 5.1.5 of ISO 25780: 2011

The maximum permissible deviation from straightness of a surface line shall not exceed the

values given in Table 3 in ISO 25780, based on a 6m length. Flowtite® conforms to the

requirements of Table 3 in ISO 25780.

For proper sealing of the Flowtite® coupling, a smooth, dimensionally accurate outside spigot

surface is needed on each end of the pipe. Flowtite® manufacturing equipment chamfers the

edge of the pipe to avoid damage to the rubber gaskets, while simultaneously milling the

external surface. This equipment rotates the pipe and mills both ends using water-cooled

diamond-tipped tools.


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3.10 Pipe Fittings and Accessories

Flowtite® pipe fittings are moulded or fabricated using the same materials that are used to

produce the Flowtite® pipe. Fittings are supplied with spigot ends to suit the Flowtite® jacking

pipe couplings.

The standard range of fittings includes:

Double bell or socketed couplings.

Bends, 11¼º, 22½º, 45º, and 90º with spigoted or flanged ends.

Tees, either equal or reduced with spigoted or flanged ends. Eccentric tees and flanged nozzles can be manufactured to order.

Reducers, concentric or eccentric with spigoted or flanged ends.

End caps are available in all Flowtite® pipe sizes.

Y’s and other fittings can be manufactured to order.

Manhole couplings connectors with or without puddle flanges.

Transition pieces between standard Flowtite® pipe and Flowtite® jacking pipe.

See also the Flowtite® GRP Pipe and Fittings Engineering Design and Installation Guide.

4 SCOPE OF THE APPRAISAL

The scope of this product appraisal applies to the Flowtite® GRP jacking pipe as specified in

Section 3, for non-pressure applications using various trenchless installation methods such

as Slip Lining, Micro Tunnelling and Pipe Jacking.

5 APPRAISAL CRITERIA

5.1 General

Appraisal criteria is determined by the WSAA Infrastructure Products and Materials (IPAM)

Network and regularly reviewed to ensure that the criteria reflect the requirements of WSAA

members.

5.2 Quality Assurance Requirements

The WSAA product appraisal network accepts GRP pipes and fittings manufactured under

cover of a third party certified management system complying with ISO 9001 and having ISO

Type 5 product certification in accordance with ISO 25780 by a JAS-ANZ accredited

Certification Assessment Body (CAB) or by a CAB accredited by international accreditation

system recognised by JAS-ANZ.

5.3 Performance Requirements

Flowtite® GRP jacking pipes have successfully completed all long term testing for appraisal

for compliance with the requirements of ISO 25780 – Plastic piping systems for pressure

and non-pressure drainage and sewerage - Glass-reinforced thermosetting plastics (GRP)

systems based on unsaturated polyester (UP) resin Pipes with flexible joints intended to be

installed using jacking techniques.

The following Product Specifications are also relevant to this application:

WSA PS – 205J Centrifugally Cast Glass Reinforced Plastics (CC-GRP) Pipes for Pressure

and Non-Pressure Applications – Water Supply and Sewerage – Installed Using Trenchless

Installation Methods.

A copy of the above Product Specification can be found in Appendix D or downloaded from

the WSAA website.


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6 COMPLIANCE WITH APPRAISAL CRITERIA

6.1 Compliance with Quality Assurance Requirements

RPC Pipe Systems complies with the requirements of ISO 9001:2008 and is independently

certified with certificate number QEC23699.

Many Amiantit Group of Companies and licensees of Flowtite Technology have certification

that addresses the manufacture of GRP pipes and fittings. Given that the Lonsdale plant was

the thirteenth plant designed, constructed, equipped and commissioned under license to the

Amiantit Group and given that all procedures and documentation relevant to the production

and testing of pipes and fittings are supplied by the licensee, there is reasonable expectation

that RPC Pipe Systems will achieve certification of their products.

