RTR - Assembly Instruction Butt-And-Wrap Lamination Joint (16 Bars)-BONDSTRAND

BONDSTRAND©, LTD.

AMLANTIT

Assembly Instructions

Assembly Instructions For Bondstrand® Butt-and-Wrap Lamination Joint (16 Bars) Scope

These assembly instructions cover the bull-and-wrap jointing system of Bondstrand® RTR pipes and fittings with plain ends (tapered-joint butt-andwrapping for 16-bar pressure-rated joints). The procedure applies to pipe sizes 1” (25 mm.) to 40’ (1000 mm.) ND.

Description

The bull-and-wrap joint typically consists of two plain pipe ends which have been prepared for joining by sanding and tapering the outside surface in the joint area (tapered ends as in Figure 2). These spigots are abutted end to end and aligned on the same centerline, and the joint overwrapped with overlapping layers of resin-impregnated fiberglass fabrics (boat tape and woven roving). Each layer becomes increasingly thicker to provide a laminate or build-up that can accommodate both internal pressure and longitudinal forces.

Materials of Construction

The butt-and-wrap laminate consists of fiberglass reinforcement materials and an epoxy resin system to impregnate and bind the reinforcement materials. For estimated material requirements per size of joint, please refer to Table I for 16-bar pressure rating.

Fiberglass Reinforcement. .

Glass Woven Roving

•

Boat Tape

Owens-Corning, PPG, Carl Freudenberg, etc. Owens-Corning, PPG, Carl Freudenberg, etc.

500 gm./ m.2 150 gm.lm.2

Resin System. . .

Epoxy Resin

Shell Epikote 827 DER 330

or DOW

Hardener (Curing

IPD (Isophoronediamine)

100 Parts by Weight 24 Parts by Weight

Agent) .

Adhesive

Ameron RP34 Adhesive or RP48 Adhesive

1

For Initial Jointing

Materials (Cont...)

Important: Store all fiberglass components in a dry but not too cool area in order to avoid surface condensation when used in warmer conditions outside. Perform moisture-content checks by weighing samples prior to and after one hour of heating at 115°C. A moisture content higher than 0.2% makes the fiberglass fabric unacceptable for lamination use. Since the curing agent IPD is hygroscopic, keep it stored in closed containers when not in use. Prepare IPD batches shortly before mixing with the resin component.

Equipment Check List

El Hacksaw El Abrasive Cutting Disc (Diamond Grit or Carborundum) ci Pipe Supports ci White Marker El Wrap-Around ci Flapper-Wheel Sanders (Grit-60) ci Drilling Machine ci Balance (Weighing Scale) ci Air-Relieve Rollers (1.5” through 0.375” Diameter) ci Infra-Red Burners or Hot-Air Guns ci Heating Blankets ci Resin Mixer ci Paint Brush, 4”-Wide ci Rubber Scraper Plate

Pipe End Preparation Pipe Culling. Note: This initial step shall be applicable only if a factory-prepared pipe end needs to be cut and replaced, or a pipe length requires field adjustment. Mark the pipe section to be cut using a wrap-around and a white marker. Cut the pipe using a hacksaw or a cutting disc.; make sure that a proper square cut has been made see Figure I Step I. -

Preparation of Lamination Area. Refer to Table 2 for the required lamination length to be prepared for sanding and tapering. •

For Pipes 1O”ND and Larger. The area to be prepared for lamination should be equal to one-half of the nominal size see Lamination Length or L in Table I or Table 2.

•

For 8”ND Pipes or Smaller. The lamination length shall always be 120 mm. Mark the required lamination lengths and proceed to the end-preparation step.

For tapered-joint butt-and-wrap, grind the lamination section into a gradual slope. See P1gw-c I, Step 2. Sand or grind the cross section of the pipes (the cut ends) as well.

