BRITISH STANDARD

BS 6464:1984
Incorporating
Amendment No. 1
Specification for
Reinforced plastics
pipes, fittings and
joints for process plants
UDC 621.643.2:678.067.5:66.026
Confirmed
January 2009
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BS 6464:1984
This British Standard, having
been prepared under the
direction of the Plastics
Standards Committee, was
published under the authority
of the Board of BSI and comes
into effect on
28 September 1984
BSI 03-1999
The following BSI references
relate to the work on this
standard:
Committee reference PLM/9
Draft for comment 76/50861 DC
ISBN 0 580 13776 7
Committees responsible for this
British Standard
The preparation of this British Standard was entrusted by the Plastics
Standards Committee (PLM/-) to Technical Committee PLM/9 upon which the
following bodies were represented:
British Chemical Distributors and Traders Association Ltd.
British Gas Corporation
British Plastics Federation
British Steel Industry
British Valve Manufacturers Association Ltd.
Copper Tube Fittings Manufacturers Association
Department of the Environment (Housing and Construction)
Department of the Environment (PSA)
Electricity Supply Industry in England and Wales
Engineering Equipment and Materials Users Association
Institution of Civil Engineers
Institution of Municipal Engineers
Institution of Public Health Engineers
Institution of Water Engineers and Scientists
National Association of Plumbing, Heating and Mechanical Services Contractors
Plastics and Rubber Institute
Plastics Land Drainage Manufacturers Association
Royal Institute of Public Health and Hygiene
STC Water Regulations and Fittings Scheme
Water Companies Association
Water Research Centre
The following bodies were also represented in the drafting of the standard,
through subcommittees and panels:
British Adhesive Manufacturers Association
British Board of Agrment
Greater London Council
Heating and Ventilating Contractors Association
Institute of Plumbing
Ministry of Agriculture, Fisheries and Food
Pitch Fibre Pipe Association of Great Britain
Amendments issued since publication
Amd. No. Date Comments
6294 November
1990
Indicated by a sideline in the margin
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BS 6464:1984
BSI 03-1999 i
Contents
Page
Committees responsible Inside front cover
Foreword iii
Section 1. General
1 Scope 1
2 Definitions 1
3 Nomenclature, symbols and units for design 1
Section 2. Materials and properties
4 Thermosetting resin systems 2
5 Fibrous reinforcement 2
6 Aggregates and fillers 2
7 Thermoplastics liners 2
8 Cement for bonding spigot and socket joints 2
9 Mechanical properties 3
10 Thermal properties 3
11 Chemical properties 4
12 Construction of a chemical liner 4
13 Flammability 4
Section 3. Design and design calculations
14 General 5
15 Laminate design and thickness 6
16 Design calculations for pipes subject to internal pressure 7
17 Design calculations for pipes subject to vacuum 7
Section 4. Dimension markings and information
18 Dimensions 8
19 Tolerances on dimensions of pipes and fittings 9
20 Marking 9
21 Information 9
Section 5. Construction and workmanship
22 Manufacturing conditions in works involving the cure of resins 10
23 Manufacturing procedure 10
24 Thermoplastics liners 10
25 Fittings 11
26 Joints 15
Section 6. Testing
27 Tests for design 18
28 Production testing 19
29 Welding procedure tests for thermoplastics linings 20
30 Tests for production welds in thermoplastics linings 20
31 Production samples for mechanical tests on a laminate 20
Section 7. Inspection and testing
32 Facilities for inspection and testing 20
33 Certification of inspection and testing 20
Appendix A Information to be given with an enquiry or tender or on
receipt of an order 22
Appendix B Methods of test 22
Appendix C Worked examples of the design method specified in section 3 28
Appendix D Methods of manufacture of reinforced plastics pipes 34
Appendix E Acceptable limits of visual defects 35
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BS 6464:1984
ii
BSI 03-1999
Page
Appendix F Pipework fabrication methods 36
Figure 1 Limits of pressure and diameter 37
Figure 2 Relationship between thickness and glass content for
laminates with resin of relative density, (+), 1.1 to 1.3 38
Figure 3 Relationship of unit modulus to winding angle 39
Figure 4 Factor related to temperature 39
Figure 5 Factor related to cyclic loading 40
Figure 6 Butt joint build-up for lined pipe 41
Figure 7 Pipework shapes for fabrication methods 1 and 2 42
Figure 8 Flanged pipe fittings for method 3 43
Figure 9 Typical stub flanges (type A) 44
Figure 10 Typical full faced flanges (types B and C) 45
Figure 11 Butt joint build-up for unlined pipe 46
Figure 12 Test piece for the determination of shear strength
of bond between thermoplastics lining and laminate 46
Figure 13 Test piece for the determination of lap shear
strength of laminate 47
Figure 14 Test for the determination of peel strength of
bond between thermoplastics liner and laminate 48
Figure 15 Test piece for the tensile strength of thermoplastics
sheet and welds 49
Figure 16 Typical examples of laminate construction 50
Figure 17 Biaxial failure envelope 51
Table 1 Derivation of definitions relating to symbols 3
Table 2 Minimum mechanical properties of reinforced
laminate layers 4
Table 3 Factors to be applied to design unit load of continuous
rovings for different winding angles 3
Table 4 Factor relating to method of manufacture 5
Table 5 Factor relating to loss in ultimate tensile strength 6
Table 6 Minimum socket depths 12
Table 7 Equations for calculating fittings dimensions 13
Table 8 Minimum separation dimensions to be used
in equations of Table 7 13
Table 9 Dimensions of flanges 14
Table 10 Thickness and mating dimensions of flanges
and backing flanges 15
Table 11 Minimum butt joint overlay lengths including taper 17
Table 12 Acceptable limits of visual defects 35
Table 13 Pipework fabrication methods 36
Publications referred to Inside back cover
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BS 6464:1984
BSI 03-1999 iii
Foreword
This British Standard has been prepared under the direction of the Plastics
Standards Committee. Its purpose is to establish a general standard for the
design and manufacture of reinforced plastics pipes and fittings for process plant.
The manufacture of pipes and fittings in reinforced plastics involves a number of
materials, plastics and reinforcing systems and a number of different methods of
manufacture.
Metallic pipes, being made from materials which are isotropic, may conveniently
be designed by calculating permissible stresses, based on measured tensile and
ductile properties. Reinforced plastics are usually anisotropic, and the design
method adopted in this standard, being based on unit loading, is particularly
suited to the design of composite materials.
This standard includes a method of calculation for an appropriate laminate
construction based on the allowable unit loading and unit modulus for the type of
composite concerned. Design factors are included to cover such variables as:
a) deterioration of the composite properties over a long period;
b) effect of temperature on the properties of the composite;
c) repeated or alternating loading.
The nominal pipe sizes specified in this standard have been selected from those
under consideration within Technical Committee 138, Plastics pipes and fittings
for the transport of fluids, of the International Organization for Standardization
(ISO).
It is implicit that pipes and fittings covered by this standard should be made only
by manufacturers and operators (see 23.1 and 24.4) who are competent and
suitably equipped to fulfil all the requirements of this standard.
It is expected that these principles will be proved by documentation of past
experience or by prototype testing, being supplied to the satisfaction of the
purchaser or the nominated inspecting authority as appropriate.
Attention is drawn to BS 5480 which covers pressure and non-pressure GRP
pipes, joints and fittings intended for conveying, above or below ground, liquids
including potable and non-potable water, foul sewage and storm water.
The following publications give information on stress/strain analysis of laminates
(see clause 9 and 15.1).
Jones, R M, Mechanics of composite materials, McGraw Hill (1975)
Calcote, L R, The analysis of laminate composite structures,
van Nostsand (1969)
Eckold, G C, Leadbetter, D, Soden, P D, and Griggs, P R, Lamination theory in
the production of pipeline envelopes for filament wound materials subject to
biaxial loading, Composites (1978)
A British Standard does not purport to include all the necessary provisions of a
contract. Users of British Standards are responsible for their correct application.
Compliance with a British Standard does not of itself confer immunity
from legal obligations.
Summary of pages
This document comprises a front cover, an inside front cover, pages i to iv,
pages 1 to 52, an inside back cover and a back cover.
This standard has been updated (see copyright date) and may have had
amendments incorporated. This will be indicated in the amendment table on
the inside front cover.
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BS 6464:1984
BSI 03-1999 1
Section 1. General
1 Scope
This British Standard specifies requirements for the
materials, properties, design calculations,
manufacture, inspection and testing of reinforced
plastics pipes, fittings and joints consisting of
thermosetting resin systems with glass fibre
reinforcement (GRP) for process plants.
Constructions both with and without a lining of
thermoplastics are included. The information to be
supplied for designs for pipes and fittings to this
standard is given in Appendix A.
This British Standard is not applicable in the
following circumstances:
a) where the product of the design pressure in
bar
1)
and the nominal diameter in millimetres is
more than 11 000 (see Figure 1);
b) where the operating temperature is outside the
limits of 10 C to + 110 C;
c) where the pipes may be subject to some applied
external pressure other than that due to soil
loading or vacuum;
d) where there is a non-taint requirement, e.g. for
the water and food industries, as no requirements
are given for the effect of GRP on those materials.
NOTE 1 In addition to the specific exclusions above, the
following points are emphasized and it should not be assumed
that pipes made in accordance with this standard will necessarily
be universally suitable for chemical plant use.
1) Unstressed dip coupon testing of sample laminates may not
necessarily give a valid indication of the long term resistance
of the material to the actual internal and external chemical
environment.
2) Relatively small changes in the concentration of organic
solvents and fluctuations in the operating temperatures can
have marked effect on the chemical resistance of a GRP
laminate.
3) Most of the practical experience and design data on which
this standard is based relates to pipes which were made by the
hand lay-up process and contained large proportions of
chopped strand mat reinforcement, and most of the practical
experience under operating conditions was obtained with
small diameter pipes which were only subject to low positive
pressure.
4) In many chemical plants pipework may be subject to
occasional applied loads or impacts, which are not a part of the
normal operating conditions. Care should be taken where
such hazards are liable to arise.
It is recommended therefore that manufacturers of
GRP pipes should demonstrate their ability to
produce satisfactory pipe and fittings for any
specific duty, either by producing documentary
evidence of past performance under similar
conditions or by making and testing prototype units.
NOTE 2 The titles of the publications referred to in this
standard are listed on the inside back cover.
2 Definitions
For the purpose of this British Standard the
definitions given in BS 1755-1 apply, together with
the following.
2.1
curing
2)
the chemical reaction resulting in the final
polymerized product
NOTE It may be effected at ambient temperature or by the use
of heat. In certain resin systems the full cure has to be effected in
two stages of which the first may, and the second does, involve
the application of heat. This second stage is known as the
post-cure.
2.2
laminate
2)
a resin reinforced with a form of glass fibre material
2.3
laying-up
2)
a process of applying or producing laminates in
position on a former prior to cure
2.4
aggregates
an inert granular material of a size range
between 5 mm and 0.05 mm used as a design part of
the structure
NOTE Aggregates, such as silica sands, may be incorporated
where they are a design part of the composite structure.
2.5
inert fillers
a fine material with a particle size below 0.05 mm
2.6
angle of lay,
the angle of the application of continuous rovings
with respect to the horizontal axis
3 Nomenclature, symbols and units for
design
Several terms relating to the strength and load
carrying capacity of individual layers of composite
laminate are used in this standard. Some have
similar but quite distinct meanings and because of
their similarity and their application, particular
care is required in their use. The terms concerned
are listed in Table 1, with their definitions, symbols
and units.
1)
1 bar = 10
5
N/m
2
= 100 kPa.
2)
These definitions differ from those given in BS 1755-1.
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BS 6464:1984
2
BSI 03-1999
The following additional symbols with their terms
are used in the design calculations:
Section 2. Materials and properties
4 Thermosetting resin systems
NOTE 1 The thermosetting resins used for the manufacture of
pipes and fittings may be of a number of types. There are many
resin systems in each type and the properties of these systems
vary, especially with respect to chemical resistance and heat
distortion point.
Polyester and epoxy resin systems shall comply with
BS 3532 and BS 3534 respectively.
In order for the chemical reaction, resulting in the
final polymerized product, to take place hardeners,
catalysts and accelerators shall be added to the
resin in accordance with the manufacturers
recommendations.
NOTE 2 The amount of hardener, catalyst and/or accelerator
used is critical, as it can affect both the rate of reaction and extent
of the cure.
NOTE 3 If specified at the placement of an order, the outer
layer of resin may incorporate pigments, dyes or specific
ultraviolet light absorbers to prevent the transmission of UV
light and/or for identification purposes.
5 Fibrous reinforcement
The glass fibre reinforcement used in the body of the
laminate shall comply with BS 3396, BS 3496,
BS 3691 or BS 3749, as appropriate, and shall have
a surface treatment compatible with the resin.
6 Aggregates and fillers
The resin used shall contain only fillers as required
for viscosity control; they shall be limited to a
maximum of 5 % of the mass of the resin and shall
not interfere with the capability to visually inspect
the laminate.
Special additives, such as aggregates, graphite and
fire retardants, etc., shall only be used to impart
special properties, e.g. stiffness, conductivity.
7 Thermoplastics liners
If thermoplastics liners are used, the material shall
be selected on the basis of resistance to the fluid to
be carried.
If unplasticized polyvinyl chloride (uPVC) is the
specified liner, uPVC pipe complying with BS 3505
or BS 3506 shall be used. In the case of nominal
sizes greater than 500 mm uPVC sheet complying
with BS 3757 shall be used for fabrication
(see clause 24).
The minimum thickness for uPVC shall be 2.5 mm.
If used, the minimum thickness of polypropylene
shall be 2 mm except for pipe of diameter 80 mm or
less, for which the minimum thickness shall
be 1.5 mm.
NOTE Specialized liners such as CPVC, FEP, PVDF and PTFE
may be required for very difficult process conditions.
8 Cement for bonding spigot and
socket joints
The manufacturer shall ensure that the bonding
cement will be satisfactory for the chemical
conditions specified, and shall state the minimum
ambient conditions required for the bonding system
to cure properly.
The bonding cement shall develop a minimum
internal shear strength of 7 N/mm
2
, when tested in
accordance with the method described in B.2.
When tested in accordance with the method
described in BS 5350-C5, using double overlapped
joint test pieces, bond materials to be used to join
GRP sockets and spigots shall have a minimum
bond strength of 7 N/mm
2
.
K overall design factor determined from the
equation (1),
k
1
factor relating to method of manufacture,
k
2
factor relating to long term behaviour,
k
3
factor relating to temperature,
k
4
factor relating to cyclic loading,
k
5
factor relating to curing procedure,
n
x
number of layers of type x in construction
under consideration,
m
x
mass of reinforcement per unit
area (kg/m
2
glass) in one layer of type x,
u
x
design unit loading
[N/mm {per kg/m
2
glass}] for a selected
layer of type x,
X
x
unit modulus of a selected layer of type x
[N/mm {per kg/m
2
glass}]