RPC Pipe Systems has provided assurance that internationally, Flowtite® pipe is

manufactured, as appropriate, in compliance with the requirements of the following

international standards:

ASTM

ASTM D3262

Standard Specification for “Fiberglass” (Glass-Fiber-Reinforced

Thermosetting-Resin) Sewer Pipe

ASTM D3517 Standard Specification for Fiberglass (Glass-Fiber-Reinforced

Thermosetting-Resin) Pressure Pipe

ASTM D3754 Standard Specification for Fiberglass (Glass-Fiber-Reinforced

Thermosetting-Resin) Sewer and Industrial Pressure Pipe

AWWA

AWWA C950 Fiberglass Pressure Pipe

AWWA M-45 Fiberglass Pipe Design Manual

ISO

ISO 10467

Plastics piping systems for pressure and non-pressure drainage and sewerage

-- Glass-reinforced thermosetting plastics (GRP) systems based on

unsaturated polyester (UP) resin

ISO 10639

Plastics piping systems for pressure and non-pressure water supply -- Glass-

reinforced thermosetting plastics (GRP) systems based on unsaturated

polyester (UP) resin

Other Standards

DIN 16868

Wound and filled glass fibre reinforced polyester resin pipes - Dimensions

BS 5480 Specification for glass reinforced plastics (GRP) pipes, joints and fittings for

use for water supply or sewerage

6.2 Compliance with Performance Requirements

RPC Pipe Systems has submitted the Flowtite® GRP jacking pipe systems for appraisal by

the Australian Water Industry as a fully tested, quality assured product, with documented

case histories (both local and international) and certified engineering standards.

RPC Pipe Systems is currently in the process of finalising ISO Type 5 Certification of Flowtite

GRP pipe. All long term testing required by ISO 25780 has been completed successfully.

Short term testing to verify the compressive strength of Flowtite® GRP pipe has been

conducted by the University of Adelaide. A copy of the test reports appears in Appendix B.


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6.2.1 Production and type test requirements to ISO 25780:2011.

Quality Control is a key function of the company’s manufacturing processes and the Quality

Control system extends from the acquisition of raw materials and continues through the

automated pipe production until the final despatch of the products. The jointing, external load

capacity, and environmental protection aspects of the pipes are continuously tested for full

reliability. The finished products are subjected to all of the rigorous testing requirements

prescribed by the relevant International Standards before being delivered to customers.

6.2.2 Mechanical Characteristics

6.2.2.1 Initial specific ring stiffness - Batch release test

Ref: Clause 5.2.1 of ISO 25780: 2011

The initial stiffness of Flowtite® GRP jacking pipes is designed to be above the nominal

values in all cases. Initial stiffness is part of daily quality control in all Flowtite ® factories. If

during quality control the stiffness is measured to be less than nominal the product is rejected

and downgraded to the next lower stiffness class.

Testing of pipes produced during ongoing manufacture has indicated that initial specific ring

stiffness meets the requirements of the ISO product standards.

6.2.2.2 Long-term specific Creep Stiffness - Type test


The long-term specific ring stiffness of Flowtite® GRP pipe was performed using the long-

term creep stiffness method in accordance with ISO 25780:2011.

The tests were conducted in the Flowtite laboratory in Sandefjord, Norway on pipe

manufactured in Lonsdale. A type test report for a section of DN600, PN10, SN5000 Flowtite

FP2.1 design pipe, confirms that the pipe fulfils the requirements of the ISO standard.

The long-term specific ring stiffness of Flowtite® pipe has been measured in creep according

to ISO 10468 and reported by Flowtite® (nominated Test report T-2012-201) as shown in

Table 4:

TABLE 4 RESULTS OF LONG-TERM SPECIFIC RING STIFFNESS OF FLOWTITE® GRP

Sample Initial stiffness Stiffness at 12000 h Creep ratio at 50 yr

1523A-33-1 6349 5205 0.76

1523A-33-2 6233 5026 0.74

The test specimen was considered having a wall structure that is the same as the pipe

intended to be used in jacking installations.

6.2.2.3 Initial resistance to failure in a deflected condition - Batch release test


The initial resistance to failure in a deflected condition is part of daily quality control in all

Flowtite® factories. The test procedure is Flowtite® Test method P 202, which is based on

ISO 10466 as nominated in ISO 10467 and ISO 10639. The criteria from Clause 5.2.3 of ISO

10467 and ISO 10639 are shown in Table 5:


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TABLE 5 RESULTS OF INITIAL RESISTANCE TO FAILURE IN A DEFLECTED

CONDITION

Stiffness class

SN

Deflection, %

Level A - No surface cracks Level B - No failure

2500 15 25

5000 12 20

10000 9 15

Testing of pipes produced during ongoing manufacture has indicated that initial resistance

to failure meets the requirements of the ISO product standards.

6.2.3 Resistance of pressure pipes internal pressure - Type test

Ref: Clause 5.7 of ISO 25780:2011 - (Specifies ISO 15306 test procedure within ISO 10467 and ISO 10639)

Flowtite® jacking pipes, for the purpose of this appraisal, are only considered for non-

pressure applications.

