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transcript
PIPE INSTALLATION HANDBOOK
Matched Tapered Bell & Spigot Joints
•REDTHREAD®II •GREENTHREAD® •SILVERSTREAK® •F-CHEM®
ManualNo.F6000April1,2007
FIBER GLASS SYSTEMS L. P.PIPE INSTALLATION HANDBOOK
Matched Tapered Bell & Spigot Joints
Thisfabricationmanualisofferedtoassistyouintheproperfabricationand installationprocedureswhenassemblingyourFiberGlassSystems(FGS)pipingsystem.
If you do not find the answer to your questions in themanual,feelfreetocontactusoryourlocalFGSdistributor.
FGSproductsmustbe installedandused inaccordancewithsound,provenpracticeandcommonsense. The information supplied by FGS in itsliteraturemustbeconsideredasanexpressionofguidelinesbasedonfieldexperienceratherthanawarrantyforwhichFGSassumes responsibility. FGS offers a limited warranty of itsproductsintheTerms and Conditions of Sale.Theinformationcontained in the literature and catalogs furnished by FGScannotensure,ofitself,asuccessfulinstallationandisofferedtocustomerssubjecttotheselimitationsandexplanations. It is the policy of FGS to improve its products continually.Therefore, the company reserves the right, without notice, tochangespecificationsand/ordesignatanytimewithoutincurringan obligation for equipment previously sold. DescriptionscontainedinthiscatalogareforthepurposeofidentificationandneitherlimitnorextendthestandardproductlimitedwarrantysetforthintheTerms and Conditions of Sale and Trade Customs.
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TABLE OF CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iFabrication&InstallationAssistance . . . . . . . . . . . . . . . . . iv
Part IPIPE PRODuCTS
PipeProducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 DescriptionofPipeProducts . . . . . . . . . . . . . . . . . . . . .1 PipeGrades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 FabricationAccessories. . . . . . . . . . . . . . . . . . . . . . . . . .6JoiningSystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Part IISITE CONSIDERATIONS
StorageandHandling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Tools,Equipment,andSupplies . . . . . . . . . . . . . . . . . . . . .10SuggestedCrewSetUp. . . . . . . . . . . . . . . . . . . . . . . . . . .12AdverseWeatherRecommendations. . . . . . . . . . . . . . . . .14BurialRecommendations . . . . . . . . . . . . . . . . . . . . . . . . . .15Anchors,GuidesandSupports. . . . . . . . . . . . . . . . . . . . . .22
Part IIIGENERAL INSTALLATION
ReadThisFirst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24CuttingFGSPipe................................25
Part IVFABRICATION OF RED THREAD II, GREEN THREAD, AND
SILVER STREAK PIPE AND FITTINGS
TaperingFGSPipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26TaperingToolReferenceChart. . . . . . . . . . . . . . . . . . . . . .28JointPrep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29AdhesiveMixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30JointAssembly..................................31 CloseTolerancePiping . . . . . . . . . . . . . . . . . . . . . . . . .31 Take-OffDimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .33 1”-6”BellxSpigotJoints. . . . . . . . . . . . . . . . . . . . . . . .37 8”-24”BellxSpigotJoints. . . . . . . . . . . . . . . . . . . . . . .38 T.A.B.Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40JointCure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 HeatCollars&HeatPacks . . . . . . . . . . . . . . . . . . . . . .42Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
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PART VFABRICATION OF F-CHEM PIPE AND FITTINGS
JointPrep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50JointAssembly..................................50JointCure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 HeatBlankets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 TappingintoaLine . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Part VI INSTALLATION CONSIDERATIONS
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63WaterHammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63Flanges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64ConnectingtoOtherSystems. . . . . . . . . . . . . . . . . . . . . . .73PaintingPipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Part VIIHELPFuL INFORMATION
Conversions....................................76DecimalEquivalentsofFractions . . . . . . . . . . . . . . . . . . . .77DefinitionofTerms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78HowToReadFlangedorReducingFittings . . . . . . . . . . . .83HowToFigurea45°Offset . . . . . . . . . . . . . . . . . . . . . . . .84
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©2005,NATIONALOILWELLVARCO
®TrademarkofVarcoI/P,Inc.
RT REDTHREAD®IIpipingsystemsRTPP REDTHREADIIPerformance Plus pipingsystemsGT GREENTHREAD®pipingsystemsGTPP GREENTHREADPerformance Plus pipingsystemsSS SILVERSTREAK®pipingsystemsFC F-CHEM®pipingsystems
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ENER
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RT, G
T, SSFA
BR
ICATIO
NF-C
HEM
FA
BR
ICATIO
NIN
STALLATIO
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ERATIO
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HELPFu
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Standard Abbreviations
FABRICATION AND INSTALLATION ASSISTANCE
Installing FGS fiberglass pipe is different from installingcarbon steel, stainless steel, lined steel and even otherfiberglass piping systems. Learning the proper methods toprepareandmake-upbell&spigotjointscanhelpensurethereliabilityandlong-termperformanceofyourpipingsystem.
FGS offers the TQI Plus (ASME B31.3) Fabricationand Assembly certification program. Qualified Field ServiceRepresentativestrainfabricationandassemblycrews,conductandsupervisefabricationwork,andinspectworkinprogress.
For complete information concerning these trainingseminars,contactyourlocalFGSdistributororFGS.
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SAFETYThissafetyalertsymbolindicatesanimportantsafetymessage.Whenyouseethissymbol,bealerttothepossibilityofpersonalinjury.
CAuTIONAsthispipemaycarryhazardousmaterialand/oroperateatahazardouspressurelevel,youmustfollowinstructionsinthismanualtoavoidseriouspersonalinjuryorpropertydamage. Inanyevent, improper installationcancauseinjuryordamage.Inaddition,installersshouldreadandfollow all cautions and warnings on adhesive kits, heatpacks, propane torches, etc. to avoid personal injury.Also, observe general safety practices with all saws,tools, etc. to avoid personal injury. Wear protectiveclothing when necessary. Make sure work surfacesare clean and stable and that work areas are properlyventilated.
!
PART IPIPE PRODuCTS
DESCRIPTION OF PIPE PRODuCTS
The performance characteristics of a fiberglass pipesystem depend on several important elements including theresinandcuringagent,aswellasthemanufacturingprocessandtypeandthicknessofthepipe’scorrosionbarrier. FGSpipingsystemsaremanufacturedusingepoxy,vinylester,orisophthalicpolyesterresinsystems.Allareheatcuredfor optimum chemical resistance and physical properties.Match your temperature, pressure and chemical resistancerequirementstothepipingsystem.
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FGS PIPE GRADES
RED THREAD II & RED THREAD II Performance PlusEpoxy pipe grade that provides long service life, lightweightand corrosion resistance. Used for light chemical servicesinsalts,solventsandpH2 to13solutionsup to210°Fandpressures to 450 psig.Available in 2”-24” pipe sizes.T.A.B.(Threaded and Bonded bell & spigot) is the primary joiningmethodfor2”-6”diameterpipe.Matchedtaperedbell&spigotjoiningmethodisusedfor8”-24”pipe.
GREEN THREAD & GREEN THREAD Performance PlusEpoxy pipe with 15-35 mil resin-rich liner that providesexcellent chemical resistance to dilute acids and caustics.Rated for temperatures up to 225°F and pressures to 450psig.Matchedtaperedbell&spigotconnectionisprovidedonall1”-24”pipesizes.
SILVER STREAKCustomfilamentwoundpipeisspeciallydesignedforabrasiveand corrosive services found in flue gas desulfurization. Itis a proprietary blend of epoxy resin and abrasion-resistantadditives. Rated for temperatures to 225°F and 150 psig.Availablein2”-24”pipesizes.
F-CHEM Custom filament wound construction offers more flexibilityin resin systems, corrosion barriers and wall thickness thanourstandardproducts.Rated for temperatures to250°Fand150 psig. Let us assist you in selecting the right pipe for aspecific application. Available in 1”-72” pipe sizes. Joiningmethodsincludeplainendbuttandwrap,O-ringbell&spigotormatchedtaperedbell&spigot.
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FITTINGS
FGSfittingsarecolorcoded.GREENTHREADfittingsaregreen and may be used with REDTHREAD II and GREENTHREADpipe.SILVERSTREAKfittingsareblack.F-CHEMfittings are color matched to the pipe. Be sure to use thecorrectgradeofpipeandfittingsforyourservice.ConsultFGSFittings &Accessories Bulletins for pressure rating limits onvariousfittings.Thelowestratedfittingdeterminesthesystempressurerating. Mostcompression-moldedfittingshaveacenterlinedotorcrosswhichwillassistyouinmakingmeasurements.
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ADHESIVES
FGS adhesives are formulated for specific use withthe companion pipe grades. Use only the recommendedadhesivewitheachpipegrade-donotmixsystems!Standardadhesivesareatwo-componentsystem(PartsAandB)whichmustbemixedpriortouse.Detailedinstructionsforadhesivesareprovidedwitheachkit.Readtheseinstructionsthoroughlyandfollowtherecommendedprocedures.Thecuretimeandpot-life of the adhesive is dependent on temperature. Referto the adhesive instructions. Ambient temperatures above100°Frequireextracarebythefabricatortoassuresufficientworking time of the adhesive. Refer to Adverse Weather Recommendationsonpage14.
ADHESIVE SELECTION
FGSstandardadhesivekitsaredesignedtobeusedwithspecificpipingsystemsasshowninTable2.
ADHESIVE WORKING LIFE
Workinglifeorpotlifeisthetimeittakesfortheadhesivetohardeninthemixingcan.RefertoTable1below.
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TABLE 1. Fiber Glass Systems Adhesives Estimated Pot Life
NOTE:Potlifeisthetimeavailableforfabrication.Timesmayvarydependingupontemperature,humidity,quantitymixed,etc.
Pipe Resin
Systems Adhesive
Pot Life@ 70°F (min.)
(see note)
Pot Life@ 90°F (min.)
(see note)
Epoxy 7000 25 15
Epoxy 8000 15 8
VinylEster CL-100 20 10
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TAB
LE 2
. Adh
esiv
e Se
lect
ion
R
efer
to B
ulle
tin N
o. D
4000
for
mor
e in
form
atio
n
use
with
thes
e Pi
ping
Sys
tem
sM
ax.
Tem
p.K
itN
br.r
Num
ber
of B
onds
per
kit
1"11
/2"
2"3"
4"6"
8"10
"12
"14
"16
"18
"20
"24
"
RTI
I/GT
PE
RF.
