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SECTION 13230

FIBERGLASS REINFORCED PLASTIC (FRP) FABRICATIONS


PART 1--GENERAL

1.01 DESCRIPTION

This section specifies general requirements for fiberglass reinforced plastic (FRP)
fabrications. Equipment-specific requirements are detailed in other sections of the contract
documents pertaining to specific equipment. This section is intended to be used in conjunction
with the other related equipment specification sections and design drawings. It is intended to
specify materials, describe methods of work, and provide for documentation of quality and
acceptance.

1.02 QUALITY ASSURANCE

Quality, as represented by raw materials used, manufacturing practices employed, and
condition of the finished product, is of prime importance. Knowledge of new technology in the
interest of improved quality and/or lower cost is welcomed. However, any change of raw
materials, alteration of construction, or other deviations from the requirements of the
Specification sections or design drawings must be submitted in detail and approved in writing by
the Construction Manager.

1.03 REFERENCES

A. REFERENCES:

This section contains references to the following documents. They are a part of this
section as specified and modified. In case of conflict between the requirements of this section
and those of the listed documents, the requirements of this section shall prevail.

Unless otherwise specified, references to the documents in this section shall mean the
documents in effect at the time of Advertisement for Bids or Invitation to Bid. If referenced
documents have been discontinued by the issuing organization, references to those documents
shall mean the replacement documents issued or otherwise identified by that organization or, if
there are no replacement documents, the last version of the document before it was discontinued.
Where document dates are given in the following listing, references to those documents shall
mean the specific document version associated with that date, whether or not the document has
been superseded by a version with a later date, discontinued or replaced.
Reference Title
AISC and Research Council for
Riveted and Bolted Structural
J oints (RCRBSJ )
Specification for Structural J oints Using ASTM A325
or A490 Bolts
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Reference Title
American Institute of Steel
Construction (AISC)
Specification for the Design, Fabrication, and Erection
of Structural Steel for Buildings
AMCA 500 D Laboratory Methods of Testing Dampers for Rating
API 12P, American Petroleum
Institute (API)
Specification for Fiber Reinforced Plastic Tanks
ASME/ANSI RTP-1 Reinforced Thermoset Plastic Corrosion Resistant
Equipment
ASTM C582 Standard Specification for Contact Molded Reinforced
Thermosetting Plastic (RTP) Laminates for Corrosion-
Resistant Equipment
ASTM D883 Definitions of Terms Relating to Plastics
ASTM D2471 Gel Time and Peak Exothermic Temperature of
Reacting Thermoset Resins
ASTM D2563 Recommended Practice for Classifying Visual Defects
in Glass-Reinforced Plastic Laminate Parts
ASTM D2583 Test for Indentation Hardness of Rigid Plastics by
Means of a Barcol Impressor
ASTM D2584 Ignition Loss of Cured Reinforced Resins
ASTM D3299 Filament-Wound Glass Fiber Reinforced Polyester
Chemical-Resistant Tanks
ASTM D3567 Determining Dimensions of Reinforced Thermosetting
Resin Pipe and Fittings
ASTM D3982 Standard Specification for Contact Molded
Fiberglass (Glass Fiber Reinforced Thermosetting
Resin) Duct and Hood
ASTM D4097 Contact-Molded Glass Fiber Reinforced Thermoset
Resin Chemical-Resistant Tanks
ASTM E84 Standard Method of Test for Surface Burning
Characteristics of Building Materials
AWS D1.1, American Welding
Society (AWS)
Structural Welding Code
National Bureau of Standards
Voluntary Product Standard
PS 15-69
Custom Contact-Molded Reinforced-Polyester
Chemical Resistant Process Equipment
Iron and Steel Society Pocketbook of Standard Steels
IBC International Building Code
IMC International Mechanical Code
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1.04 DEFINITIONS
A. The terminology of this specification is consistent with ASTM D883. Fabricators
are responsible for correct interpretation. Further definitions are as follows.

B. EQUIPMENT: The FRP equipment, as listed in the pertinent equipment section,
including all ancillary equipment, work, and materials as described in this section
and related sections specification.

C. FABRICATOR: The primary party responsible for fabrication of the FRP
equipment.

D. FIELD J OINING CONTRACTOR: The party responsible for the field joining of
the equipment. This may be the same party as the Fabricator and/or the
Contractor.

