Please note, this is a technical article describing the steps to a successful FRP joint installation. If you are looking for information on RPS Field Service installation, please visit the Field Service page.
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In our previous article, we looked at basic principles for designing and fabricating supports for an FRP piping system. In this, our final article in the series, we are going to take a look at installation of FRP piping systems.
While installation might not typically be considered as part of the pipe system design, it is such an important part of a successful system that we believe it needs to be emphasized here. Without doubt, more issues arise in FRP piping systems due to improper installation than due to any other single cause. There are a number of steps that must be followed to provide assurance that problems won’t arise later, and also to comply with the requirements of ASME NM.21.
These steps include:
For any FRP piping system, the manufacturer should prepare jointing instructions that apply to the specific piping system of interest. This would include general instructions that apply to almost any FRP jointing operation, and should also include specific instructions for each type of joint and each size of pipe of interest. General instructions would typically address issues such as safety, required tooling, appropriate ambient conditions, surface preparations, etc. Specific instructions would include laminate sequences and reinforcement dimensions. Collectively, these instructions are referred to as the Bonding Procedure Specifications or “BPS”. This is the terminology used in the ASME piping codes, i.e. B31.1 “Power Piping” and B31.3 “Process Piping”, as well as the new ASME standard for FRP piping, NM.21, and is completely analogous to the Welding Procedure Specifications used for metallic piping systems.
While all of the instructions must be followed for proper jointing, it is worthwhile emphasizing the need for proper surface preparation. It is probably safe to say that no single step in the jointing process is more important than the surface preparation. If this is not done properly, there is a very good chance there will be problems later.
Once the BPS has been prepared it needs to be qualified. There are a number of differences between B31.1 and B31.3 and NM.2 with respect to the requirements for procedure qualification, but in all cases, a sample spool must be assembled, examined for quality, and pressure tested. In the case of B31.3 and NM.2, the test spool must include each type of joint to be qualified, and the spool must survive a pressure test of 3 times the design pressure for 1 hour. A record is prepared to document the specifics of the jointing process and the results of the qualification testing. This record is referred to as the Procedure Qualification Record, or “PQR”.
Once the BPS has been qualified, the bonders themselves must be qualified to make joints using that procedure. The first step in this process is to ensure the bonders are properly trained. This would typically include a 2 – 3 day training course by the pipe manufacturer, and would address all aspects of bonding from proper storage and handling of materials, to joint preparation, and laminating techniques. RPS regularly conducts these types of courses for 3rd party installation teams and owners’ maintenance staff. RPS can also provide further installation services including quality control of jointing operations, supervision of installation crews, and full responsibility of jointing and installation activities.
After a bonder has received appropriate training for the type of joint to be made, he/she assembles a similar test spool to that used for the procedure qualification. Again, the spool has to be examined for quality and pressure tested. The same requirements apply for the bonder qualification as for the procedure qualification. Each qualified bonder is assigned a unique identifier so that each joint made by that bonder can be traced to the bonder. A bonder remains qualified to the procedure for as long as they continue to make joints using that procedure. A bonder would have to be re-qualified if he/she did not use the procedure for more than 6 months, or if there were any reason to question the bonder’s ability make joints to the BPS.
A record is prepared to document the results of the bonder qualification. This record is referred to as the Bonder Qualification Record, or “BQR”.
After examination of the completed joints, the final step in ensuring the joints have been properly made is the performance of a hydrotest. ASME B31.1, B31.3, and NM.2 all require piping systems to be tested prior to being put into service. This is usually accomplished with a hydrotest at a pressure of 1.33 to 1.5 times the design pressure for the system. The pressure is held for a minimum of 10 minutes after which the joints must be examined for leaks.
Fiber-Reinforced Plastic (FRP) is a lightweight, durable composite of fibers (e.g., glass, carbon) and resin (e.g., polyester, epoxy). It’s used in construction, automotive, aerospace, and DIY projects for its corrosion resistance and strength. Costs range from $2–$20 per square foot. This guide covers composition, manufacturing, applications, costs, and more.
