OPERATIONS & MAINTENANCE MANUAL FOR
GRP LINING WATERPROOFING
Date 03/21/2024
LOOTAH LOCI
LOCATED ON PLOT NO. JVC 14JMRP 002
ATJUMERIAHVILLAGECIRCLE
DUBAI, UAE
VERSION HISTORY
Ve Implemented Revisio Approved Approval Reason
rsi By n By Date
on Date
#
1 Sarathkumar S 03/21/24
O&M Manual Page 2 of 13
TABLE OF CONTENTS
1 INTRODUCTION .................................................................................................................... 5
1.1 Purpose .................................................................................................................... 5
2 SYSTEM DESCRIPTION ...................................................................................................... 5
2.1 Key Features ........................................................................................................... 5
2.2 ADDITIONAL FEATURES ..................................................................................... 5
2.3 MATERIALS and tools ........................................................................................... 6
2.4 Health & Safety ......................................................................................................... 7
3 STANDARD FIBREGLASS LINING PROCEDURES ....................................................... 7
3.1 Substrate preparation ............................................................................................ 7
3.1.1 Suitable Conditions .............................................................................................. 7
3.2 Primer application ................................................................................................... 7
3.3 Fibreglass lining application .................................................................................. 8
4 SYSTEM USAGE/REPAIR .................................................................................................... 8
4.1 Instructions ................................................................................................................ 8
4.2 Fibreglass (GRP) Repair ........................................................................................... 8
4.2.1 Identify the damaged area(s):............................................................................... 9
4.2.2 Remove loose debris: ........................................................................................... 9
4.2.3 Perform surface abrasion: .................................................................................... 9
4.2.4 Create a uniform repair section: ........................................................................... 9
4.2.5 Reinforce underlying substrate& Mask off area: ................................................. 9
4.2.6 Cut the glass fibre mat (CSM): .......................................................................... 10
4.2.7 Prepare polyester resin: ...................................................................................... 10
4.2.8 Apply the catalyzed resin to the glass fibre mat: ............................................... 10
4.2.9 Use a paddle roller to consolidate laminate: ...................................................... 10
4.2.10 Sand back laminate: ........................................................................................... 10
4.2.11 Prepare resin topcoat or preferred paint: ............................................................ 10
5 ROLES AND RESPONSIBILITIES .................................................................................... 10
5.1 Project Manager ...................................................................................................... 10
5.2 Project Engineer ...................................................................................................... 10
5.3 QA/QC Inspector/ Engineer .................................................................................... 11
5.4 Site Supervisor ........................................................................................................ 11
5.5 HSE Officer ............................................................................................................. 11
5.6 Technicians .............................................................................................................. 11
5.7 Helpers / cleaners .................................................................................................... 11
6 FAQS ....................................................................................................................................... 11
6.1.1 How long will a fibreglass lining last? .............................................................. 11
6.1.2 Can I use a Fibreglass lining instead of a full surface or structure
replacement? .................................................................................................................. 11
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6.1.3 Who installs fibreglass linings? ......................................................................... 12
6.1.4 How difficult is it to install a fibreglass lining? ................................................. 12
6.1.5 How does thickness affect fibreglass lining performance?................................ 12
APPENDIX A: OPERATIONS & MAINTENANCE MANUAL APPROVAL ......................12
APPENDIX B: REFERENCES .................................................................................................13
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1 INTRODUCTION
1.1 PURPOSE
The following O&M manual is designed to provide you with general guidance on how
to create a fibreglass (GRP) lining or coating and how its maintenance and repair
can be done. These instructions are intended to supplement Q&M manual and to
provide applicators with guidance on their fibreglassing work. The versatility of
fibreglass means it can be applied to a range of surfaces and shapes to provide
strong, durable protection. Furthermore, it can be sanded back to become almost
identical to the underlying structure.
2 SYSTEM DESCRIPTION
2.1 KEY FEATURES
• Inner & Outer protection
Because fibreglass GRP creates a seamless, homogenous layer that is fully bonded
to the underlying substrate, it protects gaps, holes, cracks, etc in your water tank and
manholes. Here the most vulnerable aspects of your surfaces, that is, layer facing
the greatest amount of physical stress from water pressure.whether they’re concrete
floors, internal walls of storage tanks, slab soffit all are protected. Because the fibres
provide a structural backbone and topcoat means that localized impact is spread
across a larger area, ultimately acting as a shock absorber for the underlying
surface.