PLU
S20
0°F
2014
1815
135
21
1 /2
1 /2
2069
84
32
21
13 /
41 /
2
RE
DT
HR
EA
DII
(Joi
nts
Per
Can
)15
0°F
7014
2518
106
32
1
7024
96
42
1
7069
84
32
21
RE
DT
HR
EA
DII
GR
EE
NT
HR
EA
DS
ILV
ER
STR
EA
K22
5°F
8014
4527
2115
85
32
11 /
21 /
2
8024
2012
96
42
1
8069
84
32
21
13 /
41 /
2
Num
ber
of B
onds
per
kit
14"
16"
18"
20"
24"
30"
36"
42"
48"
54"-
72"
F-C
HE
M20
0°F
CL-
100
11/2
11/2
11
3 /4
1 /2
1 /3
1 /4
1 /5
Con
tact
the
fact
ory
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FABRICATION ACCESSORIES
Heat Collars and Heat Blankets:FGS offers high temperature heatcollars and silicone heat blanketsfor use in curing of adhesive joints.Theblanketsandcollarshaveapre-set thermostat which controls thetemperature of the unit. See page44 for heat collar page 54 for heatblanket cure times for adhesive jointfabrications.
Heat Guns:Highwattageelectricheat guns are also available toheatF-CHEMadhesivejoints.Theheatgunsare1600wattcapacity.
FGS Heat Packs: A heat pack unit consisting of ties andreactants in a plastic bag attached to foil paper is alsoavailable.Heatpackswillcurejointswithinonehour.
Tapering Tools: FGSmatchedtaperedjointsrequirevarioustools formakingthetaperedspigot in the field(RT,GT,SS).Refer toTable6onpage28 forselectionofproper taperingtool.
Come-Along: Specificallydesigned hydraulic come-alongsare available for 8”-24” pipingsystems (RT,GT,SS).Especiallyuseful for long straight runs ofpipe.
Manual Come-Along: Kit consistsof two manual cable puller come-alongsandonestrapclampkit.Itisamechanicalaidusedtojoinlargerdiameter piping. The come-alongismostuseful for8”-16”pipesizes
toaidinthealignmentandlandingofthespigotendintothebell.
Strap Clamp Kit: FGS offersStrap Clamp Kits that can beused in conjunction with come-alongsforbonding8”-24”fittings.
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JOINING SYSTEMS
Bell and Spigot Joint: The adhesive bonded, tapered belland spigot joint is a primary joining method for the followingproducts: 1"-24"GREENTHREADpipingandpipetofittings 2"-24"REDTHREADIIpipingandpipetofittings 2”-24”SILVERSTREAKpipetofittings 4”-72”F-CHEMpiping* *Pipetopipejointsalsoavailableinbutt&wrap.Pipe is suppliedwith one endtapered(thespigot)and the other endbelled (integral bellor factory bondedcoupling) to accept a tapered spigot. The joint is made byapplyingadhesivewhich,whencured, iscompatiblewiththepipingsystemsforjointstrengthandcorrosionresistance.
T.A.B. (Threaded and Bonded) Joint:TheT.A.B.jointistheprimaryjoiningmethodforthefollowingproduct:
2"-6"REDTHREADIIpipingandpipetocou-plings.
The joining sys-tem combinesboth threads andadhesives on thebonding surfaces.The mechanical locking action of these promotes positivemakeup which prevents backout during adhesive curing.Standardtaperedbellfittingsareusedwiththissystem.
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PART IISITE CONSIDERATIONS
STORAGE AND HANDLING
A. Pipe and Fittings Fiberglassreinforcedpipe,fittings,andadhesivesrequirespecial storage and handling. Care should be taken intransporting, unloading, handling, and storing FGS productstopreventimpactandotherdamage. When transportingpipe, thespacersunderandbetweenthe pipe joints must be of sufficient width to avoid pointloading, which could produce cracking or buckling damage.Aminimumoffourspacersshouldbeusedforsupporting14"andlarger40'longpipejoints.Morespacersshouldbeusedforsmallerpipeorifpipeisstackedovereightfeethigh. Due to its light weight, lifting equipment is usually notrequiredfor1"-14"pipe.Whenliftingequipmentisrequired,use nylon slings or chokers. Do not allow chains or cablesto contact thepipeduring transport orhandling. If apipeorfabricationismorethan20feetlong,useatleasttwosupportpoints. For storage, a board (2 x 4 minimum) should be placedunder each layer of pipe approximately every five feet. Theintent is to support the pipe and distribute the load evenly.Thepipeshouldalsobebracedoneithersideofthepiperackto prevent unnecessary pipe movement.Avoid placing FGSpipe on sharpedges, narrow supports, or other objects thatcouldcausedamagetothepipewall.WhenstoringFGSpipedirectlyontheground,selectaflatareafreeofrocksandotherdebristhatcoulddamagethepipe. FGSpipeisfurnishedfactorypackagedincompact,easy-to-handlebundlescompletewithprotectiveendcaps.Leavethesecaps inplaceuntil installation time toprotect thepipeendsaswellas topreventdirtorothermaterial fromgettingintothepipe.Fittingsarepackagedincardboardboxesandshouldbestored inadryarea. If fittingsare removed fromtheboxes,protectmachinedbellsandspigotsfromexposuretodirectsunlight. FGSpipecanbedamagedwhenjointsorbundlesofpipeare dropped during handling or shipping. Severe localizedimpactblowsmayresultindamagetothefiberglassreinforcedstructure in the pipe wall. Before installation, inspect the pipe's outer surface for any damage.DonotusedamagedpipeunlessinspectedandapprovedbyaFGSrepresentative.If impact damage occurs, the damaged areas may be
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recognizedbyastartypefractureonthepipe.Pipethathasbeendamagedshouldhavealengthcutawayapproximatelyonefooteithersideoftheimpactedsite.
Note: weight. straps.
B. AdhesiveFGS vinyl ester adhesives can be damaged by storage inwarm places. FGS recommends that CL-100 adhesive bestoredinadryareawheretemperaturesdonotexceed80°F.Refertoadhesiveinstructionsincludedineachkitforstorageliferecommendations.
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Material Safety Data Sheets (MSDS) are available from FGS at http://www.smithfibercast.com
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TOOLS, EQuIPMENT and SuPPLIES REQuIRED FOR INSTALLATION
Formaximumefficiency,thefollowingtoolsandequipmentarerecommendedpriortoanyinstallation:
clampkit• HandTools -Level-MarkingPen-TapeMeasure-PipeWrap -Hacksaw(22-28teeth/inch) -Taperingtool(Seepages26-28) RT,GT,SS)• PowerTools -Powertaperingtools(Seepages26-28) aluminumoxide,carbideordiamond cuttingblade -Heatgun,heatblanketorcollar -T.A.B.wrenches(for2”-6”T.A.B.jointpipingsystems)• Expendables -Clean,Dry,Lint-FreeShopCloths SS),(30-60gritforF-Chem) -Impermeablegloves -Chemicalsplashgoggles
NOTE: Youmustuse theproper tool for taperingeachsizeandtypeofpipe(seepages26-28).
Equipment for Cool Weather (Below 70°F) pipe assembly:• Heatsource -Portabletorchwithspreadertip,or -Portableelectricheatlamp,or -Industrialhotairgun• Ameansofmaintainingadhesivekitsat70°-80°F: -Aboxwitha25wattlightbulb,or -Insideofavehicle.• Heatassistedcuring -Electricheatingcollarsorblankets -Chemicalheatpacks
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Additional equipment for 8”-24” pipe assembly (RT, GT, SS):•Hydrauliccome-alongortwocome-alongswithmanilarope ornylonslings(forreducedslippage)•Strapclampkit•Sledgehammer,12-16lbs.,anda4x4blockofwood
Additional equipment for applying saddles:•Powersanderwith30-60gritsandingdisc(preferred for6”andlargersaddles).•Hoseclamps
SuGGESTED LABOR TIMES FOR FGS BELL X SPIGOT PIPING SYSTEMS
Table 2.1(1)Placinginhangersfiguresarebasedonone-workeroperationfor1"-4";twoworkersfor6"-10";threeworkersfor12"-24".Totaltimesshouldbefiguredbymultiplyingfiguresgivenbyworkersneededperoperation.(2)2000seriesPowerTools
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PipeSize
Placingin
Hangers(Min/Ft)
(1)
SetUp(Min.)
(10)
Scribe&Cutting(Min/Jt)Hand/power
HandTapering(MinJt)
PowerTapering(Min/Jt)
JointMakeup
(Min)(7/8)
1" .7 3.0 1.33/1.25 1.0 .25(2) 1.011/2" .7 3.0 1.33/1.25 1.5 .25(2) 1.0
2" .7 3.0 1.50/1.25 2.0 .25 1.53" .7 3.0 2.0/1.33 3.0 .25 2.04" .8 4.0 5.0/2.5 4.0 .25 3.06" 1.0 5.0 7.0/3.0 5.0 2.5(3) 4.08" 1.2 7.0 4.5/3.5 22.0 8.0(4,5,9) 5.0
10" 1.4 7.0 NA/5.0 35.0 10.0(9) 6.012" 1.7 8.0 NA/5.0 40.0 12.0(9) 8.014" 2.3 9.0 NA/5.0 NA 12.0(5,9) 10.016" 2.3 10.0 NA/6.0 NA 12.0(9) 12.018" 2.5 12.0 NA/8.0 NA 25.0(6) 14.020" 3.0 12.0 NA/8.0 NA 28.0(6) 16.024" 3.0 14.0 NA/10.5 NA 30.0(6) 20.0
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(3)2"-6"HandTaperingTool(4)IndividualTaperingTool(5)8"-16"GrindingTaperingTool(6)18"-24"GrindingTaperingTool(7)Eachjointmakeupcalculationincludescleaning,sand-ing,applyingadhesiveandproperengagement.Allowthreeminutesformixingadhesive.(8)Theunits(time)listedabovearebasedonusingexperi-encedcrewsonfittingintensiveruns.Forstraightrunpipe,contactyourlocalFGSrepresentative.(9)TimedoublesforPerformancePlusproducts.(10)Includessetupforhydraulicormanualcome-alongandsettingpipestandlevels.
These numbers are based on installations using experi-enced crews in typical installation conditions. They do not include extreme weather conditions, time used for gathering supplies and tools, break time, manpower is-sues, etc. Assume 6 hours of productive labor for every 8 hours worked. Adjustment factors should be applied to these base units to compensate for prevailing production and job conditions. Because of all the variables involved, Fiber Glass Systems is not responsible for any differen-tial between these numbers and actual results.
SuGGESTED CREW SET-uP AND ASSEMBLYManpowerrequirementschangedependingonwhether
theinstallationissimple,consistingoflong,straightruns,orcomplex.Italsodependsonpipesize,installationtem-perature,andothersimilarinfluences.Followingaresomegeneralguidelinesthatareapplicabletomostinstallations.Ifyouhaveanyquestions,pleasecontactanFGSrepresenta-tiveforinformation.