E. MAT: A fibrous material consisting of randomly oriented chopped or swirled
glass filaments loosely held together with a binder.

F. CHOPPED GLASS: A fibrous material consisting of randomly oriented chopped
filaments applied directly to a mold surface or laminate under construction by a
chopper gun.

G. FIBER PROMINENCE (J ACKSTRAW): The distinct visibility of individual
glass strands causing a loss of translucency of the laminate.

1.05 SUBMITTALS

Submittals shall be provided in accordance with Specification Section 01300. Submittal
requirements for FRP fabrications are detailed in those specification sections pertaining to
specific equipment.
PART 2--PRODUCTS

2.01 GENERAL

All products shall be new, of current design, and produced by approved manufacturers
who specialized in the fabrication of such products.

Stainless steel hardware and fabricated parts (including anchor bolts, anchor lugs, lifting
lugs, hangers, etc.) shall be AISI Type 316.

Gaskets for use with FRP flanges shall be flat, full-faced, and drilled to match the drilling
of the mating flange(s). Gasket material shall be as specified in the pertinent equipment section.

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2.02 MATERIALS

A. RESIN:
1. The equipment shall be fabricated using the corrosion-resistant resin(s)
specified in the pertinent equipment section, or equal as approved by the
Construction Manager. The resin shall be used throughout all laminates.
2. Catalysts and promoters shall be of the type and amount recommended by
the resin manufacturer for use with their resin in the required service. The
Construction Manager will review the Fabricator's choice of resin/catalyst
before fabrication begins to verify compliance to the resin manufacturer's
recommended procedures. Positive measurement control of catalysts,
promoters, and resins shall be maintained at all times.
3. No fillers, additives, or pigments shall be employed in the resin except as
specified below, and in the pertinent equipment section. A thixotropic
agent for viscosity control may be used in the proportion and type
recommended by the resin manufacturer as approved by the Construction
Manager. No thixotropic agent is to be used in the corrosion liner or on
surfaces to be in contact with the corrosive environment.
4. Resin putty shall be made using the same resin as was used in the original
fabrication of the parts to be joined. Resin putty shall contain a minimum
15 percent by weight of milled glass fibers. A fumed-silica additive such
as Aerosil 200 or Cab-O-Sil TS-720 shall be added to increase the
viscosity of the putty. The use of silica flour, grinding dust, or other fillers
is not allowed.
5. When specified in the pertinent equipment section, antimony trioxide or
antimony pentoxide shall be added to the resin in the amount necessary to
achieve the required fire retardancy rating in the structural wall only.
Resin manufacturer's recommendations shall be followed. The corrosion
liner shall not contain this additive.
B. REINFORCEMENT:
1. Type and sequence of reinforcement to be used shall be as designated in
the pertinent equipment section, the construction details, or on the design
drawings.
2. Glass fiber reinforcement used shall be a commercial grade corrosion-
resistant borosilicate glass, except as otherwise noted.
3. All glass fiber reinforcing shall have an epoxy compatible silane type
surface finish and binder that is specifically recommended by the glass
manufacturer for the particular resin system to be used. This surface
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finish should allow the maximum possible chemical bonding between the
resin and glass.
4. Surfacing veils shall be Type C (chemical grade) glass, 10 mil thickness,
unless otherwise specified. An apertured polyester surfacing veil, such as
Nexus or approved equal, shall be used only when indicated in the
pertinent equipment section. The Construction Manager is not aware of an
equal product.
5. Mat shall be Type E (electrical grade) glass, 1-1/2 oz. or 3/4 oz. per sq. ft.,
as specified in the pertinent equipment section, with nominal fiber length
of 1.25 +0.75 inches.
6. Continuous glass roving used in chopper guns for spray-up shall be Type
E chopper roving.
7. Woven roving shall be 24 oz. per sq. yd. Type E glass and have a 5 x 4
plain weave.
8. Continuous roving used in filament wound construction shall be Type E
glass winder roving with a yield of 200 yards or more per pound.
9. Unidirectional reinforcement shall be weft unidirectional fabric, Type E
glass, 15.7 oz./sq. yd., such as Hexcel Knytex, Brunswick Technologies,
Inc., W-16, or equal.
2.03 FABRICATION