• Virtually maintenance-free
Furthermore, the coating requires virtually no maintenance, can withstand repeated
power-washing and can expand and contract (typically 3 – 8 %) to more extreme
weather conditions, unlike more brittle resins.
2.2 ADDITIONAL FEATURES
Tailored strength: adjusting the ratio of resin to glass fibre mat can favour the lining
to greater flexibility, or conversely greater tensile strength.
Chemical Resistance: performance regarding the interaction of GRP linings with a
range of chemicals can also be evaluated by working with suppliers and
manufacturers.
Electrical conductor: glass fibre and its resin ingredients are poor conductors of
electricity, so close proximity to electrical hazards is not an issue.
Drinking water compatible: standard resins can leach trace amounts of resin into
water. For dry or occasionally wet surfaces, this is not a problem, but when in close
proximity to water used for drinking or aquatic lifeforms, a WRAS-approved resin is a
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necessity.
Non-slip surfaces: applications at high risk of slips and trips necessitate a non-slip
finished. Here, grit can be embedded into the external coating offering enhanced
grip.
Colour choices: BS and RAL colour schemes as well as transparent coatings where
appropriate.
Fire Retardant: although already low, the risk of fire can be further reduced
incorporating ingredients to conform to BS476: Part 7 Class II (surface spread of
flame) or Class 0 (combustibility) Class I flame spread. Flame retardant composites
made from fiberglass are well known.
Hygiene: Biological contaminants. Porous substrates like wood, concrete and
corroded metals provide a breeding ground. When applied, a glass fibre lining with a
topcoat finish offers a non-porous, homogeneous surface that also minimizes
surface-localised adhesion of biological components.
Thermal resistance: thermoset resins have a very high heat distortion point,
therefore, can be suitable where liquid temperatures are higher.
2.3 MATERIALS AND TOOLS
Followings are the main materials and tools which we are usually used in
GRP lining.
Materials
• Glass fibre chopped strand mat
• Unsaturated polyester resin
• Topcoat
• Catalyst/Hardener
Tools
• Paint brush
• Paddle roller
• Paddle roller
• Paddle roller
• Paddle roller
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• Polyester roller
2.4 HEALTH & SAFETY
Please familiarize yourself with the Material Safety Data Sheets (MSDS) before
starting.
Personal protective equipment (PPE) should be worn at all times.
Recommended PPE includes safety goggles, gloves and overalls. A suitable
mask is advised if work is being performed indoors. Use of the products in
applications not specified or not described in this manual, may result in
improper function, personal injury, or damage of the product or material.
3 STANDARD FIBREGLASS LINING PROCEDURES
3.1 SUBSTRATE PREPARATION
A brief visible and physical inspection will be performed to determine the
underlying qualities and the condition of the substrate material being lined will
determine the most suitable preparation method. Where the underlying material
still has its own inherent structure then high-pressure grit blasting is the most
efficient way to prepare the surfaces of the material to be lined. This is typically
used on tank walls. This will remove any existing corrosion, scale and process
residues.
3.1.1 Suitable Conditions
• Avoid water: good resin curing, and bonding requires dry conditions –
that is surface should be dried out and rain avoided by checking the
weather forecast. Be sure to plan ahead and check the weather in
advance for any rainfall.
• Temperature: any work with resin should be done at warm temperatures
ideally around 20ºC, as this ensures the resin will cure correctly. Resin
will not cure adequately below 15°C and may require catalyst
concentration adjustment. Temperatures above 30ºC may see curing
that is too fast.
• Dust and grease: any impurities present on the surface (e.g., dust,
grease, rust, etc.) – or in the surrounding atmosphere should be reduced
as much as possible. Resin bonding and curing is greatly affected by
impurities.
3.2 PRIMER APPLICATION
A primer is used to enhance the adhesion between the glass fibre lining and
the substrate. Due to its lower viscosity than the resin, it can penetrate
microcracks and pores, whilst also offering a strong bond between the
substrate and the glass fibre lining.
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3.3 FIBREGLASS LINING APPLICATION
Resin-saturated catalyzed glass fibre mat (usually 600 grams although 450
grams or 4 x 450 gram CSM ) is hand-laid on to the primed surface. A paddle
roller is used to drive out air and maximize surface contact with the substrate.
This layer is usually 3-5 mm thick with 5 cm overlaps are applied when wet to
avoid gaps maintain consistency.
