An American National Standard

Designation: D 4024 – 00

Standard Specification for

Machine Made “Fiberglass’’ (Glass-Fiber-Reinforced
Thermosetting Resin) Flanges1
This standard is issued under the fixed designation D 4024; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (e) indicates an editorial change since the last revision or reapproval.

1. Scope D 1600 Terminology for Abbreviated Terms Relating to

1.1 This specification covers reinforced-thermosetting resin Plastics2
flanges other than contact-molded flanges. Included are re- D 1898 Practice for Sampling of Plastics4
quirements for materials, workmanship, performance, and D 5421 Specification for Contact Molded “Fiberglass’’
dimensions. (Glass-Fiber-Reinforced Resin) Flanges3
1.2 Flanges may be produced integrally with a pipe or D 5685 Specification for “Fiberglass” (Glass-Fiber-
fitting, may be produced with a socket for adhesive bonding to Reinforced Thermosetting-Resin) Pressure Pipe Fittings3
a pipe or fitting, or may be of the type used in conjunction with F 412 Terminology Relating to Plastic Piping Systems3
either a metallic or nonmetallic backup ring. 2.2 ANSI Standards:
1.3 The values stated in inch-pound units are to be regarded B 16.1 Cast Iron Pipe Flanges and Flanged Fittings5
as the standard. The values in parentheses are given for B 16.5 Pipe Flanges and Flanged Fittings5
information only. In cases where materials, products, or equip- 3. Terminology
ment are available only in SI units, inch-pound units are
omitted. 3.1 Definitions:
1.4 The following precautionary caveat pertains only to the 3.1.1 General—Definitions are in accordance with Termi-
test methods portion, Section 11, of this specification: This nology D 883 or Terminology F 412. Abbreviations are in
standard does not purport to address all of the safety concerns, accordance with Terminology D 1600, unless otherwise indi-
if any, associated with its use. It is the responsibility of the user cated. The abbreviation for reinforced-thermosetting-resin pipe
of this standard to establish appropriate safety and health is RTRP.
practices and determine the applicability of regulatory limita- 4. Classification
tions prior to use.
4.1 General—This specification covers machine-made
NOTE 1—Contact molded flanges are covered in Specification D 5421 reinforced-thermosetting-resin flanges defined by type (method
and referenced in Specification D 5685. of manufacture), grade (generic type of resin), class (configu-
NOTE 2—There is no similar or equivalent ISO standard.
NOTE 3—For purposes of this specification, polyester includes viny-
ration of joining system), and pressure rating. Flanges com-
lester resins. plying with this specification are also given numerical classi-
fications relating to rupture pressure, sealing test pressure, and
2. Referenced Documents bolt torque limit.
2.1 ASTM Standards: 4.1.1 Types:
D 618 Practice for Conditioning Plastics and Electrical 4.1.1.1 Type 1—Filament-wound flanges manufactured by
Insulating Materials for Testing2 winding continuous fibrous glass strand roving or roving tape,
D 883 Terminology Relating to Plastics2 either preimpregnated or impregnated during winding, into a
D 1599 Test Method for Short-Time Hydraulic Failure Pres- flange cavity under controlled tension.
sure of Plastic Pipe, Tubing, and Fittings3 4.1.1.2 Type 2—Compression-molded flanges made by ap-
plying external pressure and heat to a molding compound that
is confined within a closed mold.
1
This specification is under the jurisdiction of ASTM Committee D-20 on
Plastics and is the direct responsibility of Subcommittee D20.23 on Reinforced
Plastic Piping Systems and Chemical Equipment.
Current edition approved March 10, 2000. Published May 2000. Originally
4
published as D 4024 – 81. Last previous edition D 4024 – 00. Annual Book of ASTM Standards, Vol 08.02.
2 5
Annual Book of ASTM Standards, Vol 08.01. Available from American National Standards Institute, 11 West 42nd Street,
3
Annual Book of ASTM Standards, Vol 08.04. 13th Floor, New York, NY 10036.

Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.