x
allowable strain for each type of reinforcing
material,
allowable strain, determined from resin
properties,

d
maximum design strain,

R
strain to failure of the unreinforced resin
determined by the method described in
Method 320C of BS 2782:Method 320 A to
F:1976.
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BS 6464:1984
BSI 03-1999 3
Table 1 Derivation of definitions relating to symbols
9 Mechanical properties
The mechanical properties of the laminate layers
shall be not less than the values given in Table 2
when tested in accordance with the appropriate
methods described in Appendix B.
The values given in Table 2 apply to laminates
incorporating only E glass reinforcement and
complying with BS 3396, BS 3496, BS 3691 or
BS 3749, and having a glass content by mass as
determined by the method described in
BS 2782:Method 1002 within the range shown in
Figure 2.
If higher values for mechanical properties are used
as a basis for design the manufacturer shall
demonstrate their accuracy.
If continuous rovings are filament wound at an
angle to the pipe axis, values of circumferential
and longitudinal unit modulus shall be calculated
by application of the graph in Figure 3 and the
factors given in Table 3 as appropriate to the angle.
The use of other values for the factors in Table 3 is
permitted if a rigorous anisotropic elastic analysis is
carried out (see 14.1). This analysis shall allow for
the contribution from each layer in the laminate and
for interaction between normal and shear strains
(see foreword). It shall be ensured that the strain
transverse to the fibre direction is less than 0.1 %.
In the absence of a rigorous anisotropic elastic
analysis the axial strain shall be not
more than 0.1 % for winding angles greater
than 75.
Table 3 Factors to be applied to design unit
load of continuous rovings for different
winding angles
10 Thermal properties
The heat distortion temperature of the fully cured
resin system used for the reinforced laminate, when
determined in accordance with
BS 2782:Method 121A, shall be not less than 20 C
higher than the design temperature of use of the
pipe and fitting.
Term Definition Derivation Symbol Unit
Ultimate tensile
unit strength
The strength of a constituent
layer of a laminate, expressed
as force per unit width, per
unit mass of reinforcement.
Obtained from the fracture
load of a laminate of known
construction, in a tensile
test.
u N/mm
(per kg/m
2
glass)
Layer design
unit loading
The load permitted to be
applied to a constituent layer
of a laminate, for the pipe or
fitting under consideration.
Determined by multiplying
the unit modulus, X, by the
allowable strain for the
particular laminate layer.
u
x
N/mm
(per kg/m
2
glass)
Unit modulus The ratio of the load per unit
width per unit mass of glass to
the corresponding direct
strain, in a loaded tensile test
piece.
Obtained from the
measured load at 0.2 %
strain in a tensile test.
X N/mm
(per kg/m
2
glass)
Laminate design
unit loading
The load permitted to be
applied to a laminate,
expressed as force per unit
width. The subscripts indicate
a main (U
LAM
) or an overlay
(U
OVL
)laminate.
Obtained by summing the
load carrying capacities of
all the layers in the
laminate.
U
LAM
U
OVL
N/mm width
Unit load The force per unit width
carried by a laminate resulting
from pressure or other loads
applied to the pipe or fitting.
Obtained from the
appropriate design
calculations for the pipe or
fitting under consideration.
Q N/mm width
Filament winding
angle to axis

Circumferential
factor
Longitudinal
factor
0 < < 15 0 1
15 < < 75 0.5 0.5
75 < < 90 1 0
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BS 6464:1984
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BSI 03-1999
Table 2 Minimum mechanical properties of reinforced laminate layers
11 Chemical properties
NOTE 1 The chemical resistance of resins varies with the type,
the source and the state of cure.
In the absence of case histories, the suitability of a
laminate for a particular duty shall be established
by tests carried out in accordance with the methods
described in BS 4618-4.1. The test pieces shall be
representative of the pipe when made and test
conditions shall be consistent with conditions of the
intended use. Particular attention shall be paid to
maintaining the concentration of trace materials in
test liquors and to the temperature of the test.
When assessing the chemical resistance of a
laminate, in addition to determining changes in
mass, dimensions, and strength, the laminate shall
be examined for blisters, resin crazing, change in
appearance of the fibres and loss of gloss, any of
which may be significant.
NOTE 2 Attention is drawn to the fact that the chemical
resistance of a laminate under stress may be different to that of
an unstressed coupon. The duration of the tests is important, as
the results of short term tests can be misleading.
12 Construction of a chemical liner
NOTE The basis of the design of GRP pipes is the strength of
the glass reinforcement. Glass is adversely affected by many
chemicals and therefore it is necessary to protect the structural
laminate from process liquors. The type and extent of the
protection required depends upon the operating conditions and it
may be that more than one of the liners described will be
satisfactory for any particular process condition. It is important
that the integrity of the selected liner is maintained throughout
the pipework system.
12.1 Thermoplastics liners. Where a
thermoplastics lining is used the minimum bond
strength of the reinforcement to the lining shall
be 7.0 N/mm
2
in direct shear and 7 N/mm width in
peel, when tested by the methods described in B.6
and B.7.
NOTE This strength will normally be achieved by the inclusion
of a laminate with a minimum of 450 g/m
2
chopped strand mat
and glass content between 25 % and 33 % immediately behind
the thermoplastics liner.
12.2 Thermoset liners. Thermoset liners available
in constructions shall be as follows.
Type 1 shall comprise a corrosion barrier
consisting of a resin rich layer reinforced with C
glass or synthetic fibre tissue with a thickness of
between 0.25 mm and 1.0 mm. This barrier shall
be followed by an initial laminate containing a
minimum of 900 g/m
2
chopped strand mat with
glass content of between 25 % and 33 % by mass
when determined by the method described in
BS 2782:Method 1002.
Type 2 (epoxide resin construction only) shall
comprise a corrosion barrier consisting of a resin
rich layer reinforced with C glass or synthetic
fibre tissue with a uniform thickness of 0.25 mm
to 1.0 mm.
Type 3 shall comprise a corrosion barrier
consisting of a resin rich layer of thickness
between 1 mm and 2 mm which shall be
reinforced.
13 Flammability
Where pipe is intended to convey flammable fluids
the resin in the external surface layers shall be
modified so as to have a surface spread of flame
characteristic that complies with clause 2 of
BS 476-7:1971. The test shall be carried out on a
laminate representative of that to be used for the
pipe.
Type of reinforcement Property
Ultimate tensile
unit strength
(see B.3)
Unit modulus
(see B.4)
Lap shear
strength
(see B.5)
N/mm
(width per
kg/m
2
glass)
N/mm
(width per
kg/m
2
glass)
N/mm
2
Chopped strand mat 200 14 000 7.0
Woven roving cloth
square woven
250 16 000 6.0
biased woven less than 5.1 : 1
major direction
minor direction
430
90
23 000
10 000
6.0
6.0
baised woven equal or more than 5.1 : 1
major direction
450 25 000 6.0
Continuous rovings 500 28 000 6.0
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BS 6464:1984
BSI 03-1999 5
Section 3. Design and design
calculations
14 General
14.1 Considerations for design. The
manufacturer shall ensure that the information set
out in Appendix A is available before commencing a
design.
All pipes, fittings and joints shall be designed to the
maximum continuous pressure rating under the
most severe combination of all loads due to the
following:
a) internal pressure or vacuum;
b) test pressure requirement;
c) bending loads from pipe and contents;
d) earth loading;
e) design temperature change and consequent
thermal expansion or contraction;
f) bending moments due to applied external loads;
g) vibration;
h) all anchor loads.
The design of fittings shall be confirmed as
satisfactory by the testing of prototypes.
NOTE 1 All pipes should be designed to take the maximum
design end load due to pressure except when rubber ring seals are
used when the end load requirement may be waived.
NOTE 2 The anchor loads should be determined from the
pipeline flexibility calculations and pressure thrust, the latter
being equal to the maximum pressure times the largest internal
cross section of the pipe.
NOTE 3 In the consideration of the membrane strains an equal
strain in all layers should be assumed.
NOTE 4 Loads may be imposed by personnel during erection
and operation and should be acknowledged.
14.2 Basis for design
NOTE 1 The design procedure in this standard takes advantage
of the ease with which the laminate details can be varied to suit
the loads imposed by operating and test conditions in the
different regions.
When designing for process plant pipework in reinforced plastics
it is most desirable to work in terms of unit load (i.e. force per unit
width per unit mass of glass) rather than stresses (i.e. force per
unit area).
Where the design calculations require the use of
allowable compressive unit loadings these shall be
determined by the method of substituting the
ultimate compressive unit loading for the ultimate
tensile unit loading in equation (2).
Ultimate compressive unit load shall be determined,
when required, for each laminate layer concerned by
the method described in BS 2782:Method 345A.
Where the design incorporates reinforcement with
directional properties (e.g. woven rovings), the
orientation of the fibres shall be specified in order to
ensure that the structural properties required by
the design are attained.
NOTE 2 Worked examples of this design method are given
in Appendix C.
14.3 Conditions for design
14.3.1 Design temperature. The design temperature
shall be the maximum temperature it is possible for
the pipe to attain under operating conditions
(including boil-out, where applicable).
14.3.2 Design pressure. The design pressure (i.e. the
pressure to be used in the equation for the purpose
of calculation) shall be not less than:
a) the pressure that will exist in the system when
the pressure relieving device starts to relieve, or
the set pressure of the pressure relieving device,
whichever is the higher;
b) the maximum pressure that can be attained in
service where this pressure is not limited by a
relieving device.
The value of the design pressure to be used in the
equations in this section shall include the static
head where applicable, unless this is taken
separately into account in the equation.
14.3.3 Design vacuum
NOTE The design vacuum is the lowest pressure to be
generated in the pipe during operation.
Pipes subject to vacuum shall be designed to avoid
the risk of failure due to elastic instability.
14.4 Factors for design
14.4.1 Design factor. The design factor K shall be
calculated from equation (1).
k
1
to k
5
represent part factors determined by the
method of manufacture and operating conditions.
The intention of this procedure is that no pipe or
fitting designed in accordance with this standard
shall have a design factor of less than 6.
Values for part factors k
1
to k
5
are determined as
follows:
a) Factor relating to method of manufacture, k
1
.
This factor shall be the value taken from Table 4
appropriate to the method of manufacture to be
adopted.
Table 4 Factor relating to method of
manufacture
K = 3 k
1
k
2
k
3
k
4
k
5
(1)
Method of manufacture Part factor k
1
Handwork 1.5
Repeatable machine controlled work 1.5
Spray application 3.0
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BS 6464:1984
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b) Factor relating to long term behaviour, k
2
. This
factor shall be 1.2 for pipe having a
thermoplastics liner. The factor for pipe without
a thermoplastics liner shall be chosen within the
range 1.2 and 2.0 based on the following criteria.
If data are not available a factor of 2.0 shall be
used.
After exposing unstressed laminate to the
process conditions expected for the design
lifetime of the pipe the loss in ultimate tensile
strength shall be used to fix the value of the
factor in accordance with Table 5.
Table 5 Factor relating to loss in ultimate
tensile strength
NOTE It is emphasized that thermoplastics liners are used
for chemical resistance only and should not be considered as
contributing to the strength of the pipe, but they may
influence other properties of the pipe, e.g. thermal expansion.
c) Factor relating to temperature, k
3
. This factor
is dependent on the heat distortion temperature
of the resin system and shall be determined
from Figure 4.
d) Factor relating to cyclic loading, k
4
. This factor
shall be determined from Figure 5, having regard
to the expected operating conditions of the pipe.
e) Factor relating to the curing procedure, k
5
.
Where the pipe is subjected to a complete curing
procedure, including a full post-cure at elevated
temperature in the manufacturers works, this
factor shall be 1.1; for all other curing procedures
the value of 1.4 shall be used.
14.4.2 Allowable design strain
14.4.2.1 The allowable design strain for the
constituent components of the pipe, i.e. liner, resin
system and each type of reinforcing material, in the
principal direction shall be calculated.
14.4.2.2 The allowable strain for the thermoplastics
liner portion of the pipe shall be taken as a value
of 0.2 %.
14.4.2.3 The allowable strain, , for each type of
resin system shall be 0.1
R
or 0.2 % whichever is the
lesser.
NOTE If confirmation is required by testing a laminate the
method described in BS 2782:Method 320C should be used.
14.4.2.4 The allowable strain for each type of
reinforcing material shall be calculated from
equation (2).
14.4.2.5 Considering all the constituent parts
in 14.4.2.2 to 14.4.2.4 the allowable design
strain,
d
, shall be the lowest value so calculated.
14.4.3 Allowable unit loading. The allowable unit
loading for each type of resin and reinforcing
material shall be calculated from equation (3).
15 Laminate design and thickness
15.1 Laminate design. For each pipe or fitting a
proposed laminate construction shall be determined
by taking into account the design unit loading for
each constituent layer (as calculated from 14.4.3).
These loadings shall be related to the unit loads to
be carried in the region concerned.
The overall unit modulus for the proposed laminate
construction shall be calculated from equation (4).
The laminate design unit loading U
LAM
shall be
calculated from equation (5).
The above procedure shall not apply where
continuous rovings are filament wound at an
angle to the pipe axis. Values of circumferential
and longitudinal unit modulus for individual layers
shall be obtained by reference to Figure 3. Values of
circumferential and longitudinal design unit load
shall be calculated by application of the factors
given in Table 3.
NOTE 1 It is possible that more than one combination of layers
may satisfy the requirements of the laminate.
Alternatively, all but one (or two interdependent) values of n
x