6.2.4 Resistance to strain corrosion - Type test

Ref: Clause 5.3 of ISO 25780:2011 - Specifies ISO 10467 test procedure

The published strain corrosion resistance of Flowtite® pipes is 0.66% (see Flowtite® test

report T-2011-205 at www.flowtite.com). Using the equation in Clause 10.6 of ISO 10952 as

specified in ISO 10467 Clause 5.4.2.1, this value can be converted to deflection and

compared with the requirement. By using the thickest of the pipes in each stiffness class the

following deflections are obtained. Refer to Table 6:

TABLE 6 RESISTANCE TO STRAIN CORROSION – TYPE TEST RESULTS

Stiffness SN 2500 SN 5000 SN 10000

Deflection, % 14.3 11.3 9.0

Comparing these values with the requirements in Table 17 of ISO 10467 shows that these

requirements are met.

Type testing of product manufactured in Lonsdale by RPC Pipe Systems (report T-2012-198)

shows a long term strain after 50 years is extrapolated to be 0.9% strain.

6.2.5 Joint performance - Type test


Flowtite® Jacking pipes are joined using flexible non-end-load bearing joints with elastomeric

seals.

Type GR joints have been tested in accordance with the requirements of ISO 25780 Clause

7.5 as demonstrated in test report T-2014-233.

Type SE couplings are proprietary couplings as supplied to RPC Pipe Systems by Ritec

GmbH & Co. Type SE joints have been tested in accordance with the requirements of ISO

25780 Clause 7.5 as demonstrated in test report 2013-244 R1.

6.2.6 Longitudinal compressive strength


Longitudinal compressive test was performed to determine the longitudinal compressive

stress at break for sample DN 478 GRP jacking pipe by the University of Adelaide (Report

C150711-RP-01). For a DN 478 jacking GRP pipe sample the minimum compressive stress

http://www.flowtite.com/


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at break is 90 N/mm2. Results obtained were 93.9 N/mm2 which is higher than the minimum

proving the sample fulfils the requirements of ISO 25780.

6.2.7 Permissible Jacking Forces

Ref: Clause 5.5 ISO 25780:2011

6.2.7.1 General

Permissible jacking forces are calculated to determine the force that can be applied to a pipe

during the jacking operation. Therefore the declared jacking load, ultimate longitudinal load,

the theoretical jacking load (concentric) and the eccentric jacking loads are to be determined.

Flowtite® used a DN478, SN320,000 Jacking Pipe for these results.

Material safety factors () of 1.75 and 3.5 have been used for assessment.

6.2.7.2 Ulitmate Longitudinal Load

The ultimate longitudinal load is the calculated value of the concentric longitudinal load that

the pipe withstands just before it breaks. This calculated value is used to determine the

permissible jacking forces of a jacking pipe.

Flowtite® tested a DN 478, SN320,000 jacking pipe and calculated its ultimate longitudinal

load to be Fult =3520kN.

Therefore the jacking pipe sample tested can withstand a concentric longitudinal load of

1428kN just before the pipe will break.

6.2.7.3 Designed Jacking Load and permissible eccentric jacking forces

RPC Pipe Systems has calculated that the theoretical design jacking load as;

• Fj,calc = 793 kN, which gives a Safety Factor of >3.5

RPC Pipe Systems have calculated the permissible eccentric jacking force on the pipe using

the estimated maximum angular deflection to still achieve a closed joint.

RPC Pipe Systems have declared the permissible eccentric longitudinal force the system

can withstand during a jacking operation is 793kN, taking into account the material safety

coefficient ( 1.75) and the estimated angular deflection.

Permissible jacking forces were calculated using the methods described in Annex C of ISO

25780 using minimum compressive strength at break as 85 N/mm2.

6.2.8 Specific initial longitudinal compressive modulus.

Clause 5.6 ISO 25780:2011

RPC Pipe Systems used a DN478, SN32,000 jacking pipe for these results.

The specific initial longitudinal compressive modulus expressed as Ec,m is the ratio of the

applied stress to the resulting strain below the elastic limit, both measured concurrently

during a short term compression test.

The specific initial longitudinal compressive modulus, Ec,m, is determined by selecting any

point from the performed quality control test data and using strain gauge at the tested

specimens.

A test piece taken from the pipe wall is compressed, at a uniform rate of strain in the direction

parallel to the longitudinal axis of the pipe, until failure occurs.

The ratio of the applied stress to the resulting strain below the elastic limit was calculated to

be 9900 MPa and declared as 8000-10000 MPa.


