PIP/Materials/TBT-PIP-012

GRP Pipe Installation

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GRP Pipe Installation

Toolbox Talk Record

Ref: TBT-PIP-012  |  Issue: 1  |  Date: March 2026
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What?

  • Glass reinforced plastic (GRP) pipe is a composite material used for sewers, process lines, and water mains.
  • GRP pipes are lightweight compared to concrete or ductile iron but can be brittle if mishandled.
  • Cutting GRP generates fine glass fibre dust that irritates the skin, eyes, and respiratory system.
  • Joints are typically made using couplings with elastomeric seals or laminated overwrap connections.
  • The pipe must be bedded and surrounded with granular material to the specified compaction levels.
  • Point loading from rocks, concrete lumps, or poorly graded backfill can crack the pipe wall.
  • GRP pipes must be stored on flat ground with cradles or bearers to prevent deformation.
  • Laminated joint connections involve resin and glass fibre matting that require COSHH controls.
  • Deflection testing after installation verifies the pipe has been properly bedded and supported.
  • UV exposure can degrade GRP pipe surfaces — prolonged storage outdoors should include UV protection.

Why?

Dust hazardsCutting GRP releases glass fibre dust that causes severe skin irritation and respiratory harm without controls.
Product integrityGRP is brittle under point loads — improper handling, bedding, or backfill can crack pipes and cause joint failure.
Chemical exposureLaminated joints use polyester or epoxy resins that require COSHH assessment and skin protection.
Do Don't
  • Wear RPE, eye protection, and long sleeves when cutting GRP pipe
  • Use a diamond blade or fine-toothed saw designed for composite cutting
  • Bed the pipe on granular material free from rocks and sharp objects
  • Compact backfill in even layers as specified to prevent point loading
  • Store pipes on flat ground with cradles to prevent rolling and deformation
  • Follow the COSHH assessment for resin and hardener used in laminated joints
  • Inspect each pipe length for cracks or damage before lowering into the trench
  • Complete deflection testing after backfilling to verify proper installation
  • Protect stored GRP pipes from prolonged UV exposure with covers or sheeting
  • Use appropriate lifting slings — chain slings can damage the pipe surface
  • DON'T cut GRP pipe without RPE and eye protection — glass fibre dust is harmful
  • DON'T drop, drag, or roll GRP pipes along the ground during handling
  • DON'T bed GRP pipe on ungraded material containing rocks or concrete lumps
  • DON'T compact backfill directly over the pipe with heavy equipment
  • DON'T stack GRP pipes higher than the manufacturer's recommended limits
  • DON'T apply resin for laminated joints without gloves and skin protection
  • DON'T use damaged or cracked pipe lengths — reject and replace them
  • DON'T store GRP pipes in direct sunlight for extended periods without UV covers
  • DON'T use chain or wire rope slings to lift GRP pipes — use webbing slings
  • DON'T skip deflection testing — it confirms the pipe is properly supported

See also: Pipeline Safety Awareness | Pipe Material Selection and Handling
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