A. Suggested Crew Size for 1” - 6” straight run pipe (long runs)
Athree-workercrewistheminimumrecommendedcrewsize.Afour-workercrewissometimesmoreefficient,evenwheninstalling1”-6”diameterpipe.
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Man # Crew Description #1 Clean/prep/align
Removesendcaps,sandsandcleansjointandalignspipeforbonding.
#2 Adhesive mixer/bonder Mixesadhesiveandappliestobellandspigot.
#3 Assembly man Helpsmakeupjointandchecksforlockup.
#4 Pre-heat/prep/supplies
(optional through 4"; recommended on 6”) Pre-heatsjointsandhelpskeeppipealigned.Alsoapplies
heatcollarsduringcoolweather.(Allhelpinmovingsup-pliesandequipmentfromjointtojoint.)
B. Suggested Crew Size for 8” - 48” straight run pipe (long runs)
Asixorsevencrewmembersisrecommended.
Man # Crew Description #1 Clean/prep/align
Removesendcaps,sandsandcleansjointandhelpsalignjointforinsertion.
#2 Adhesive mixer/bonder
Mixesadhesiveandappliestobellandspigot.Marksinsertiondepthanddetermineswhenjointislockedup.Assistswithcome-along.
#3 Adhesive mixer/Bonder
Helps#2withadhesiveandassistswithcome-along.
#4 Pre-heat/alignment man Pre-heatsjoints,helpsalignjointsandassistswithcome-
along.
#5 Alignment man Setslevelofpipeandalignsjointforproperinsertion;
directstractordriver.
#6 Truck driver/Supply man (optional) Drivessupplytruckandassistswithallaspectsofinstal-
lation.Alsocoordinatesheatcollarsduringcoolweatherandicechestduringhotweather.
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#7 Tractor Operator Operatessideboomtractor,trachoeorbackhoe. (Allhelpinmovingsuppliesandequipmentfromjointto
joint.)
C. In more complex pipe assemblies,thecrewsizewilldependontheamountoftaperingandprefabricationneeded.Inmostcases,athree-workercrewisthemini-mumforanysizepipinginstallation.Insomeinstances(smalljobswithonlyafewjoints)onlyoneortwocrew-menwillberequired.
RECOMMENDATIONS FOR FABRICATION IN ADVERSEWEATHER CONDITIONS
FGSpipingcanbeinstalledinadverseweathercondi-tionswhenthenecessaryprecautionsaretaken.
Actualworkwilloftenbemorequicklycompletedinhightemperatureconditions.Lowtemperaturescanincreasetheworktime20%-35%overnormalshopconditions.Asimilarincreaseiscommonforhighmoistureconditions.
Hot Weather Installation TipsHotweatherconditions,temperaturesabove90°F,will
greatlyreducetheworkingtimeoftheadhesive.Thefollow-ingstepsarerecommendedwhenfabricatinginhotweatherconditions:1. Avoiddirectsunlightonthejoiningsurfaces.2. Storeadhesiveinacoolarea.3. KeepF-CHEMadhesiveinicechestpriortomixing.4. Keepmixedadhesiveinanicechestwithsealedbagof
iceoricepack.4. Refertothefieldfabricationinstructionssuppliedinthe
adhesivekitfortheproperamountofcatalystinCL-100.
Cold Weather Installation TipsAdhesivecuretimeisdirectlyrelatedtothetemperature.
Coldertemperaturesresultinlongercuretimes.Thefollowingstepsshouldbeusedwhenfabricatingin
coldertemperatures:1. Adhesivekitsshouldbeplacedinawarmroomforsixto
twelvehoursbeforeapplicationinordertoreachtempera-turesof80°F-100°F.Thiswillmakemixingmucheasierandspeedcuretimes.Oruseaboxwitha25-wattlightbulbtowarmadhesivekits.
14
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2. Whenpossible,pipingshouldbebondedindoorsintosubassemblies.Thewarmerconditionsoftheseareaswillallowfastercuretimes.
3. Pre-warmbondingsurfacesto80°F-100°Fwhentempera-turefallsbelow70°F.
4. Refertothefieldfabricationinstructionssuppliedintheadhe-sivekitfortheproperamountofcatalystforvinylesterkits.
5. Aheatgun,collarorblanketmaybeusedtoobtainafastercuretime.Applyalayeroffiberglassinsulationoraweldingblanketaroundtheheatcollarsorblanketswheninstallationtemperaturesarebelow50°F.
Extreme Moisture
Adhesive Joints• Iffittingsorpipehavemoistureonthebondingsurface,
wipethemdrypriortosanding.• Sandpipeorfittingsimmediatelybeforeapplyingthe
adhesivetobondthejoint.Sandsurfacesuntilafresh,drysurfaceispresent,thenremovedustwithacleandrycloth,andapplyadhesive.
• Cureperthepreviousrecommendationsfornormal,ex-tremeheatorextremecoldtemperatures.
BuRIED INSTALLATIONS
Thesearegeneralguidelinesonly.FormoredetailsseeFGSEngineeringandDesignGuideE5000.ForinstallationsusingULlistedREDTHREADIIApipingseespecialinstruc-tionscontainedinManualNo.B2160.
15
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16
Pipe Bending Allowance for Standard RED THREAD
Size(In)
X (Ft)(Straight run from
pipe)
Y (Ft)(Offset from straight
run)
2
10 0.8020 3.7030 9.0040 18.10
3
10 0.5520 2.5030 5.9040 11.10
4
10 0.4220 1.9030 4.4040 8.20
6
20 1.2230 2.9040 5.4050 8.60
8
20 0.8940 4.0060 9.4080 17.50
10
20 0.7140 3.2060 7.5080 13.80
12
20 0.6040 2.7060 6.3080 11.60
14
20 0.5340 2.4060 5.5080 10.00
16
20 0.4640 2.1060 4.8080 8.80
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* Basedon1000psisoilmodulus.Contactthefactoryfordetailedinformationforyourspecificapplication.
** F-CHEMisdesignedforspecificburialapplicationsac-cordingtoAWWAC950.
A. Burial Depth1. MinimumBurialDepth Minimumdepthinunpavedareasforpipesubjected
tovehicularloadsdependsonpipegrade,pipesize,vehicleaxleweight,andthebeddingmaterial.Withastandardlegalaxleloadof34,000lbs.,themini-mumdepthofcover(fromthetopofthepipetothe
17
Size(In)
X (Ft)(Straight run from
pipe)
Y (Ft)(Offset from straight
run)
18
20 0.4140 1.9060 4.3080 7.90
20
20 0.3740 1.7060 3.9080 7.10
24
20 0.3140 1.4060 3.2080 5.90
TABLE 3. Burial Depths*
Product Minimum (Ft.)
Maximum (Ft.)
1"-4"REDTHREADII 2 15
6"-24"REDTHREADII 3 15
1"-12"GREENTHREAD 2 15
14"-24"GREENTHREAD 3 15
1"-12"SILVERSTREAK 2 15
14"-24"SILVERSTREAK 3 15
F-CHEMCustomPiping** 3-5 12-20
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surface)formoderatelycompactednon-claybearingsoilsisshowninTable3.
Thepipeshouldalwaysbeburiedbelowthefrostline.
2. MaximumBurialDepth Maximumburialdepthisdependentonthebackfill
material.Formoderatelycompactedsoilsthatdonotcontainlargeamountsofhighlyexpansiveclays,themaximumburialdepthisshowninTable3.
B. Trench Preparation Finalbeddingofthetrenchmustbeasuniformandcon-
tinuousaspossible.Beforebackfilling,fillallgapsunderthepipewithproperbeddingmaterial.Avoidsharpbendsandsuddenchangesinslope.Itisimportanttoremoveallsharprocks,cribbage,orotherforeignobjectsthatcouldcomeincontactwiththepiping.
C. Bedding Requirements Fiberglasspipecanbedamagedbypointcontactorwear
withthetrenchbottomandwalls,improperbeddingmate-rials,oradjacentpipe.Userecommendedbeddingmate-rialaminimumof6inchesthickatthebottom,sides,andtopofthepiping(refertoTable4).Adjacentpipesshouldbespacedthegreaterof6inchesoronepipediameter.Thepipingcanbelaiddirectlyontheundisturbedtrenchbottomifthenativesoilmeetstherequirementsofarecommendedbeddingmaterial(refertoTable4).Neverlayfiberglasspipingdirectlyagainstnativerockorshale.Alwaysusedry,unfrozenbeddingmaterialsthatdonotcontainforeignobjectsordebris.Neverusewaterfloodforcompaction.Slurriescanbeusedthatareintendedforburialofflexiblepipingsystems.Whenusingslurries,caremustbetakentopreventfloatingordeformationofthepiping.
18
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D. Pipe Support Fiberglasspipeisflexibleandrequiresthesupportofthe
beddingmaterialtokeepthepiperoundinburialapplica-tions.Itisveryimportantthatarecommendedbeddingmaterialisproperlycompactedaroundtheentirecircum-ferenceofthepipe.(RefertoTable4)Tampthebeddingmaterialunderthebottomhalfofthepipingtopreventvoidsorareasoflowcompaction.Vibratoryorsimilartampingequipmentcandrivesmallstonesordebrisintothepipewalliftheyarepresentinthebeddingmaterial.Avoidstrikingthepipewithtampingequipmentasthepipemaybefractured.
19
CompactedNativeFill
Backfill
Bedding
Areas“a”mustfirmlysupportpipehaunches
TABLE 4. Recommended Bedding MaterialsBeddingMaterial CompactionProctor
Density
Crushedrockorpeagravel3/4”maximumsize
NotRequired
Coarse-grainedsandorsoilwithlittleornofines
75-85%
Coarse-grainedsandorsoilwithmorethan12%fines
85-95%
Sandorgravelwithmorethan30%coarse-grainedparticles
85-95%
Sandorgravelwithlessthan30%coarse-grainedparticles
Greaterthan95%
6" Min.
6" Min. SITE C
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Consult the factory if the pipe will be subject to vacuum or high water tables.
E. Road Crossings Whenlayingfiberglass
pipeunderroadcross-ings, itmaybeneces-sary to pass the pipethroughconduittopro-tect the pipe. Pad thepipetopreventrubbingor point loads againsttheconduit.
F. Wall Penetrations Wherethepipegoesthroughorpassesunderaconcrete
structure,precautionsmustbetakentopreventbendingorpointloadingofthepipeduetosettling.Aminimum2"thickpadofresilientmaterialshouldbewrappedaroundthepipetoprovideflexibilityandpreventcontactwiththeconcrete.Ifboltsareusedintheresilientmaterial,careshouldbetakenthatthebolts,nuts,orwasherscannotcomeintopointloadcontactwiththepipe.Beddingdepthunderthepipeshouldbeincreasedtoaminimumof12"oronepipediameter,whicheverisgreater,foronepipejointlengthawayfromtheconcrete.