Wondering what FRP plastic is and how it’s used? This beginner’s guide explains everything you need to know about fiber-reinforced plastic, from its benefits to practical applications, in a clear, easy-to-read format. Whether you’re exploring industrial uses or DIY projects, we’ve got you covered.
Fiber-reinforced Plastic, or FRP plastic, is a strong yet lightweight composite material made by combining a plastic resin with reinforcing fibers—usually glass, carbon, or aramid. This blend creates a material that’s tougher, more durable, and more resistant to wear than regular plastic.
You might’ve also heard terms like fiber-reinforced polymer, FRP composite, or glass-reinforced plastic (GFRP). These are often used interchangeably, but here’s a quick distinction: fiberglass or GFRP refers specifically to FRP made with glass fibers. In contrast, FRP can be reinforced with various fiber types, not just glass. According to the Composites Manufacturing Magazine (), FRP’s versatility stems from its customizable fiber-resin combinations.
Fiber-reinforced plastic (FRP) traces its roots to the early s with the invention of Bakelite, one of the first synthetic plastics. By the s, researchers began experimenting with adding fibers—like glass—to plastic resins to improve strength and durability.
The breakthrough came during World War II, when fiberglass-reinforced plastic was used in radar domes and aircraft parts. It was light, strong, and easy to mold—perfect for military needs. For example, the Boeing B-29 Superfortress used FRP components to reduce weight by 15% compared to aluminum (Journal of Composite Materials, ).
After the war, FRP quickly found its way into civilian industries. From boats and cars to pipes and buildings, its unique mix of strength and flexibility made it a go-to material. Today, FRP is everywhere, and it continues to evolve with new fiber types and smarter resins.
At its core, FRP is made from two key ingredients: fibers and a plastic resin. The fibers give the material strength. The resin holds everything together and gives it shape.
The most common fibers used are:
Then comes the resin, also called the matrix. It’s usually a thermosetting plastic like polyester, epoxy, or vinyl ester. The resin surrounds the fibers, protects them from damage, and transfers loads between them.
Think of it like this: the fibers are the bones, and the resin is the skin. Together, they form a tough, reliable material that outperforms regular plastic.
The Fiber-reinforced plastic (FRP) manufacturing process depends on what the final product needs to do—be it strong, flexible, lightweight, or all of the above. But in every case, it’s about combining fibers with resin in a way that maximizes performance.
Case Study: The San Francisco-Oakland Bay Bridge used pultruded FRP rebar to reduce corrosion and extend lifespan by 20 years (Civil Engineering Journal, ).
For DIY Enthusiasts: Hand lay-up is accessible for small projects like custom panels or furniture. Materials cost $10–$50 per square meter, depending on fiber and resin type.
So, what makes FRP stand out?
FRP isn’t just tough—it’s versatile. That’s why you’ll find it in almost every major industry today.
Case Study: Tesla’s Model 3 uses carbon FRP in its battery enclosure, reducing weight by 10% compared to aluminum (Automotive Engineering Review, ).
Why choose FRP over other materials? It all comes down to performance and practicality.
If you are looking for more details, kindly visit FRP Pipes.
FRP has challenges.
One major challenge is recycling. Since FRP is a mix of fibers and resin, it’s harder to break down or reuse compared to single-material products. Most FRP waste ends up in landfills, which raises sustainability concerns.
There’s also the issue of brittleness under certain loads. If not properly designed, FRP can crack or delaminate under impact or long-term stress.
And while it’s heat-resistant to a point, extreme temperatures can weaken some types of resin (e.g., polyester FRP degrades above 120°C).
Still, innovations are underway. New bio-based resins and greener manufacturing methods are being developed to reduce FRP’s environmental footprint—so the future looks promising.
