Section 4 Plastic pipes and fittings

4.1.1 This Section gives the general requirements for plastic pipes and fittings, with or without reinforcement, intended for use in the services listed in the relevant Rules dealing with design and construction. Hoses and mechanical couplings are not covered by these requirements.

4.1.2 Pipes and fittings intended for application in Class I, Class II and Class III systems for which there are Rule requirements, are to be manufactured in accordance with the requirements of Ch 14, 1 General requirements and this Section.

4.1.3 As an alternative to Ch 14, 4.1 Scope 4.1.2, plastic pipes and fittings which comply with National or proprietary specifications may be accepted, provided that the specifications give reasonable equivalence to the requirements of this Section or, alternatively, are approved for a specific application. The survey and certification are however to be carried out in accordance with the requirements of this Section.

4.2.1 The requirements for design approval are detailed in the relevant Rules.

4.2.2 The design submission is to include a materials list with confirmation that the materials listed have properties and characteristics conforming with those values used in the design submission. As a minimum, the details given should include the following:

1. Resin.

2. Accelerator (type and concentration).

3. Catalyst or curing agent (type and concentration).

4. Reinforcement.

5. Cure/post-cure conditions.

6. Resin/reinforcement ratio.

7. Wind angle (or lay-up sequence) and orientation.

8. Dimensions and tolerances.

This submission is to include similar details for the fittings together with a description of the method of attachment of the fittings to the pipes.

4.2.3 Any alteration of the component materials or manufacturing operations from those used in the design submission will necessitate a completely new submission.

4.2.4 If the piping manufacturer anticipates the possible use of alternative materials, these should be listed in the design submission. Proof that the modified product will meet the specified requirements will be needed prior to its use.

4.3.1 Plastic pipes and fittings intended for use in Class I, Class II and Class III systems are to be manufactured at facilities approved by LR, using materials approved by LR.

4.3.2 A Manufacturing Specification is to be submitted. This is to contain details of the following:

1. All constituent materials.

2. Manufacturing procedures such as lay-up sequence or wind angle, the ratios of curing agent to resin and reinforcement to resin, the laminate thickness, the mandrel dwell time (initial cure) and the cure and post-cure conditions.

3. Quality control procedures including details and frequency of tests on the incoming materials, tests made during production and on the finished piping.

4. Acceptance standards and tolerances, including all dimensions.

5. Procedures for cosmetic repair.

6. System for traceability of the finished piping to the batches of raw materials.

7. Method of bonding pipes and fittings.

4.3.3 Details of all raw materials are to be submitted for approval and are to be in accordance with the Manufacturing Specification and the design submission.

4.3.4 All batches of raw materials are to be provided with unique identifications by their manufacturers.

4.3.5 No batch of material is to be used later than its date of expiry.

4.3.6 The piping manufacturer is to ensure that all batches of materials are used sequentially.

4.3.7 The piping manufacturer is to maintain records of the amounts of resin and reinforcement used, in order to ensure that the proportions remain within the limits set in the Manufacturing Specification.

4.3.8 Records are to be kept of the wind angle and/or the orientation of the reinforcement.

4.3.9 The piping manufacturer is to ensure that each item of piping is traceable to the batch or batches of material used in its manufacture. The unique identifications referred to in Ch 14, 4.3 Manufacture 4.3.4 are to be included on all documents.

4.3.10 The curing oven is to be suitable for the intended purpose and all pyrometric equipment is to be calibrated at least annually and adequate records maintained.

4.3.11 The temperature of the pipe or fitting is to be controlled and recorded by the attachment of suitably placed thermocouples.

4.4.1 The piping manufacturer is to have a quality assurance system approved to ISO 9001 or equivalent. This system should ensure that the pipes and fittings are produced with uniform and consistent mechanical and physical properties in accordance with acceptable standards.

4.5.1 Dimensions and tolerances are to conform to the Manufacturing Specification.

4.5.2 The wall thicknesses of the pipes are to be measured at intervals around the circumference and along the length in accordance with an appropriate National Standard. The thicknesses are to accord with the Manufacturing Specification.

4.5.3 The responsibility for maintaining the required tolerances and making the necessary measurements rests with the manufacturer. Occasional checking by the Surveyor does not absolve the manufacturer from this responsibility.

4.6.1 The composition of the pipes and fittings is to be in accordance with the Manufacturing Specification.

4.6.2 Where alternative materials are used (see Ch 14, 4.2 Design requirements 4.2.4), the manufacturer is to demonstrate to the Surveyor's satisfaction, and prior to their introduction, their suitability with respect to the performance of the piping. Otherwise, full testing as specified in Ch 14, 4.7 Testing will be required.