20
Proper Bedding Improper Bedding
EnsureFirmCompaction
NoVoids
SelectBedding
ThickPadofRe-silientMaterial
“O”RingBell&Spigot
ThickProtectiveLayerofResilientMaterial
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G. Timing Testandcoverthepipeassoonaspossibletoreducethe
chanceofdamagetothepipe,floatingofthepipeduetoflooding,orshiftingofthelineduetocave-ins.
H. Two Point Lifting of Red Thread II
ThistableprovidesinformationconcerningsafeliftpointsforRTIIduringinstallation.Thefollowingtablehasbeencompiledfortwoliftpointsandthemaximumlengthofpipethatmaybesafelyliftedandthecriticallocationoftheliftpoints.
21
TABLE 4.H
NominalSize(In)
PipeLengths(Feet)
CantileverLength(Feet)
Mid-SpanLengths(Feet)
Number Length Min. Max. Min. Max.
8 3 120 24 26 68 72
10 3 120 20 28 64 80
12 3 120 22 31 58 76
14 3 120 22 31 58 76
16 3 120 20 35 50 80
18 3 120 19 36 48 82
20 4* 160 31 37 86 98
24 4* 160 29 40 80 102
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ANCHORS, GuIDES AND SuPPORTS
A. Pipe Hangers Pipehangerssuchasthoseshownareoftenusedto
supportFGSpipeinbuildingsandpiperacks.However,theuseoftoomanyhangersinsuccessioncanresultinanun-stablelinewhencontrolvalvesoperate,andduringpumpstart-upandshutdown.Toavoidthiscondition,thedesignershouldincorporateauxiliaryguidesperiodicallyinthelinetoaddlateralandaxialstability.
B. Pipe Guides Guidesarerigidlyfixedtothesupportingstructureand
allowthepipetomoveintheaxialdirectiononly.Properguideplacementandspacingareimportanttoensurepropermovementofexpansionjointsorloopsandtopre-ventbucklingoftheline.
Theguidingmechanismshouldbeloosesoitwillallowfreeaxialmovementofthepipe.“U”bolts,double-nuttedsotheycannotbepulleddowntight,areoftenutilizedforguides.
Primaryandsecondaryguides,i.e.,thoseimmediatelyadjacenttoexpansionjoints,arespacedmorecloselythanintermediateguides.RefertoFGSManualNo.E5000,Engineering & Piping Design Manual, fordetails.
Pipingenteringexpansionjointsorexpansionloopsre-quireadditionalguides.RefertoFGSManualNo.E5000, Engineering & Piping Design Manualfordetails.
C. Pipe Supports: PipingsupportsforFGSpipeshould
bespacedatintervalsasshownintheproductbulletins.
22
1/16”Min.-1/8”Max.clearanceperside
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NOTE:Properlyspacedsupportsdonotalleviatetheneedforguidesasrecommendedintheprecedingsection.Supportsthatmakeonlypointcontactorthatprovidenarrowsupportingareasshouldbeavoided.Somemeansofincreasingthesupportingareashouldbeused;sleevesmadefromhalfofaFGScouplingorpipearesuitable.Supportpumps,valvesandotherheavyequipmentindependentofthepipe.Refertopumpandvalveconnectioninstructionsonpage74.
D. Pipe Anchors: Pipeanchorsdivideapipelineintoindividualexpandingsections.Inmostapplications,majorpiecesofconnectedequipment,suchaspumpsandtanks,functionasanchors.Additionalanchorsareusuallylocatedatvalves,nearchangesindirectionofthepiping,atblindendsofpipe,andatmajorbranchconnections.Provi-sionsforexpansionshouldbedesignedintoeachoftheindividualpipesec-tions.
Caution: Donotinstallmorethanoneexpansionjointbe-tweenthesametwoanchorsinanystraightpipesection.
DonotanchorFGSpipebyapplyingexternalpres-sureaspointloads,suchasa"U"-bolt,directlytothebarepipe.RefertoFGSManualNo.E5000,Engineering & Piping Design Guide,forathorough
discussiononsupports,anchorsandguides.
23
!
AnchorSleeves
Clamp,snugbutnottight
WeldorBoltAnchortosupportmember
Snugfit
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PART IIIGENERAL INSTALLATION
INSTRuCTIONS
Beforebeginningtheactualassemblyprocedures,readandmakesureallinstallersthoroughlyunderstandthefollow-inginstructions.
All bonding surfaces must be clean, dry and factory fresh in appearance before applying adhesive.Whenendcapshavebeenlost,surfaceswillweatherandresultinlossofbondstrengthWhensurfacesareweathered,re-taper(RT,GT,SS)spigots.SandbellsandF-CHEMspigotstoachieveafactoryfreshappearance.(Note:T.A.B.™couplingsthathaveweatheredmustbereplaced.)
Matching tapered bell and spigot joints require a very thin adhesive bond line for maximum strength and du-rability. Theadhesiveusedwithtaperedjointsisverystrongwhenusedinbondlinesafewthousandthsofaninchthick.Thesameadhesivemaybebrittleinthicksectionsresult-inginpoorbondstrength.Toachieveathinbondline,thematchedtaperedanglesofthejointaredesignedtomechani-cally“lock-up”whenwedgedtogether.
using mechanical force assures “lock up” and a thin bond line. Hammeringawoodenblockplacedagainstthebellendofpipe,orusingmechanicaldevicessuchascome-alongsshouldbeusedto“lockup”thejoint.
Note:ForT.A.Bjoints,specialT.A.B.wrenchesarerequiredtoachievethemechanicallockupinthejoint.
Adverse weather conditions require special precau-tions when bonding pipe.(Seepage14,Recommendations for Fabrication in Adverse Weather Conditions)Theadhesiveisveryviscous(thick)whencoolorwhenappliedtocoolpipe.Thethickadhesivecanactuallybestiffenoughtopreventjoint“lockup.”Whentheadhesiveishotorwhenitisappliedtohotpipe,theavailableworkingtimemaybesignificantlyreduced.
Matched tapered bell and spigot joints that are not “locked up” can fail prematurely.
24
IMPORTANT • READ THIS FIRST
RT,
GT,
SS
FAB
RIC
ATIO
N
CuTTING FIBERGLASS PIPE
FGSpipeshouldbecutusingoneofthemethodsreferredtounderToolsandEquipmentonpage10.
1. Measurepipe,rememberingtoallowforspigotandfittingdimensions.
2. Scribeacuttingguidearoundthepipetoensureaper-pendicularcutforproperfit.
3. Holdthepipefirmlybutnottothepointofcrushing.Ifchainvisesorothermechanicalholdingdevicesareused,careshouldbetakentopreventcrushingorpointloadingofthepipe.Topreventdamagetothepipe,180degreesectionsofFGSpipecanbeusedforprotectivecovers.
4. Sawthepipeassmoothlyaspossible.Thepipeendsshouldbesquarewithin1/8inch.
PART IV
25
Note:Forintegraljoint(IJ)bellends,thebellendmustbecutoffbeforetapering.MeasuretheO.D.ofthepipenearthebellenduntilyouseetheO.D.starttogetlarger.Cutthepipeatthispoint.Dependingonpipesizethedistancefromtheendofthebellcanvaryanywherefrom12"to36".
RT, G
T, SS FA
BR
ICATIO
N
FABRICATION OF RED THREAD II, GREEN THREAD AND SILVER STREAK PIPE AND FITTINGS
TAPERING FGS PIPEVarioustoolsareavailablefromFGSformakingtheta-
peredspigotinthefield.Toreproduceastandardtaper,thetaperingtoolmustbe
markedoradjusted.Theprocessvariesdependingonthetoolbeingusedandtheproductbeingtapered.Pleaserefertoindi-vidualtoolinstructionsfortapering.
RefertoTable6onpage28forspecificbulletinnumberandpropertaperangleforeachsizeandtypeofpipe.
Do not taperoverthebellendofintegraljointpipe.Seepage25forcuttinginstructions.
A. 1"-6" Tool (Bulletin F6600)-Ahand-heldtoolthatcanbeadaptedforpowerwhenalargenumberoftapersisnecessary.Differentpipingsystemsrequiredifferentmandrels.
B. Model 2100/ 2102 Tool (Bulletin F6625/ F6624)-PowertoolfortaperingandscarfingREDTHREADIIandREDTHREADIIApiping.
C. Model 2300 Tool (Bulletin F6627)-Powertoolespeciallydesignedfortapering1”-4”GREENTHREADpiping.
D. 8", 10", or 12" Tapering Tool (Bulletin F6608 or F6612)-Thesetoolsaredesignedformanualorpower(i.e.,Ridgid300or700powerdriveorequal)operation;thereisatoolforeachsizepipe.
26
RT,
GT,
SS
FAB
RIC
ATIO
N
E. 8"-16" Grinding Tapering Tool (Bulletin F6616)-Thisisanelectricallypoweredgrindingtool.Thetoolcomeswithdifferentsizemandrelstotaper8"-16"pipe.
Additional material will be needed:1.Sturdyworkbench(preferablywithametaltop)orstandtoholdthetool2.Two20"longpiecesof1"diametersteelpipe.Mounttheseontopofthebenchparalleltoeachother,ona2-footcenter,extendingoffthebench12".3.Twoadjustablepipestandswithhardrubberrollersat90degreeangletopipe,i.e.thestandmustallowthepipetorotate.4.Thistoolrequiresapproximately3,000wattsof115vacpowerforoperation(30ampbreaker).Werecommend5,000watts(50ampbreaker).Asthelengthofextensioncordsin-creases,thepowerlostinthecordincreases.Table5showsmaximumallowablelengthsforvarioussizecords:
F. 8"-16" Taper/Scarf Tool (Bulletin F6622)-Thisisanelectricallypow-eredtaperingtool.Thetoolcomeswithdifferentsizemandrelstotaper8"-16"pipe.
G. 18"-24" Tapering Tool (Bulletin F6621)-Thisisanelec-tricallypoweredtaperingtool.Thetoolcomeswithdifferentsizemandrelstotaper18"-24"pipe.
Note: Sometoolsmaybeusedwithotherpipesystemswithspecial-ordertooling.Inthesecases,supplementaltoolinstruc-tionsarealsoavailable.Besuretospecifywhichpipesystemyouwillbetaperingwhenorderingtools.