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6.2.9 Abrasion resistance

RPC Pipe Systems has supplied a copy of the Flowtite® Test Report No. T-97-113-B,

Abrasion Resistance Test. This test report describes an abrasion resistance test program

using the Darmstadt rocker test procedure (Ref DIN 19565) performed on DN 600, PN 10,

SN 5000 Flowtite® pipes. The average abrasion loss was found to be 0.34 mm / at 100,000

cycles (See page 10 in the Flowtite® GRP Pipe and Fittings Engineering Design and

Installation Guide.

The abrasion resistance of an individual pipeline material is difficult to determine because

test methods do not duplicate the varied abrasion conditions in sewers. Many comparative

Darmstadt rocker tests have resulted in a performance rating for plastics pipe materials that

exceeds other harder pipe materials. The test results indicate minimal wear and a calculated

life expectancy well beyond the requirements of most water agencies.

6.2.10 Temperature and pressure re-rating

Temperature and pressure re-rating is described in the Flowtite® GRP Pipe and Fittings

Engineering Design and Installation Guide and nominates 35ºC and below as requiring no

pressure re-rating. Re-rating is required for temperatures 36ºC to 50ºC and further re-rating

for temperatures 51ºC to 70ºC.

6.2.11 Resistance to Ultraviolet degradation

Flowtite® technical data states that there is no evidence to suggest that ultraviolet

degradation is a factor that affects the long term service life of Flowtite ® pipes. The exposed

outermost surface will be affected by discoloration and in the longer term glass fibres will be

exposed. If desired, the external surface of the Flowtite® pipe may be painted with two part

urethane paint compatible with GRP. However this will become an item requiring ongoing

maintenance.

6.2.12 Other Technical Data

For additional information refer to Flowtite® GRP Jacking Pipe Systems product guide in

Appendix A.

7 FITTING INSTRUCTIONS, TRAINING AND INSTALLATION

The Australasian Society Trenchless Technology has developed Trenchless Guidelines,

Standards and Specifications to assist industry users in Australia and New Zealand in

utilising these technologies. These documents are not intended to replace any existing

relevant manuals or standards. It remains the users responsibility to ensure that all relevant

laws, standards and specifications are adhered to during the course of a Works with use of

these trenchless technologies.

These Guidelines, Standards and Technical specifications are available from the

Australasian Society Trenchless Technology (ASTT) website. (http://astt.com.au).

8 REPAIR FOR NON-PRESSURE GRPJACKING PIPE FOR SEWERAGE

APPLICATIONS

The Flowtite® Installation Guide for Buried provides information on GRP repair procedures

and methods.

9 PRODUCT MARKING

Ref: Clause 6 in ISO 25780:2011

Flowtite® pipes are labelled in accordance with Clause 6 of ISO 25780: 2011 and includes:

Number of the applicable standard(s)

Manufacturers declared pipe external diameter

http://astt.com.au/


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Stiffness rating, (SN)

Pressure rating, (PN)

Permissible jacking load

The code letter “C” for the conveyance of surface water or sewage

The number of the standard (as above);

The nominal size (DN)

The stiffness rating, SN;

The pressure rating, PN;

The manufacturers name or identification; and

The date of manufacture in text or code.

Refer to Appendix H for an example of the pipe marking.

10 PACKAGING AND TRANSPORTATION

RPC Pipe Systems has advised that all products will be transported to site in timber cradles

and storage on site by the purchaser should be as per the manuals provided.

The Flowtite® Installation Guide for Buried Pipes has a Section titled ‘Shipping Handling and

Storage’. That Section provides comprehensive information and instruction complete with

diagrams and has Clauses titled:

Inspecting Pipe.

Repairing Pipe.

Unloading and Handling Pipe.

Site Pipe Storage

Storing Gaskets and Lubricant.

Transporting Pipe.

Handling Nested Pipes.

11 PRODUCT WARRANTY

The products are covered by the normal commercial and legal requirements of the

Competition and Consumer Act 2010, which covers manufacture to the relevant standard.

Additional warranties may be negotiated on a project specific basis.

12 WATER AGENCY EXPERIENCE WITH THE PRODUCT OR FIELD TESTING

REPORT

Table 7 lists a number of significant projects supplied to Australian water authorities.


