AN INTRODUCTION TO

GRP Products
 ohnston Pipes Limited has been operating at

J Doseley, Telford since 1904; there are two main areas

of activity, GRP and Concrete. Established in the
early 1970’s the GRP (Glass Reinforced Plastic) pipe
factory is dedicated to the supply of pipes and fittings
both nationally and internationally for use in a wide
variety of applications.

The Concrete division manufacture concrete drainage

products, which are supplied throughout the United
Kingdom for use in sewerage and storm water pipelines.

Product Origin
HOBAS Engineering of Switzerland developed the centrifugal casting
process for Glass Reinforced Plastic (GRP) pipes manufacture in the 1960s.
Centrifugal casting of GRP offers several unique advantages over filament
winding techniques. The thick inner core of aggregate gives improved
strength and robustness to the product. The pipe also can carry a thicker
gel coat for improved corrosion and abrasion resistance.
Johnston Pipes recognised these benefits and became the first licensee, in
1973, to manufacture GRP pipes using the HOBAS technique. Today, the
company continues to build on its experience by offering new products
such as Stormfox and Egg-shaped liner units.

Quality Assured
Every pressure pipe and joint is tested to 1.5 times working pressure before
leaving our Telford works.

BS5480: 1990 Product Standard.

BS EN ISO 9002. 1990 Quality System Standard and in transition to
BS EN ISO 9000: 2000

Every unit is thoroughly inspected as part of the quality control
system.

Further Information
Please contact either our Sales or Technical team on:-
Sales Hotline: 01952 632330 Fax: 01952 503833 / 632323
Website: www.johnston-pipes.co.uk
Email: grpsales@johnston-pipes.co.uk

Technical Support Services

Johnston Pipes provide on-going technical support to customers:

The design and detailing of pipes, fittings, joints and
specials, to customer specification.

Supplying technical information on GRP pipes and fittings.

Liaison with the client engineer, pre-contract, to assist
with the design of the pipeline.

Site Support Services

A full after-sales back-up and installation advice service is provided, to
include:

On-Site presentations on the handling and storage of GRP pipes
& fittings.

On-Site advice upon the installation (before and during) of GRP
pipes & fittings.

Advice on the testing of pipeline systems and commissioning,
once installed.

Post installation advice on maintenance/additional work to GRP
pipelines with presentations and manuals for the water
company operatives.

Contractors Certification scheme.

01 JOHNSTON PIPES LTD

 Product Range
STANDARD PRESSURE CLASSES Diameters marked with ∆ are dimensionally
compatible with ductile iron pipes and fittings.
NOMINAL INTERNAL

OUTSIDE DIAMETER
DIAMETER (DN) MM

GRP Fittings
LENGTH (M)
FULL PIPE

O.D. (MM)

Glass Reinforced Plastic (GRP) fittings are made in

10 BAR

16 BAR

24 BAR
0 BAR

6 BAR

both standard and non-standard forms to customer

specification.
Fittings are available for non-pressure and pressure
300∆ 6 324 ✔ ✔ ✔ ✔ ✔ applications.
Protected ductile iron, coated steel or stainless steel
350∆ 6 376 ✔ ✔ ✔ ✔ ✔ fittings are compatible and may be used with all
classes of GRP pipes.
400∆ 6 427 ✔ ✔ ✔ ✔ ✔ Examples of types of fittings include:

Bends - to any specified angle (even horizontal
450∆ 6 477 ✔ ✔ ✔ ✔ ✔ and vertical changes of direction in a single
bend).
500∆ 6 530 ✔ ✔ ✔ ✔ ✔
Tapers - Concentric and level invert.

Tees and Branches - Equal and unequal,
✔ ✔ ✔ ✔ ✔
square or angled.
616 6 616

Manholes - side entry, straight through
or with change of direction.
633∆ 6 633 ✔ ✔ ✔ ✔ ✔

Bellmouths - Integral or flanged.

Any combined fitting of above.
700 6 718 ✔ ✔ ✔ ✔
Every pressure pipe is tested to 1.5 times working
800 6 819 ✔ ✔ ✔ ✔ pressure before leaving our works.