may be fixed and the remaining value(s) determined.
The suitability of purpose of a laminate construction
shall be checked in every case using equation (6).
If the sum of the X, m and n terms exceeds Q by a
large margin, the laminate is overdesigned. If the
sum of the terms is less than Q, one or more of the
values of n shall be increased or a different laminate
construction proposed. In all cases the calculation
shall be repeated for the new construction.
Loss in tensile strength Factor k
2
< 20 % 1.2
> 20 % < 50 % Interpolate between
20 % = 1.2
50 % = 2.0
> 50 % Material unsuitable
(2)
u
x
=
d
X
x
(3)
X
LAM
= (X
1
m
1
n
1
+ X
2
m
2
n
3
+ ... X
x
m
x
n
x
) (4)
U
LAM
=
d
X
LAM
(axial direction) (5)
U
LAM
> Q (6)
e
x
=
u
X
x
K
-----------
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BS 6464:1984
BSI 03-1999 7
The response of continuous roving wound pipe to
biaxial loading applied simultaneously is different
from the response when loads are applied
independently. To assess the behaviour of combined
loads a complete anisotropic stress/strain analysis
shall be carried out and the response of the laminate
to the combined load examined (see foreword). The
normal or shear strain in each layer shall be
less than that calculated in 14.4.2.5. If the analysis
is not available a biaxial failure envelope shall be
constructed as shown in the worked example
in Appendix C.
NOTE 2 Additional considerations are necessary if the
pipework is to be subject to vacuum or external pressure
considerations (see clause 17).
15.2 Thickness. Where values of thickness are
required in the equations in this section the
thickness of the laminate in the region under
consideration shall be taken as the sum of the
thicknesses of the individual layers making up that
laminate.
The nominal thickness of each layer, for design
purposes, shall be determined from the glass
content for that layer by using the graph
(see Figure 2).
In no case shall the actual laminate thickness
(excluding any corrosion barrier) be less than 4 mm
for pipes manufactured with chopped strand mat
and 2 mm for filament wound pipes.
Abrupt changes in laminate thickness shall be
avoided. The blending taper between regions of
differing thickness shall be not steeper than 1 in 6.
16 Design calculations for pipes
subject to internal pressure
NOTE The equations in this section are derived from thin shell
theory.
16.1 Pipes subject to internal pressure.
The circumferential and axial unit loads Q
c
and
Q
a
(in N/mm) shall be calculated from equations (7)
and (8).
where
16.2 Pipes subject to combined loads
16.2.1 Horizontal pipes. The maximum axial unit
load, Q
a
, shall be calculated from equation (9) for the
combined effects of the following:
a) pressure and/or vacuum;
b) bending moments due to self-mass;
c) bending moments due to mass of contents;
d) bending moment due to any other external
source.
where
M is the total bending moment.
16.2.2 Vertical pipes. The maximum axial unit load
for conditions a) to d) in 16.2.1 plus the addition of
the mass of pipe, fittings, contents, and attachments
above or below the point of consideration shall be
calculated from equation (10).
where
F is the algebraic sum of all the appropriate
vertical forces acting on the pipes adjacent to the
support.
Vertical forces causing tension in the pipe shall be
considered positive, and forces causing compression
shall be considered negative.
16.3 Permissible axial compressive load.
A check calculation shall be made to ensure that the
region of the pipe subject to the highest compressive
load is adequate to resist collapse by local buckling.
To make this check the overall unit modulus, X
LAM
,
(for the axial direction using axial compressive
properties) for the proposed construction shall be
calculated from equation (4).
The permissible maximum axial compressive unit
load, Q
p
, to resist buckling shall then be calculated
from equation (11) which includes a safety factor
of 4.
The maximum compressive unit load shall in no
case exceed the value calculated in equation (6). If in
the original design it does, the laminate
construction shall be modified, and the necessary
calculations repeated until this condition is
satisfied.
17 Design calculations for pipes
subject to vacuum
17.1 Pipes without stiffening rings. The
circumferential unit load, Q
c
, shall be calculated
from equation (7).
(7)
(8)
p is the internal pressure (gauge) (in N/mm
2
);
D
i
is the internal diameter (in mm).
Circumferential unit load Q
c
pD
i
2
----------- =
Axial unit load Q
a
pD
i
4
----------- =
(9)
(10)
(11)
Axial unit load Q
a
=
pD
i
4
-----------
4M
;D
i
2
-------------
Axial unit load Q
a
pD
i
4
----------
4M
;D
i
2
-------------
F
;D
i
---------- =
Q
p
0.6tX
LAM
4D
i
---------------------------- =
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BS 6464:1984
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The maximum direct axial unit load, Q
a
, shall be
calculated from equations (9) or (10) as appropriate.
From each of these values the appropriate thickness
of laminate shall be calculated and the largest value
obtained shall be used for calculations. Using as a
basis a laminate construction which satisfies this
requirement, the total thickness of the laminate, t,
shall be determined as described in 15.2.
The composite modulus of the laminate,
E
LAM
(in N/mm
2
), shall also be calculated from
equation (12).
where
The value of t shall be greater than the value of the
minimum wall thickness, t
m
, obtained using
equation (13) which includes a safety factor of 4.
If in the proposed design this condition is not
fulfilled the design shall be changed either by
re-designing the laminate or by providing additional
stiffening rings (see 17.2). The calculation shall
then be repeated until an acceptable construction is
indicated.
17.2 Pipes with stiffening rings. If the
calculations in 17.1 indicate an unacceptable
laminate thickness it may be preferable to re-design
the pipe to include stiffening rings.
The design of pipes with stiffening rings may be
approached by two methods.
a) Method 1. To fix the distance between
stiffeners by utilizing the spacing between
flanges, anchors, or additional stiffeners and
checking the minimum thickness required to
prevent collapse by using equations (13) or (14),
which includes a safety factor of 4, dependent on
the value of the stiffener distance/diameter ratio:
where
b) Method 2. To fix the construction and hence
thickness and calculate the required distance
between stiffeners from equation (15).
The distance between stiffeners in either case shall
not exceed the value of J calculated from
equation (15).
For a proposed stiffening ring profile and
composition it is then necessary to determine the
diameter (D
s
) of the neutral axis of the stiffening
ring. Subsequently it shall be ensured that the
second moment of area of the designed stiffening
ring, l, is not less than the value obtained from
equation (16):
where E
LAM
has been calculated from equation (12).
The permissible length of shell, J
s
, which may be
regarded as effectively contributing to the amount of
the stiffening ring section shall be
but in no case shall J
s
be taken as greater than J.
Stiffening rings shall extend completely round the
circumference of the pipe and any joints in the
stiffener shall be so designed as to develop the full
stiffness of the ring.
Section 4. Dimension markings and
information
18 Dimensions
18.1 Diameters
18.1.1 Unlined pipelines. The nominal size of pipes
and fittings shall be one of the following values:
(12)
X
LAM
is the overall unit modulus of the
laminate under consideration determined
from equation (4);
t is the total thickness of the laminate.
(13)
(13)
E
LAM
X
LAM
t
----------------- =
t
m
D
o
4p
2E
LAM
------------------- -
,
_
0.33
=
(14)
J is the distance between the centre line of
stiffeners;
D
o
is the outside diameter = D
i
+ 2t.
(15)
(16)
J
s
= 0.75 (D
o
t) (17)
25 32 40 50 65 80 100 125
150 200 250 300 350 400 450 500
600 700 800 900 1 000
l
0.18D
o
JD
s
2
p
E
LAM
---------------------------------------- =
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BS 6464:1984
BSI 03-1999 9
The manufacturer shall declare the actual internal
diameter, in mm, of the pipes and fittings related to
the relevant nominal size.
18.1.2 uPVC lined pipelines using extruded pipe and
moulded fittings. The nominal size of pipe and
fittings up to and including 500 shall be based on
the nominal size of the extruded pipe (see clause 7).
NOTE Account should be taken, on sizing of the system, of any
consequential reduction of the bore size below that of unlined
pipe.
18.1.3 uPVC lined pipelines using fabricated
linings. The nominal size of pipe and fittings
above 500 shall be one of the relevant sizes specified
in 18.1.1.
18.1.4 Polypropylene lined pipelines using
fabricated lining. The nominal size of pipe and
fittings above 80 shall be one of the relevant sizes
specified in 18.1.1.
19 Tolerances on dimensions of pipes
and fittings
19.1 Diameters. The tolerances on the declared
diameter measured at 23 2 C shall be as follows:
1.5 mm for pipes up to and including 150
nominal size;
3 mm for pipes over 150 and up to 600 nominal
size;
0.5 % of the declared internal diameter for
pipes over 600.
All deviations from roundness, such as ovality, with
the exception of pipe deformation due to its own
weight, shall be contained within these tolerances.
19.2 Length. The tolerances on length shall be as
follows:
1.5 mm for cut or fabricated lengths of pipe
up to 4 m in length;
3.0 mm for cut or fabricated pipe larger
than 4 m in length.
19.3 Squareness of ends. All unflanged pipe shall
be cut square with the axis of the pipe to
within 3 mm for all nominal sizes up to and
including 400 and to within 4 mm for all nominal
sizes over 600.
19.4 Deviation from straightness. For pipes of
nominal size greater than 150 the deviation from
straightness of the bore of the pipe shall not
exceed 0.3 % of the effective length of the pipe
or 15 mm, whichever is the smaller. Deviation from
straightness shall be measured with the pipe in an
unstrained vertical position. Measurements shall be
taken at four equidistant points around the
circumference. The average value of the maximum
and minimum vertical distance between a straight
edge, or taut chord, touching the ends of a pipe, and
the wall of the pipe in the case of a concave curve or,
in the case of a convex curve, between a straight
edge or taut chord which touches the wall of the pipe
and is equidistant from the wall at the two ends of
the pipe, and the wall of the pipe at the end, is
expressed as a percentage of the effective length of
the pipe.
19.5 Fittings. Tolerances on angles of fittings shall
be 1 for nominal sizes up to 600 and 0.5 for
nominal sizes greater than 600.
20 Marking
Each pipe and fitting shall be permanently marked
with the following information:
a) manufacturers name or initials and
identification code;
b) nominal size;
c) pressure rating and temperature rating;
d) number and date of this standard,
i.e. BS 6464:1984
3)
;
e) resin type and thermoplastics liner type if
used.
21 Information
21.1 The manufacturer shall declare the lining and
laminate system to be employed which shall be
specified in full including the following details
determined at the design stage:
a) lining system;
b) number of layers and notional thickness of
each layer;
c) total minimum thickness of the laminate
system;
3)
Marking BS 6464:1984 on or in relation to a product is a claim by the manufacturer that the product has been manufactured to
the requirements of the standard. The accuracy of such a claim is therefore solely the manufacturers responsibility. Enquiries as
to the availability of third party certification to support such claims should be addressed to the Director, Quality Assurance
Division, BSI, Maylands Avenue, Hemel Hempstead, Herts HP2 4SQ for certification marks administered by BSI or to the
appropriate authority for other certification marks.
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BS 6464:1984
10
BSI 03-1999
d) composition of each layer, including:
1) type and mass of reinforcement, e.g. chopped
strand mat, woven cloth, continuous rovings
etc.;
2) percentage by mass of fibrous
reinforcement;
3) type of resin system.
NOTE Information on different methods of manufacture is
given in Appendix D.
21.2 The manufacturer shall give recommendations
for the installation of pipes and fittings complying
with this standard either for above ground or below
ground situations.
Section 5. Construction and
workmanship
22 Manufacturing conditions in works
involving the cure of resins
Materials shall be stored and used in compliance
with the suppliers instructions; reinforcement
materials shall be stored dry.
Unless a hot curing resin system is being used the
temperature of the working area shall be
maintained above 15 C for any laminating process
and the cure cycle of the resin system. All other
laminating work shall be discontinued whenever
the air temperature falls to 10 C or the dew point is
reached (when condensation occurs).
The working area shall be suitably divided into
clearly defined sections for preparation of
reinforcement, mixing of resins, application,
trimming and finishing.
23 Manufacturing procedure
23.1 The manufacturer shall eliminate as many
variables as possible to ensure consistency in both
materials and fabrication, and shall provide
adequate supervision at all stages of manufacture.
NOTE All operators to be employed should be experienced in
carrying out the type of work involved in the order.
Representative test pieces of laminate should be submitted to
prove the competence of each operator unless evidence of prior
satisfactory work is available.
23.2 The requisite amount of resin, catalyst or
hardener and any other ingredient such as
accelerator or permitted filler, shall be accurately
measured and thoroughly mixed. The amounts of
mixed resin and reinforcement used in the laminate
and the number and type of layers applied shall be
recorded where applicable; the records shall be
made available to the purchaser or inspecting
authority.
23.3 Where hand lay-up is used in the
manufacturing procedure, rolling shall be used to
consolidate the laminate. Whilst good rolling is
essential, the rolling pressure shall not be sufficient
to cause disturbance of the distribution of the
reinforcement or to break the fibre strands.
The manufacturer shall ensure that good adhesion
is obtained between successive layers of the
laminate either by appropriate scheduling of the
manufacturing operation or by removing the surface
of the cured resin to expose the fibres.
Adjacent pieces of reinforcement shall be
overlapped by not less than 50 mm. The edges shall
be worked out by brushing with a stippling action
and all joints shall be staggered through the
thickness of the laminate.
Where directionally biased reinforcement is used
care shall be taken to ensure that the high strength
fibres are adequately aligned in the correct direction
to give the required strength.
The number, size and distribution of air bubbles,
pits or inclusions shall be not greater than
previously submitted samples. Acceptable limits of
visual defects shall be in accordance
with Appendix E.
23.4 Care shall be taken to avoid low exotherm,
monomer loss (in polyester resins) and resin
drainage. Excessive exotherm shall be avoided in all
laminates. An elevated temperature post cure shall
be applied where this is required by the design
procedures (see 14.4).
24 Thermoplastics liners
24.1 If uPVC is the required liner uPVC pipe
complying with BS 3505 or BS 3506 shall be used
for lining pipe up to 500 mm diameter. In the case of
larger pipes uPVC sheet complying with BS 3757
shall be used and this shall be stress relieved in an
oven at temperatures between 120 C and 140 C
for 15 min from attaining this temperature.
All forming operations of uPVC shall be performed
at a temperature between 120 C and 140 C.
24.2 Polypropylene and PVDF liners if required
shall be formed from extruded sheets to which is
attached a glass fibre backing. The thickness of the
sheet shall be as specified in clause 7.
24.3 All welds shall be butt welds
Before welding of the liner commences the edges to
be welded, together with a filler rod, shall be
suitably cleaned. In addition, glass backed
thermoplastics liners shall have the glass backing
stripped back to a distance between 3 mm and 6 mm
on either side of the weld preparation to ensure that
no glass filaments are included in the welded joint.
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BS 6464:1984
BSI 03-1999 11
If welding is done by the hot gas filler rod technique,
nitrogen or compressed air free from moisture, dirt
and oil shall be used for welding. In all cases the
grade of material of the filler rod shall be compatible
with the liner material being welded. All edges to be
butt welded by filler rod shall be chamfered to give
an included angle and a land as shown in Figure 6.
24.4 All welds shall be fully penetrating. Welds
completed from one side only shall have
at least 70 % of the material strength; where there
is reasonable access to the weld from both sides the
weld shall have at least 85 % of the material
strength.
Tests shall be made by the method described in B.8.
There shall be no obvious undercutting, degradation
of the material or breaks in the weld run.
NOTE All welders engaged on the fabrication of thermoplastics
liners should be required to demonstrate their ability to weld to
the requirements of liners to this standard.
24.5 The external surface of the weld shall be
finished to a smooth contour before laminating and
tested by the use of a high frequency spark tester at
a voltage of 20 kV 10 %. Any weld that shows
evidence of notches, lack of fusion or holes shall be
rejected. (See clause 30.)
24.6 In the case of flanged pipes the lining material
shall be carried over the face of the flange.
25 Fittings
25.1 The minimum dimensions of sockets shall be as
specified in Table 6.
25.2 The minimum dimensions of fittings,
dependent upon the method of fabrication to be used
for the pipeline described in Appendix F, shall be
calculated from the appropriate method given in
Table 7 using the relevant values given in Table 8.
NOTE 1 The location of the dimensions in Table 7 and
Table 8 are shown in Figure 7 and Figure 8.
NOTE 2 The preferred method of manufacture for fittings
from 25 to 600 nominal size is by one-piece moulding.
25.3 The minimum thicknesses of flanges shall be as
given in Table 9. The minimum dimensions of GRP
backing flanges and drilling dimensions in
accordance with class 150 of BS 1560, class 150 of
BS 3293 and Table 10 of BS 4504 shall be as given
in Table 10.
NOTE The relationships of these dimensions are given in
Figure 9 and Figure 10.
25.4 Pipe supports shall have a minimum width
of 25 mm and a minimum contact arc of 120 on the
underside of an above ground pipe.
NOTE The frequency of support shall be such that the ratio of
deflection to span should not exceed 1 : 300 when the pipe is filled
with the process fluid at the design temperature.
Piping should be supported and anchored so as to prevent undue
loads on connected equipment, and at the same time to permit
controlled expansion and contraction between anchors and
changes of direction.
Anchors should be so designed that the loads are properly
transmitted into the wall of the pipe.
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BS 6464:1984
12
BSI 03-1999
Table 6 Minimum socket depths
Nominal size
of pipe
Minimum socket depth at various pressures
Up to 2.5 bar 4 bar 6 bar 10 bar 16 bar 25 bar 40 bar 64 bar
mm mm mm mm mm mm mm mm
25
32
40
50
65
80
100
125
150
200
250
300
350
400
450
500
600
700
800
900
1 000
25
25
25
36
40
40
50
60
65
75
100
100
100
100
105
105
110
115
120
135
150
25
25
25
36
40
40
70
75
75
75
100
100
100
100
105
110
115
120
120
135
150
25
25
25
36
40
40
70
75
75
75
100
100
105
120
120
125
150
175
200
225
250
25
25
32
36
40
40
70
75
75
75
100
100
120
135
143
165
200
235
265
300