FRP is often compared to materials like fiberglass, carbon fiber, metal, and even PVC—and for good reason. Each has its strengths, depending on the job.
If you’re wondering how FRP stacks up against fiberglass, we’ve already covered that in detail [in this article → FRP vs Fiberglass: What’s the Difference?]. It breaks down the key similarities and differences to help you choose the right fit.
Compared to metal, FRP is lighter and corrosion-resistant, making it easier to handle and more durable in harsh environments. And when stacked against carbon fiber, FRP is more affordable, though not quite as strong or lightweight.
Even traditional materials like wood or PVC can’t match FRP when it comes to long-term durability and weather resistance.
Material Weight (kg/m³) Cost ($/m²) Corrosion Resistance Tensile Strength (MPa) FRP 1,800 $2–$20 High 300–1,500 Steel 7,850 $1–$5 Low 400–1,200 Aluminum 2,700 $5–$10 Medium 100–400 PVC 1,400 $1–$3 High 40–60 Wood 600–800 $1–$4 Low 20–100Not all FRP is created equal. The right choice depends on what you need it to do.
Start with the fiber type. If you need affordability and general strength, glass fiber (GFRP) is a solid pick. For high-performance parts where weight really matters—like in aerospace—carbon fiber may be better. Aramid fibers are great for impact resistance.
Read more: Fiberglass vs Carbon Fiber Reinforced Plastic: Which One Should You Use and Why?
Then, consider the resin. Polyester is cost-effective. Epoxy offers high strength and chemical resistance. Vinyl ester is a good middle ground.
Also think about the manufacturing method. Pultrusion is great for uniform parts like beams. Hand lay-up works well for custom shapes. Each method affects the finish, strength, and cost.
Finally, match your FRP to your environment. Will it face chemicals? Heat? Outdoor exposure? A little planning ensures your FRP performs exactly the way you need it to.
Checklist for Choosing FRP:
FRP isn’t standing still—new developments are making it even better.
One big trend is sustainability. Manufacturers are exploring bio-based resins and natural fibers like flax or hemp to reduce environmental impact. These eco-friendly options aim to solve FRP’s recycling challenge without losing performance.
There’s also a push toward smart composites. Imagine FRP that can sense stress, temperature, or damage in real time. That’s already in the works.
And as 3D printing evolves, we may soon see custom FRP parts made on demand, cutting waste and speeding up production.
Is FRP waterproof? Yes. FRP is highly water-resistant, which is why it’s used in boats, bathrooms, and outdoor structures. It doesn’t absorb moisture or swell like wood.
Can FRP be recycled? It’s tricky. FRP isn’t easily recyclable because it’s made of mixed materials. But newer methods and bio-based alternatives are in development.
Is FRP stronger than steel? FRP isn’t stronger in all ways, but it has a better strength-to-weight ratio. That means it can deliver similar strength at a much lower weight.
Can FRP handle heat? Yes—but only to a point. High temperatures can affect certain resins. For high-heat use, specialized heat-resistant FRP is recommended.
Is FRP safe for food or medical use? Some FRP products are made to meet food-grade or medical standards. Always check for certifications if safety is a concern.
What’s the best way to use FRP in DIY projects? Use GFRP with hand lay-up for garden structures or furniture ($10–$50/m²)
How much does FRP cost? GFRP: $2–$5/ft²; carbon FRP: $15–$20/ft².
Fiber-reinforced plastic (FRP) might seem complex at first, but it’s really just a smart mix of strength, flexibility, and durability. From construction sites to car factories, it’s helping industries build better, lighter, and longer-lasting products.
EuP Egypt, a member of EuP Group – a leader in the masterbatch industry since , provides high-performance materials for industries like automotive and construction. Certified to ISO and ISO , we’ve supplied glass fiber-reinforced engineering compounds for over 500 projects, including electrical enclosures and bridge panels.
For more information, please visit Glass lined accessories.