27
TABLE 5. Extension Cord LengthWire Size
(AWG)Suggested Length
(Ft.)Maximum Length
(Ft.)12 20 22
10 30 36
8 50 57
RT, G
T, SS FA
BR
ICATIO
N
28
TABLE 6. Tapering, Scarfing and Cutting Tool Reference Chart
Tool
Prod
uct
Tool
Tap
er A
ngle
Bul
letin
#C
omm
ents
1"-
6"H
and
Tape
ring
RT
GT
1"=
3°;
11 /
2=
21/2
°2"
-6"
=1
3 /4°
F660
0S
peci
fyp
rodu
ctto
rece
ive
corr
ectm
andr
els.
Pow
era
dapt
er
sepa
rate
.Use
sR
idgi
d®7
00o
requ
ival
entp
ower
driv
ew
itha
R
idgi
d77
4ad
apte
r.
2"-
6"M
odul
ar
RT/
GT
13/4
°F6
603
Spe
cify
the
prod
uctt
ore
ceiv
eco
rrec
tman
drel
s.
2100
Pow
erR
T13
/4°
F662
5Ta
pers
2”&
3”;
Sca
rfs3
”&4
”21
02P
ower
RT
13/4
°F6
624
Tape
rs2
”-4
”;S
carfs
3”
2300
Pow
erG
T1"
=3
°;2
=2
1 /2°
3"-
4"=
13 /
4°F6
627
Tape
rs1
”-4
”
2700
Pow
erS
S13
/4°
F663
2To
olfo
r2"-
4"S
ilver
Stre
ak
2"-
6"(
Uni
que)
S
SA
djus
tabl
eF6
605
2”-6
”tap
era
ngle
=13
/4°.S
etto
olo
n11 /2
° to
cutc
orre
ctta
per.
Use
sR
idgi
d70
0or
equ
iv.w
ith7
72a
dapt
er.
8"T
aper
ing
RT
GT
0or
1°
F660
8(T
aper
)F6
609
(Sca
rf)Ta
pers
and
sca
rfs.U
ses
Rid
gid
700
ore
quiv
alen
tpow
erd
rive
with
aR
idgi
d77
4ad
apte
r.10
"&1
2"
Tape
ring
RT
GT
0or
1°
F661
2(T
aper
)F6
613
(Sca
rf)Ta
pers
and
sca
rfs.O
rder
sca
rfing
ada
pter
kit
forS
econ
dary
C
onta
inm
ent.
Use
774
ada
pter
.
8"-
16"
Tape
ring/
Sca
rf
RT/
GT
SS
MO
S0
or1
°F6
616
(Tap
er)
F661
7(S
carf)
F662
2
Tape
rsa
nds
carfs
.Som
eS
ILV
ER
STR
EA
Ka
ndP
erfo
rman
ce
Plu
sw
illh
ave
tob
edo
uble
cut
.
8"-
24"T
aper
ing
RT
1°-
Sta
ndar
d11
/4°
-MO
SF6
621
Tape
rs1
8”-
24”
JOINT PREP forRED THREAD II, GREEN THREAD and SILVER STREAK
Allbondingsurfacesmustbecleananddrybeforebonding.• ForT.A.B.joints,cleanwithanacceptablesolventand
cleanrag.WirebrushesmayalsobeusedforcleaningT.A.B.surfaces;however,theymustbecleanandfreeofoilycontaminates.
• Forsmoothtapers,sandpaperorsolvent(orboth)maybeused.Sandjustlightenoughtoremoveanycontami-nates.
• Usecautionasoversandingcanchangethetaperangleorenddimension,andcreateflatspotsonthespigot.
• Whensurfaceshaveweathered,sandorretaperspigotsandsandbellstoachieveafactoryfreshappearance.Cutatleast1”fromspigotsbeforeretapering.T.A.B.couplingsmustbereplaced.
• Bondingsurfacesmustbedry,sobesureallsolventhasevaporatedbeforeapplyingadhesive.
Note: use of a solvent as a cleaning method is optional.Somealternatecleaningsolventsareacetone,methylenechloride,andmethylethylketone.Aftercleaning,besureanyresidualsolventhasevaporatedbeforeapplyingadhesive.DONOTUSESOLVENTSTHATLEAVEANOILYFILMONTHEBONDINGSURFACES.
WARNING: Somedegreasersandsolventsareextremelyflammable.Donotsmokeorusenearanopenflame.Weareyeprotection.Besuretoreadwarninglabelsoncontainers.
Neverusegasoline,turpentine,ordieselfueltocleanjoints.
Solventcontainersmaybeunderpressure.Usecautionwhenremovinginnerseals,especiallyinwarmweather.Usewithadequateventilation.
29
!
RT, G
T, SS FA
BR
ICATIO
N
ADHESIVE MIXING
Whentheweatheriscoolortheadhesivehasbeenstoredinacoolenvironment(below70°F),prewarmtheadhesivekits.(Donotheatabove100°F!)1. Forepoxyemptyallofthecontentsofthehardenerbottle
intothecanofbaseadhesive.2. Mixallofthebaseepoxyadhesivewithallofthehardener.
NEVERATTEMPTTOSPLITAKIT.Cutthroughtheadhe-sivewiththeedgeofthemixingsticktoassistinmixingthetwocomponents.
3. Mixuntiltheadhesivehasauniformcolorandaconsistentflowoffthemixingstick.Wipedownthesides,bottom,andundertherimofthecanwiththemixingsticktoassurecom-pletemixture.
Completeinformationandsafetyprecautionsarepackagedwitheachadhesivekit.Reviewallsafetyprecautionsthor-oughlybeforemixingtheadhesive.
30
ADHESIVE DISPOSAL: Once the adhesive and hardener havebeen mixed and reacted, nothing can be extracted, and it isclassified as non-hazardous material. Dispose of in a nor-mal manner as other solid waste. Excess adhesive andhardener can be mixed, allowed to react, and disposed of asabove. If extra jars of adhesive or hardener have accumulatedwithouttheothercomponenttomixandreact,contactyourFGSregionalmanager.Hardener jars,whenemptyarenotsubject toEPAregulationandcanbedisposedofinanormalmanner.Theseguidelinesarebasedonfederalregulations.Stateandlocalregula-tionsandordinancesshouldbereviewed.
RT,
GT,
SS
FAB
RIC
ATIO
N
JOINT ASSEMBLY forRED THREAD II, GREEN THREAD and SILVER STREAK
A. Close Tolerance Piping ThetaperedbellandspigotsystememployedbyFGScanbereadilyusedtoachievedimensionalaccuracywhererequiredbyaparticularpipelayout.Aswithanymatchedtaper,minorvariationsintoleranceinthebellorspigotwillaf-fecttheinsertiondepth.Inapplicationswherethefinalmake-uplengthofanassemblyisnotcritical,thesevariationsareofnoconsequence.However,whentheinstallationissuchthatclosetolerancesmustbemaintained,youmustcompensateforthesevariations.Itispossibletoaccuratelyreproducetapers(spigots)inthefieldwiththefieldtaperingtools.Thisprovidesameansofachievingdimensionalaccuracy.Calculation to Achieve a Desired Length
Mostclosetoleranceinstallationsaremadetoprintscall-ingoutCLtoCL(centerlinetocenterline)dimensions.
Whenfabricatingtothesedimensions,followthesepro-ceduresperthefigurebelow.1. Obtainthecenterlinetofacedimension(A)offittings
tobeusedfromTables8or9onpages33-36.2. Createaninsertiongaugebycuttingashortsection
ofpipe;12”longforsmalldiametersand18”longforlargerdiameters.Taperthepipeusingtheinstruc-tionssuppliedwitheachtool.Checkdryinsertion.Theinsertionlengthshouldbewithin+1/8”ofafactoryspigotinsertion.
3. Obtaininsertionlength(IL)byinsertingthegauge(madewiththetoolbeingused)intoafittingandmeasuring.(Note:Measureeachendofeachfitting,becausetheinsertionmayvaryforeachbell.)Youcanprepareanduseashortnippleasastandardinsertion
31
RT, G
T, SS FA
BR
ICATIO
N
gauge.(Note:Youmustprepareanewgaugeifyouchangetaperingtoolsormakeanychangestothetoolyouareusing.)Alwaysaddamake-updimension(refertoTable7)tothismeasurement,sincetheadhesivewillactasalubricantandallowgreaterpenetrationthanwhenthesurfacesaredry.TABLE 7. Approximate Make-up Dimensions (M)*
Pipe Diameter (In.) Approximate Make-up Dimensions* (In.)
1and11/2 1/16
2 1/83and4 3/16
6 1/48 3/8
10and12 5/814 3/416 118
Usefielddevelopeddimensions2024
4. ToachieveaspecifiedCLtoCLdimension,thelengthofpipetocutisequaltotheCLtoCLdistanceminusthesumofthecenterlinetofacedimensionofthefittings(“A”dimension)plusthesumofthemeasured
insertionlengths(IL)plusthesumofthemake-upallowance(M),or
LengthofPipetoCut=(CLtoCL)-(A+A)+(IL+IL)+(M+M)
Note:Eachbellofeachfittingmayhaveaslight-lydifferentinsertiondepthwithastandardtaper.Eachbellofeachfittingshouldbechecked
withastandardtaperandmarked.
ConsultFGSFittingsBulletinsNo.A1350orA1355forcompletefit-tingdimensions.
32
*CAUTION:Make-updimensionsdependonthetightnessofthedryfit.Ifthefielddevelopeddimensionsvary,usefielddevelopeddimensions.
RT,
GT,
SS
FAB
RIC
ATIO
N
33
TAB
LE 8
. T
ake-
off D
imen
sion
s fo
r RT,
GT
Fitti
ngs
(Con
tact
FG
S fo
r SS
Dim
ensi
ons)
Dim
ensi
ons
are
used
toc
alcu
late
pip
ele
ngth
requ
irem
ents
to
mee
tpip
elin
ece
nter
lin
eto
cen
terl
ine
dim
ensi
ons.
Size
(In.
)45
° El
bow
90°
Elbo
wTe
eLa
tera
l (In
.)C
ross
AB
123
/823
/423
/437
/821
/223
/411
/227
/833
/833
/851
/431
/433
/82
25/8
33/8
33/8
65/8
23/4
33/8
333
/445
/845
/873
/441
/445
/84
37/8
51/8
51/8
943
/851
/86
43/8
61/8
61/8
121 /
253
/461
/88
81/8
115 /
811
5 /8
161 /
473
/811
5 /8
1085
/813
1 /8
131 /
819
5 /8
83/4
131 /
8
1291
/214
1424
3 /4
113 /
414
1412
1 /2
1919
321 /
215
3 /4
1616
131 /
420
1 /4
201 /
435
3 /4
173 /
417
1 /4
RT, G
T, SS FA
BR
ICATIO
N
34
Tabl
e8.