25
25
40
40
50
60
70
75
85
110
150
180
220
240
270
300

25
40
40
40
65
85
100
120
135
180
220
270
300

50
50
50
75
95
115
145
180
215
285

58
75
95
150
185
230
290

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BS 6464:1984
BSI 03-1999 13
Table 7 Equations for calculating fittings dimensions
Table 8 Minimum separation dimensions to be used in equations of Table 7
Dimension Fabrication method
Method 1 Method 2 Method 3
B R + L
2
R + L
3
R + A + L
2
C C
1
+ L
2
C
1
+ L
3
C
1
+ A + L
2
E
1
S
d
+ D/2 S
d
+ D/2 + L
3d
S
d
+ D/2 + A
d
E
2
S
d
+ d/2 S
d
+ d/2 + L
3D
S
d
+ d/2 + A
D
L
1
L
2d
+ L
2D
+ 2.5 (Dd) L
3D
+ L
3D
+ 2.5 (Dd) A
D
+ A
d
+ L
2D
+ 2.5 (Dd)
H H
d1
+ H
d2
NOTE 1 Subscripts D and d refer to the values for the related diameter of each branch.
NOTE 2 For location of dimensions see Figure 7 and Figure 8.
All dimensions in millimetres.
Nominal size
D or d
A C1 H R S L2 L3
25
40
50
80
150
150
150
175
50
50
75
100
100
100
125
125
75
115
150
225
75
75
75
75
50
50
50
50
75
75
75
75
100
150
200
250
200
225
275
300
125
100
125
100
150
200
225
250
300
225
300
250
75
125
150
200
50
75
75
75
100
125
175
200
300
350
400
450
350
400
450
475
125
150
175
175
275
325
350
375
300
350
400
450
225
275
300
350
75
100
100
100
225
275
325
350
500
600
700
800
500
500
500
550
200
225
275
325
400
450
525
575
500
600
700
800
375
450
525
600
100
100
100
100
375
450
350
400
900
1 000
600
650
350
400
625
675
900
1 000
675
750
100
100
450
500
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BS 6464:1984
14
BSI 03-1999
Table 9 Dimensions of flanges (see Figure 9 and Figure 10)
Stub flange (type A)
thickness, N
A
Stub flange outside
diameter, D
a
Flange (type B)
thickness, N
B
Flange (type C)
thickness, N
C
Design strain 0.2 % 0.16 % 0.13 % 0.1 % BS 1560:
Class 150
BS 4504:
Table 10.
0.2 % 0.1 %
Pipe nominal
size
Pressure up to 10 bar Pressure up to 10 bar
mm mm mm mm mm mm mm mm
25
32
40

23
24
25
10
b
10
b
10
b
50
65
10
10
10
10
10
11
12
13
102
121
107
127
28
30

80
100
125
150
10
14
15
16
11
15
16
17
12
16
17
18
14
18
19
20
133
172
194
219
142
162
192
218
32
32
32
32

200
250
300
350
18
22
26
26
20
24
29
29
22
26
31
31
24
28
34
34
276
337
406
448
273
328
378
438
38
45
50
55

400
450
500
600
28
30
31
35
30
32
34
38
33
35
36
40
36
38
39
44
511
546
603
714
489
539
594
695
55
60
60
65

Pressure up to 6 bar BS 3293:

Class 150
BS 4504:
Table 10
Pressure up to 6 bar
700
800
900
1 000
36
39
43
46
39
42
47
50
43
46
50
54
47
50
55
59
829
937
1 045
1 159
810
917
1 017
1 124
55
60
65
70

a
D = pitch circle diameter (p.c.d.) bolt hole diameter.
b
These require a 6 mm steel backing flange (Figure 11, type A).
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BS 6464:1984
BSI 03-1999 15
Table 10 Thickness and mating dimensions of flanges and backing flanges (see Figure 10)
26 Joints
26.1 General. The types of joints in general use are
as follows:
a) butt;
b) cemented spigot and socket;
c) flanged;
d) spigot and socket with elastomeric sealing
rings.
NOTE 1 Type d) is not usually designed to take end loads.
Selection of the type of pipe joint shall be governed
by the duty requirements, details of the pipe
construction and economic considerations. In all
cases the detail of the joint shall be so designed that
the chemical resistance of the joint is acceptable for
its application.
All joints of types a), b) and c) shall be designed and
constructed to take at least the same end load as the
pipe.
NOTE 2 The recommended jointing fabrication methods for
factory and site use are given in Appendix F.
Where the design of a butt joint is developed it shall
incorporate an additional design factor of 1.2 the
pipe properties.
When uPVC is the lining material injection moulded
fittings with sockets suitable for solvent cementing
may be used and in such cases the following
requirements shall apply.
1) uPVC pipe shall comply with either BS 3505 or
BS 3506 and sizes shall not exceed 150 nominal
size.
2) Fittings shall comply with BS 4346-1. The use
of moulded stub or full face flange fittings with
sockets is not permitted. Flanges shall be as
detailed in 26.4.4.
3) Solvent cements shall comply with BS 4346-3
and shall be chosen such that the chemical
resistance of the joint is suitable for the chemical
conditions within the pipe.
Pipe
nominal
size
Backing flange
thickness
a
, W
Outside diameter and drilling information in
accordance with class 150 of BS 1560
Outside diameter and drilling
information in accordance with Table 10
of BS 4504
Pressure 10 bar
O.D P.C.D. Hole
diameter
Bolts O.D. P.C.D Hole
diameter
Bolts
Solid Split
b
Number Size Number Size
mm mm mm mm in mm in mm mm mm
25
32
40
50
65