The glass fibre chopped strand mat should be cut to size for each section of the
surface. This should be done prior to preparing the polyester resin, which
should have a catalyst content of 1 – 3 % depending on the type and quantities
required. This should be well mixed but also carefully mixed to avoid excessive
air. It should also be used promptly and so small amounts of resin should be
applied to manageable areas.
4 SYSTEM USAGE/REPAIR
4.1 INSTRUCTIONS
Whilst fibreglass (GRP) repairs have a high strength-to-weight ratio and
excellent durability, some reinforcement may be required to fibreglass
application. There is no one-size-fits all approach, but if the surface is
expecting impact, abrasion or other physical stress and the structure
underneath is hollow, then underlying reinforcement is strongly recommended
to provide a support structure.
Patch repairs are generally very effective for water storage tanks and
superficial damage or wear and tear. However, this manual does not specify
repair fillers and users should seek materials in line with the underlying
structure. Generally, water tank and manhole might be less complex, simply
relying on chopped strand matting fragments or layered matting. The purpose
of this manual is not to recommend a filler type but to detail the application of a
lining or coating made from fibreglass as a means of repair.
4.2 FIBREGLASS (GRP) REPAIR
Conducting regular inspections is the first step in maintaining your
waterproofing membrane.
The following section assumes adequate precautions have been taken to
ensure a safe working environment. It also assumes users have the correct
tools and materials available and have taken adequate care to prepare the
underlying pond structure and surface.
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4.2.1 Identify the damaged area(s):
when the problem area or areas have been identified, ensure it has been
drained of any liquid and is dry.
Note: moisture, chemical contaminants and other impurities like dust and
grease interfere with the resin binding process and weaken the repair.
4.2.2 Remove loose debris:
if there is excess debris on the surface, it may be more practical to remove that
first, prior to drying it out.
4.2.3 Perform surface abrasion:
sandblasting, shot blasting or any other form of abrasion can be used to scale
back damaged aspects of the surface. This is very specific to the surface being
repaired.
Note: if you are re-lining a larger region of the surface, it is advisable to remove
the existing lining by sanding back the existing surface. Depending on the
application, the level of abrasion required could range from sandblasting to grit
blasting if the existing layer is bound strongly to the underlying substrate.
Note: preferably, you want to have a rendered finish here with a slight texture.
This is to ensure the surface is fairly flat and smooth to allow the glass fibre
matting to be laminated onto.
Note: safety is a large consideration here. Care should be taken to avoid
exposure to dust and debris via inhalation (use a dust mask), eyes (wear safety
goggles) and skin (sharp debris can penetrate the skin).
4.2.4 Create a uniform repair section:
damaged regions are likely to have jagged edges with an irregular surface. To
assist in repairs, the user might want to consider creating a more uniform
section out of the repair. This can be created by cutting out the inside edge of
the damaged section. A uniform (square or rectangular surface) is desirable
and a 45o angle is preferrable as this will promote a more consistent ‘layered’
laminate. Note: larger repair sections without any underlying structure should
consider a support structure. In such instance, applicators may wish to use a
back mound to support the laminate prior to curing and prevent it from warping.
4.2.5 Reinforce underlying substrate& Mask off area:
Add reinforcement to the damaged area in line with the structural requirements.
Note: fibreglass is malleable until the resin has cured. As such, some repair
sections may require a back mound to support the laminate until it has cured.
Once reinforcement has been added, mask off the area with a suitable tape
slightly extending the masking tape by approximately 1 inch all around the
crack.
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4.2.6 Cut the glass fibre mat (CSM):
Measure the dimensions and cut to size using a Stanley knife or equivalent.
Note: cut and size the CSM in advance of resin application to pre-defined,
square meter sections. In such cases, the size should be around 10% larger
than needed to ensure complete coverage of the target surface. Note: when
preparing an overlap between two sections of CSM, ensure that the overlap is
around 5 cm. this will ensure a seamless barrier once cured.
4.2.7 Prepare polyester resin:
In a clean bucket, measure out a workable amount of polyester resin. An MEKP
catalyst needs to be added to the polyester resin prior to application to facilitate
curing. This is added in a 1 – 4 % weighted ratio to that of the resin. Amounts
added outside of this range will lead to sub-optimal curing and laminate failure.