A. MOLDS:
1. Molds constructed of Masonite, wood, or other porous material must be
completely covered with mylar or other suitable material to produce a
smooth and glossy inner surface on the FRP equipment.
2. Molds and mandrels shall be hard-surfaced such that working the wet
laminate will not cause local displacement of the material or air
entrapment. Covering of mandrels with cardboard is not acceptable. If
submitted, Contractor shall demonstrate that it produces an RTP-1 Level 2
liner quality before being approved by the Construction Manager prior to
start of fabrication.
3. Certain construction details shown on the design drawings assume the
availability of specific tooling and/or molds. Alternate mold
configurations may be considered by the Construction Manager in the
interest of cost savings or betterment. Any deviations from the
dimensions shown on the design drawings must be approved by the
Construction Manager prior to the start of fabrication.
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B. VESSEL ASSEMBLY:
1. All cutouts from the equipment are to be marked, indicating their original
location, and retained. All cutouts become the property of the
Construction Manager.
2. Centerlines marked on the equipment for use in assembly shall not be
removed until after inspection by the Construction Manager.
3. Flanged nozzles shall be installed with boltholes straddling principle
centerlines of the vessel. For tank tops, nozzle boltholes straddle radial
centerlines. Other layouts take precedence when detailed on the design
drawings.
4. When requested, Fabricator shall supply to the Contractor, at the earliest
possible time, a template which locates anchor bolt holes within +1/8-inch
for each vessel.
5. When specified, or indicated on the design drawings or construction
details of the pertinent equipment section, a non-skid surface shall be
provided on the exterior surface of domed covers. Silica grit may be
applied in conjunction with the final resin coat, or other methods
employed if approved by the Construction Manager.
6. The Fabricator shall furnish and overlay on the outside of the equipment a
plastic nameplate showing the following information:
a. Name of manufacturer
b. Date of manufacture
c. Construction Manager's purchase order number
d. Equipment name/number
e. Resin number and manufacturer
f. Design pressure and temperature
g. Vessel diameter, height, and weight

