FRP pipe: an effective solution for wastewater management

Fibre-reinforced plastic (FRP) is a composite material composed of a polymer matrix strengthened by fibres, also referred to as fibre-reinforced polymer.

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Commonly employed fibres include carbon, glass, basalt or aramid. In some cases, other fibres like wood, asbestos, and paper have been utilised. While vinyl ester, polyester, epoxy thermosetting plastics are used as matrix materials. In some cases, phenol formaldehyde resins are also used.

Fibreglass-reinforced pipes are experiencing a rapid surge in demand because they play a vital role in the industrial sector. These pipes, made from FRP, are non-metallic and crafted by continuously wrapping fibreglass filament saturated with a specialised combination of epoxy resin and curing chemicals. Their applications range from piping systems to tankers, and various vessels across numerous fields and industries. The global FRP pipe industry is gaining momentum owing to an expansion of the building and construction sector and the benefits of FRP pipe in the construction domain.

Features of FRP pipes:

• Lightweight

FRP pipes, designed from a combination of 1/10 P.S.C., 1/5 steel, and 1/8 C.I., exhibit a reduced strength-to-weight ratio compared to alternative materials. Their lightweight construction enables easy handling, installation, modification, and repair of FRP pipes.

• Non-corrosive

FRP pipes inherently possess corrosion resistance. In many cases, fibreglass-reinforced plastics stand as the sole material capable of withstanding certain parameters. Additionally, their corrosion resistance, typically coupled with cost efficiency, positions them as the most viable solution. The corrosion resistance of Fibreglass Reinforced Plastic pipes depends on both the overall resin content and the specific resin employed in the pipe's laminate. Thus, a higher resin content equals to increased resistance against corrosion.

FRP pipes offer an excellent solution for transporting corrosive wastewater and sewage. Their smooth inner surface effectively facilitates the flow of various fluids. Corrosion resistance is a crucial attribute in these applications.

• Flexibility

FRP pipes offer versatility in shaping various equipment pieces or configurations using permanent or temporary molds. For instance, constructing ductwork with FRP pipes is highly feasible as it enables the production of different types of rectangular transitions, Tee inlets, circular transitions, flanges, and elbows at a minimal expense. Additionally, Fibreglass Reinforced Plastic pipes are a suitable option for lining both new and existing structures.

Computer software programmes have significantly improved the design of FRP systems. These programmes include various functionalities such as analysing gas flow, chemical composition, liquid flow, and thrust blocks, and providing installation information.

Recent developments transforming the FRP pipe industry:

RPS Composites introduced a robust and durable joint specifically designed for FRP (Fibreglass Reinforced Plastic) piping systems.

RPS Composites, based in Franklin, Ohio, US, has introduced the RPS Grooved Adapter, specially designed for use in combination with RPS fibre-reinforced polymer (FRP) piping systems. This adapter is designed for use with a Victaulic Style 296-A coupling, resulting in a sturdy and dependable joint for FRP piping. As per the RPS, the most appealing feature of the Grooved Adapter is its ease of use, enabling coupling or uncoupling within minutes without requiring any specialised tools or training. Specifically designed for mild corrosive environments such as water, seawater, and wastewater, the RPS Grooved Adapter offers practicality and convenience in its application.

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The RPS FRP adapters have undergone rigorous testing and meet the ASME NM.2- Proof of Design qualification test standards. These tests include static pressure, cyclic pressure evaluations, and hydrostatic strength testing.

CPP has successfully installed the tallest Fibre Reinforced Polymer (FRP) stack liner for the Bangladesh-India Friendship Power Company

CPP (Chemical Process Piping), a company specialising in industrial piping solutions producing GRP and FRP-based pipes, has introduced an FRP stack in the FGD (Flue Gas Desulfurisation) plant established by BIFPCL (Bangladesh India Friendship Power Company). This joint venture operates on a 50:50 partnership between the Bangladesh Power Development Board and the National Thermal Power Corporation.

CPP has accomplished Phase I of the Maitree Super Thermal Power Plant project in collaboration with BHEL and Simplex in Bangladesh. Marking a significant achievement, CPP stands as the pioneering entity in this sector by successfully constructing an 800 ft FRP stack for the MW coal-fired power station located in Rampal, Bangladesh. This accomplishment positions CPP as the foremost FRP manufacturer in this region to employ vertical winding technology for filament winding the FRP stack, a pioneering approach adopted for their project in Bangladesh. The project itself represents an environmentally friendly initiative, leveraging supercritical technology for the thermal power plant.

To sum up, the global FRP pipe industry is experiencing growth due to the advantages of these pipes in the construction sector and the rapid growth of the construction and building sector. The potential of FRP pipes in wastewater management will present remunerative growth opportunities to the market in the upcoming years.

FRP (Fiber Reinforced Plastic) is a polymer that’s made from plastic mold and reinforced by glass fibers. It’s a light and extremely strong alternative to conventional glass and plastic.

It holds a central place in a construction industry that’s expected to be worth around 1 trillion US dollars in , and is increasingly used in construction.

It has revolutionized a wide array of industries—from aerospace to automotive, and marine. Its strength is also comparable to carbon fibers, which is why FBR can be found in ballistic armor.

Here’s a breakdown of the perks of using FRP products:

Corrosion Resistance

One of the primary reasons for using FRPs is their corrosion resistance—a function of the resin content and the type of resin used. This makes the use of FRPs an economically acceptable and long-lasting solution. Consequently, the need for long-term maintenance is mitigated, helping organizations save on material costs and labor down the line.

Bridges and platforms constructed from reinforced concrete or wood fall apart after around 20 years, requiring new investments and expensive repairs. FRP, however, won’t experience corrosion like other construction materials and is built to last!

Weight advantages

FRP is known to have a low weight-to-strength ratio. In fact, for the same strength, FRP is about one-seventh the weight of steel and approximately half of aluminum’s. FRP’s lightweight properties are ideal for pipes and tanks owing to its comparatively low cost and ease of installation. This material is also less labor intensive, especially in scenarios where equipment is mounted on existing structures, for example, scrubbers on rooftops or mezzanines and FRP tank trailers.

Using lighter construction materials helps you save on labor costs and makes it easier for workers during installation and removal processes. FRPs place less stress on the infrastructure—meaning the structure will experience less wear and tear in the long run.  

High Strength

The high strength of FRPs plays a major role in applications like pultruded shapes, missiles , etc. The material has increased flexural strength in comparison to timber, which is the reason why FRPs are used in filament wound pipes and ducts.

Increased flexibility

Owing to the flexibility of Fiberglass Reinforced Plastic, it is used in a wide variety of applications that require temporary or permanent molds. You can mold equipment into various configurations like elbows, circular or rectangular transitions, flanges or tee inlets all at minimal tooling cost. FRPs are also widely used to line existing structures.

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