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TABLE 7 AUSTRALIAN WATER AUTHORITIES - PROJECTS

Year Project Authority Description

2014 Ryan Rd Yarra Valley Water 622m OD530 SN90,000

767m OD447

SN100,000

2014 Alphington Sewer Project Melbourne Water 97m OD1335 SN32,000

63m OD820 SN120,000

2014 Canada Bay Canada Bay Council 336m OD1300

SN20,000

552m OD1400

SN20,000

2014 Cooper Street Yarra Valley Water 45m OD363 SN100,000

2015 Ellenbrook Water Corporation 512m OD478 SN32,000

2015 Darlington to Peachy Trunk Main City of Gold Coast 153m OD447

SN100,000

475m OD530

SN100,000

13 DISCUSSION

The RPC Pipe Systems Lonsdale plant was the 13th in a series of standard ‘turn -key’

manufacturing plants that have been successfully constructed and commissioned throughout

the world. There are now 22 plants constructed around the world. There is reasonable

justification for being confident that the Lonsdale plant is capable of producing non-pressure

jacking pipes and fittings to meet ISO standards in sizes suitable for the Australian and New

Zealand water industries.

As a licensed Australian manufacturer of an international product, RPC Pipe Systems has

been able to present considerable information on Flowtite® GRP pipe and fittings to

demonstrate a mature, widely used, tested and proven product range. The technical data

presented, available on the Flowtite® web site and included throughout this report is

extensive. The rapid responses to all technical and other questions raised, demonstrates a

willingness to cooperate and a ready availability of expertise from RPC Pipe Systems and

Amiantit / Flowtite®.

Amiantit provides technical expertise from Flowtite Technology AS located in Sandefjord,

Norway and they were responsible for commissioning the Lonsdale plant and providing RPC

Pipe Systems with technical support and oversight of the Australian Flowtite® pipe and

fittings production. Flowtite Technology AS will also be responsible for verification testing of

the Lonsdale pipe to meet Amiantit and ISO Standard requirements, particularly the long -

term hydrostatic pressure tests and resistance to strain corrosion.

The RPC Pipe Systems manufacturing plant for Flowtite® pipe has been equipped with a

complete QC laboratory and automatic hydrostatic testing machines for all diameter pipes

and associated couplings. Every pipe and coupling will be tested during manufacture and all

test results logged and recorded. More detailed information is available in the AFIL

catalogues available from RPC Pipe Systems.

14 LIFE EXPECTANCY

Based on the product information provided, the international reputation of the product and

subject to design, installation and commissioning in compliance with the manufacturer’s

instructions and relevant WSAA Water Supply and Sewerage Codes, Flowtite® GRP jacking


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pipe and fittings (FS and FP) could be expected to achieve an ‘A’ rating – Life expectancy in

excess of 100 years before major rehabilitation. This rating would be conditional on the future

work items being completed and should only be considered a general guide to life

expectancy and may increase or decrease as a result of the quality of installation, system

operating conditions, operating environment and other geographical and site specific factors.

15 FUTURE WORKS

RPC Pipe Systems is required to achieve ‘Product Certification’ to ISO 25780 for their

Australian manufacture of Flowtite™ GRP jacking pipes and couplings by 1 July 2016.

16 REPORT RECOMMENDATION

It is recommended that WSAA members and associates, subject to any specific requirements

of the member or associate, accept or authorise the Flowtite® GRP jacking pipes and

couplings as detailed in this report for use in non-pressure sewerage applications subject to

the design, installation and commissioning in accordance with specifications provided by

RPC Pipe Systems and relevant WSAA Sewerage Code or WSAA Members or Associated

Members integrated WSAA Code editions.


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17 DISCLAIMER

This Product Appraisal Report (Report) is issued by the Water Services Association of

Australia Limited on the understanding that:

This Report applies to the product(s) as submitted. Any changes to the product(s) either

minor or major shall void this Report.

To maintain the recommendations of this Report any such changes shall be detailed and

notified to the Product Appraisal Manager for consideration and review of the Report and

appropriate action. Appraisals and their recommendations will be the subject of continuous

review dependent upon the satisfactory performance of products.

WSAA reserves the right to undertake random audits of product manufacture and installation.

Where products fail to maintain appraised performance requirements the appraisal and its

recommendations may be modified and reissued. Appraisal reports will be reviewed and

reissued at regular intervals not exceeding five (5) years.

The following information explains a number of very important limits on your ability to rely on

the information in this Report. Please read it carefully and take it into account when

considering the contents of this Report.

Any enquiries regarding this report should be directed to the Program Manager, Carl

Radford, Phone: 03 8605 7601 email [email protected].

17.1 Issue of Report

This Report has been published and/or prepared by the Water Services Association of

Australia Limited and nominated Project Manager and peer group of technical specialists

(the Publishers).