7. Butt joints or shell joints are to be in the number and location(s) as shown
on the design drawings. Additional joints are not allowed except as
approved by the Construction Manager. Slip joints, "mod joints," or other
methods not conforming to the design drawings are not allowed. If joint
locations are not indicated on the design drawings, Fabricator shall
propose number and location for approval by Construction Manager.
8. Allowable tolerances shall be as listed in RTP-1, Fig. 4-1 and NM 7-1,
except as modified herein or on the design drawings.
9. When joining components, gaps at mating edges shall be limited to
1/4-inch maximum, and misalignment of inside surfaces shall not exceed
1/3 of the lesser wall thickness.
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10. The outside surface of vessel flat bottoms after assembly shall be flat
within +1/2-inch. In addition, localized indentations or protrusions shall
not exceed +1/4-inch within two feet.
11. Nozzle cutout reinforcement shall be applied as specified on the design
drawings.
12. When reinforcing materials are cut to facilitate placement around an
installed nozzle or opening, joints in successive reinforcing layers shall be
staggered to avoid overlapping and shall not be placed so that the joints
are parallel to the axis of the tank. The principal fiber direction of the
woven roving reinforcement shall be parallel to the tank axis.
C. DUCTWORK ASSEMBLY: NOT USED
D. ALL LAMINATES:
1. Refer to the pertinent equipment section for reinforcement sequences. No
deviations in number or sequence of plies will be allowed without
approval by the Construction Manager.
2. Positive methods shall be used to assure uniform total thickness of the
laminate and uniform glass-to-resin ratio without surplus resin or
unsaturated glass.
3. All laminate thicknesses shown on the design drawings are construction
minimums. It is the responsibility of the Fabricator to verify that
minimum thicknesses are obtained using the laminate sequences specified.
4. The minimum allowable structural laminate thickness shall be the total
laminate thickness less the specified sacrificial corrosion liner thickness.
5. Interruptions in laminating sequence should only occur after exotherm
plies (E or e), as described in the pertinent equipment section. If an
exotherm interruption becomes otherwise necessary, it shall follow the
application of a ply of mat and be succeeded by a ply of mat. This may
require an additional ply beyond that specified.
6. Laminating sequence interruptions shall not exceed 24 hours, and the in-
process surface must retain acetone sensitivity until laminating is resumed.
Lack of compliance with these procedures, or any indication that
contamination of the surface has occurred, shall require that surface
preparation be accomplished before resuming. Before resuming
lamination, any rough areas or projections shall be touch-ground to allow
full contact of the succeeding wet laminate.
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7. An exotherm interruption is specifically prohibited within the corrosion
liner. An exotherm interruption between the corrosion liner and the
structural layers is limited to a maximum of twelve hours.
8. Chopped strand glass applied by chopper gun is allowed in lieu of mat
layers in the structural laminates only. Application must be mechanically
controlled in order to assure uniform thickness and glass-to-resin ratio.
The specific methodology must be approved by the Construction Manager
prior to fabrication. Chopper gun application of the corrosion liner is not
allowed.
9. All non-mold surfaces shall be coated with resin containing wax additive
in the amount necessary to allow full cure of the surface. In the case of
interior primary corrosion surfaces, such as interior overlays, this wax coat
shall be applied within 24 hours of original lamination. In the case of
exterior surfaces, this wax coat shall also contain a UV stabilizer in the
type and amount recommended by the resin manufacturer.
10. The exterior surface of all equipment shall be resin rich and reinforced
with one layer c-glass surfacing veil, except as otherwise specified.
11. When specified in the pertinent equipment section, the exterior coat shall
be an opaque pigmented surface coat, applied only after Construction
Manager's inspection. Color to be selected by the Construction Manager.
12. Saturation of reinforcement prior to application to equipment shall not be
performed on waxed paper or other contaminated material. Saturation of
reinforcement on clean paper or cardboard is allowed.
13. All cut edges shall be thoroughly coated with resin so that no glass fibers
are exposed. Cut edges exposed to the corrosive service shall be sealed
with a corrosion liner laminate. All voids shall be filled with resin putty.
E. CORROSION LINER LAMINATES (inner surface and interior layers):
1. The inner (corrosion service) surface of all laminates shall be resin-rich
and reinforced with surfacing veil of the type and number of layers as
described in the pertinent equipment section.
2. The interior layer of the corrosion liner shall consist of 1-1/2 oz. per sq. ft.
mat in the number of layers specified in the pertinent equipment section.
Each ply shall be rolled separately to remove entrapped air.
3. Chopped glass applied by chopper gun is not allowed in the corrosion
liner.
4. All plies of the inner surface and interior layer are to gel completely
before proceeding with the structural laminates, but in no case shall the