10
10

14
14
115
125
134
152
178
79.4
88.9
98.4
120.6
139.7
5
/
8
5
/
8
5
/
8
3
/
4
3
/
4
15.9
15.9
15.9
19.0
19.0
4
4
4
4
4
1
/
2
1
/
2
1
/
2
5
/
8
5
/
8
115
140
150
165
185
85
100
110
125
145
14
18
18
18
18
4
4
4
4
4
M12
M16
M16
M16
M16
80
100
125
150
10
12
12
13
14
17
17
18
190
229
254
279
152.4
190.5
215.9
241.3
3
/
4
3
/
4
7
/
8
7
/
8
19.0
19.0
22.2
22.2
4
8
8
8
5
/
8
5
/
8
3
/
4
3
/
4
200
220
250
285
160
180
210
240
18
18
18
22
8
8
8
8
M16
M16
M16
M20
200
250
300
350
15
18
21
22
21
25
30
31
343
406
483
533
298.4
362.0
431.8
476.2
7
/
8
1
1
1
1
/
8
22.2
25.4
25.4
28.6
8
12
12
12
3
/
4
7
/
8
7
/
8
1
340
395
445
505
295
350
400
460
22
22
22
22
8
12
12
16
M20
M20
M20
M20
400
450
500
600
24
25
27
32
34
35
38
45
597
635
698
813
539.8
577.8
635.0
749.3
1
1
/
8
1
1
/
4
1
1
/
4
1
3
/
8
28.6
31.8
31.8
34.9
16
16
20
20
1
1
1
/
8
1
1
/
4
1
1
/
4
565
615
670
780
515
565
620
725
26
26
26
30
16
20
20
20
M24
M24
M24
M27
Pressure 6 bar Dimensions and drilling in accordance with
class 150 of BS 3293
700
800
900
1 000
29
32
35
39
41
45
49
55
927
c
1 061
c
1 168
c
1 289
c
864
c
978
c
1 086
c
1 200
c
1
3
/
8
1
5
/
8
1
5
/
8
1
5
/
8
34.9
41.3
41.3
41.3
28
28
32
36
1
1
/
4
1
1
/
2
1
1
/
2
1
1
/
2
895
1 015
1 115
1 230
840
950
1 050
1 160
30
33
33
36
24
24
28
28
M27
M30
M30
M33
a
Based on rubber gaskets with a seating stress of 2.32 N/mm
2
.
b
Two-part split flanges.
c
These values are metric conversions.
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BS 6464:1984
16
BSI 03-1999
4) Before application of glass fibre reinforcement,
all external steps at the joints shall be blended
into the pipe surface with a minimum taper
of 1 in 6 using a filled resin paste which shall
satisfy the bond shear strength requirement
of 12.1.
5) The design temperature of systems
incorporating injection moulded fittings shall not
exceed 40 C and the design pressure shall not
exceed 6 bar.
26.2 Alignment. The alignment of the pipes shall
be such that the step at the joint shall not exceed the
following.
NOTE It is recommended that jigs should be used to ensure
that butt and cemented joints are aligned and held rigidly in this
position during the jointing process. The position of the pipes
should be maintained until the joint has adequate mechanical
strength.
26.3 Lined pipe. The joint shall be so constructed
that only the liner comes in contact with the fluid. In
the case of flanged pipes the lining material shall be
carried over the face of the flange. In the case of butt
joints the thermoplastics liners shall be joined by
welding.
26.4 Joint types
26.4.1 Butt joints in unlined pipes. The ends of the
pipe shall be chamfered back at a slope of 1 in 6
leaving intact the chemical resistant inner
laminate. The surface of the pipe to be overlaid shall
be freshly abraded to remove the resin-rich surface
and expose the glass fibre over an area
extending 25 mm beyond the joint overlay. The
chemically resistant resin cement shall be applied to
the ends of the pipe with the pipes butted and fixed
in position (see Figure 11). The space between the
two chamfered surfaces shall be filled to a depth of
at least 3 mm using the resin cement. The initial
layer, of minimum width 50 mm over the chamfered
surfaces shall consist of a laminate of chopped
strand mat and the specified resin.
In the case of type 1 and type 3 pipes (see 12.2) the
minimum total mass of chopped strand mat shall
be 900 g/m
2
which shall be applied in at least two
layers. The glass content of the laminate shall be
between 25 % and 33 % when determined by the
method described in BS 2782:Method 1002.
In the case of type 2 pipes (see 12.2) the minimum
mass of chopped strand mat shall be 600 g/m
2
and
have a glass content between 25 % and 33 % when
determined by the method described in
BS 2782:Method 1002.
The joint shall be overlaid with suitable laminates
such that the hoop, axial and inter-laminar sheer
strengths of the joint shall be at least equal to the
strength of the pipe.
The length of the overlay for pipes up to and
including nominal size 100 shall be not less than the
values given in Table 10. For pipes with nominal
size greater than 100 the overlay length shall be
calculated from the equations (18) or (19).
where
An outer-layer of chopped strand mat shall be
provided, together with an outer resin-rich layer.
The outer edges of the overlay shall taper down to
the pipe so that they do not form stress raisers.
When practicable the interior of the joints shall be
freshly abraded to remove the glass finish and
sealed with a minimum of 900 g/m
2
chopped strand
mat followed by a surface tissue layer and sealing
coat. This internal laminate shall not be considered
as making a contribution to the strength of the joint.
The pipe manufacturer shall provide precise details
of the laminate to be used for the joint and shall
provide full test evidence that illustrates that a joint
so produced is satisfactory.
26.4.2 Butt joints in lined pipes. The ends of the pipe
shall be chamfered back at a slope of 1 in 6 leaving
intact the thermoplastics liner (see Figure 6). The
liner shall be prepared for welding as specified
in 24.3, fixed in position and welded. The bond
strengths between the area adjacent to the weld and
the overlay shall comply with 12.1. The initial
overlay using 600 g/m
2
of chopped strand mat shall
have a glass content of between 25 % and 33 % when
determined by the method described in
BS 2782:Method 1002.
The joints shall then be overlaid with a suitable
laminate such that the hoop axial and inter-laminar
shear strengths of the joint shall be at least equal to
the strength of the pipe.
The length of the overlay for pipes up to and
including 100 nominal size shall be not less than the
appropriate value given in Table 11.
Pipe nominal size Step
Up to and including 200 1 mm
Above 200 up to and including 400 1.5 mm
Above 400 2 mm
(18)
(19)
U
LAM
is determined in the axial direction.
Overlay length
2KU
LAM
Lap shear strength
------------------------------------------------------ =
or
D
i
2
------ whichever is the greater
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BS 6464:1984
BSI 03-1999 17
For pipes of nominal size greater than 100 the
overlay length shall be calculated from
equations (18) or (19), whichever is the greater,
where U
LAM
is determined in the axial direction.
An outer layer of chopped strand mat shall be
provided, together with an outer resin rich layer.
The outer edges of the overlay shall taper down to
the pipe so that they do not form stress raisers. The
pipe manufacturer shall provide precise details of
the laminate to be used for the joint and shall
provide full test evidence that illustrates that the
joint so produced is satisfactory.
Table 11 Minimum butt joint overlay
lengths including taper
26.4.3 Cemented spigot and socket joints in unlined
pipes and fittings. Either parallel or taper spigot
and socket joints shall be used. The socket shall be
formed either as an integral part of the pipe or
fitting or as a part of a socket coupling. Socket joints
shall comply with the following.
a) In all cases the hoop axial and interlaminar
shear strength of the socket joint shall be at least
equal to the hoop axial and interlaminar strength
of the pipe.
b) The depth of the socket shall be equal to or
greater than the appropriate value given
in Table 5 always provided that the design strain
limitation is observed, or as calculated from
equation (20), whichever gives the greater value.
where
U
LAM
is in the axial direction
c) The manufacturer shall provide a cement that
is suitable for the process conditions for which the
pipe is intended.
d) The joint shall be designed so that the
thickness of the cement is between 0.15 mm
and 1.5 mm.
e) The bond between the pipe, socket and cement
shall have a minimum strength of 7 N/mm
2
. The
type test to prove conformance shall be carried
out by the method described in BS 5350-C5 using
double overlap joints as test pieces.
f) The manufacturer shall state the minimum
ambient conditions required for the bonding
cement to cure and provide precise details of the
method of assembly and proof of suitability.
g) When practicable the interior of the joints shall
be freshly abraded to remove glass and shall be
sealed with a laminate containing a minimum
of 900 g/m
2
chopped strand mat which shall be
covered by a surface tissue layer and sealing coat.
26.4.4 Flanged joints
26.4.4.1 General. Flanged joints are classified
according to type as follows.
Type A: stub flange with backing flange
(see Figure 9).
Type B: full faced flange with or without
thermoplastics liner (see Figure 10).
Type C: full faced flange with or without
thermoplastics liner with backing flange
(see Figure 10).
For pipe systems which have a test pressure
above 16 bar only stub flanges with loose steel
backing flanges shall be used.
Full faced flanges shall not be used for mating to
raised face flanges.
Prototype testing shall be carried out on all flange
designs to show that the flanged joint will seal
under the combined force of maximum design
pressure plus an applied bending moment, M
t
,
determined from equation (21).
where
U
LAM
is determined in the axial direction.
Unless there are records of satisfactory operating
performance each flange design shall be proved by
test. The test pressure on flanged joints of nominal
size up to 600 shall be 6 the rated pressure for the
pipes with a pressure rating up to 10 bar.
26.4.4.2 Manufacturing tolerances. All flanges shall
comply with the following.
a) Flatness. Flange faces shall not be concave and
shall be flat to within the following limits:
up to and including 450 nominal size
1 mm deviation;
above 450 nominal size
1.5 mm deviation.
Nominal
size of
pipe
Minimum length of overlay for various
design working pressures
Up to 2.5 bar 4 bar 6 bar 10 bar 16 bar
mm mm mm mm mm
25
32
100
100
100
100
100
100
100
100
100
100
40
50
100
100
100
100
100
100
100
100
100
100
65
80
150
150
150
150
150
150
150
150
150
150
100 150 150 150 150 150
(20) Socket depth
U
LAM
K
Lap shear strength
------------------------------------------------------ =
(21) M
t
=
;
4
----- U
LAM
pD
i
4
----------
,
_
D
i
2
1.3
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BS 6464:1984
18
BSI 03-1999
The back faces of flanges shall be smoothed flat
and shall be parallel to the flange face.
b) Squareness. Flanges shall be square to the pipe
or fittings to within 1 up to 100 nominal size and
to within 0.5 above 100 nominal size.
26.4.4.3 Assembly. Manufacturers
recommendations on the sequence of tightening
bolts and nuts shall be followed. If the maximum
torque is specified the threads of all bolts and nuts
shall be greased.
26.4.5 Socket and spigot joints with elastomeric
sealing rings
NOTE Socket and spigot joints are primarily designed for use
with underground pipes but, in general, are not suitable if end
loads have to be transmitted through the pipe.
Alternative designs of joints making provision for end loads are
available.
26.4.5.1 Joint quality. When used the socket and
spigot joint shall be at least equal to the pipe in
quality and performance, excluding axial
properties.
At the test pressure, the joint shall not leak in the
following conditions:
a) angular deflection;
b) draw;
c) misalignment;
d) diameter distortion;
e) combination of a) to d).
The elastomeric sealing ring shall comply with
BS 2494, and shall be free from substances that can
have a detrimental effect on the pipe material and
contents.
The elastomeric sealing ring shall have suitable
chemical resistance and the volume swelling shall
not exceed 20 % after immersion in the process fluid
for 4 weeks at the temperature of intended use.
26.4.5.2 Joint requirements. For pressure pipe the
following joint requirements shall be met when
gauge pressures of 0.1 bar and 1.5 nominal
pressure of the pipe, measured at the top of the pipe,
are maintained for 30 min.
For non-pressure pipe the following joint
requirements shall be met when gauge pressures
of 0.1 bar and 1.5 bar, measured at the top of the
pipe, are maintained for 30 min.
a) Angular deflection. The joint shall withstand,
without leakage and without stressing the spigot
and socket, a minimum free angular deflection of:
3 for pipes of nominal size equal to or
less than 500;
2 for pipes of nominal size greater than 500
and up to and including 900;
1 for pipes of nominal size greater than 900
and up to and including 1 000.
The manufacturers shall advise the angular
deflection permissible at installation.
b) Draw. The joint shall withstand without
leakage a minimum draw of 0.25 % of the
maximum pipe length, in addition to angular
deflection.
c) Misalignment. The joint shall withstand
misalignment without leakage when a force
of 20 N/mm of internal diameter, D
i
, is applied.
For this maximum misalignment the
compression of the elastomeric sealing ring shall
remain within limits appropriate to the type of
ring used.
d) Diameter distortion. When the barrel of the
pipe (excluding the socket) has reached a
maximum diameter distortion of 5 % of the
nominal diameter, the resultant ovality in the
joint shall not allow leakage. In no case shall the
distortion load exceed that given in c).
e) Combination of joint requirements. The joint
shall withstand a combination of angular
deflection, draw, misalignment, and diameter
distortion as indicated in a), b), c) and d) above.
Section 6. Testing
27 Tests for design
27.1 General. Manufacturers shall demonstrate
their ability to design and/or produce satisfactory
pipes and fittings for the specified duty. If
acceptable documentary evidence of past experience
is not available, prototype pipe shall be made and
tested.
NOTE The prototype tests may be witnessed by the purchaser
or inspecting authority.
27.2 Manufacture of prototype pipes and
fittings. Prototype pipes and fittings shall be as
follows:
a) the pipes and fittings shall be identical in
design and manufacture to the proposed
production pipe;
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BS 6464:1984
BSI 03-1999 19
b) the length of the test pipe shall be
at least 1 500 mm or 5 pipe nominal size,
whichever is greater;
c) the prototype test assembly shall incorporate
features which are typical of the pipeline design,
e.g. bends, branch connections, flanges and pipe
joints;
d) the length of pipe for the negative pressure test
shall be representative of the maximum designed
free installation length.
27.3 Tests to be applied to prototype pipes and
fittings. Where the proposed pipe system is
designed so that the pipes are not subjected to end
load in service, provision shall be made in the test to
avoid incurring end loads. The tests shall
demonstrate resistance to specific modes of failure
and shall include one or more of the following
appropriate to the intended service conditions.
a) Strain determination test. Determination of
general and local strains by measurement (using
strain gauges or other suitable methods) when
the pipe is hydrostatically pressurized to the
design pressure.
b) Fatigue test. Determination of the fatigue
strength of the pipe and/or fitting by cyclic
variations of pressure between limits.
NOTE The test fluid should be preferably the process fluid.
c) Short term burst pressure test. Determination
of the factor of safety to failure and the mode of
failure by hydrostatically pressurizing the pipe
until failure occurs.
d) Buckling test under negative internal pressure.
Determination of the resistance to collapse under
negative pressure. The length of the test pipes
shall be as specified in item d) of 27.2.
All pipes and fittings shall be adequately supported
during the tests described in 27.4.
27.4 Performance during prototype testing.
Pipes and fittings shall meet the following criteria.
a) Strain determination test. The measured strain
shall not exceed 0.26 % when the pipe is tested
hydrostatically to at least 1.3 times the design
pressure strain.
b) Fatigue test. The pipe shall withstand 10 times
the estimated number of pressure cycles required
in the life of the pipe.
c) Short term burst pressure test. The pipe shall
withstand a pressure at least K (see 14.4) times
the rated pressure without bursting, and
weepage shall not occur below a pressure
of 0.75 K rated pressure.
NOTE To determine the burst pressure it is permitted to use
a loose liner in a separate pipe test piece.
d) Buckling test under negative internal pressure.
The pipe shall withstand a negative pressure of 4
times the design negative pressure or 0.1 bar
gauge whichever is the lower pressure.
27.5 Records of tests. Records of all prototype
tests shall be retained by the manufacturer and
shall be made available to the purchaser and
inspecting authority as required.
27.6 Chemical tests. Chemical resistance tests
shall be done whenever there is no previous
experience of the process conditions. The test
specimens used shall be representative of the pipe
as produced.
27.7 Additional tests. Additional tests such as the
heat distortion temperature test, mechanical
properties of the laminate, abrasion or bond
strength between lining and laminates shall be
carried out where previous experience is not
documented.
28 Production testing
28.1 General. The frequency at which production
pipes are to be tested shall be agreed at the tender
stage.
NOTE It is recommended that a minimum of 10 % of pipes and
fittings should be hydrostatically pressure tested at the
manufacturers works.
28.2 Dimensional requirements. The dimensions
of test pieces shall be as follows.
a) Diameters, lengths and straightness shall be
within the specified tolerances given in clause 19.
Due care shall be taken to avoid the effect of
self-weight of the pipe or fitting.
b) Flatness of flange faces and alignment to pipe
shall be within the tolerances given in 26.4.4.2.
NOTE Flatness of flanges should be assessed only after all
the reinforcement has been applied and the resin has cured.
28.3 Surface finish. The pipes and fittings shall be
inspected for surface defects and comply with
Appendix E.
28.4 Cure. The extent of cure of the laminate shall
be tested by determining the Barcol hardness in
accordance with the method described in
BS 2782:Method 1001 which shall be within 10 % of
the resin manufacturers published value. The
acetone extract shall not exceed the resin
manufacturers recommendation.
28.5 Hydrostatic testing. Pipes shall be
hydrostatically tested to 1.3 times the design
pressure. The test pressure shall be applied and
maintained for a sufficient time to permit a
thorough examination to be made of the pipe but in
any case for not less than 1 h. Any indication of
leakage or excessive strain shall be cause for
rejection.
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BS 6464:1984
20
BSI 03-1999
NOTE Care should be taken to ensure that the test pressure is
not exceeded during hydrostatic testing. Over-pressurization
may lead to laminate damage which is irreparable and would be
cause for rejection of the pipe.
28.6 Examination after pressure testing. On
completion of the pressure test the pipe and/or
fitting shall be inspected internally and externally.
Any indication of cracking, resin crazing, or
excessive strain shall be cause for rejection. Where
practicable pipes with thermoplastics linings shall
be spark tested after completion of testing; any
evidence of cracking or weld defect shall be cause for
rejection.
29 Welding procedure tests for
thermoplastics linings
The test pieces shall incorporate 300 mm long butt
welds made by joining two pieces of the material to
be used for the lining, each 300 mm long
and 125 mm wide. The weld shall be made in the
same way as the production welds and shall include
at least one stop and start in each run. Welding
procedure for the test welds shall be in accordance
with clause 24.
After completion, the test weld shall be examined
visually and by the use of a high frequency spark
tester giving a minimum peak voltage of 20 kV. Any
weld showing evidence of notches, lack of fusion or
pinholes shall not be used for tensile testing.
Test pieces shall be machined from the welded
sample and subjected to the tensile test described
in B.8. The tensile strength across the weld shall be
not less than 70 % or 85 % of the tensile strength of
welded sheet as appropriate to the type of weld
(see 24.4).
NOTE If any test weld shows evidence of notches, lack of fusion
or pinholes or the tensile strength requirements of 24.4 are not
met, the welding procedure should be modified or the welder
receive further training, as appropriate, until all test welds are
satisfactory.
30 Tests for production welds in
thermoplastics linings
All production welds shall be examined visually and
by high frequency spark test
equipment (20 kV 10 %) at the stages specified
below:
a) after the first weld run;
b) after completion of the weld;
c) after pressure testing if practicable.
Tests a) and b) shall be completed before any primer
or reinforcement is applied to the weld area and a
temporary earthing strip shall be provided behind
the weld. This strip shall be removed after spark
testing.
Any defective areas, other than isolated pinholes, in
the first run, shall be removed and shall be suitably
repaired and again spark tested to the satisfaction
of the inspection authority before fabrication
continues. Where adjacent defects are
less than 15 mm apart they shall be treated as a
single, large defect.
31 Production samples for mechanical
tests on a laminate
31.1 General. Test pieces shall, when possible, be
taken from waste areas provided that they are
typical of the laminate they represent. Where this
method is impracticable test pieces shall be laid up
by the operator at the same time, with the same
materials and in the same manner as the item they
represent, and cured under the same conditions as
the main laminate.
31.2 Mechanical properties of laminates. The
following tests shall be carried out to verify the
material properties specified in section 2:
a) ultimate tensile unit strength (see B.3);
b) ultimate compressive unit loading if required
(see 14.2);
c) unit modulus (see B.4);
d) lap shear strength (see B.5);
e) shear and peel strengths, if a thermoplastics
lining is used (see B.5 and B.7).
Section 7. Inspection and testing
32 Facilities for inspection and testing
The manufacturer shall furnish and prepare the
necessary test pieces for the tests specified. If the
testing is to be done at his own works the
manufacturer shall supply the necessary labour and
appliances. Failing facilities at his own works the
manufacturer shall arrange for the tests to be made
elsewhere.
When required by the order or drawing, test pieces
shall be made available for test in the purchasers
laboratories. When specified all tests shall be
witnessed by the inspecting authority and due
notice shall be given by the manufacturer to permit
compliance.
33 Certification of inspection and
testing
In case of joint responsibility for the inspection and
testing of pipes and fittings signed documentary
evidence of the results of all the completed
inspections and tests shall be forwarded to the
inspecting authority responsible for witnessing the
final tests, prior to the conduction of these tests.
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BS 6464:1984
BSI 03-1999 21
Upon satisfactory completion of the order the
organizations responsible for design, construction
and inspection shall furnish duplicate copies of a
certificate to the purchaser, stating that the design,
construction and testing comply with the
requirements specified in this standard. Where
applicable the actual tests results obtained shall be
stated on or with the certificate.
NOTE Inspection should include the following stages as
appropriate:
a) inspection of workshop conditions where manufacture will
be carried out;
b) inspection of works records relating to the control and issue
of materials, resin mixing, etc.;
c) identification of the materials of construction and their
storage conditions;
d) approval of welding procedures and welders;
e) witnessing of spark tests on welds in thermoplastics linings
where these are incorporated;
f) examination during hand lay-up, spray application,
winding, die-moulding and jointing of resin glass laminates;
g) examination of any repairs carried out during construction;
h) examination on completion of construction, during pressure
testing, and before any pigmented coatings are applied.
Where it is required to use transmitted light during
inspection, agreement should be reached between the
purchaser and the manufacturer on the stage for applying any