900 6 923 ✔ ✔ ✔ ✔
All information is provided as a guidance only.
1000 6 1026 ✔ ✔ ✔ ✔

1100 6 1143 ✔ ✔ ✔

1200 6 1226 ✔ ✔ ✔

1300 6 1348 ✔ ✔ ✔

1400 6 1448 ✔ ✔ ✔

1500 6 1534 ✔ ✔ ✔

1600 6 1638 ✔ ✔

1700 6 1740 ✔ ✔

1800 6 1841 ✔ ✔

1900 6 1943 ✔ ✔

2000 6 2045 ✔ ✔

2100 5.7 2105 ✔ ✔

2200 6 2249 ✔ ✔

2300 5.7 2397 ✔ ✔

2500 3.1 2555 ✔ ✔

JOHNSTON PIPES LTD 02

 Applications
Pipe Jacking
Twice the compressive strength of concrete.
Smooth outside surface with in-wall joints.
Potentially lower jacking loads.
Resilient material improves distribution
of jacking forces.

Above Ground Pipelines

Weathering and UV degradation protection
are accommodated during manufacture.
Natural sand colour blends in with the
environment
Simple support details.
6m lengths as standard.

Treatment Works
Reduced number of fittings and flanged joints.
Economical low pressure pipes when required.
Flexible and harnessed joints available.
Fully detailed drawings supplied.

Reservoirs
Potable water approval available on the inside and
the outside of the pipes.
Provides an excellent solution to DWi approval
requirements.
Full range of fittings available.
Lightweight, easy handling in retrofit applications.
Corrosion Resistant.

Hydroelectric Schemes
Lightweight, easy handling on difficult terrain.
Robust pipes ideal for harsh environments.
Pipe pressures can be taylored to suit pressure
differentials along the line.
Unaffected by acidic groundwater.
Low wave speed velocity reduces peak surge
pressure.
Pipes suitable for surges +_ 25%PN as standard.

03 JOHNSTON PIPES LTD

Applications
Trunk Water Mains
Suitable for urban and cross-country pipelines.
Suitable for POTABLE and raw water as approved by
DWi under regulation 25(1)(a) of the 1989 Water Act.
Corrosion resistant in all naturally occuring soils.
Full range of diameters and pressure ratings.
Push-fit jointing system.
Can be installed with selected as-dug material.

Re-Lining
Quality assured, factory made lining units.
Rigidity to resist grouting forces.
Lightweight for easy handling.
In-wall and pressure joints as required.
Circular, egg-shaped, and segmented units available.

Sewage Rising Mains

Corrosion resistant material to suit industrial effluents.
Excellent abrasion resistance.
Can be cut to length on site.
Lightweight for site handling.
Suitable for surge and cyclic pressures.

Marine Pipelines
Inherently corrosion resistant material.
Easily handled and jointed by divers.
Negative buoyancy.
Heavy duty thick walled pipes available.

Power Station
Cooling Systems
& Industrial Effluents
Up to 2500mm diameter and operating
temperatures to 75˚ are available.
Make-up and purge lines for saline
water cooling water circuits.
Pipe pressure rating to suit the application.
All types of purpose-built fittings typical.

JOHNSTON PIPES LTD 04

 Features Benefits

Corrosion Resistant Suitable for all natural ground conditions

(Acidic/saline/soils of low resistivity).
No need for cathodic protection systems as
GRP pipes do not suffer from electrolytic corrosion.
No need to line GRP pipes with protective coatings.
Ideal pipe for relining of corroded pipelines.
Unaffected by stray electrical ground currents.
No pitting of exterior walls by aggressive soils.

High Stiffness GRP pipes can be buried to depths exceeding 15m.

Pipes Pipes will resist full vacuum.
Performance is predictable and reliable.
Can be installed with selected as-dug material.

Smooth Colebrook White roughness coefficient ks=0.03mm.

Minimal sliming and maximum velocity due to
Internal
smooth inside surface.
Surface Reduced pumping costs due to low friction losses.
Reduced pipe diameters required due to low friction
losses.

Constant Pipes can be cut and jointed, on site, at any point

along their length, leading to little wastage.
Outside
Pipes are ideal for use with many proprietary
Diameter mechanical couplings.
Less friction produced with jacking pipes.

Choice of Standard and non-standard fittings manufactured.

Any degree of bend available.
Fittings
Many configurations of fittings available.
Fittings delivered with the pipes.
Fabricated fittings are made of the same material.
GRP pipes are compatible with most other pipe
material fittings.