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interruption exceed twelve hours. The surface must retain acetone
sensitivity until the structural laminate is applied. Lack of compliance to
either of these aspects shall be cause for rejection of the corrosion liner.
5. Completed corrosion liner, as described above, shall contain not less than
20 percent nor more than 30 percent glass (by weight). No thixotropic
material shall be used in the liner resin nor in the fabrication of any FRP
components intended for direct contact with the process stream.
Completed liner shall be the minimum thickness specified in the pertinent
equipment section. Completed liner shall meet visual defects
requirements of RTP-1, Table 6-1, Level 2.
6. All edges of surfacing veils in wet lay-up shall be lapped a minimum of
one inch.
7. A separately cured unreinforced gel coat shall not be used.
8. Antimony shall not be used in the corrosion liner.
F. HAND-LAYUP STRUCTURAL LAMINATES:
1. The corrosion liner laminate shall be followed by structural laminates of
varying construction types, as specified in the pertinent equipment
sections, or on the design drawings.
2. For hand-layup structural laminates, reinforcement shall consist of mat
and woven roving in the sequence specified in the pertinent equipment
section.
3. All woven roving shall have a ply of mat on each side. Two adjacent plies
of woven roving are not permitted.
4. All edges of woven roving material in wet lay-up shall be lapped a
minimum of two inches. Lapped edges of adjacent layers shall be
staggered to obtain the maximum possible strength.
5. Laminates containing primarily 1-1/2 oz. per sq. ft. mat layers in
conjunction with woven roving shall contain not less than 35 percent or
more than 45 percent glass (by weight).
6. Laminates containing primarily 3/4 oz. per sq. ft. mat layers in conjunction
with woven roving are considered to be high strength laminates and shall
contain not less than 45 percent or more than 55 percent glass (by weight).
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G. FILAMENT WOUND STRUCTURAL LAMINATES:
1. The corrosion liner laminate shall be followed by structural laminates of
varying construction types, as specified in the pertinent equipment section,
or on the design drawings.
2. For filament wound structural laminates, reinforcement shall consist of
continuous strand fiberglass roving applied with a minimum of
interruptions until the specified minimum thickness is attained. This
laminate shall contain the percentage of glass (by weight) specified in the
pertinent equipment sections.
3. Each complete cycle of filament winding shall form a closed pattern of
winding bands which completely covers the surface with two bi-
directional layers. Each layer shall be a maximum of one roving in
thickness. Singular cycles shall not exceed a thickness of 0.06 inches,
unless otherwise specified in the pertinent equipment sections. In
laminates with helix angles greater than 75 degrees, a minimum 10% of
the structural wall thickness shall be oriented at 0 degrees (longitudinal
direction), plus or minus 5 degrees.
4. Upon request, Fabricator shall submit the following information:
a. Specific glass strand to be used and yield
b. Net thickness per cycle
c. Number of strands per inch in the winding band
d. Typical glass-to-resin ratio
5. Construction Manager retains the right to modify the laminate based on
fabricator's specific filament winding system.
6. Spacing of filaments within the winding band shall be sufficiently close
that bridging is avoided and glass content is maintained within the
specified limits. Spacing of the filaments shall be uniform across the
winding band without bunching or gapping.
7. The helix angle of winding shall be as specified in the pertinent equipment
sections, as measured from the centerline of revolution of the equipment
shell.
8. Tolerance on helix angle is +2 degrees, -2 degrees, unless otherwise noted
in the pertinent equipment sections.
9. If layers of mat or chopped glass are needed to ensure proper bonding
between the corrosion liner and filament winding, or within the filament
winding to accommodate the fabricator's manufacturing methods, or to
provide for laminates of acceptable quality, they may be added at the
Fabricator's option. These layers are considered to be extra material and
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will result in a thickness greater than specified. The amount of filament
winding and unidirectional roving specified must still be applied.
10. If for any reason, winding is interrupted to the point where the outer
surface is gelled or exotherm temperatures are excessive, production shall
stop and the laminate shall be allowed to cure. Any prominent ridges left
on the cured surface shall be ground to smooth the projections and prevent
bridging. Following the grinding, a bedding layer of 3/4 oz. per sq. ft. mat
or chopped glass shall be applied and thoroughly rolled to remove air.
Winding with continuous strand may be resumed before this layer gels.
The additional mat layer is extra material and will result in a wall
thickness greater than that specified.
H. SURFACE PREPARATION:
1. SURFACE ABRASION:
a. Prior to starting secondary overlays, adequate surface abrasion
with no surface contamination is required. Every precaution shall
be taken to assure adequate surface preparation and a good bond of
the secondary overlays.
b. Prior to making all overlays, the cured or wax coated surfaces of
the area to be overlayed must be roughened thoroughly by
grinding. The roughened area shall extend 1-inch minimum