pigmented coating.
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BS 6464:1984
22
BSI 03-1999
Appendix A Information to be given with an enquiry or tender or on receipt of
order
The information detailed below is to be given with an enquiry or tender or on receipt of order as
appropriate.
a) Process conditions:
1) materials to be conveyed including minor constituents (names, concentrations and densities);
2) design pressure or vacuum and temperature;
3) operating pressure or vacuum and temperature;
4) mode of operation, e.g. process cycling conditions;
5) risk of surge pressures, e.g. from pumps and valves;
6) any abrasion or erosion problems which may be encountered.
b) Site conditions:
1) nature of ambient atmosphere including any extremes of temperature;
2) in the case of buried pipes, information on ground conditions and expected loading, e.g. traffic.
c) Materials of construction:
1) lining material (which may consist of thermoplastics material or a resin rich layer and its
reinforcement);
2) resin systems to be used;
3) form(s) of reinforcement including type, number and arrangement of individual layers including
any sacrificial layers if used;
4) forms of stiffening where used;
5) mechanical properties of materials;
6) if required, fire resisting finish;
7) if required, pigments or UV absorbers in outer layer.
d) Design details:
1) essential dimensions, including tolerances on drawings;
2) nominal thickness, including tolerances, of corrosion-resistant lining (thermoplastics or resin rich
layer) which does not contribute to strength;
3) details of welds in thermoplastics linings;
4) bolting and flange materials and details;
5) details of supporting arrangement, anchor points including integral reinforcement;
6) gasket materials and details;
7) details of external finish.
e) Standards of testing and inspection
f) Name of inspecting authority or organization
g) Requirements for packaging, despatch and installation
Appendix B Methods of test
B.1 General
B.1.1 Tests. This appendix describes methods for the testing of resins, laminates and thermoplastics for
pipes and fittings in reinforced plastics. Tests are specified for the determination of the following
properties:
a) internal shear strength of bonding cement;
b) ultimate tensile unit strength of laminate and laminate layers;
c) unit modulus of laminate and laminate layers;
d) lap shear strength of laminate;
e) shear strength of bond between thermoplastics lining and laminate;
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BS 6464:1984
BSI 03-1999 23
f) peel strength of bond between thermoplastics lining and laminate;
g) tensile strength of thermoplastics sheet and welds.
NOTE Recommended methods for tests to determine the following properties when required are as follows:
B.1.2 Accuracy of testing equipment. Testing machines shall be calibrated in accordance with BS 1610 and
shall be maintained to grade A.
Extensometers, including ancillary or autographic equipment, shall be calibrated in accordance with
BS 3846 and shall satisfy at least grade E requirements.
B.2 Internal shear strength of bonding cement
B.2.1 Test pieces. Lap joints shall be assembled from laminates, 100 mm min. 25 1 mm 3 mm min.
thick, of equivalent resin reinforcement system to the socket and spigot materials and cement to give a
minimum cement layer between laminates
of 25 1 mm 12.5 0.5 mm 1.5 mm max. thick. The assembly shall be carried out in accordance with
the cement manufacturers instructions.
The ends of the laminates that are clamped to the tensile machine shall be built up to ensure the force is
applied along the cemented joint.
Three test pieces shall be tested.
B.2.2 Conditioning and temperature of test. The test pieces shall be conditioned at 20 5 C for not
less than 3 h immediately before testing. The test shall be carried out at 20 5 C.
B.2.3 Procedure. Measure the cross-sectional area of the cemented part of the joint.
Clamp the test piece in the serrated jaws of a suitable tensile testing machine so that the jaws grip the built
up faces of the end pieces and the test pieces are in axial alignment with the direction of pull.
Apply a force to the test piece by separating the jaws at a constant rate between 5.0 mm/min
and 6.5 mm/min.
Record the maximum force at which the joint fails.
Test pieces which fail within the laminate or at the laminate/cement interface shall be disconnected and
the test shall be repeated, unless the calculated shear strength is greater than that specified in clause 8.
B.2.4 Calculation. Calculate the internal shear strength, S
c
, for each test piece from equation (22).
where
B.2.5 Report. The test report shall include the following:
a) identification of the laminate structure;
b) identification of the cement;
c) conditioning temperature of the test pieces;
d) individual test results;
e) date of the test.
B.3 Ultimate tensile unit strength of laminate and laminate layers
NOTE The tests for ultimate tensile unit strength and unit modulus (see B.4) may be combined using the same test pieces.
B.3.1 Test pieces. The form and number of test pieces shall be as described in BS 2782:Method 1003 for
type II or type III specimens.
B.3.2 Conditioning and temperature of test. The test pieces shall be conditioned at 20 5 C for not
less than 3 h immediately before testing. The test shall be carried out at 20 5 C.
B.3.3 Procedure. Measure the mean width of the test piece to the nearest 0.05 mm and number of laminate
layers.
water absorption: BS 2782:Method 430B
electrical properties: BS 2044
cure of resin (Barcol hardness): BS 2782:Method 1001
(22)
F is the maximum force (in N);
A
c
is the cross-sectional area of the cemented joint.
S
c
F
A
c
------ =
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BS 6464:1984
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Clamp the test piece in the serrated jaws of a suitable tensile testing machine so that the jaws grip the
entire faces of the end pieces and the test piece is in axial alignment with the direction of pull.
Apply a force to the test piece by separating the jaws at a constant rate such that fracture occurs in 0.5 min
to 1.5 min. Report the maximum force applied.
Results obtained on test pieces that break within the area of the end pieces shall be disregarded and
additional test pieces tested.
B.3.4 Calculation. Calculate the ultimate tensile unit strength u (in N/mm per kg/m
2
glass) from
equation (23).
where
B.3.5 Report. The test report shall include the following:
a) identification of the laminate or laminate layers;
b) conditioning temperature of the test pieces;
c) when necessary, the direction of the major axes of the test specimens in relation to the direction of
some feature of the material from which they were cut;
d) whether the faces of the test pieces where machined;
e) ultimate tensile unit strength of the material, reported as the arithmetic mean of the ultimate tensile
unit strengths of the test pieces;
f) date of the test.
B.4 Unit modulus of laminate and laminate layers
B.4.1 Principle. The unit modulus shall be calculated from a determination of the tensile force necessary
to produce in the test piece an extension of 0.10 mm on a length of 50 mm (0.2 % strain).
B.4.2 Test pieces. The form and number of test pieces shall be as described in BS 2782:Method 1003 for
type II and type III specimens.
B.4.3 Conditioning and temperature of test. The test pieces shall be conditioned at 20 5 C for not
less than 3 h immediately before testing and the test carried out at 20 5 C.
B.4.4 Procedure. Measure the mean width of the test pieces to the nearest 0.01 mm and count the number
of laminate layers.
Clamp the test piece in axial alignment with the direction of pull between the jaws of a suitable tensile
testing machine.
Clamp an extensometer on the test piece. The extensometer shall be of a type that will measure extension
over a length of 50 1 mm of the test piece to an accuracy of at least 0.0025 mm. Apply a small initial
tensioning force f to the test piece for the purpose of straightening it. (This force should be not
greater than 10 % of the expected force at 0.2 % strain.) With this initial force on the test piece, set the
indicating device to zero. Increase the force steadily by separating the jaws at a rate of 1 mm/min 25 %,
until the increase in extension indicated by the extensometer reaches 0.1 mm. Note the force, F, on the test
piece at this extension. If the test is also to be used for the determination of ultimate tensile unit strength
the extensometer should be removed as quickly as possible and the test continued as required by B.3.
(23)
F
max
is the maximum force (in N);
b is the width of test piece (in mm);
n
x
is the number of laminate layers in the test piece;
m
x
is the mass of glass (in kg/m
2
) in one layer of laminate in the test piece.
u
F
max
b n
x
m
x
---------------------- =
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BS 6464:1984
BSI 03-1999 25
B.4.5 Calculation. Calculate the unit modulus X (in N/mm per kg/m
2
glass) from equation (24) or (25)
where
In cases where it is expected that 0.2 % strain may give rise to danger of fracture of the test piece, it is
permissible to carry out the test at 0.1 % strain (corresponding to an extension of 0.05 mm over a 50 mm
gauge length). The initial force shall be correspondingly smaller, and the unit modulus
(in N/mm per kg/m
2
glass) shall be calculated from equation (26) or (27).
B.4.6 Report. The test report shall include the following:
a) identification of the laminate;
b) conditioning temperature of the test pieces;
c) percentage strain at which the unit modulus was determined;
d) when necessary, the direction of the major axes of the test pieces in relation to the direction of some
feature of the material from which they were cut;
e) unit modulus of the material, reported as the arithmetic mean of the unit modulus of the test pieces;
f) individual test results;
g) date of the test.
B.5 Lap shear strength of laminate
B.5.1 Test pieces.Test pieces shall conform to the dimensions and shape given in Figure 13. They shall have
a minimum thickness of 3 mm and the overall length of the test pieces may be varied to accommodate the
requirements of the available testing equipment. The edges of the test pieces shall be smooth but not
rounded or bevelled.
Two parallel saw cuts, one in each opposite face of the test piece and 12.5 mm apart, shall be sawn across
the entire width of the test piece and shall be parallel within 0.8 mm (see Figure 13). The depth of saw cuts
shall be half laminate thickness plus the thickness of one layer, or half laminate thickness + 0.1, 0 mm if
the number of layers or the thickness per layer is unknown. Saw cuts shall be as narrow as possible.
If the laminate is made entirely from chopped strand mat or by spraying five test pieces shall be tested. If
the laminate contains woven rovings or other directional reinforcement 10 test pieces, five parallel with
each principal axis of anisotropy, shall be tested.
B.5.2 Conditioning and temperature of test. The test pieces shall be conditioned at 20 5 C for not less
than 3 h immediately before testing. The test shall be carried out at 20 5 C.
B.5.3 Procedure. Clamp the test piece in the jaws of the tensile testing machine and axially align the test
piece with the direction of pull.
Apply a force to the test piece by separating the jaws at a constant rate of between 5.0 mm/min
and 6.5 mm/min.
Record the maximum force at which separation of the layers occurs.
Test pieces that fail prematurely or at an obvious flaw shall be discarded and retests made.
(24)
or
(25)
F is the force required to produce 0.2 % strain (in N);
f is the force applied to straighten the test piece initially (in N);
b is the test piece width (in mm);
n
x
is the number of laminate layers in the test piece;
m
x
is the mass of glass (in kg/m
2
) in one layer of laminate in the test piece.
(26)
or
(27)
X
x
F f
0.002 bn
x
m
x
-------------------------------------- =
X
LAM
F f
0.002 b
-------------------- =
X
x
F f
0.001 bn
x
m
x
-------------------------------------- =
X
LAM
F f
0.001 b
-------------------- =
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BS 6464:1984
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NOTE A shear-type failure with some peeling at the interlaminar bond should result.
B.5.4 Calculation. Calculate the lap shear strength, S
s
, for each test piece from equation (28).
where
B.5.5 Report. The test report shall include the following:
a) identification of the laminate;
b) conditioning temperature of the test pieces;
c) lap shear strength of the laminate reported as the arithmetic mean of the lap shear strengths of the
test pieces;
d) individual test results;
e) date of the test.
B.6 Shear strength of bond between thermoplastics lining and laminate
B.6.1 Test pieces. The test piece shall be cut from the full thickness of the external laminate and lining and
shall be of the form and dimensions shown in Figure 12.
Three test pieces shall be used.
B.6.2 Conditioning and temperature of test. The test pieces shall be conditioned at 20 5 C for not
less than 3 h immediately before testing. The test shall be carried out at 20 5 C.
B.6.3 Procedure. Make two thin saw cuts at right angles to the major axis 20 mm apart, symmetrically
about the transverse centreline on the test piece. One cut shall be through the full thickness of the
thermoplastics material but not into the laminate, the other shall be through the full thickness of the
laminate but not into the thermoplastics material.
Measure the cross-sectional area between the saw cuts.
Clamp the test piece in the serrated jaws of a suitable tensile testing machine and axially align with the
direction of pull.
Apply a force to the test piece by separating the jaws at a constant rate of 25 6 mm/min.
Record the maximum force at which separation of the layers occurs.
If the test piece breaks other than at the interface and the calculated shear strength is less than that
specified in clause 8 the test shall be repeated. If the repeat test fails the bond strength shall be recorded
as failed.
B.6.4 Calculation. Calculate the shear strength of the bond from the maximum force and the area under
shear and express in N/mm
2
.
B.6.5 Report. The test report shall include the following:
a) identification of the liner/laminate;
b) conditioning temperature of the test pieces;
c) individual test results and the position of failure;
d) date of the test.
B.7 Peel strength of bond between thermoplastics lining and laminate
B.7.1 Test pieces. The test piece shall be cut from the full thickness of the laminate and lining and shall be
of the form and dimensions shown in Figure 14.
Five test pieces shall be tested.
B.7.2 Conditioning and temperature of test. Test pieces shall be conditioned at 20 5 C for not less
than 3 h immediately before testing. The test shall be carried out at 20 5 C.
B.7.3 Procedure. Make a saw cut at one end of the test piece at the interface of the laminate and
thermoplastics material across the width of the test piece and for 20 mm along its length. The saw cut shall
include, as far as possible, equal amounts of laminate and thermoplastics material.
(28)
F is the maximum force (in N);
a is the distance between saw cuts (in mm);
b is the width of test piece (in mm).
S
s
F
ab
------- =
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BS 6464:1984
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Clamp the laminate horizontally in the jaws of a vice or clamp and apply a force to the thermoplastics lining
by means of weights until the force is just sufficient to peel the lining from the laminate. During this
operation ensure that the plane of the force remains normal to the laminate/thermoplastics interface
(see Figure 14).
B.7.4 Calculation. Calculate the peel strength of the bond from the total force at peel and the measured
width of the test piece, and express in newtons per millimetre width.
B.7.5 Report. The test report shall include the following:
a) identification of the lining/laminate;
b) conditioning of the test pieces;
c) bond peel strength of the thermoplastics lining/laminate combination reported as the arithmetic mean
of the bond peel strengths of the test pieces;
d) individual test results;
e) date of the test.
B.8 Tensile strength of thermoplastics sheet and welds
B.8.1 Test pieces. The test piece from sheet shall be of the shape and dimensions shown in Figure 15 and
the full thickness of the sheet.
The test piece of a weld shall be of the shape and dimensions shown in Figure 14.
Three test pieces shall be used for either test.
B.8.2 Conditioning and temperature of test. The test pieces shall be conditioned at 20 5 C for not
less than 3 h immediately before testing. The test shall be carried out at 20 5 C.
B.8.3 Procedure. Measure the mean width and thickness to the nearest 0.02 mm.
Clamp the test piece at the widened ends or insert plugs if available and mount in the tensile testing
machine in axial alignment with the direction of pull. Apply a force to the test piece by separating the grips
at a constant rate of 25 6 mm/min until it breaks, the range of the testing machine being such that the
maximum force falls between 15 % and 85 % of the maximum scale reading.
B.8.4 Calculation. Calculate the tensile strength, B, for each test piece of the sheet and welded sheet from
equation (29).
where
Calculate the arithmetic mean of the three results from each test and express the average value for the
welded test pieces as a percentage of the average value for the sheet test pieces.
B.8.5 Report. The test report shall include the following:
a) identification of the thermoplastics sheet;
b) individual results and arithmetic mean of the tensile strength of the sheet;
c) individual results and arithmetic mean of the tensile strength of the weld;
d) percentage tensile strength of the weld compared with that of the sheet;
e) date of the test.
(29)
F is the maximum force (in N);
A is the original cross-sectional area (in mm
2
).
B
F
A
---- =
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BS 6464:1984
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Appendix C Worked examples of the design method specified in section 3
C.1 General. The design method in this standard, being based on unit loadings, is particularly suited to
the design of laminar constructions. Correctly applied, the method ensures that each layer of the composite
carries the proportion of the total load appropriate to its strength, and that nowhere in the composite
laminate excessive strains can occur that might lead to local debonding and subsequent service failure.
The results of many tests done on resin/glass fibre composites have shown that both the ultimate tensile
load and the unit modulus values obtained are proportional to the mass of glass reinforcement contained
in the laminate layer. For each of these properties a single value may, therefore, be utilized over the full
range of glass contents normally used for each type of reinforcement (see Table 2), and the design
calculations are thus considerably simplified.
The thickness of a laminate layer is also very largely controlled by the mass of glass specified and the glass
content, being subject to only small variation resulting from manufacturing technique. Layer thicknesses
for given glass contents and masses may be obtained from Figure 2.
C.2 Example: Pipe design for internal pressure without vacuum
C.2.1 Design criteria. Consider the design for a pipe having an internal diameter of 1 000 mm and for an
internal pressure of 5 bar (0.5 N/mm
2
).
The pipe is assumed to be manufactured by hand lay-up for any chopped strand mat and woven roving
constructions, (k
1
= 1.5), and machine controlled for continuous rovings construction, (k
1
= 1.5).
In addition the following assumptions will be made:
a) the long term behaviour, k
2
= 1.2;
b) the cyclic stressing 10
4
for the life of the pipe, k
4
= 1.4;
c) full post cure will be used, k
5
= 1.1.
For the purpose of the illustration two operating temperatures will be considered with resins being
required with different heat distortion temperatures.
The circumferential unit load calculated from equation (7) = 250 N/mm.
Therefore the laminate shall be designed so that its design strength is not less than this calculated value
[see equation (6)].
For the purposes of these examples it is assumed that the axial load, Q
a
, does not exceed Q
c
so that a
laminate designed to withstand the latter will be satisfactory.
C.2.2 Design constructions
C.2.2.1 All chopped strand mat (CSM) construction. For this construction the operating temperature is
assumed as 60 C, the heat distortion temperature of the resin to be used is 100 C and its fracture strain
is 3.5 %.
a) Determine the design factor K [see equation (1)].
K = 3 k
1
k
2
k
3
k
4
k
5
= 3 1.5 1.2 1.0 1.4 1.1
= 8.3
b) Determine the allowable design strain.
Allowable resin strain (see 14.4.2.3)
= 0.1
R
= 0.1 3.5
= 0.35 %
As this is greater than 0.2 % this latter value is taken as the allowable resin strain.
Allowable laminate strain [see equation (2)].
= 0.17 %
e
x
u
X
x
K
----------- =
200 100
14000 8.3
------------------------------- =
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BS 6464:1984
BSI 03-1999 29
The allowable design strain,
d
, is taken as the least of these = 0.17 %
c) Determine the laminate construction.
Overall unit modulus [see equation (4)].
X
LAM
= X
mn
= 14 000 mn
Laminate design unit loading [see equation (5)].
The design requirement is satisfied if U
LAM
is at least equal to the circumferential unit load
[see equation (6)].
hence 0.17 140 m n = 250
m n = 10.5 kg/m
2
glass
Thus a suitable construction of laminate would be as follows [see Figure 16(a)]:
C.2.2.2 Chopped strand mat and woven roving construction. In practice a large proportion of laminates are
not all CSM and they incorporate woven rovings. A simple form of this type of construction is shown in
Figure 16(b) where alternate layers of woven roving complying with the requirements of
BS 3749 (800 g/m
2
) and CSM (450 g/m
2
) are used.
For the calculation an operating temperature of 80 C is assumed and a dual resin system will be used with
the following properties.
The method of calculation is as follows.
a) Determine the design factor K [see equation (1)].
K = 3 k
1
k
2
k
3
k
4
k
5
= 3 1.5 1.2 1.25 1.4 1.1
= 10.4
b) Determine the allowable design strain.
Allowable resin strain (see 14.4.2.3).
Resin A = 0.1 2.5 = 0.25 %
Resin B = 0.1 1.75 = 0.175 %
As the value for resin B is less than 0.2 % its value (i.e. 0.175 %) is the allowable resin strain.
U
LAM
=
d
X
LAM
resin rich inner layer with tissue
two layers of 300 g/m
2
(one at each surface) 0.6 kg/m
2
sixteen layers of 600 g/m
2
9.6 kg/m
2
one layer 450 g/m
2
0.45 kg/m
2
resin rich outer layer with tissue
10.65 kg/m
2
Property Resin
A B
Fracture strain 2.5 % 1.75 %
Heat distortion temperature 125 C 100 C
0.17
100
------------- 14000 m n =
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BS 6464:1984
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Allowable laminate strain [see equation (2)].
Chopped strand mat (CSM):
Woven rovings (WR):
The allowable design strain,
d
, is taken as the least of these = 0.137 %.
c) Determine the laminate construction.
The resin A is selected to form an inner corrosion resistant laminate (2 600 g/m
2
) and as the resin for
the resin rich inner and outer layers with tissue.
If the number of layers of woven rovings is n, the number of CSM (450 g/m
2
) is n 1. These are in
addition to the corrosion resistant laminate and the usual CSM (300 g/m
2
) laminate under the outer
resin rich layer.
Laminate design unit loading (in N/mm) [see equation (5)].
As this value shall be at least equal to, Q
c
, i.e. 250 N/mm
n = 9.01 say 10.
Thus a suitable construction of laminate would be as follows [see Figure 16b)].
C.2.2.3 Chopped strand mat and continuous rovings construction. In this construction the continuous
roving laminates are laid by a machine controlled process between a CSM (2 600 g/m
2
) corrosion resistant
laminate and a CSM (450 g/m
2
) under the outer resin rich layer [Figure 16c)]. One type of resin as
in C.2.2.1 is considered.
a) Determine the design factor [see equation (1)].
Chopped strand mat (CSM):
K = 3 k
1
k
2
k
3
k
4
k
5
= 3 1.5 1.2 1.0 1.4 1.1 = 8.3
Continuous rovings (CR):
K = 3 1.5 1.2 1.0 1.4 1.1 = 8.3
(2 0.6 14000 + 0.45 14000
(n 1) + 0.8 16000 n)
Resin A
resin rich inner layer with tissue
two layers of 600 g/m
2
CSM