4.2.8 Apply the catalyzed resin to the glass fibre mat:
Once the glass fibre has been fitted in place, a polyester roller should be used to
disperse and drive the resin into the mat, applying moderate pressure.
4.2.9 Use a paddle roller to consolidate laminate:
Immediately after the polyester roller has saturated resin in the glass fibre
matting region, use a paddle roller to refine the laminated surface. Moderately
roll the paddle roller across the laminate surface. If the surface is non-uniform,
consider using another instrument to ensure a consistent finish. Note: the aim
here is to drive air and bubbles out, whilst also ensuring a more consistent
resin-to-glass fibre ratio.
4.2.10 Sand back laminate:
once the laminate has cured and is not tacky to the touch lightly sand back the
surface using 180-grit sandpaper and remove any dust. Acetone may be
needed to fully clean surface.
4.2.11 Prepare resin topcoat or preferred paint:
once the laminate has hardened and has a mildly sticky texture to touch,
prepare the topcoat or paint.
5 ROLES AND RESPONSIBILITIES
5.1 PROJECT MANAGER
• Project Manager shall be responsible for the overall design integrity,
approval, resorting and meeting program milestone while maintaining
quality finishes.
• Provide his subordinates with the information they need to fulfill their
responsibilities.
5.2 PROJECT ENGINEER
• Ensure job completion on time as per approved schedule
• Ensure highest quality and safety on site
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5.3 QA/QC INSPECTOR/ ENGINEER
• Supervise of Quality Control activities involving all materials; undertake
the, more complex inspection and resolve technical and client issues on
Quality Engineering.
• Liaise with internal and external concerned parties to co-ordinate
presence at inspections.
• Carry out more complex Quality function activities, such as Procedure
Qualification Test.
5.4 SITE SUPERVISOR
• Ensures the work is done as per approved drawing
• Ensures good housekeeping at site at all times
• Ensures the method statement and risk assessment is followed on site.
• Maintain records of work done and submit to Project Engineer.
5.5 HSE OFFICER
• Safety Supervisor / TKS SSRS Card holder
• Monitor and implement all HSE related issues
• Arrange necessary HSE requirements at site
5.6 TECHNICIANS
• Undergone Confine Space Entry Training
• Technicians shall be skilled, experience and trained
• Technicians will be monitored and supervised by the Site Supervisor
5.7 HELPERS / CLEANERS
• Responsible to keep / maintain the area clean.
6 FAQS
6.1.1 How long will a fibreglass lining last?
Fibreglass has proven lifetimes of many decades, the overall life will depend on
the quality of the installation, the type of environment that the lining is exposed
to and the level of maintenance and repair work undertaken. Standard
estimates range from 10 to 50 years.
6.1.2 Can I use a Fibreglass lining instead of a full surface or structure replacement?
Yes, this is one of the reasons GRP linings are so popular. They can save a
substantial amount versus a full replacement, particularly on bunds, water
tanks, ponds, flat roofs, cooling towers and more.
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6.1.3 Who installs fibreglass linings?
In short, anyone can install one. However, the skill level will dictate the quality
of the outcome. Stranded uses trained specialists to install lining and coating
systems.
6.1.4 How difficult is it to install a fibreglass lining?
It is moderately difficult because there are a number of factors that can cause
the quality of the glass fibre laminate to be badly installed. Installers should
carefully follow the manufacturer’s instructions or choose a trained specialist.
6.1.5 How does thickness affect fibreglass lining performance?
In one study on composite-based liners, increasing the thickness from 4 mm to
6 mm reduced the failure rate from 2% to 0.09% for CFRP. For GFRP, an
increase from 4 mm to 6 mm resulted in a lower failure rate, from 10% to 0.3%.
It should be noted that this thicker layer resulted in a higher COV for thickness
– an indicator of variation – which can affect lining uniformity in more sensitive
applications.
Appendix A: Operations & Maintenance Manual Approval
The undersigned acknowledge they have reviewed the LoCi Residential
apartment JVC-002 Operations & Maintenance Manual and agree with the
approach it presents. Changes to this Operations & Maintenance Manual will
be coordinated with and approved by the undersigned or their designated
representatives.
Signature: Date:
Name:
Title:
Role:
Signature: Date:
Name:
Title:
Role:
Signature: Date:
Name:
Title:
Role:
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APPENDIX B: REFERENCES
The following table summarizes the documents referenced in this document.
Document Description Location
Name and
Version
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