1
 D 4024
4.1.1.3 Type 3—Resin-transfer-molded flanges manufac- 200 psi (1.4 MPa) pressure rating, a burst pressure in excess of
tured by pumping a thermosetting resin into glass reinforce- 600 psi (4.1 MPa), a sealing test pressure of 225 psi (1.6 MPa),
ments that have been cut to size and clamped between matched and a bolt torque limit greater than 75 lbf·ft (102 N·m).
molds. NOTE 4—Flanges with identical classification from different manufac-
4.1.1.4 Type 4—Centrifugally-cast flanges are made by turers may not be interchangeable due to nonstandardization of pipe or
applying resin and reinforcement to the inside of a mold that is socket diameter, socket length, taper angle, or combination thereof.
rotated and heated, subsequently polymerizing the resin sys-
tem. 5. Materials and Manufacture
4.1.2 Grades: 5.1 Flanges manufactured in accordance with this specifi-
4.1.2.1 Grade 1—Epoxy resin. cation shall be composed of reinforcement imbedded in or
4.1.2.2 Grade 2—Polyester resin. surrounded by cured thermosetting resin. The composite struc-
4.1.2.3 Grade 3—Furan resin. ture may contain granular or platelet fillers, thixotropic agents,
4.1.3 Classes: pigments, or dyes.
4.1.3.1 Class 1—Integrally-molded flange manufactured di- 5.2 The resins, reinforcements, and other materials, when
rectly on a pipe section, pipe stub, or fitting. combined as composite structure, shall produce a flange that
4.1.3.2 Class 2—Taper to taper adhesive joint flange manu- will meet the performance requirements of this specification.
factured with a tapered socket to be used in conjunction with a
pipe or fitting with a tapered spigot section and a suitable 6. Performance Requirements
adhesive. This joining method provides an interference fit over 6.1 Flanges shall meet the following performance require-
the entire length of the bond line. ments when joined for testing according to the manufacturer’s
4.1.3.3 Class 3—Straight-taper adhesive joint flange manu- recommended practice for field installation:
factured with a tapered socket to be used with a pipe or fitting 6.1.1 Sealing—Flanges shall withstand a pressure of at least
with an untapered spigot section and a suitable adhesive. This 1.5 times the rated design pressure without leakage when tested
joining method provides an interference fit at the bottom of the in accordance with 11.4.
socket. 6.1.2 Short-Term Rupture Strength—Flanges shall with-
4.1.3.4 Class 4—Straight adhesive joint flange manufac- stand a hydrostatic load of at least four times their rated design
tured with an untapered socket for use with a pipe or fitting pressure without damage to the flange when tested in accor-
with an untapered spigot and a suitable adhesive. This joint dance with 11.5.
provides no interference fit. 6.1.3 Bolt Torque—Flanges shall withstand, without visible
4.1.4 Pressure Rating—Pressure rating shall be categorized sign of damage, a bolt torque of at least 1.5 times that
by a single letter designation. Pressure designations are shown recommended by the manufacturer for sealing of the flange at
in Table 1. its rated pressure when tested in accordance with 11.6.
4.1.5 Rupture pressure, sealing test pressure, and bolt torque
limit shall be categorized by single arabic number designations 7. Content Requirements
as indicated by the cell classification system of Table 2.
4.2 Designation Code—The flange designation code shall 7.1 Percentage Extractable Material— Flanges shall con-
consist of the abbreviation RTR, followed by the type, grade, tain no more than 5 % extractable material when tested in
and class in arabic numerals, the pressure rating category as a accordance with Annex A1.
capital letter, and three arabic numbers identifying the cell 7.2 Recycled or Repprocessed Thermosetting Plastics—
classification designations of the rupture pressure, sealing test Flanges shall not contain any recylced or reprocessed thermo-
pressure, and the bolt torque limit, respectively. Thus, a setting plastics which might otherwise be added as fillers.
complete flange designation code shall consist of three letters,
three numerals and one letter, and three numerals. 8. Dimensions
4.2.1 Example—RTR-112D-334. This designation describes 8.1 Dimensions and Tolerances:
a filament-wound, glass fiber-reinforced epoxy resin flange 8.1.1 Flange and Bolt Dimensions—Flanges of 24 in. (610
with a taper to taper adhesive joining system. The flange has a mm) or smaller diameter shall conform to the values given in
Table 3 for bolt circle, number and size of bolt holes, and
outside diameter. Flanges larger than 24 in. (610 mm) in
TABLE 1 Pressure Categories diameter shall conform to the values for bolt circle, number
and size of bolt holes, and outside diameter for Class 125 cast
Pressure Rating iron flanges in ANSI B 16.1. The tolerance for the flange
Designation
psi MPa dimensions provided in Table 3 shall be the same as those
A 50 0.35 contained in ANSI B 16.1.
B 100 0.69 8.1.2 Flange Face—The flange face shall be perpendicular
C 150 1.03
D 200 1.38 to the axis of the fitting within 1⁄2°, and shall be flat to 61⁄32 in.
E 250 1.72 (1 mm) for sizes up to and including 18 in. (457 mm) diameter
F 300 2.07 and 61⁄16 in. (2 mm) for larger diameters.
G 400 2.76
H 500 3.45 8.1.3 Washer Bearing Surface—Washer bearing surface
shall be flat and parallel to the flange face within 61°.