beyond the proposed overlay edge. The roughened area must be
completely coated with wax coat at the completion of the joint.
c. Grinding shall be sufficiently deep that all traces of glossy resin
coat are removed and that glass fiber is exposed over the entire
abraded surface.
d. The edges of the abraded surface shall be "feathered" out such that
no sharp discontinuities exist.
e. For surface abrasion by grinding, grinding disks shall be new and
not contaminated, with a grit size of 16 to 24.
f. FRP joint application must begin within four hours of surface
abrasion, or else abrasion must be repeated.
2. FINAL SURFACE PREPARATION:
a. Within 15 minutes prior to beginning FRP joint application, dust
shall be removed from the abraded area by vacuuming or brushing
with clean non-metallic brushes, or wiping with clean dry rags.
b. Solvent wiping the abraded area is not allowed.
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c. Air blowing the abraded area is not allowed.
d. If any indication of contamination is present after this final surface
preparation, the abraded area shall be scrubbed with solvent and
allowed to evaporate to verify removal of the contaminant. Repeat
this solvent wash if necessary. Surface abrasion must be repeated
after solvent washing.
I. J OINING LAMINATES:
1. FRP joining laminates are subject to all applicable requirements specified
in other sections for laminates.
2. FRP joints shall be reinforced with an overlay of glass reinforcement and
resin which extends equally within +1/2-inch on each side of the joint. A
smooth contour is required. Minimum thickness, ply sequence, and ply
widths of FRP joints shall be as specified in the pertinent equipment
sections.
3. Tolerance on width of joint reinforcement plies is +1 inch, -0 inch.
Woven roving plies shall not exceed the width of the mat ply below them.
4. Parts to be joined shall be restrained to prevent movement until
completion and cure of the joint overlay.
5. Parts shall be fitup, and it shall be verified that all tolerances and assembly
requirements of sections are satisfied. The void between component parts
shall be completely filled with resin putty, taking care not to extrude an
excessive amount of putty into the interior.
6. The puttied area shall be ground to a smooth contour and final surface
preparation repeated.
7. The abraded area to be overlaid shall be resin coated immediately prior to
applying glass reinforcement, using a stiff brush to work resin into the
rough surface. The resin coat shall be applied only to an area as wide (+1
inch, -0 inch) as the next exotherm stage of the joint sequence and shall be
repeated prior to each exotherm stage. No thixotropic material shall be
used in this resin.
J . ENVIRONMENT:
1. It is the Fabricator's responsibility to maintain conditions in the FRP
laminate work area during all times when the final surface preparation and
FRP laminate application are in process in order to not jeopardize the
reliability of the laminate or secondary bond. As a minimum, controls
shall include the following.
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2. All surfaces to be overlaid and all materials are to be maintained within a
range of 60 to 95 degrees F. This temperature must also be at least 5
degrees F greater than the dew point, as measured with a sling
psychrometer. During the exotherm stage(s) of each laminate sequence,
and during any unplanned exotherms, the temperature of the curing
laminate will likely exceed 95 degrees F. No further lamination may
proceed until the exotherm has completed and the laminate has cooled to
95 degrees F or less. No attempt shall be made to cool the curing laminate
prematurely.
3. Prepared surfaces and materials shall be protected from blowing dust,
moisture, and other contaminants.
4. If any of the above conditions are violated while the final surface
preparation or FRP laminate application are in-process, work shall stop
immediately and the process must begin again with surface abrasion.
5. Materials shall be stored in a dry area and within the temperature and
humidity limits recommended by the manufacturers.
K. FLANGES:
1. Except as otherwise specified on the design drawings, flanges shall be
made by hand-layup construction with nozzle neck and flange made
integrally in one piece and fabricated in accordance with the dimensions
shown on the design drawings. All layers of reinforcement in the nozzle
neck and hub shall extend uninterrupted into the flange.
2. Unless otherwise noted on the design drawings, additional hub thickness
shall be built-up using alternating layers of 1-1/2 oz. per sq. ft. mat and
24 oz. per sq. yd. woven roving.
3. Additional thickness in the flange shall be built-up using "ring" cutouts of
mat, evenly distributed throughout the flange thickness.
4. Press molded or filament wound flanges are not allowed.
5. To obtain proper seating, bolt holes shall be spotfaced for SAE size
washers. Overall machine facing of the back of flanges is not permitted.
Bolt holes and all other cut surfaces shall be resin coated. Spotfacing shall
not produce a flange thickness less than that specified in the pertinent
equipment section.
6. Bolt holes in flanges are to straddle principal centerlines of the equipment.
Tolerance in bolt hole locations and in diameter of bolt circle shall be
+1/16-inch.
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7. Flange faces shall be flat to +1/32-inch up to and including 16-inch
diameter and +1/16-inch for larger diameters.
8. Resin coat all flange bolt holes so that no fibers are exposed.
2.04 FABRICATION QUALITY CONTROL