1Ta
keo
ffan
dno
min
ald
ryin
serti
ond
imen
sion
sfo
rlow
pre
ssur
e,1
50/2
25p
sig,
RE
DT
HR
EA
Da
ndG
RE
EN
TH
RE
AD
pro
duct
s.
Fori
nfor
mat
ion
onfi
tting
sno
tlis
ted
inth
ista
ble,
con
tact
Fib
erG
lass
Sys
tem
sTe
chni
calS
ervi
ceD
ept.
orre
fert
oB
ulle
tinA
1350
on
our
web
site
ath
ttp://
ww
w.s
mith
fiber
cast
.com
Siz
e(I
n)45
ºE
lbow
(In)
90º
Elb
ow(I
n)Te
e(In
)Fl
ange
s(In
)
Ax-
RT
x-G
TA
x-R
Tx-
GT
Ax-
RT
x-G
TM
olde
d
FW
x-R
Tx-
GT
12
⅜N
A1
⅛2
¾N
A1
⅛2
¾N
A1
⅛1
⅜N
A1
⅛1.
52
⅞N
A1
¼3
⅜N
A1
¼3
⅜N
A1
¼1
⅜N
A2
2 ⅝
1 ⅝
1 ⅝
3 ⅜
1 ⅝
1 ⅝
3 ⅜
1 ⅝
1 ⅝
2 ⅜
1 ⅝
33
¾1
⅞1
⅞4
⅝1
⅞1
⅞4
⅝1
⅞1
⅞2
¾1
⅞4
3 ⅞
1 ⅞
1 ⅞
5 ⅛
1 ⅞
1 ⅞
5 ⅛
1 ⅞
1 ⅞
2¾
1 ⅞
64
⅜2
½2
⅜6
⅛2
½2
⅜6
⅛2
½2
⅜
2½
2½
88
⅛4
¼3
½11
⅝4
¼3
½11
⅝4
¼3
½3
¼3
108
⅝4
¼3
⅝13
⅝4
¼3
⅝13
⅝4
¼3
⅝4
⅞3
¾12
9½
43
⅞14
43
⅞14
4
3 ⅝
4½
4
1412
½6
619
66
196
62
3 ⅛
2 ⅛
1613
¼6
⅛6
⅛20
¼6
⅛6
⅛20
¼6
⅛6
⅛2
3 ⅛
2 ⅛
Con
tact
Fib
erG
lass
Sys
tem
sTe
chni
calS
ervi
ceD
ept.
for1
8"-2
4"d
imen
sion
s.
(1)R
efer
toB
ulle
tinA
1350
fori
nfor
mat
ion
on2
"-12
"fila
men
twou
ndfl
ange
s.X
dim
ensi
ons
are
nom
inal
dry
inse
rtion
leng
ths.
P
ipe
mus
tbe
driv
ento
geth
era
ndfu
llylo
cked
up
toa
ssur
efu
lljo
ints
treng
th.
Act
uali
nser
tions
sh
ould
be
+1/8
"of
afi
eld
mea
sure
dfa
ctor
yin
serti
onfo
r1"-
6"a
nd¼
"fo
r8"
and
larg
er.
Inse
rtio
n de
pths
are
for
tool
set
up
only
. D
o no
t use
in
sert
ion
dept
hs (x
) for
clo
se to
lera
nce
pipi
ng.
Ref
erto
join
tass
embl
yin
stru
ctio
nsfo
rcom
plet
ein
form
atio
non
join
tloc
kup
.
35
INSERTION DEPTHS FOR SILVER STREAK
SizeCoupled/Mitered
FittingsFilament Wound
Fittings2 1.84 2.64
3 2.36 2.86
4 1.99 3.13
6 2.87 2.76
8 3.47 5.28
10 4.34 5.12
12 4.82 6.40
14 5.47 4.55
16 6.27 5.61
Table8.2Takeoffandnominaldryinsertiondimentionsforlowpressure,150/225 psig, SILVER STREAK products. Refer to BulletinA2000orwww.smithfibercast.comformoreinformation.
RT, G
T, SS FA
BR
ICATIO
N
36
TAB
LE 9
. T
ake-
off D
imen
sion
s fo
r RT/
GT
Perf
orm
ance
Plu
s Fi
tting
s
Siz
e(In
)
45º
Elb
ow(L
ong
Rad
ius)
(In)
90º
Elb
ow(L
ong
Rad
ius)
(In)
Tee
(In)
Flan
ges
(In)
Ax-
RT
x-G
TA
x-R
Tx-
GT
Ax-
RT
x-G
TA
-Van
Sto
ne8
12½
65⅛
19½
65
⅛13
½6
5 ⅛
6¼
1014
½6½
6½
23¼
6½
6½
15¾
6½
6½
712
16½
77
277
717
¾7
77
¾14
17¾
5¾5
¾30
5¾
5¾
19½
5¾
5¾
816
205¾
5¾
345
¾5
¾21
½5
¾5
¾9
1824
⅞40
26 ⅜
10½
2029
⅝47
¼31
¼12
½24
35 ⅞
5735
15½
Xdimensionsarenominaldry insertionlengths.Pipemustbedriventogetherandfullylockeduptoassurefulljointstrength.Actualinsertionsshouldbe+¼"for8"andlargerjoints.Insertion depths are for tool set up only. Do not use insertion depths (x) for close tolerance piping. Refer to joint assembly instructions forcompelteinformationonjointlockup.
Dimensionsareusedtocal-culatepipelengthrequirementstomeetpipelinecenterlinetocenterlinedimensions.
RT,
GT,
SS
FAB
RIC
ATIO
N
B. 1” - 6” Bell & Spigot Joint THESPIGOTMUSTBEALIGNEDANDLOCKEDINTHEBELL.Acockedormisalignedjointwillresultinfalse“lockup”andprematurejointfailureeitherduringtestingoratalaterdate.
1. Whenambienttemperatureisbelow70°F,prewarmthebondingsurfaces.Useahotairgun,propanetorchorothercleanburningheatsourcethathasaspreader
typetip,andapplyheatuniformlytobellandspigotuntilwarmtothetouch.Checktemperaturebytouch-ingoutsideofthebellandinsideofthespigottoavoidcontactwithcleanbondingsurfaces.Ifhottothetouch,letcoolbeforeapplyingadhesive.Whenusingatorchtopreheat,warmthebellfirst.Itisthickerandwillholdheatlonger.Ifanelectricheating
collarisusedtoprewarm,placethejointtogetherdry,thenheattheO.D.ofthebelltoavoidcontami-natingthespigot.CAuTION: Donotusechemicalheatpacksforprewarming.
2. Brushadhesiveonboththebellandspigotbondingsurfaces,applyingathinuniformcoatingtoeach.To
minimizecontamination,applyadhesivetothebellfirst.Adhesiveshouldalwaysbeworkedintothemachinedsurfacebyapplyingpressureduringapplication.Thiswill“wetout”themachinedsurfaceandmaintaintherequiredthinbondline.Besurethatadhesiveisdeepdownintothebellpasttheinsertiondepthandthatallmachinedtapersurfacesonthespigot
andthecutendofthepipeareuniformlycovered.Excessadhesivewillmakethejointmoredifficulttolock.
3. Alignandlockthejoint.For2"orsmallerpipe,insertthespigotintothebelluntilsurfacestouch,thenpush
andturnatthesametimeuntilalockisachieved.Onlyaquartertoahalfturnisusuallyneeded.On3”-6”diameterpipeoronfittings,pushingandturningtolockthejointisimpracticalanddrivingforcemustbeused.Ahammermaybeusedtoassistinjointlock-up.Placea2x4board
flatacrossthebell.Thefirstfewrapsshouldbelighttopreventanytendencyofthejointtobackout.
37
RT, G
T, SS FA
BR
ICATIO
N
Iftheadhesiveorthepipesurfacesarecool,pushandholdforafewsecondstoallowtimefortheadhesivetostartflow-ingoutofthetaperedjoint.
4. Checklockupbymovingfreeendofthepipeinanupanddownorsidetosidemotion.Themovementmustbesufficienttomovethejointbeingchecked.Nomovementshouldbevisibleinthejoint.Ifanymove-mentexists,thejointisnotproperlylockedup.Avoidexcessmovementasthiscoulddamagethespigot.
C. 8” - 24” Bell & Spigot Joint1. Longruns(ditchpiping)mustbesupportedatthejoint
sectionatalltimesuntilfullycured.Liftingnearthecenterofthepipewithabackhoeorsideboomtractorwithoutpropersupportunderthejointcancausedam-agetojointsthatarenotcured.Liftingnearthecenterofthepipeforalignmentisacceptableaslongasthejointdoesnotsupporttheweightofthepipingsection.Blocksorskidsshouldbeusedtosupporttheentirejointsectionuntilthejointisfullycured.Installpipeinstraightalignment;neverinstallpipeinabind.
2. 8"-24" hydraulic come-alongisrecommendedforpipetopipeconnections.Alljointspulledtogetherwiththistypeofdevicemustbevibratedduringinstallationtohelpalignthespigotinthebellandpreventafalselockuporcockingofthejoint.RefertoBulletinsNo.F6618orF6619fordetailedinstructionsonhydrauliccome-alongs.
a. Whenusingahydrauliccome-alongon8”-24”pipe,makesurepipeisrestingonblocksbeforecome-alongcollarsareremoved.Donotremovecollarswhilepipeisstillattachedtocableortractor.Ifcollarsarerestingonblocksafterbonding,leavepressureoncome-alongandliftgentlywiththechains,justenoughtoremovecollars.Donotplaceexcessivebendingstressacrossthejoint.
38
RT,
GT,
SS
FAB
RIC
ATIO
N
3. Strap clamp kitsareavailablefromFGSforpipetofittingconnections.Whenusedinconjunctionwiththehydrauliccome-along,aheavydutyband(strap)clampandtworingbeltstrapsareusedtopullthejointtogeth-er.RefertoBulletinNo.F6641fordetailedinstructionsonStrapClampKits.
4. Ratchet-type come-alongscanbeusedasanalterna-tivetothehydrauliccome-alongs.Usetwo,oneoneachsideofthejoint.Useaheavy-dutystrapclampkittoattachthecome-alongstothepipe.Slings,or5/8”orlargermanilaropes,arealsoacceptable.Aseriesofhalf-hitcheswillgripthepipewhenusingrope.Allowroomtooperatethecome-alongsbyplacingthestrapclamps,slingsorropes18”-24”oneachsideofthejoint.Takeupcome-alongstogethersothatthejointstaysinalign-ment.Forcethejointtogetheruntilitissolid.Rapthejointtogetherwitha12-15lb.sledgehammerandaboardwhilekeepingpressureonthecome-alongstoensurethejointisfullyengaged.