Adhesive Fit Layer. Position the pipe sections for joining. Prepare the adhesive mixture according to given instructions. Coat the cut ends with adhesive in order to protect them against penetration of the medium. Coat the external surfaces of the pipe ends approximately 100 mm. in width, and join them together (Figure 1 Step 3). -

Wet out the boat tape with adhesive and apply a minimum of 3 layers circumferentially onto the jointed pipe ends see Figure 1 Step 3. Use a heating blanket to cure the initial laminate for one hour. Sand the surface after curing before proceeding to the following step. —

2

Prepare all equipment and construction materials required for the joint lamination see Table 1 for estimated material requirements per joint size. Do not use humid or damp fiberglass materials; use hot-air guns or oven-dry the fiberglass fabrics before use. —

Lamination Procedure

Start the lamination of the filled sections within two hours after sanding or tapering; re-sanding of the lamination area shall be required if the waiting period exceeds two hours. Remove any possible dew by slightly heating the pipe ends from the inside by a heating blanket. Prepare the resin mix using the correct mixing ratio Resin 100 Parts by Weight; Hardener 24 Parts by Weight. Take note of the pot life after mixing. The amount of the mixture depends on the diameter. Several batches could be used depending on the weather, temperature and gelling time. Be sure that the curing agent is carefully mixed with the resin. The temperature of the resin and curing agent mixture should not exceed 25°C. •

For Pipes 3”ND or Smaller. For the hand lay-up of the laminate structure, use boat tape as in Table 2 with 50% overlap. Be sure to obtain the minimum required lamination thickness as indicated in Table 2.

•

For Pipes Bigger than 3”ND. For the hand lay-up of the laminate structure, use boat tape and woven roving in the sequence as shown in Table 2 and with 50% overlap until the minimum required laminate thickness is achieved.

Make sure that each applied layer of boat tape or woven roving is thoroughly impregnated with the resin mixture. Apply the layers in a circumferential direction onto the pipe-joint ends Figure 1 Steps 4 and 5.

—

see

During the wrapping process, tension must be applied so that the resin under the layer being laid could be pressed out. Avoid air getting into the laminate by using the air-relieve rollers continuously. To give the finishing touch, apply one final layer of boat tape spirally wrapped onto the whole surface of the laminate. Use air-relieve rollers to avoid air enclosures. After the final boat tape layer, smooth out the resin from the exterior of the laminate, using a rubber scraper, to leave a resin-rich surface. Before curing, use a heat source (hot-air blower, flood light etc.) to allow the laminate to gel. Use heating blankets, to cure the buff-and-wrap joint laminate. Check if the heating blanket is working properly. Temperatures in excess of 120 C should be easily achieved if the heating blanket works properly. The surface contact between the heating blanket and the laminate should be as large as possible; fit the blanket as snugly as possible to the joint. Cure the laminate for 4 hours’ minimum. Wherever possible, apply a heating blanket on the inside as well and close the pipe ends to avoid drafts. In cold weather, insulate the heating blanket to trap the heat, but do not cover the blanket’s thermostat housing. After curing, use sandpaper to remove the rough edges of the laminate and to generally smooth out the extemal surface. 3

Curing and Finishing

Lamination Procedure

Figure 1.

Tapered Ends Jointing (16-Bar Pressure Rating)

(Figure 1...)

STEP 1: PIPE CUTTING

STEP 2: SANDING/GRINDING

STEP 3: FIT LAYER

I

S

NDd

STEP 4: LAMINATION L

L 2L

STEP 5 LAMINATION

Table I. Estimated Material Requirement per Butt-&-Wrap Lamination Joint: 16-Bar Pressure Rating

Figure 2.

ND

L

L 2L

Note:

L L

= =

120 mm. for Pipe Sizes 1”-8”ND ¼ ND for Pipe Sizes 10”ND and Above

Adhesive

Laminate Material Requirement

Ameron RP-34

.

Nominal Diameter

or

Ameron RP-48

Boat Tape

Woven Roving

Epoxy Resin

1PD Curing Agent

“Wit’

-

(In.)

(mm.)

3-oz. Kit

6-oz. Kit

(Kg.)

(Kg.)

(Kg.)

(Kg.)

1

25

1

-

0.15

-

0.12

0.03

1%

40

1

-

-

0.17

0.04

2

50

1

-

0.21 0.24

-

0.19

0.04

3

80

1

-

0.35

-

0.27

0.07

4

100

1

-

0.10

0.37

0.38

0.09

6

150

1

-

0.15

0.81

0.77

0.19

8

200

-

1

0.19

1.34

1.24

0.30

10

250

-

1

0.33

2.11

1.96

0.47

12

300

-

1

0.47

3.63

3.30

0.80

14

350

-

2

0.60

5.17

4.65

1.11

16

400

-

2

0.98

7.46

6.80

1.64

18

450

-

2

1.21

10.23

9.24

2.21

20

500

-

3

1.50

14.00

12.50

3.00

24

600

-

3

2.59

23.87

21.34

5.12

28

700

-

4

3.65

40.84

35.89

8.61

30

750

-

4

4.88

49.83

44.13

10.59

32

800

-

4

5.56

60.30

53.11

12.75

36

900

-

5

7.01

85.98

74.99

17.99

40

1000

-

6

9.92

118.20

103.32

24.79

5

2o

Recommended Layering Sequence for the Laminate Structure: 16-Bar Pressure Rating

R,9~5

Table 2.

i~.,-.