A. ALLOWABLE VISUAL DEFECTS:
1. Fabricator shall take care to minimize the amount of defects in all
laminates. In no case shall visual defects in any area of the equipment
exceed the maximum allowable levels of visual defects set forth in RTP-1,
Table 6-1, Level 2.
2. Visual defects shall be as defined in ASTM D2563 and ASME/ANSI
RTP-1, Table 6-1.
3. Presence of visual defects in excess of the allowable levels shall be
grounds for rejection of the equipment.
B. FRP FABRICATION:
1. Fabricator shall be responsible for implementation of a comprehensive
quality assurance procedure. The minimum requirements are described
below.
2. Fabricator shall designate personnel to inspect equipment while in-process
and after completion to assure compliance to all aspects of the
specification and design drawings. Inspection shall include, as a
minimum, checks for visual defects, laminate thickness and sequence,
glass content, Barcol hardness, dimensional tolerances, adherence to
construction details, surface preparation, and environmental conditions.
Fabricator's inspector shall complete a report of the findings including
method of measurement for each separate assembly.
3. Prior to use of any resin, Fabricator shall test resin to establish cure
characteristics and verify that it meets the resin manufacturer's acceptance
standards.
4. Resin testing shall be performed in accordance with ASTM D2471. Gel
time to peak exotherm and peak exotherm temperature shall be recorded.
5. If the Fabricator in any way alters the resin after receipt, such as through
the addition of styrene, promoters, or other additives, one test shall be
performed for each drum or portion thereof mixed with additives.
6. Fabricator shall provide documentation for each test, including resin type,
manufacturer, batch and lot number, drum number, complete listing of all
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additives with amounts added, and description and manufacturer of each
additive.
7. Fabricator shall inspect all glass reinforcement prior to use in fabrication
and shall not use any glass that does not meet the manufacturer's
acceptance standards. Glass material that is wet or has been wet shall not
be used. For each type of glass and lot number used, Fabricator shall
record the manufacturer, product description, binder type, product code,
production date, and lot number. For mat, woven roving, unidirectional
roving, and cloth, records shall also include actual measured weight per
square yard of material.
8. Fabricator shall retain all nozzle cutouts and other excess laminate, clearly
marking each piece to identify its original location. These laminate
samples become the property of the Construction Manager. For areas
where valid laminate samples are not available, sample plugs shall be
taken at the Construction Manager's request. Repair of subsequent holes
will be performed in a manner approved by the Construction Manager.
9. Fabricator shall verify glass content of corrosion liner and structural
laminate on available samples in accordance with ASTM D2584. This test
shall be completed, and the results reported for each major component
where samples are available.
10. Prior to final shipment of the equipment, Fabricator shall provide the
Construction Manager with a complete quality control report, consisting of
copies of all records maintained for compliance with this section.
C. CONSTRUCTION MANAGER'S INSPECTION:
1. The Construction Manager shall be permitted access to the equipment
during fabrication and upon completion for the purpose of verifying
compliance to the contract documents. The Construction Manager's
inspection is not intended to replace the Fabricator's own quality control
procedures.
2. In no respect does inspection of any equipment by the Construction
Manager relieve the Fabricator of compliance with the contract
documents. A final inspection shall be performed by the Construction
Manager when the Fabricator certifies that all the terms and requirements
of the contract documents have been satisfied. At least five days notice
shall be given the Construction Manager prior to this inspection.
3. The Fabricator is required to notify the Construction Manager at the
completion of particular milestones during fabrication. The Fabricator
shall give at least 48 hours notice prior to occurrence of these milestones,
as follows:
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a. View tooling prior to fabrication
b. Beginning application of corrosion liner for each part
c. Extraction of each part prior to beginning assembly
d. Upon completion of each separate assembly
4. Construction Manager reserves the right to include additional milestones.
5. In the event the equipment is not to the stage of completion designated for
a milestone inspection or is not complete as required for a final inspection
at the time specified by the Fabricator, the Fabricator agrees to assume the
cost of the inspector's time and expenses and further agrees that such
charges be deducted from the cost of the equipment.
6. Construction Manager shall be allowed to photograph the equipment while
in-process and/or upon completion.
7. Construction Manager retains the right to employ the use of magnification
or other special viewing or measurement devices during inspection.
8. At the time of final inspection, the Fabricator shall assure that the
equipment is cleaned of all foreign material and workings which might
block the view of the Construction Manager. The equipment shall be in a
position that allows for easy access and viewing and, at the request of the
Construction Manager, shall be moved to allow viewing of all parts of the
equipment.
9. Evidence of poor workmanship or lack of compliance with any aspect of
the contract documents will be grounds for rejection of the equipment.
10. Subsequent repair of rejected equipment may, at the Construction
Manager's option, be undertaken in an attempt to bring the equipment to
an acceptable state. Repair procedures must be approved by the
Construction Manager prior to implementation.
D. CONSTRUCTION MANAGER'S ACCEPTANCE:
1. The Construction Manager may employ destructive testing, such as
ultimate tensile or flexural strength tests or glass content ignition tests, on
available samples or use other non-destructive test methods, such as
acoustic emission or ultrasonic polygauge thickness measurement, on the
completed equipment for verification of compliance to the contract
documents.
2. Testing performed by the Construction Manager shall be accomplished
through use of applicable ASTM test methods when appropriate.
3. Hardness tests shall be made for acceptance by the Construction Manager
on the liner surface using the Barcol impressor, Model GYZJ 934-1,
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calibrated at two points in accordance with ASTM D2583. Ten readings
will be taken in a localized area, deleting the two highest and two lowest,
and averaging the remaining six. Minimum acceptable Barcol hardness
will be a reading of 30, unless otherwise specified in the pertinent
equipment section.
4. An acetone sensitivity test shall also be performed by the Construction
Manager as an acceptance criterion. Evidence of a sticky or tacky surface
following rubbing with an acetone-saturated cloth shall be grounds for
rejection of the equipment.
2.05 SHIPPING