5. Fitting to pipe jointscanbemadebyplacingthe
fittingagainstasolidstructuresuchasawall,sideofthetrench,truckbumper,etc.Drivethespigotendofthepipeintothefittingusinga12-16lb.sledgeham-merandalargeblockofwood.Placetheblockagainstthepipeendawayfromthefitting.Careshouldbetakenwhilehammeringasexcessiveforcecandamagethepipeendorfitting.
39
RT, G
T, SS FA
BR
ICATIO
N
Pipe PipeSize HydraulicPressure Grade (In.) (psig)RT,GT,SS 8-10 1500-1750 12-16 1750-2000
RTPP,GTPP 8-10 1500-2000 12-16 2000-2500
TABLE 10. Hydraulic Come-Along Pressures
D. T.A.B. Joint: T.A.B.Jointinstallationproce-duresfollowthenormalbellandspigotoperationsofcleaning,ad-hesivemixing,etc.asdescribedabove.TwoT.A.B.wrenchesarerequiredwhenjoiningT.A.B.pipe.SeparatewrenchesareavailablefromFGSforeachsizepipe.Thewrencheslockaroundthepipeandforcethepipeintoaveryslightovalshape.Therefore,thewrenchesmustbe6"to12"awayfromthejointtoassuregoodjointmakeup. 1. Coverallmachinedareasonthespigotandatleastone-halfinchbeyondthelastthreadinthebellwiththeproperadhesive.
2. ScrewthepipetogetheruntilfirmusingT.A.B.jointwrenches.DONOTOVERTIGHTEN.
Connectionsintofittingsaremadeusingthenormalbellandspigotmethods.Athreadedspigotcanbebondedintoasmoothbell(fitting),orasmoothspigotcanbebondedintoathreadedbell.
E.SaddlesandReductionsNote:3033Adhesiveisrecommendedforsaddles.
Positionthesaddleonthepipeandmarkaroundthesaddlebase.Useafile,asander,orroughsandpaper(16to40grit)toremoveallsurfaceglossfromthepipeO.D.wherethesaddleistobebonded.(Forlargediameterpipe,adiscsanderisusuallymorepractical.)Usecircularorrandompat-ternmotionduringsandingtoeliminategroovesonthepipesurface.Aftersanding,positionthesaddleonthepipeandmarktheholetobecutinthepipe.Cutaholethesamesizeasthesaddleoutletusingapilotdrillandcircularholesaworsabresaw.Donotforcethecutteroritwillfraytheedgesoftheholeexcessively.Cleanallbondingsurfacesasrequired.Note:Besurecleaner(ifused)hasevaporatedbeforeap-plyingadhesivetothebondingsurfaces.ApplyaheavycoatofadhesivetotheO.D.ofthepipe,I.D.ofthesaddle,andtheedgesofthepipewallexposedbythehole.Placethesaddleovertheholeandclampwithtwohoseclampsorabandingtool.(Note:Bandingtoolmustbeatypethatdoesnotleaveslackinthebandswhenthetoolisremoved.Use
40
RT,
GT,
SS
FAB
RIC
ATIO
N
T.A.B.Wrenches
41
metalbanding.)Usingalargescrewdriver,handtightenthehoseclampsalternatelyuntilsecureandadhesivesqueezesoutallthewayaroundthesaddle.ThiswillensurethatthepipeO.D.conformstothesaddleI.D.Youcanremovetheclampsorleavetheminplaceaftertheadhesiveiscured.Allow adhesive to cure before bonding in the side run. Usetwobandingtoolstopullthesidesofthesaddledownalternately.Iftwotoolsarenotavailable,tightenthefirstbandsnug,thesecondbandtight,andaddathirdband,pulledtight,onthefirstside.Three-quarterinchbandingisrecommended.Ifthesaddlesareusedonnon-standardpipe(pipenotlistedinFGSlitera-ture),contactyourFGSrepresen-tativeforspecialinstructions.
F.Reducer BushingsInstallreducerbushingsusingablockofwoodandahammerandthesameproceduresasforbellandspigotpipe.Thewoodblockshouldbesizedtoallowthereducerbushingtobecounter-sunkinthebell.Somereducerbushingswillbecoun-ter-sunkbeforetheyareactuallylockedup.Formaximumchemicalresistancewith8"andlargerGreenThreadreducerbushings,coatallmachinedsurfaceswithadhesivejustbeforeassembly.
RT, G
T, SS FA
BR
ICATIO
N
42
JOINT CuRE
A. Ambient CureCuretimeisthetimerequiredfortheadhesiveinthe
assembledjointtoharden.Curetimedependsonthetypeofadhesiveandtheambienttemperature,asshowninTable11.
Youcanshortencuretimebyapplyingheat.Althoughalloftheadhesiveswillcureatambienttemperaturesabove70°F,itisrecommendedtheybeheat-curedattemperaturesofatleast275°Ftomaximizephysicalpropertiesandcorro-sionresistance.Seepage43forinstructionsforusingFGSheatcollarsforheat-curingjoints.
B. High Temperature Heat CollarRefer to Bulletin No. F6640 for complete operating
instructions.
TABLE 11. Adhesive Ambient Cure TimeAdhesive Type Temperature (°F) Cure Time (hrs.)
7000
110 290 380 570 860 1855 24
8000
110 190 280 470 660 1255 18
NOTE:Curetimeisthetimebeforethelinecanbetested.Timesmayvarydependingupontemperature,humidity,etc.
RT,
GT,
SS
FAB
RIC
ATIO
N
NOTE:Donotbendorfoldheatingcollarasthismaybreaktheheatingelementsandcausethecollartoworkimproperlyornotatall.
For Pipe and Fittings:1. Usethesamesizeheatingcollarasthepipesizeyou
areinstalling,withtheexceptionofflanges.Donotuseaheatingcollarthatisdesignedforalargersizepipe.
2. Withtheun-insulatedflaponthebottom(nexttothefitting),carefullywraptheheatingcollararoundthejoint.Feedthestrapthroughthesquarering.CAUTION:Theun-insulatedflapisextremelyhotwhenthecollarison.DONOTTOUCHwithbarehands.
3. Tightenthestrapsuntiltheheatingcollarissnugagainstthejoint.
For Flanges:1. For1",11/2"and2"flanges,anindustrialheatgunmaybe
usedtocurethejoint.Besurethattheendofthegunisatleastsixinchesfromtheopeningoftheflange.
2. For3"through16"flangejoints,useaheatingcollarthatisonepipesizesmaller.Removethestrapsfromtheheatingcollar.
3. CarefullyturnthecollarinsideoutwiththeheatedareafacingtheI.D.ofthepipe.PlacetheheatingcollarintheI.D.oftheflange.Asplitringofpipemaybeusedtoholdthecollarinplacewhilethejointiscuring.
For Saddles:1. Placetheheatingcollaroverthesaddleoutlet.During
coolweather,awindshieldisrecommendedtokeepheatonthejoint.Saddlesmustbeheatcuredfortwohours.
Allowthejointtoreturntoambienttemperaturebeforeapply-ingstresstothejoint.NOTE: FGSHighTemperatureelectricheatingcollarsarede-signedtofitaroundfittings,andwilloverlaponpipejointsandcouplings. Exceeding the recommended cure time on pipejointswheretheheatingcollaroverlapsmayshortenthelifeoftheheatingcollarand/ordamagethepipe.Theuseofinsulationmaybenecessarybelow40°Ftopreventheatloss.
43
RT, G
T, SS FA
BR
ICATIO
N
NOTE: Heatblanketcure time refers to that timewhen theheatsourcecanberemovedandthepipeinstalledandtestedat recommended pressures. Heat blanket hours pertain to70°F-100°Ffabricationenvironment.Curetimeswillbelongerfor colder temperatures. For temperatures below 70°F, see“Cold Weather InstallationTips” on page 14 or consult FGSTechnicalServices.Ifnoheatsourceisavailable,adhesiveswillcureatambienttemperaturesof70°F-100°Fin24hours.(1) Includessleevecouplings.
250°F(3) 18"jointsrequiretheuseofone8"andone10"heatingcollar 20"jointsrequiretheuseoftwo10"heatingcollars 24"requirestheuseoftwo12"heatingcollarsC. FGS Heat Packs FGSheatpacksthatcurejointsinapproximatelyonehourarealsoavailable.RefertoBulletinNo.D4500forcompleteinstructionsthatareincludedwitheachkit.Observeallsafetyprecautionslistedontheinstructionsheetsthataccompanytheheatpacks.
44
TAB
LE 1
2. H
igh
Tem
pera
ture
Hea
t Col
lar C
ure
Tim
es fo
r Adh
esiv
e Jo
int F
abric
atio
n
Pipe
Sys
tem
&
Adh
esiv
e G
rade
Pipe
Siz
e (In
.)C
ure
Tim
e (M
inut
es)
Pipe
(1)
Fitti
ngFl
ange
(2)
Perf
. Plu
sR
edT
hrea
dII
7000
or8
000
Ser
ies
Adh
esiv
e
2-6
1020
15N
/A8
2020
2030
1027
2727
3512
3030
3040
1434
3434
4516
3838
3860
18(3
)70
7070
120
20(3
)80
8080
120
24(3
)90
9090
120
Gre
enT
hrea
dS
ilver
Stre
ak80
00S
erie
sA
dhes
ive
2-6
1220
15N
/A8
2020
2030
1027
2727
3512
3030
3040
1434
3434
4516
3838
3860
18(3
)70
7070
120
20(3
)80
8080
120
24(3
)90
9090
120
Caution:Theadhesivebeadwillcurefasterthantheadhesiveinthejoint.Itisimportantthatthejointnotbepressurizeduntilithasbeensubjectedtothe
propertime-temperaturecycle.Atemperatureversustimetopressurecurveisindicatedintheinstructionspackagedwitheachadhesivekit.
REPAIRS for RED THREAD, GREEN THREAD & SILVER STREAK Piping Systems
Fiberglasspipingsystemsarerelativelysimpletorepair.Normally,repairmeanscuttingoutafittingoradamagedsec-tionofpipeandreplacingitwithnewmaterial.
Caution:Alwaysdetermineexactlywhatfluidhasbeeninthepipingsystem.Contactmaybeharmfultohumans.Takenecessaryprecautions.
Alwaysusethesamepipegrade,fittings,andadhesiveonnewpartsasisintheexistingsystem.Donotmixpipegrades.
Inspecting for Potential Causes of Joint Failure
Joint Backout–Ifthebeadisnolongernexttotheedgeofthebell,thejointbackedoutbeforetheadhesivecured.