Approximately 1/10th the weight of concrete pipes.

Lightweight
Approximately 1/5th the weight of iron pipes.
6m Lengths
Lower installation costs.
Reduced transport costs, due to the ability to ‘nest’
the pipes.
Reduced environmental impact due to fewer vehicle
movements.

05 JOHNSTON PIPES LTD

 Benefits Features

Standard joints available from stock. Push Fit Sleeve Couplings

Easy jointing.
Captive rubber seal saves time - each GRP pipe has
one coupling pre-fitted.
Reduced installation cost.
The leak tight performance of GRP couplings is
unsurpassed by any other type of gasket joint on the
market.

Pressure rating to suit application.

Variable pipe pressure ratings means lower overall Choice of Pressure Rating
cost.

Little reduction in flow area or coefficients, due to

smooth internal surface aiding self-cleaning.
Non Tuberculating
GRP pipes have an abrasion resistance equal to other
plastics and better than cementitious pipe materials. Abrasion Resistant
No need to line GRP pipes with protective coatings.
Economic whole life costs of pipes. Resistant to Chemical &
Design life of pipes in excess of 100 years, if required Biological Attack
(50 years as standard).

For re-lining projects this permits a greater recovery

of flow in rehabilitated pipelines.
Superior Strength: Wall Thickness
GRP pipes can be designed to carry the full Ratio
structural dead and live loads with no support from
the existing pipes.

GRP pipes have a jacking compressive High Axial Compressive Strength

strength of 90 MN/m2.

Consistent, reproducible quality. Computer Controlled

Quality assured to BS EN ISO 9002.
Production
Over 30 years performance record. Proven
Produced throughout the world by over 20 factories.
Performance

JOHNSTON PIPES LTD 06

 Joint Selection
Several joint designs are available
to meet the requirements of many
different applications. The FWC
coupling is normally utilised for
direct bury, above ground and
some other installations. Lining,
jacking and tunnel installations
can have in-wall joints.
Service
DIRECT BURY
Non-Pressure > FWC Coupling
Pressure > FWC Coupling
ABOVE GROUND
Non-Pressure > FWC Coupling
Pressure > FWC Coupling
LINING
Non-Pressure > In-Wall Joint
Pressure > Pressure Dependent
JACKING
Non-Pressure > In-Wall Joint
Pressure > Pressure Dependent
TIE-INS
Non-Pressure > Mechanical
Coupling/ Flange Adaptor
Pressure > Mechanical
Coupling/ Flange Adaptor
07 JOHNSTON PIPES LTD
Standard FWC Joint
FWC Joint
GRP pipes are jointed utilising the unique sleeve collar joint (FWC
joint). This consists of a corrosion resistant GRP wrapping bonded
mechanically and
chemically to the
full width EPDM
rubber sealing
profile. The FWC
joint is normally
delivered to site
already jointed onto
one end of the pipe
or fitting, or can be
supplied separately to allow for the re-use of off-cuts.
Usage
The site operative has only to ensure the joint is clean and lubricated
before pushing home the joint. This activates the twin seals on that
side of the joint. There is one compression seal on each outer edge
and a twin pressure activated seal on each side of the central
register.
The pipe joint is designed for use with plain-ended pipe hence the
joint will fit at any point along the length of a pipe. This enables
short length pipes to be cut on site and then jointed with minimal
delay. The joint has a low profile against the pipe barrel and
protrudes only approximately 25mm. As the joint is a ‘non-integral’
part of the pipe barrel it tends to follow any changes in shape of the
pipe without generating stress concentrations.
The rubber central register acts as a positive aid to the contractor to
obtain an even joint gap between pipe ends. This is advantageous in
the event of possible pipeline settlement or longitudinal expansion.
The joint has sealing profiles on either side to accommodate a
maximum straight draw up to 35mm or angular deflection. Details of
the dimensions and weights of joints are given in pipe products and
design guide.
Other Joints
Location Joint
The location joint is an in-wall joint using a GRP band. The main use of the
joint is for non-pressure lining applications (e.g. sewer renovation). A mastic
sealant is typically used to provide an airtight seal and prevent grout ingress.
Stainless Steel In-Wall Joint
This can be used as an alternative
to the GRP location joint or jacking joint.
Jacking Joint
Similar in form to an in-wall location joint with a sealing gasket. Used for
pipe jacking applications.
Harness Joint
The harness joint consists of a metal harness with tie rods
and nuts as appropriate. The joints are used where a
continuous pipeline is required in order to restrain bends,
vertical pipe work or other instances where longitudinal
loads cannot be restrained externally. With this jointing
arrangement thrust blocks are not required. Harness Joint

Hobas DC Locked Coupling

The Hobas DCL coupling is an all GRP coupling, up to
1200mm diameter, BUT is used only for low pressure/low
tensile applications. (i.e. Max. 2 bar pressure, on DN 1200).
Refer to the technical department for usage of these joints.