The Report has been prepared for use within Australia only by technical specialists that have

expertise in the function of products such as those appraised in the Report (the Recipients).

By accepting this Report, the Recipient acknowledges and represents to the Publisher(s)

and each person involved in the preparation of the Report that the Recipient has understood

and accepted the terms of this Disclaimer.

17.2 Limits on Reliance on Information and Recommendations

17.2.1 Disclaimer of liability

Neither the Publisher(s) nor any person involved in the preparation of the Report accept(s)

any liability for any loss or damage suffered by any person however caused (including

negligence or the omission by any person to do anything) relating in any way to the Report

or the product appraisal criteria underlying it. This includes (without limitation) any liability

for any recommendation or information in the Report or any errors or omissions.

17.2.2 Need for independent assessment

The information and any recommendation contained (expressly or by implication) in this

Report are provided in good faith. However, you should treat the information as indicative

only. You should not rely on that information or any such recommendation except to the

extent that you reach an agreement to the contrary with the Publisher(s).

This Report does not contain all information that a person might require for the purposes of

assessing any product discussed or appraised within it (Product). The product appraisal

criteria used in preparing this Report may not address all relevant aspects of the Product.

Recipients should seek independent evidence of any matter which is material to their

decisions in connection with an assessment of the Product and consult their own advisers

for any technical information required. Any decision to use the Product should take into

account the reliability of that independent evidence obtained by the Recipient regarding the

Product.

mailto:[email protected]


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Recipients should also independently verify and assess the appropriateness of any

recommendation in the Report, especially given that any recommendation will not take into

account a Recipient’s particular needs or circumstances.

WSAA has not evaluated the extent of the product liability and professional indemnify

insurance that the provider of the product maintains. Recipients should ensure that they

evaluate the allocation of liability for product defects and any professional advice obtained

in relation to the product or its specification including the requirements for product liability

and professional indemnity insurance.

17.3 No Updating

Neither the Publisher(s) nor any person involved in the preparation of this Report [has] [have]

any obligation to notify you of any change in the information contained in this Report or of

any new information concerning the Publisher(s) or the Product or any other matter.

17.4 No Warranty

The Publisher(s) do[es] not, in any way, warrant that steps have been taken to verify or audit

the accuracy or completeness of the information in this Report, or the accuracy,

completeness or reasonableness of any recommendation in this Report.


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APPENDIX A – TECHNICAL MANUALS BROCHURES

AVAILABLE FROM RPC PIPE SYSTEMS OR THE FLOWTITE WEBSITE

Technical Manuals Brochures Manuals Documents Referenced

To obtain a copy of the FLOWTITE® GRP Jacking

Pipe Systems or FLOWTITE® Design Guide

please send an email with your details to

[email protected]. The FLOWTITE®

Design Guide is available in hard copy and CD

format.



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To obtain a copy of the FLOWTITE® Installation

Guide for Buried Pipes please send an email to

[email protected]. The Installation

Guide is available as a PDF file.

A copy of the Project Quality Plan- Jacking Pipe Inspection and Test Plan is available for the WSAA Members Only

website.



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APPENDIX B - QUALITY CERTIFICATIONS

Copies of the following Quality Certification Certificates are available for downloading from

the WSAA ‘Members Only’ IPAM Portal Website.

TABLE B1 RPC PIPE SYSTEMS PTY LTD – MANAGEMENT SYSTEMS

Applicants Business

(Attach all QA system certificates in full including schedules and last audit report)

Quality Systems Standard AS 9001:2008

Certification licence no. QEC23699

Certifying agency SAI Global

First date of certification 16 May 2007

Current date of certification* 4 April 2013

Expiry date of certification** 16 May 2016

TABLE B2 FLOWTITE TECHNOLOGY AS R&D LAB– MANAGEMENT SYSTEMS

Applicants Business

Østre Kullerød 3, 3241 Sandefjord

Quality Systems Standard1 AS 9001:2008

Certification licence no. 752-01

Certifying agency Intertek

First date of certification 27 March 1996

Date of Issue 7 June 2014

Expiry date of certification 16 June 2017

Note 1 Scope of Certification is Design of machinery and processes for production and testing of GRP/GRE pipe

products. Training, testing, research and development of GRP/GRE products.