0.6 kg/m
2

Resin B
ten layers of 800 g/m
2
WR
alternate with nine layers
450 g/m
2
CSM
one layer 300 g/m
2
CSM
8.0 kg/m
2

4.1 kg/m
2
0.3 kg/m
2
Resin A resin rich outer layer with tissue
13.0 kg/m
2
&
CSM
U
CSM
X
CSM
K
-------------------
200 100
14000 10.4
------------------------------------ 0.137 % = = =
e
WR
U
WR
X
WR
K
-----------------
250 100
16000 10.4
------------------------------------ 0.141 % = = =
U
LAM
e
d
X
LAM
=
0.137
100
---------------- =

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BS 6464:1984
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b) Determine the allowable design strain.
Allowable resin strain (see 14.4.2.3)
= 0.1
R
= 0.1 3.5 = 0.35 %
As this is greater than 0.2 % this latter value is taken as the allowable resin strain.
Allowable laminate strain [see equation (2)]
The allowable design strain,
d
, is taken as the least of these = 0.17 %.
c) Determine the laminate construction.
Assume the continuous rovings are laid at an angle of 55 to the pipe axis with a mass per layer
of 600 g/m
2
and n laminates are used.
Circumferential unit modulus of the laminate construction [see equation(4)].
X
LAM(c)
= 14000 (2 0.6 + 0.45) + 9900 0.6 n
The design requirement is satisfied if X
LAM(c)
is at least equal to the circumferential unit load
[see equation (6)].
Hence (14000 (2 0.6 + 0.45) +
+ 9900 0.5
4)
0.6 n) = 250
n = 41.73 say 42
Thus a suitable construction of laminate would be as follows:
Because this pipe does not have similar properties in circumferential and axial directions, the allowable
loading in the axial direction should now be checked.
Provided the axial load does not exceed 136 N/mm, the above laminate will be satisfactory. If this is not
the case then the allowable axial loading will have to be increased to the design value by further
application of additional layers of chopped strand mat, woven rovings or continuous rovings.
CSM:
CR:
4)
Factor relating to angle of lay (see Table 3).
resin rich inner layer with tissue
two layers of CSM (600 g/m
2
) 1.2 kg/m
2
42 layers CR (600 g/m
2
) laid at 55 25.2 kg/m
2
one layer of CSM (450 g/m
2
) 0.45 kg/m
2
resin rich outer layer with tissue
26.85 kg/m
2
U
LAM(a)

= (14000 (1.2 + 0.45) +
+ 4500 0.5
4)
0.6 42)
= 136 N/mm.
&
x
u
X
x
K
----------- =
200 100
14000 8.3
--------------------------------- 0.17 % = =
&
x
u
X
x
K
------------- =
550 100
28000 8.3
--------------------------------- 0.24 % = =
0.17
100
-------------
0.17
100
-------------
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BS 6464:1984
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If circumferential and axial loads are applied simultaneously it is necessary to establish whether the
allowable loads under these conditions are less than those in the above calculation.
This may be done by the construction of a biaxial failure envelope (see Figure 17) using information
obtained from the physical testing of the proposed laminate.
The following conditions are applied:
Where U
a
and U
c
are the allowable axial and circumferential unit loads under biaxial loading.
The completed biaxial failure envelope shows the combinations of loads which may be applied to the
laminate, for example, from Figure 17, a combined load of U
a
= 80 N/mm and U
c
= 160 N/mm would be
satisfactory but a combination of U
a
= 80 N/mm and U
c
= 160 N/mm would not be satisfactory.
C.2.3 Thickness calculations. If we assume a glass content of 30 % for CSM, 50 % for woven rovings
and 65 % for continuous rovings Figure 2 gives the thicknesses expected for these constructions for a resin
density of 1.3 as follows:
Therefore the thicknesses of the laminates (excluding surface reinforced gel coats) in the three
constructions are as follows.
a) The all CSM construction of example C.2.2.1 requires a total mass of 11.25 kg/m
2
glass and the design
thickness of this laminate is calculated as:
2.2 10.65 = 23.4 mm
b) The mixed CSM/WR construction of example C.2.2.2 will have a design thickness:
c) The mixed CSM/CR construction of example C.2.2.3 will have a design thickness:
C.3 Example: pipe design for vacuum with internal pressure
C.3.1 Design laminate construction. Assume for the purpose of this example that example C.2.2.2 has a
vacuum duty of full vacuum in addition to 5 bar pressure. Since the internal pressure duty is greater than
the vacuum duty the pipe will be strong enough for the membrane forces. It is, therefore, only necessary to
consider buckling.
The design laminate construction for C.2.2.2 is:
5.55 kg/m
2
CSM + 8.0 kg/m
2
WR having a total thickness of 21.8 mm.
Unit modulus of laminate:
X
LAM
= 5.55 14000 + 8.0 16000 = 205700 N/mm
1) if Q
c
> 0 and Q
a
> 0
or if Q
c
< 0 and Q
a
< 0
then U
c
= U
LAM(c)
and U
a
= U
LAM(a)
or 2) if Q
c
> 0 and Q
a
< 0
or if Q
c
< 0 and Q
a
> 0
then U
c
= U
LAM(c)
(1 U
a
/U
LAM(a)
)
and U
a
= U
LAM(a)
(1 U
c
/U
LAM(c)
)
CSM: 2.2 mm per kg/m
2
glass.
WR: 1.2 mm per kg/m
2
glass.
CR: 0.85 mm per kg/m
2
glass.
for CSM layers (1.2 + 0.3 + 9 0.45) 2.2 = 12.2 mm
for WR layers 10 0.8 1.2 = 9.6mm
total design thickness
= 21.8 mm
for CSM layers (1.2 + 0.45) 2.2 = 3.6 mm
for CR layers 0.6 42 0.85 = 21.4 mm
total design thickness
= 25.0 mm
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BS 6464:1984
BSI 03-1999 33
Composite modulus [from equation (12)]
Substituting in equation (13) and assuming that the pipe is infinitely long, the necessary minimum
thickness, t
min
, to prevent buckling is:
This thickness is greater than the thickness required for pressure, therefore, construction needs modifying
(see C.3.2) or stiffening rings are required (see C.3.3).
C.3.2 Thickness calculation without stiffeners. The selected construction is to be in the
form 1 200 g/m
2
CSM + (n 1) layers of 450 g/m
2
CSM + n layers of 800 g/m
2
WR + 300 g/m
2
CSM.
Therefore to satisfy the required thickness:
(1.2 + 0.3) 2.2 + (n 1) 0.45 2.2 +
+ n 0.8 1.2 = 29.94
n = 14.16 say 15
Since the composite modulus varies with construction it is necessary to recheck the laminate unit modulus
to ensure that it is > 9803 N/mm
2
i.e.:
X
LAM
= (1.2 + 0.3 + 14 0.45) 14000 +
+ 15 0.8 16000 = 301200 N/mm
t = (1.5 + 14 0.45) 2.2 + (15 0.8) 1.2
= 31.56 mm
Since the modulus of the revised laminate construction is greater than the earlier modulus the proposed
construction is satisfactory.
The laminate construction required to satisfy a full vacuum design consideration is therefore as follows.
Using the revised values of D
o
(1000 + 2 31.56 mm) and E
LAM
(9544 N/mm
2
) it is necessary to recheck
the thickness, t
min
. This gives a value of 30.38 mm which is less than the original, t, and therefore the
laminate construction is satisfactory.
C.3.3 Thickness calculation with stiffeners. The laminate required for pressure may be suitable for full
vacuum if stiffeners are added.
Using equation (15) the required spacing of stiffeners, J, is given by:
Under the requirements of 21.2 the stiffening rings should have a minimum second moment of area
determined from equation (16). Assume the diameter of the neutral axis is 1 100 mm and the composite
modulus, E, is that of CSM:
E
LAM
X
LAM
t
---------------
205700
21.8
--------------------- 9436 N/mm
2
= = =
1043.6
4 0.1
2 9436
--------------------------
,
_
0.33
29.94 mm =
Resin rich inner
surface 2 600 g/m
2
CSM
Resin system A
Woven roving (BS 3749) 15 layers
450 g/m
2
CMS
14 layers
Resin system B
300 g/m
2
CMS
Resin rich outer surface
E
LAM
X
LAM
t
---------------
301200
31.56
--------------------- 9544 N/mm
2
= = =