Flanged Joint Hobas DC Locked Coupling

Where connection to flanged units is required, GRP flat
faced flanges or GRP stub flanges with backing rings are
available. These flanges can be used on pipelines to resist
longitudinal loads, or make a connection to other flanged
pipework that is subject to internal pressure. Non-standard
bolt patterns can be provided.

Flange Adaptors
A flange adaptor is a mechanical coupling to
enable a plain ended pipe to be connected to Flanged Joint
a flanged pipe or fitting.

Mechanical Couplings
Standard mechanical couplings are couplings consisting
of rubber seals and tightening systems. (e.g. VJ Type or
TeeKay couplings) and are used for tie-ins and connections
to other pipe materials.

Ductile Iron Joints Flange Adaptor

The outside diameter of GRP pipes up to and including
600mm nominal diameter are compatible with standard
ductile iron sockets. This enables existing stocks of DI
fittings to be incorporated into GRP pipelines where
corrosion resistance is not critical.

Butt & Strap Joint

A butt and strap joint is a connection fabricated using resin
and glass reinforcement to form a continuous or longer
length pipe. Mechanical Coupling

Location Joint Butt & Strap Joint

Jacking Joint Stainless Steel Joint

JOHNSTON PIPES LTD 08

Stormfox Benefits of Stormfox

Designed to fit
GRP Modular Prefabricated C.S.O Units
Cost effective
Johnston’s Stormfox design is an innovative CSO that provides
High strength specification
a solution to the problem of storm water overflows. It has been
developed to fall in line with the AMP3 programme and
Eliminates overflow of
Environment Agency ruling which requires water companies to
reduce the size of particles being discharged into rivers. oversized particles

Ease of use & installation
The GRP modular prefabricated CSO system can be designed
to fit numerous locations. The lightweight units are cost
Quicker & safer installation
effective, quick to install and can be assembled to form tank
storage, high-sided weir units, floatables storage or stilling
Improved system
pond CSO’s, as required. A full selection of screen systems
can be built-in prior to delivery to site, ready for connection to

Reduced costs
the new or existing pipework.
Complete package delivered
Dry weather flow benching is often pre-built to site with clients preferred
into the Stormfox and other pipeline screen
products to provide a narrower

Reduced disruption to traffic
channel with improved flow
characteristics during drier weather. in the installation area
The type of benching provided can
be based on client specifications.

09 JOHNSTON PIPES LTD

Non-Circular Liners
Johnston Pipes have developed a
range of non-circular liners building on
its long experience using centrifugally
cast GRP pipes in circular lining
projects. The units are filament wound
on moulds that can be bought
specifically for the project. The
finished units are robust and of
exceptional quality.

Benefits of Our Liners

Lightweight

Strong

Resilient

Highest quality

Quick delivery times

Meets client’s specific needs

Designed & tested to IGN 4-34-02

Bend units available

Low cost moulding

High tolerance jointing
Non-circular liners can be supplied
in segments, or as invert liners.

JOHNSTON PIPES LTD 10

 Further information

Please contact us for help and advice on any aspect of the use of GRP products.
Pipe Products Guide: a detailed study of GRP products available.
Design & Installation Guide: a very comprehensive study of factors to consider during design and installation.
Our website holds the electronic versions of useful documents such as technical advice sheets and brochures such as this one.

St Lukes Rd, Doseley, Telford, Shropshire TF4 3BX

TEL: (+44) (0) 1952 630300 FAX: (+44) (0) 1952 632323
Sales Hotline: (+44) (0) 1952 632330
E-mail: grpsales@johnston-pipes.co.uk
www.johnston-pipes.co.uk
Due to continual product development Johnston Pipes Limited
reserve the right to alter or change any of the specifications
detailed within this publication without notice.
October 2003