TABLE B3– OTHER CERTIFICATES

Test Laboratory Certification

Flowtite Technology Sandefjord - Norway

Test Laboratory Accreditation Document No

Test 190 Norwegian Accreditation

Test Equipment Calibration Certification (Refer to Schedule)


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APPENDIX C – PRODUCT SCHEDULE


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APPENDIX D – WSAA PRODUCT SPECIFICATIONS


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APPENDIX E - SUPPLIER CONTACTS

RPC Pipe Systems PTY. LTD 11 Christie Road,

LONSDALE SA 5160

Phone: (08) 8329 1111

Fax: (08) 8329 1122

Web site: www.rpcpipesystems.com & www.flowtite.com

Iplex Pipelines - Contact points Phone Fax

Technical Sales Managers:

Mr Michael Lancuba

7-15 Radford Rd

Reservoir, Vic 3073

(03) 9469 0320

(03) 9462 1540

Customer Services Department 13 18 40 13 18 60

Reservoir Victoria

PO Box 312

Reservoir Victoria 3073

03 9460 7000 03 6326 5277

Chipping Norton NSW

35 Alfred Road

Chipping Norton NSW 2170

02 9755 8243 02 9755 4480

Elizabeth South Australia

PO Box 133

Elizabeth South Australia 5112

08 8256 2000 08 8252 4858

Launceston Tasmania

PO Box 42 Invermay Tasmania 7248

03 6326 8031 03 6326 5277

Osborne Park Western Australia

PO Box 1194

Osborne Park Western Australia 6017

08 9340 4888 08 9340 4899

Strathpine Queensland

PO Box 5160

Brendale Queensland 4500

07 3881 9222 07 3881 1127

Winnellie Northern Territory

PO Box 39429

Winnellie Northern Territory 0821

08 8947 0466 08 8947 0347

http://www.rpcpipesystems.com/

http://www.flowtite.com/


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APPENDIX F - NATA LABORATORY TEST RESULTS

Test Reports have been made available for the purposes of preparing this product appraisal

report. The information is considered to be commercial in confidence and has not therefore

been made public. Should you require such information, please contact the manufacturer

(Appendix E).

The type testing and ongoing production testing (batch testing) confirm the Flowtite GRP

jacking pipes meet the requirements of ISO 25780:2011. Batch release testing is done in-

house on appropriate specialist testing equipment.

ISO 25780: 2011 calls up a range of performance tests which include the following:


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TABLE F1 SUMMARY OF TYPE TESTS AND BATCH TEST RESULTS

Characteristic Standard Clause Requirement Frequency Test

Result Standard

Result Pipe Size Doc ID

PIPES

Pipe Type Tests

Longitudinal Compressive

Strength

ISO 25780 5.4.2

Determine the specific initial longitudinal compressive stress at break

UN

SPEC

IFIE

D

PASS - αb,s 93.9 N/mm2 where αb,s,min = 90 N/mm2 for DN478

SN320,000 PASS DN478

C150711-RP-01

ISO 25780 5.4.4

Determine the specific initial longitudinal compressive stress at break on both rebated and unrebated test pieces

PASS Unrebated: αb,s 123 N/mm2 where αb,s,min = 90 N/mm2 for DN478 Rebated: αb,s 120 N/mm2 where αb,s,min = 90 N/mm2 for DN478

PASS DN478 C150711-RP-01

ISO 25780 5.4.6.1

The specific initial longitudinal compressive stress at break shall be higher than the declared minimum specific initial longitudinal compressive stress at break

PASS - αb,s 93.9 N/mm2 where αb,s,min = 90 N/mm2 for DN478

PASS DN478 C150711-RP-01

Specific initial longitudinal compressive

modulus

ISO 25780 5.6 Determine the specific initial longitudinal

Ec,m,Avg = 9900 MPa PASS DN478 C150711-RP-01


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Result Standard


compressive modulus

Pipe Batch Release Tests

Longitudinal Compressive

Strength

ISO 25780 5.4.4

Determine the specific initial longitudinal compressive stress at break on both rebated and unrebated test pieces

AS

PER

QU

ALI

TY P

LAN

PASS Unrebated: αb,s 123 N/mm2 where αb,s,min = 90 N/mm2 for DN478 Rebated: αb,s 120 N/mm2 where αb,s,min = 90 N/mm2 for DN478

PASS DN478 C150711-RP-01

ISO 25780 5.4.5.2 Calculate derated compressive stress of the spigot

Unrebated (Spigot): αb,s 123 N/mm2 where αb,s,min = 90 N/mm2 for DN478

PASS DN478 C150711-RP-01

ISO 25780 5.4.5.3 Calculate derated compressive stress of the barrel

Unrebated (Barrel): αb,s 123 N/mm2 where αb,s,min = 90 N/mm2 for DN478

PASS DN478 C150711-RP-01

ISO 25780 5.4.6.2

Both derated initial longitudinal compressive stresses at break for spigot and barrel of all quality control tests shall be higher than the minimum initial longitudinal compressive stresses at break