2
 D 4024
TABLE 2 Burst Pressure, Sealing Test Pressure, and Bolt Torque Limit

Property 0A 1 2 3 4 5 6 7 8
Burst pressure, psi 200 400 600 800 1000 1200 1600 2000
(MPa) (1.38) (2.76) (4.14) (5.52) (6.89) (8.27) (11.03) (13.79)
Sealing test pressure, psi 75 150 225 300 375 450 600 750
(MPa) (0.52) (1.03) (1.55) (2.07) (2.59) (3.10) (4.14) (5.17)
Bolt torque limit, lbf·ft. 20 30 50 75 100 125 150 200
(N·m) (27.1) (40.7) (67.8) (101.7) (135.6) (169.5) (203.4) (271.2)
A
0 = unspecified.

TABLE 3 Flange Dimensions, in. (mm)A

Nominal Pipe, Outside Diameter Drilling

SizeB of Flange
Diameter of Bolt Circle Diameter of Bolt Holes Number of Bolts Diameter of Bolts
⁄
12 3.50 (88.9) 2.38 (60.5) 0.62 (15.75) 4 ⁄
12 (12.70)
3⁄4 3.88 (98.6) 2.75 (69.9) 0.62 (15.75) 4 ⁄
12 (12.70)
1 4.25 (107.9) 3.12 (79.2) 0.62 (15.75) 4 1⁄2 (12.70)
11⁄4 4.62 (117.3) 3.50 (88.9) 0.62 (15.75) 4 1⁄2 (12.70)
11⁄2 5.00 (127.0) 3.88 (98.6) 0.62 (15.75) 4 1⁄2 (12.70)

2 6.00 (152.4) 4.75 (120.6) 0.75 (19.0) 4 ⁄

58 (15.9)
21⁄2 7.00 (177.8) 5.50 (139.7) 0.75 (19.0) 4 ⁄
58 (15.9)
3 7.50 (190.5) 6.00 (152.4) 0.75 (19.0) 4 5⁄8 (15.9)
31⁄2 8.50 (215.9) 7.00 (177.8) 0.75 (19.0) 8 5⁄8 (15.9)
4 9.00 (228.6) 7.50 (190.5) 0.75 (19.0) 8 5⁄8 (15.9)
5 10.00 (254.0) 8.50 (215.9) 0.88 (22.4) 8 3⁄4 (19.0)
6 11.00 (279.4) 9.50 (241.3) 0.88 (22.4) 8 3⁄4 (19.0)
8 13.50 (342.9) 11.75 (298.4) 0.88 (22.4) 8 3⁄4 (19.0)
10 16.00 (406.4) 14.25 (361.9) 1.00 (25.4) 12 7⁄8 (22.2)
12 19.00 (482.6) 17.00 (431.8) 1.00 (25.4) 12 7⁄8 (22.2)

14 21.00 (533.4) 18.75 (476.2) 1.12 (28.4) 12 1 (25.4)

16 23.50 (596.9) 21.25 (539.8) 1.12 (28.4) 16 1 (25.4)
18 25.00 (635.0) 22.75 (577.8) 1.25 (31.7) 16 11⁄8 (28.6)
20 27.50 (698.5) 25.00 (635.0) 1.25 (31.7) 20 11⁄8 (28.6)
24 32.00 (812.8) 29.50 (749.3) 1.38 (35.1) 20 11⁄4 (31.7)
A
Dimensions conform to ANSI B 16.5 for Class 150 steel flanges.
B
For larger sizes, see 8.1.1.