0/

— —~

ND:

40

Inch

ND:

1000

mm.

Lamination Length

500

(mm.)

Lamination Thickness

35.6

(mm.)

Sequence Number ofLa ers 1 2

BT BT

3 4

WR WR WR WR WR

5

6 7 8 9 10 11

BT

WR WR WR WR WR

12

-r

13 14 15 16 17 18

BT

WR WR WR Wi? WR

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

BT

WR WR WR WR WR BT

Wi? WR WR Wi? Wi? BT

35

Wi? WR WR

36

BT

34

Note:

1.

BT

2.

L

3.

Overlapping shall be 50% of each layer. Use the layering sequence as in the above table until the minimum laminate thickness is achieved.

=

=

Boat Tape, 2’ or 4” Wide; WR

Lamination Length; 2L

=

2’~x~

Woven Roving.

Total Length of Joint Lamination.

t~≤ ‘.~

=

6

Company Overview

Bondstrand Limited is a joint-venture company joining the Saudi Arabian Amiantit Company (A Saudi Joint Stock Company) of Dammam, Kingdom of Saudi Arabia, with Ameron BV (Ameron Fiberglass Pipe Group-Europe) of Geldermalsen, The Netherlands, a wholly-owned subsidiary of Ameron International Corporation, Pasadena, California, USA. This joint venture brings two firms together in an endeavor to provide high-technology fiberglass pipe products (marketed under the trade name Bondstrand®) and professional services to the rapidly growing Saudi Arabian and Gulf Region industrial market for highperformance fiberglass RTRP.

Quality Assurance lSO900l

For the design, manufacture and QC testing of Bondstrand RTRP systems, Bondstrand Ltd. has established a quality management system which conforms to both national and international standards. Bondstrand Ltd.’s quality system was audited in June 1994 by TUV-CERT. The successful audit furnished proof and certification that requirements according to DIN !S09001 EN 29001 BS 5750 Part I have been fulfilled.

Important Notice

This product literature and the recommendations for usage it contains are based on test data reasonably believed to be reliable. It is intended that this literature be used by personnel having specialized training in accordance with currently accepted industry practice and normal operating conditions. Variations in environment, changes in operating procedures, or extrapolation of data may cause unsatisfactory results. We recommend that your engineers verify the suitability of this product for your intended application. Since we have no control over the conditions of service, we expressly disclaim responsibility for the results obtained, or for any consequential or incidental damages of any kind incurred.

Amiantit Marketing and Sales Offices Central Province P.O. Box 1029 Riyadh 11431

Western Province P.O. Box 2140 Jeddah 21451

Eastern Province P.O. Box 589 Dammam 31421

Export Division P.O. Box 589 Dammam 31421

TeL #01-465-8153 Fax #01-463-1389 Tlx. #401008 AwIuA Si

TeL #02-651-5676 Fax #02-651-6149 TIx. #6OI43JAWJEDSJ

TeL #03-857 1160 Fax #03-857-1156 Tix. #803401 AwEPMSJ

TeL #03-857-1160 Fax #03-857-8824 Tix. #8OJO84APSJDAMSi

Bondstrand Ltd.° A Member of the Amiantit Group of Companies

P.O. Box 589, Dammam 31421, Saudi Arabia Phone #009663-8571160 Fax #009663-8577540 #802958 CCPDAMSJ Accredited Firm

Manufacturing Plant: First Industrial City, Dammam, Kingdom of Saudi A abia.

Bondstrand RTRP is also manufactured by Ameron Plants in Japan, Singapore, Holland, and USA.

Bondstrand Catalog No. BLAS 05 - April 1997. Revised II Januaiy 1999

Printed in the Kingdom ofSaudi Arabia

7