A. VESSELS:
1. The Fabricator shall be responsible for proper packaging, loading, and
protection of all materials to prevent transit and handling damage.
2. All equipment which is shipped in a horizontal position shall be mounted
on padded cradles contacting at least 120 degrees of the vessel
circumference. All end blocking used to prevent shifting of equipment
must be padded.
3. Equipment shall be loaded with a minimum clearance of two inches
between pieces (including external fittings, nozzles, or other projections)
and the bed of the car or truck. When two or more units are shipped
together, sufficient clearance shall be provided between units to prevent
contact in transit.
4. Flange faces shall be protected by coverings of suitable plywood or
hardboard, securely fastened.
5. Loose parts such as fasteners, gaskets, and accessory fittings shall be
packaged securely to allow storage under field conditions.
6. All dry FRP field joining materials shall be precut in the shop and layered
in order of laminate sequence, then labeled and packaged in sealed,
moisture-proof containers for shipment.
7. When a number of loose items or field joining materials are packed in
larger shipping crates, each crate will be individually marked or tagged as
to its contents, clearly listing number and type of each item contained
therein.
B. DUCTWORK: NOT USED
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2.06 HANDLING FRP EQUIPMENT

A. The equipment shall not be rolled, slid, dropped, allowed to swing into other
objects, or forced out of shape. Resulting impact and excessive distortions may
cause cracking or crazing.
B. When working in or around FRP equipment, care should be exercised to prevent
tools, scaffolding, or other objects from striking or being dropped on or inside the
equipment. Soft-soled shoes should be worn by workers entering the equipment.
C. Proper rigging and hoisting practices shall be observed at all times.
D. The use of a crane is recommended both in lifting and positioning the equipment.
Ideally, the slings or cables attached to the equipment should lift as nearly vertical
as possible, and shall under no circumstances shall slings or cables lift more than
45 degrees from vertical. A spreader bar (lifting fixture) may be necessary to
keep the lifting angle within this range.
E. Lifting lugs in most cases are not designed to accommodate lifting vessels in or
from the horizontal position. Nylon slings encircling the tank should be used for
this purpose and for righting the vessel to the vertical position.
F. Unless otherwise specified, use all lifting lugs, loaded uniformly for lifting
vessels in the vertical position. The use of spreader bars is recommended to keep
loads on lugs as nearly vertical and uniform as possible.
G. When lifting lugs are not provided, and it is necessary to use lifting slings in
direct contact with the FRP equipment, the slings shall be woven nylon or canvas
at least 3 inches wide. Care must be taken to assure that shackles, eyes, hooks, or
other objects do not come into contact with the FRP equipment.
H. Do not attach lifting slings or cables to (nor allow them to come in contact with)
any nozzles, flanges, gussets, or fittings other than lifting and/or anchor lugs.

PART 3--EXECUTION

3.01 GENERAL

FRP specialties shall be shipped, installed, joined and erected under the direction of
factory-trained specialists. Where jointing is required, workers employed for these efforts shall
have been trained in proper jointing techniques by the Fabricator. Fabricated equipment shall
have the warning, "Plastic Equipment Handle with Care" stenciled on two sides in letters a
minimum of 2 inches high.

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3.02 ASSEMBLY AND ERECTION PLANS

Prior to assembly and erection of FRP towers, tanks, stacks and similar structures, the
Contractor shall provide assembly and erection plans prepared by the Fabricator. The plans shall
provide details on handling, field connections and final installation.


**END OF SECTION**