8.2 Pipe Stop—Each adhesive joined flange shall provide environment testing is specified, tests shall be conducted in the
sufficient taper or a diametral constriction to act as a stop Standard Laboratory Atmosphere of 73.4 6 3.6°F (23 6 2°C)
during adhesive joining so that the pipe stub cannot project and 50 6 5 % relative humidity. When elevated temperature
beyond the face of the flange. testing is specified, the tests shall be conducted at the design
operating temperature 65.4°F (3°C).
9. Workmanship, Finish, and Appearance 11.3 Dimensions and Tolerances—Flange dimensions shall
9.1 Flanges shall be free as commercially practical of be measured with a micrometer of vernier calipers, or other
defects, including indentations, delaminations, bubbles, pin- suitable measuring devices accurate to within 60.001 in.
holes, foreign inclusions, and resin-starved areas. (60.02 mm). Diameters shall be determined by averaging a
minimum of four measurements, equally spaced circumferen-
10. Sampling tially.
10.1 The rate of sampling of flanges for pressure rating 11.4 Sealing—Flanged components in general arrangement
verification shall be in accordance with Annex A2. with Fig. 1 shall be bolted together using the gasket and bolt
10.2 For individual orders, only those additional tests and torque recommended for standard field installation by the
number of tests specifically agreed upon between the purchaser flange manufacturer. The assembly shall then be pressure
and seller need be conducted. tested and be required to hold the test pressure for a period of
168 hours without leakage. Retorquing to the manufacturer’s
11. Test Methods specified level after initial pressurization is permitted.
11.1 Conditioning—When conditioning is required, and in 11.5 Short-Term Rupture Strength—Flanged components
all cases of disagreement, condition the test specimens at 73.4 shall be tested in accordance with Test Method D 1599 with
6 3.6°F (23 6 2°C) and 50 6 5 % relative humidity for not free-end closure except as herein noted. The pressure in the
less than 40 h prior to test, in accordance with Procedure A of specimen shall be increased until failure of the flange occurs.
Practice D 618. Pressure testing in an atmospheric environment is permissible.
11.2 Test Conditions—The tests may be conducted at am- Minimum failure time shall be 60 s; no restriction shall be
bient temperature and humidity conditions. When controlled placed on maximum time-to-failure. Leaking past the gasket

3
 D 4024

FIG. 1 Test Assembly Configuration FIG. 2 Bolt Torquing Sequence

interface is permissible during this test. Bolt torque may be 12. Product Marking
increased as necessary during the test in order to minimize
12.1 Each flange shall be marked with the following infor-
gasket leaking and to achieve the pressure necessary to cause
mation:
flange failure. The assembly used for the test in 11.4 may be
12.1.1 The designation “ASTM D 4024” indicating compli-
used for this test.
ance with this specification,
11.6 Maximum Bolt Torque—Using the gasket and hard-
12.1.2 Identification of the flange in accordance with the
ware recommended by the flange manufacturer, bolt the flange
designation code in 4.2,
against a flat face steel flange. Tighten the nuts by hand until
12.1.3 Nominal flange size, and
they are snug. Prior to fit-up, the nuts, bolts, and washers
12.1.4 Manufacturer’s name (or trademark) and product
should be well lubricated, using a nonfluid thread lubricant.
designation.
Establish uniform pressure over the flange face by tightening
12.2 All required markings shall be legible and so applied as
bolts in 5 lbf·ft (7 N·m) increments according to the sequence
to remain legible under normal handling and installation
shown in Fig. 2. For flanges with more than 20 bolts, similar
practices.
alternating bolt tightening sequences shall be used. Increase the
bolt torque uniformly until flange failure occurs or until all 13. Precision and Bias
bolts have been torqued to five times the level recommended
by the manufacturer for field installation practice to establish 13.1 No precision and bias statement can be made for this
the bolt torque cell classification of the flange. Any sign of test method, since controlled round robin test programs have
flange damage (crumbling, flaking, cracking, or other break- not been run.
ing) shall constitute failure. NOTE 6—Thw wide variation in raw materials and constructions
allowed in this specification make round robin testing difficult to apply.
NOTE 5—The torque limits determined by 11.6 apply only to flanges
bolted up against a flat sealing surface. Significantly lower bolt torque 14. Keywords
value will normally be obtained when RTR flanges are bolted up against
raised-faced flanges. When RTR flanges must be used against raised steel 14.1 centrifugally-cast; compression-molded; filament-
flange face, the flange manufacturer should be contacted for his torquing wound; furan; machine-made; polyester; resin-transfer;
and installation recommendations. vinylester

4
 D 4024
ANNEXES

(Mandatory Information)

A1. TEST METHOD FOR PERCENTAGE EXTRACTABLE MATERIALS

A1.1 Scope A1.5.4 Gravimetric Analysis:

A1.1.1 This test method covers the procedure for determin- A1.5.4.1 Add 25 mL of methylene chloride (or other suit-
ing the percentage extractable materials in RTR flanges. able solvent) to the pulverized sample and mix.
A1.5.4.2 Place mixture on a steam bath or hot plate for 10
A1.2 Summary of Test Method min.
A1.2.1 The test method consists of filing material from the NOTE A1.2—The solvent should not be heated above its boiling point
flange, immersing this material in a solvent (methylene chlo- (for methylene chloride, 104°F (40°C)).
ride), extracting the unreacted material and, by means of
A1.5.4.3 Let mixture cool for 10 min and filter into a tared
gravimetric analysis, determining the quantity of unreacted
100-mL beaker. Wash mixture out of the 50-mL beaker and add
resin and residual solvent.
washing to filtrate. It is very important to wash the 50-mL
NOTE A1.1—For certain classes of resins, it may be necessary to select beaker and filter paper with methylene chloride several times to
a different solvent in performing this test. be sure all extractable material passes through the filter.
A1.5.4.4 Place filtrate in oven and evaporate methylene
A1.3 Significance and Use
chloride. Oven temperature should be 194 to 212°F (90 to
A1.3.1 This test method measures the amount of extractable 100°C).
material which includes unreacted resin and residual solvent. A1.5.4.5 After solvent evaporates, let beaker cool in a
A1.4 Apparatus desiccator for 15 min.
A1.5.4.6 Weigh the beaker.
A1.4.1 Beakers, 100-mL A1.5.4.7 Repeat steps 4, 5, and 6 until a constant weight is
A1.4.2 Beakers, 50-mL reached.
A1.4.3 Graduate, 25-mL
A1.4.4 Magnetic Stirrer and capsule (dental amalgam NOTE A1.3—It has been found that a 25-min drying time is satisfactory.
shaker).
A1.6 Calculation
A1.4.5 Funnel and filter paper (type) Grade 950, size 15
cm. A1.6.1 Calculate the percentage extractable materials as
A1.4.6 Hot Plate. follows:
A1.4.7 Oven. L
% extractable 5 W 3 R 3 100
A1.5 Procedure
A1.5.1 Remove 1 to 2 g of a representative sample by where:
means of a clean file. L = actual weight of residue = weight of beaker plus
A1.5.2 Pulverize the rough sample to a fine powder in a residue minus weight of beaker,
magnetic stirrer capsule. Each capsule should be pulverized for W = initial weight of pulverized sample = weight of beaker
about 3 min. plus sample minus weight of beaker, and
R = resin content of the sample.
A1.5.3 Accurately weigh the pulverized sample in a tared
50-mL beaker. NOTE A1.4—The resin content of the sample must be known.

A2. TEST METHOD OF SAMPLING FOR PRESSURE RATING VERIFICATION

A2.1 Scope A2.3 Procedure

A2.1.1 This test method describes the sampling procedure A2.3.1 Sample size shall be determined according to Prac-
which shall be used in determining the acceptance of a given tice D 1898, Appendix X3 and Table X2.1. The Acceptable
lot of flanges at the pressure rating specified according to 4.1.4 Quality Level (AQL) shall be 1.50. Inspection Level 1 shall be
and Table 1. used in determining the sample size and acceptance constant. A
flange set shall be considered to be two samples.
A2.2 Sample A2.3.2 The specification Limit Value (L) shall be the
A2.2.1 Sample size and selection shall be in accordance pressure rating times 4 for burst test qualification and shall be
with Practice D 1898 except as herein modified. the pressure rating times 1.5 for leak test qualification.

5
 D 4024
A2.4 Results resampled lot. If the lot meets the requirements of A2.4.1 after
A2.4.1 Acceptance— If the Quality Level of the sample is resampling, the lot shall be accepted at the pressure category
greater than or equal to the acceptance constant for both burst specified.
and leak testing, the lot shall be accepted at the specified A2.4.2.2 Alternatively, the lot may be derated to a pressure
pressure rating category. rating that will bring the sample’s quality level to a value equal
A2.4.2 Rejection—If the Quality Level is less than the to or greater than the acceptance constant. The lot of flanges
acceptance constant for either burst or leak testing, the lot shall shall be reclassified at the lower pressure rating category and
be rejected unless rectification is provided as follows: appropriately marked according to the designation code in 4.2.
A2.4.2.1 The lot shall be resampled at a higher inspection
level. The original test results shall be considered a part of the

SUMMARY OF CHANGES

Committee D-20 has identified the location of the following changes to this standard since the last issue
D4024–94) which may impact the use of this standard.

(1) Changed Note 1 to reference D 5685. (7) Corrected long standing error in bolt torque sequence on 8
(2) Corrected grammer in 4.1. hole flange in Fig. 2.
(3) Corrected statement construction in 4.2. (8) Clarified wording in 12.1.1.
(9) Added Precision and Bias statement.
(4) Added 7.2 on recycled materials. (10) Corrected references in A2.3.1 to appendix and table
(5) Clarified 11.2 on tolerance of operating temperature. which no longer exsisted.
(6) Deleted dualism in key for drawing in 11.4. (11) Added this “Summary of Changes” section.

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