PASS Unrebated (Barrel): αb,s 123 N/mm2 where αb,s,min = 90 N/mm2 for DN478 Rebated (Barrel): αb,s 120 N/mm2 where αb,s,min = 90 N/mm2 for DN478 Unrebated (Spigot): αb,s 123 N/mm2 where αb,s,min = 85 N/mm2 for DN478

PASS DN478 C150711-RP-01

Specific initial longitudinal

ISO 25780 5.6 Determine the specific initial longitudinal

Ec,m,Avg = 9900 MPa PASS DN478 C150711-RP-01


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Result Standard


compressive modulus

compressive modulus

SE COUPLINGS

Coupling Type Tests

Performance

ISO 25780 7.5.2

Leak Tightness when subjected to an extenal pressure differential

AS

PER

QU

ALI

TY P

LAN

No damage, leakage or weeping

No signs of damage to components or change in pressure

greater than

0.08bar/h

DN600 PN1

2013-244 R1

ISO 25780 7.5.3

Leak Tightness when subjected to internal positive pressure following assembly


Withstand without

leakage an internal

pressure of 1.5 x PN for

15mins

DN600 PN1

2013-244 R1

ISO 25780 7.5.4

Leak Tightness when simultaneously subjected to angular deflection and draw


No signs of damage to components nor leak

DN600 PN1

2013-244 R1

ISO 25780 7.5.5

Leak Tightness when simultaneously subjected to misalignment and draw under static pressure



DN600 PN1

2013-244 R1

ISO 25780 7.5.6 Leak Tightness when simultaneously

No damage, leakage or weeping No signs of damage to

DN600 PN1

2013-244 R1


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Result Standard


subjected to misalignment and draw under a positive cyclic pressure

components nor leak

Material / Joint

Properties

ISO 10467 AND ISO

25780 4.8 / 4.7.5

Effect on potable water

AS/NZS 4020 - Exposed to areas to volume ratio's up to 15,000

mm2/L Not Tested

ISO 25780 4.7 Joint Properties No damage, leakage or weeping PASS DN600 PN1

2013-244 R1

GR COUPLINGS

Coupling Type Tests

Performance

ISO 25780 7.5.2

Leak Tightness when subjected to an extenal pressure differential

AS

PER

QU

ALI

TY P

LAN


No signs of damage to components or change in pressure

greater than

0.08bar/h

DN820 PN1

T-2014-233

ISO 25780 7.5.3

Leak Tightness when subjected to internal positive pressure following assembly


Withstand without

leakage an internal

pressure of 1.5 x PN for

15mins

DN820 PN1

T-2014-233

ISO 25780 7.5.4

Leak Tightness when simultaneously subjected to angular deflection and draw



DN820 PN1

T-2014-233


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Result Standard


ISO 25780 7.5.5

Leak Tightness when simultaneously subjected to misalignment and draw under static pressure



DN820 PN1

T-2014-233

ISO 25780 7.5.6

Leak Tightness when simultaneously subjected to misalignment and draw under a positive cyclic pressure



DN820 PN1

T-2014-233

Material / Joint

Properties

ISO 10467 AND ISO

25780 4.8 / 4.7.5

Effect on potable water

PASS PASS DN80 Equiv.

AWQ 27579 AWQ 27042 AWQ 64287 4007/92.1664

ISO 25780 4.7 Joint Properties No damage, leakage or weeping PASS DN820 PN1

T-2014-233


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APPENDIX G DOUBLE BELL REKA COUPLING QUALIFICATION TEST


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APPENDIX H – EXAMPLE OF PIPE MARKING

The label below appears on each pipe and designates the class of the pipe as well as

identifies the individual pipe with a serial number (in this case 180690096). Jacking load is

stencilled on the pipe as required by the customer.


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APPENDIX I – FIELD TRIAL REPORT


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Melbourne Office

Level 8, Suite 8.02

401 Docklands Drive Docklands VIC 3008

Phone: (03) 8605 7601

Fax: (03) 8605 7612

Sydney Office

Level 11, 39 Martin Place

Sydney NSW 2000

GPO Box 915

Sydney NSW 2001

Phone: (02) 9221 5966

Fax: (02 9221 5977

www.wsaa.asn.au

http://www.wsaa.asn.au/