4.7.1 For thermoplastic pipes, the polymer manufacturer is to make the following measurements on samples taken from each batch:

1. Melting point.

2. Melt flow index.

3. Density.

4. Filler/pigment content, where applicable.

5. Tensile stress at yield and break.

6. Tensile strain at yield and break.

4.7.2 The values obtained are to be certified by the polymer manufacturer.

4.7.3 For reinforced thermoset pipes, the resin manufacturer is to determine, on samples taken from each batch, at least the following:

1. All resins:

   1. Viscosity.

   2. Gel time.

   3. Filler content, where applicable.

2. Polyester resins:

   1. Type (orthophthalic, isophthalic, etc.).

   2. Volatiles content.

   3. Acid value.

3. Epoxide resins:

   1. Free epoxide content.

4. Phenolic resins:

   1. Free phenol content.

   2. Free formaldehyde content.

4.7.4 The values obtained are to comply with the requirements of the Manufacturing Specification.

4.7.5 Where the resin manufacturer mixes batches, both the original batches and the mixed batch are to be tested in accordance with Ch 14, 4.7 Testing 4.7.1 to Ch 14, 4.7 Testing 4.7.3 as appropriate. The mixed batch is then to be given a unique batch number.

4.7.6 The polymer or resin manufacturer is to demonstrate that each batch of polymer or resin satisfies the requirement for temperature of deflection under load and this is not to be less than 80°C.

4.7.7 These measurements should be repeated on each batch by the piping manufacturer. Where this is not done, LR may require that the tests be made on a random basis by an independent laboratory.

4.7.8 The piping manufacturer is to confirm, by means of tests on at least one batch in twenty, that the temperature of deflection under load exceeds the specified minimum under manufacturing conditions.

4.7.9 Where reinforcements are used, at least the following are to be recorded, where applicable:

1. Tex of yarn(s) or roving(s).

2. Ends per 100 mm in all reinforcement orientations.

3. Weight per square metre.

4. Binder/size content.

5. Stitch type and count.

6. Type of fibre used.

7. Surface treatment and/or finish.

4.7.10 All items in Ch 14, 4.7 Testing 4.7.9 are to comply with the Manufacturing Specification.

4.7.11 The piping manufacturer is to maintain accurate records of resin and glass usage and is to calculate the resin/glass ratio on an ongoing basis.

4.7.12 During manufacture of the piping, apart from the requirements of Ch 14, 4.7 Testing 4.7.5, Ch 14, 4.7 Testing 4.7.6 and Ch 14, 4.7 Testing 4.7.8, tests are to be carried out on the constituents and final product in accordance with Table 14.4.1 Testing during manufacture of pipes.

4.7.13 The standards of acceptance are those listed in the Manufacturing Specification approved by LR.

4.7.14 At the Surveyor's discretion, sections of pipe are to be subjected to hydraulic bursting tests and/or measurements of axial strength.

4.7.15 If the batch of resin or polymer, or the curing agent, or their ratio is changed during manufacture of a batch of pipes, at least two additional measurements of the gel time are to be carried out during each shift.

4.8.1 All pipes and fittings are to be visually examined and are to be free from surface defects and blemishes.

4.8.2 The pipes are to be reasonably straight and the cut ends are to be square to the axis of the pipe.

4.9.1 Each length of pipe is to be tested at a hydrostatic pressure not less than 1,5 times the rated pressure of the pipe.

4.9.2 The test pressure is to be maintained for sufficient time to permit proof and inspection. Unless otherwise agreed, the manufacturer's certificate of satisfactory hydraulic test, endorsed by the Surveyor, will be accepted.

4.10.1 Repairs are not allowed, with the exception of minor cosmetic blemishes as detailed in Ch 14, 1.10 Rectification of defective material 1.10.1.

4.10.2 A repair procedure for these minor blemishes is to be included in the Manufacturing Specification.

4.11.1 All piping is to be identified in such a manner that traceability to all the component materials used in its manufacture is ensured. The Surveyor is to be given full facilities for so tracing the material when required.

4.11.2 Pipes and fittings are to be permanently marked by the manufacturer by moulding, hot stamping or by any other suitable method, such as printing, in accordance with Ch 14, 1.11 Identification of products and base materials. The markings are to include:

1. Identification number, see Ch 14, 4.11 Identification 4.11.1.

2. LR or Clasifications Register, and the abbreviated name of LR's local office.

3. Manufacturer's name or trademark.

4. Pressure rating.

5. Design standard.

6. Material system with which the piping is made.

7. Maximum service temperature.

4.12.1 The manufacturer is to provide the Surveyor with copies of the test certificates or shipping statements for all material which has been accepted.

4.12.2 Each test certificate is to contain the following particulars:

1. Purchaser's name and order number.

2. If known, the contract number for which the piping is intended.

3. Address to which piping is despatched.

4. Type and specification of material.

5. Description and dimensions.

6. Identification number, see Ch 14, 4.11 Identification 4.11.1.

7. Test results.