)
;

J
21.8
1043.6
--------------------
,
_
2.5
9436 1043.6
0.4 4 0.1
--------------------------------------- 3882 mm = =
E
CSM
X
t
CSM
-------------
14000
2.2
------------------ 6364 N/mm
2
= = =
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BS 6464:1984
34
BSI 03-1999
The required second moment of area is, therefore,
Considering equation (17), the length of pipe that may be considered as contributing to the stiffness of the
ring is:
Appendix D Methods of manufacture of reinforced plastics pipes
D.1 General. In the case of contact moulded pipes and some filament pipes it is possible to start with PVC
or polypropylene tubes which act as formers during the manufacturing process and provide a chemical
resistant liner in service. For chemical plant applications it is essential that the inside layers in the pipe
wall have good resistance to the process liquors and protect the main structure of the pipe. To achieve this
in pipes without thermoplastics liners a special laminate construction for the inner layer is specified. This
consists of a gel coat of the selected chemical resistant resin reinforced with a tissue of C glass or suitable
synthetic fibre backed by two layers of 600 g/m
2
chopped strand mat with a glass content of 25 % to 30 %.
It is essential that the glass content in this layer does not exceed 30 %.
D.2 Contact moulding
NOTE Contact moulded pipe is the most widely used GRP in the British chemical industry.
D.2.1 Unlined pipe. In this process the resin and reinforcement ring is applied to mandrels by hand lay-up
or by some form of mechanical application. The amount and type of glass put into the construction of the
laminate can be varied to suit any specific mechanical design requirement. Rolling is generally employed
to consolidate the resin and glass and to remove air. This process is done carefully so that the reinforcement
is not disturbed and the glass fibre strands are not broken.
The pipe is left on the mandrels until the resin has cured sufficiently to allow the pipe to be handled and
the mandrel removed.
D.2.2 Pipe with thermoplastics liners. The lining materials in common use are uPVC and polypropylene. In
the case of uPVC, pipe is available which is suitable for liners up to 500 mm. For pipe diameters greater
than 500 mm the liners are formed from sheet and welded.
For lined pipe to be successful it is necessary to promote a good bond between the thermoplastics lining and
the resin laminate. In the case of uPVC this is achieved by chemically bonding to the uPVC surface. In the
case of polypropylene or PVDF sheet used to form the tube it is supplied with a layer of woven glass fibre
for bonding purposes.
The thermoplastics liners form the mandrel for the contact moulding operation to proceed as in D.2.1.
D.3 Filament winding with continuous rovings
D.3.1 Construction
D.3.1.1 General. Filament wound GRP pipes are normally produced by winding specifically orientated
resin impregnated glass fibre continuous rovings on a mandrel, and there are two basic construction
methods for the structural thickness in current use, as follows:
a) biaxial construction;
b) helically wound construction.
In both types of construction, there is incorporated an inner layer and an interior layer consisting
respectively of a smooth resin-rich surface reinforced with surfacing tissue of glass, polyester or acrylic
fibre and a resin-rich corrosion resistant layer reinforced with glass fibres.
D.3.1.2 Biaxial construction. This method of construction consists of applying circumferentially and
longitudinally disposed glass fibres such that the corresponding circumferential and longitudinal strength
and stiffness of the finished pipe meets with design requirements.
This type of construction can be manufactured on any type of filament winding machine, either by a
discontinuous process employing a series of mandrels or a proprietory continuous machine.
J
s
= 0.75 (1043.6 21.8)
0.5
= 113.1 mm
l
0.18 1043.6 3882 1100
2
0.1
6364
------------------------------------------------------------------------------------------------------ 13.86 10
6
mm
4
= =
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BS 6464:1984
BSI 03-1999 35
D.3.1.3 Helically wound construction. In this method of construction the glass is not wound around the
mandrel at right angles to the pipe axis but a guide for the glass rovings is moved to and fro along the
mandrel so that the fibres are in a helix around the pipe.
This type of pipe is produced only by a discontinuous process using conventional lathe type machines
employing solid or collapsible mandrels.
D.4 Reinforced plastics matrix pipe. This type of pipe is made in a similar manner to that described in
D.3.1.2, the differences being that special aggregate and filler are added in a predetermined sequence.
D.5 Centrifugal moulding. In this process, resin, glass and fillers are introduced into a rotating mould
to produce the designed pipes. Pipes so produced have a fixed outside diameter.
Appendix E Acceptable limits of visual defects
The acceptable limits of visual defects are as given in Table 12.
Table 12 Acceptable limits of visual defects
Defects Liner Non-liner
Blisters None Maximum 5 mm diameter, 1 mm high
Chips None Maximum 6 mm but shall not penetrate the
surface
Cracks None None
Crazing None Slight
Discoloured areas
(due to high exotherm
or contamination)
None None
Dry spots None
10/m
2
with no individual spot greater than
100 mm
2
Entrapped air None at surface Maximum 3 mm diameter and no more than
10/500 mm
2
Exposed glass None None
Exposed cut edges None None
Foreign matter None None
Pits Maximum 3 mm diameter, 0.5 mm
deep, 100/m
2
Maximum 3 mm diameter, 1.5 mm
deep, 100/m
2
Scores Maximum 0.2 mm deep Maximum 0.5 mm deep
Sharp discontinuity Nominal size up to and
including 200 : 1 mm; nominal
size between 201 and
400 : 1.5 mm; nominal size
over 400 : 2.0 mm
Nominal size up to and including 200 : 1 mm;
nominal size between 201 and 400 : 1.5 mm;
nominal size over 400 : 2.0 mm
Surface porosity None None
Wrinkles Maximum deviation 20 % of wall
thickness but not exceeding 3 mm
Maximum deviation 20 % of wall thickness
but not exceeding 4 mm
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BS 6464:1984
36
BSI 03-1999
Appendix F Pipework fabrication methods
Pipework fabrication methods are as given in Table 13.
Table 13 Pipework fabrication methods
Method Factory workshop
Site, including site workshop where
appropriate
1 Minimum separation dimensions for workshop fabricated
sub-assemblies.
Manufacture, by techniques not requiring full butt joints,
of pipework sub-assemblies of convenient size and shape for
transport to site. The minimum separation dimensions to be
used with the sub-assemblies, method 1, is given by the
equations in Table 7 using values given in Table 8.
The terminal ends of the sub-assemblies may be flanged or
may be suitable for butt jointing after preparation on site in
accordance with 26.4.1 and Figure 11 in accordance
with 26.4.2 and Figure 6.
For terminal ends the dimensions for method 2 are to be
used.
NOTE This procedure is commonly known as the thin skin technique
whereby a sub-assembly is generally produced from pre-formed thin shells
which are integrally laminated together to produce the final sub-assembly.
Erection/assembly of the
sub-assemblies to form pipework
systems. Flanged joints and butt
joints to be made where
appropriate.
2 Minimum dimensions for but jointed pipes and fittings.
Manufacture of pipe lengths and pipe fittings (including
flanges) which have ends suitable for butt jointing after
preparation on site to the requirements of 26.4.1 and
Figure 11 or the requirements of 26.4.2 and Figure 6.
The minimum dimensions of the pipe fittings are given by the
equation in Table 7 using the values in Table 8.
Erection/assembly of the pipe
lengths and pipe fittings to form
pipework systems. Flanged joints
and butt joints to be made where
required.
3 Minimum dimensions for flanged pipes and fittings.
Manufacture of pipe lengths and pipe fittings complete with
flanged ends.
The minimum dimensions of the pipe fittings are given by the
equations in Table 7 using the values in Table 8.
Erection/assembly of the pipe
lengths and pipe fittings to form
pipework systems. Flanged joints
to be made where required.
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Figure 1 Limits of pressure and diameter
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Figure 2 Relationship between thickness and glass content for laminates with resin of relative density, (+), 1.1 to 1.3
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BS 6464:1984
BSI 03-1999 39
Figure 3 Relationship of unit modulus to winding angle
Figure 4 Factor related to temperature
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BS 6464:1984
40
BSI 03-1999
Figure 5 Factor related to cyclic loading
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BS 6464:1984
BSI 03-1999 41
Figure 6 Butt joint build-up for lined pipe
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BS 6464:1984
42
BSI 03-1999
Figure 7 Pipework shapes for fabrication methods 1 and 2 (see Appendix F)
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BS 6464:1984
BSI 03-1999 43
Figure 8 Flanged pipe fittings for method 3 (see Appendix F)
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BS 6464:1984
44
BSI 03-1999
Figure 9 Typical stub flanges (type A)
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BS 6464:1984
BSI 03-1999 45
Figure 10 Typical full faced flanges (types B and C)
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BS 6464:1984
46
BSI 03-1999
NOTE Amount of overlay, t
2
is a laminate having 1.2 times the UTUS of pipe wall liminate, t
1
.
All dimensions in millimetres.
Figure 11 Butt joint build-up for unlined pipe
Figure 12 Test piece for the determination of shear strength of bond
between thermoplastics lining and laminate
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BS 6464:1984
BSI 03-1999 47
Figure 13 Test piece for the determination of lap shear strength of laminate
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BS 6464:1984
48
BSI 03-1999
Figure 14 Test for determination of peel strength of bond between
thermoplastics liner and laminate
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BS 6464:1984
BSI 03-1999 49
Figure 15 Test piece for tensile strength of thermoplastics sheet and welds
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BS 6464:1984
50
BSI 03-1999
Figure 16 Typical examples of laminate construction
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BS 6464:1984
BSI 03-1999 51
Figure 17 Biaxial failure envelope
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52
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BS 6464:1984
BSI 03-1999
Publications referred to
BS 476, Fire tests on building materials and structures.
BS 476-7, Surface spread of flame tests for materials.
BS 1560, Steel pipe flanges and flanged fittings (nominal size 1/2 in to 24 in) for the petroleum industry.
BS 1560-2, Metric dimensions.
BS 1610, Method for the load verification of testing machines.
BS 1755, Glossary of terms used in the plastics industry.
BS 1755-1, Polymerization and plastics technology.
BS 2044, Laboratory tests for resistivity of conducting and antistatic rubbers.
BS 2494, Materials for elastomeric joint rings for pipework and pipelines.
BS 2782, Methods of testing plastics.
BS 2782-Method 121A, Determination of temperature of deflection under a bending stress of 1.8 MPa of
plastics and ebonite.
BS 2782-Method 320A to F, Determination of tensile strength, elongation and elastic modulus.
BS 2782-Method 345A, Determination of compressive properties by deformation at constant rate.
BS 2782-Method 430B, Determination of water absorption at 23 C with allowance for water-soluble matter.
BS 2782-Method 1001, Measurement of hardness by means of a Barcol impressor.
BS 2782-Method 1002, Determination of loss on ignition.
BS 2782-Method 1003, Determination of tensile properties.
BS 3293, Carbon steel pipe flanges (over 24 in nominal size) for the petroleum industry.
BS 3396, Woven glass fibre fabrics for plastics reinforcement.
BS 3496, E glass fibre chopped strand mat for the reinforcement of polyester resin systems.
BS 3505, Unplasticized PVC pipe for cold water services.
BS 3506, Unplasticized PVC pipe for industrial purposes.
BS 3532, Unsaturated polyester resin systems for low pressure fibre reinforced plastics.
BS 3534, Epoxide resin systems for glass fibre reinforced plastics.
BS 3691, Glass fibre rovings for the reinforcement of polyester and of epoxide resin systems.
BS 3749, Woven roving fabrics of E glass fibre for the reinforcement of polyester resin.
BS 3757, Specification for rigid PVC sheet.
BS 3846, Methods for the calibration and grading of extensometers for testing of metals.
BS 4346, Joints and fittings for use with unplasticized PVC pressure pipes.
BS 4346-1, Injection moulded unplasticized PVC fittings for solvent welding for use with pressure pipes,
including potable water supply.
BS 4346-3, Specification for solvent cement.
BS 4504, Flanges and bolting for pipes, valves and fittings. Metric series.
BS 4504-1, Ferrous.
BS 5350, Methods of test for adhesives.
BS 5350-C5, Determination of bond strength in longitudinal shear.
BS 5350-C6, Determination of bond strength in direct tension in sandwich panels.
BS 5480, Specification for glass reinforced plastics (GRP) pipes and fittings for use for water supply or
sewerage
5)
.
BS 5955, Code of practice for plastics pipework (thermoplastics materials).
BS 5955-7, Recommended methods for thermal fusion jointing.
5)
Referred to in the foreword only. L
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