Cocked Joint–Ifajointiscockedormisaligned,therewillusuallybealargegapbetweenthebellandspigotononeside.
Improperly Cured Joint–Iftheadhesivebeadissoftorflexible,theadhesiveisnotsufficientlycured.
Weathered Joint–Ifthemachinedareaappearsyellow,thejointmayhavebeenexposedtoUVdegradation.
Alldamagedorimproperlyassembledjointsmustberepairedorreplacedasindicatedbelow.
REPAIRING WEATHER DAMAGEIfmachinedsurfacesofpipeorfittingsareexposedto
directsunlightpriortoinstallation,alossofjointbondingstrengthmayoccur.Ifultravioletexposureisgreaterthantwohours,thefollowingstepsmustbetaken:1. Forexposedspigotends,use80to120gritsandpaper
orEmeryclothandlightlysandtoremoveUVdegrada-tion.Avoidoversandingasthismayalterthetaperangleofthespigotandmayresultinvoidsinthebondline.IfUVdegradationistoosevere,cut1”fromtheendofthepipeandretaper.
45
RT, G
T, SS FA
BR
ICATIO
N
!
!
2. Forexposedbellends(pipeorfittings),sandthoroughlyuntiltheentiresurfaceappearsfresh.Handsandingwith40gritsandpaperisrecommended.Usealightsandingoperationtopreventchangingthetaperangle.
NOTE:COUPLINGSORINTEGRALBELLSWITHT.A.B.THREADSTHATHAVEBEENOVEREXPOSEDMUSTBEREPLACED.
REPAIRING MINOR DAMAGEFordamagedareaslessthanoneinchindiameterinlightchemicalorwaterservice.
A. Flanged Systems:Ifpossible,simplyreplacetheentireflangedlength.Otherwise,cutoutthedamagedsection,thenbondnewflangestotheremainingpipeendsaccord-ingtorecommendedprocedures.Next,fabricateanewflange-by-flangespooltothelengthrequired.Boltinthenewpipesection.
Flangedfittingsshouldberemovedfromthesystemwhen
damagedandreplacedwithanewfitting.
B. Tapered Systems: Makeapatchtocoverdamagedarea.1. Cutalengthofgoodpipetoadequatelycoverthe
damagedareaandextend3”-4”oneithersideofthedamagedarea.
2. Slitthis“patch”length-wisetwiceandremoveasectionsothataboutthree-fourthsofthecircumferenceremainsfor1"-4"pipeandone-halfthecircumferencefor6"andlargerpipe.
3. Thoroughlysandtheinnersurfaceofthepatchandsandacorrespondingareaonthepipearoundthedamagedsection.
4. Cleanthebondingsurfaces,thenap-plyathickcoatingofadhesivetobothsurfaces,snapthepatchinplace,andapplypressurewithhoseclamps.Theclampsmaybeleftonorremovedaftercuring.
46
RT,
GT,
SS
FAB
RIC
ATIO
N
REPAIRING EXTENSIVE DAMAGEWhenthedamagedareainthepipewallislargerthanoneinchindiameter,orforrepairofpipeinseverechemicalser-vicethatrequiresalinedproduct,followtheseinstructions:
1. Whendamageislocal(lessthanoneinchlong,butmorethantwoinchesaroundthecircumferenceofthepipe),checktoseeifthereisenoughslackinthepipetocutoutthedamagedsec-tion,re-taperthecutends,andbondasleevecouplingbetweenthetaperedends.
2. Whendamageisextensive(toolargeforreplacementbyasinglesleevecoupling),cutoutthedamagedsection,taperthecutends,andinstalltwosleevecouplingsandapipenipple.This procedure requires sufficient slack in the line to make the final joint by lifting the pipe (or moving the pipe to one side) to engage the bell and spigot joint.
3. Ifthelinecannotbemovedsufficientlytoinstallasleevecouplingorasleevecouplingspoolpiece,taperbothendsofthepipeandinstallflanges.
4. Ifitisimpossibletotaperthepipeintheditch,youcaninstallanewsectionofpipebyoverwrappingtheplaincutends.a. Cleananarealargeenoughforinstallerstoworkon
bothsidesandunderthepipe.Cutoutthedamagedsectionofpipeandmeasurethegap.Cutasectionofgoodpipethatisnotmorethanone-halfinchshorterthanthelengthtobereplaced(1/4"maximumgaponeachend).
b. Sandtheendsofthepipetoremoveallresingloss.Alignthereplacementpipesectionwiththepipelineandblockupallsectionstomaintainalignment.Allsectionsmustberigidsotheywillnotmoveduringtheoverwrappingprocedure.Tackweldsshouldbeusedbyplacing1"x2"patchesofglassclothandad-hesive(fourpatchesspacedat90°intervalsaroundthepipe).SeeOverwrapping.
47
RT, G
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REPAIRING LEAKING JOINTSOverwrapping–Ifajointleaksbecauseofimproperinstal-lation,youcanrepairitbyoverwrappingwithglassclothandresin.Thetemperatureintheworkareashouldbe75°F-90°F.Besuretoprotecttheoverwrapfromthesun.
1. Use7-10oz.glassclothfromFGS.Componentsfortheepoxyoverwrapareavailableinan8088repairkits(seeTable13).
2. Useagrinderorsanderwithcoarsesandpaper(40gritorless)toremoveglossfiveinchesoneithersideofthejoint.
3. Beveltheshouldertoblendinwiththepipewallandaddputtytomakeasmoothtransitionfromfittingtopipe.Thelengthofthisputtyshouldbeheldtoaminimum,becausetheputtyhaslimitedpressurecapabilities.
48
TABLE 13. WELDFAST 8088-S Overwrap Repair KitsPipe
Size (In.)Layers
of GlassGlass Width
(In.)Number of kits
Required per Joint1 4 8 0.25
11/2 4 8 0.252 6 8 0.753 6 8 0.754 6 8 1.006 6 8 1.508 8 8 2.50
10 10 8 3.5012 12 8 5.0014 14 8 6.5016 16 8 8.00
RT,
GT,
SS
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CAuTION: There must not be any pressure on the line or any fluid leaking from the joint when performing this procedure.
4. Re-sandandcleansurfacesincludingbevel.5. Thoroughlymixtheadhesiveandhardenerwiththestir
stickuntilthereisauniformcolorandaconsistentflowoffthestirstick.
6. Usingapaintbrush,applythemixedadhesivetoallsandedareas.
7. Eachpieceofglassclothmustbeslightlylongerthanthepreviouspiece,becausetheO.D.ofthepipebecomeslargerasyouaddglasscloth.Cutthefirstpiecetoallowfortwoinchesofoverlap.Whenthislengthisnolongersufficienttooverlapatleastone-halfinchontheends,determineanewlengthwithtwoinchesofoverlap.
8. Centerapieceofglassclothoverthejoint.Pullontheclothwhilepositioningitandwetitoutbypaintingwithadhesive.Brushtoremoveanytrappedairbubblesinthewrap.Startatoneendoftheclothandworkaroundthecircumference,wettingtheclothwithresin.Worktheclothawayfromthestartingendandfromthecenteroftheclothtothesides.Theclothmustbethoroughlywet-tedwithadhesive,butdonotspendalotoftimeinoneareaastheclothwillwetout(loseitsshiny,whiteappear-ance)withtime.Bythetimetheclothhasbeenworkeddownsmoothlywithnoairbeneathit,mostofitwillbewettedout.
9. Topreventthicksectionsorhumpsintheoverwrap,cen-terthenextpieceofglassclothonthejointstartingfromanewpointonthecircumference.RepeatStep8untilalllayersareapplied.
10.Shouldtheoverwrapstarttogiveoffheat,discontinuewrappingandletthejointcureandcoolwithafan.Sandthecuredlayerstoremovetheglossbeforerestartingtheoverwrapprocedure.
11. Payparticularattentiontothebottomoftheoverwrapasthisistheareathatmaysagandismostdifficulttosee.
12. Intemperaturesabove90°F,protecttheoverwrapfromdirectsunlight.
49
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PART VFABRICATION OF F-CHEM PIPE AND FITTINGS
A. Matched Tapered Bell and Spigot Joint PrepNote:Itisessentialthatpipeandfittingsurfacesbe
sanded,clean,dry,andfreeofoil,grease,andsolventcon-tamination.
1. Preparethebellandspigotendsofthepipebysandingthebondingsurfaceswith36to60gritabrasive.
Thesandedareashouldextendatleast1/2"beyondthelengthofthebell.
2. Neversandmorethantwo(2)hoursbeforemakingthejoint.
3. Wipethesandedareawithaclean,dry,lint-freecloth,andavoidtouchingthesurfaceswithbarehandsordirtygloves.
DO NOT uSE SOLVENTS.
Note:F-CHEMfittingsareavailablewithflangedorplainendsonly.SeeManualNo.F6080, Pipe Installation Hand-book for Socket Joints and Butt & Wrap Joints,forjoiningF-CHEMfittingsandpipewithbutt&wrapjoints.
B. Joint Assembly1. Coupler Instructions Attachthebandsorchains
tothepipe.Havethejacksandallothermaterialready,priortomixingtheresinandcatalyst.
Placebandclampsorchainsapproximately3to4feetfromthejointonboththebellandthespigotpieces.Slipthe"D"ringsintoplaceonthehorizontalcenter-line,onbothsidesofthepipe,priortoattachingthecouplerhooks.
Unreelthecouplersandhookthejacksintoplace.Thecablesmaybeleftunattachedtoallowworkingroomfortheapplicationoftheadhesive.
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2. Mixing Weldfast CL-100 Adhesivea. MixthecanofPart"A"
resintofullydisperseanyliquidwhichmayhaveseparatedduringstorage.Itshouldbealightpurplecolor.
b. AddtherecommendedtubesofPart"B"catalysttothePart"A"resincan.
c. Mixthoroughlyforaminimumof twominutesoruntilthecolorisa consistentlightgreen.
3. Pot Life Potlife(workingtime)mayvarywithchangesintempera-
tureandhumidity.
4. Applying Weldfast CL-100 and Bonding Pipea. Usethebrushtoapplygen-
erousamountsofcatalyzedresintothebellendfirst,thenapplytothespigotend.
b. Alignthejointandguidethespigotendintothebell.
c. Attachcouplerhooksandjackthejointintofirmengagement.Checkaroundthejointlinetobesurethatitiseven,whichindicatesproperalignment.
d. Usebrushtofillinanygapsinadhesive.Leavecouplerinplaceduringinitialcure(approximatelyonehour).
TABLE 14. CL-100 Adhesive Estimated Pot Life
Pipe PotLife PotLifeResin @70°F @90°FSystem Adhesive (min.) (min.)
VinylEster CL-100 20 10
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C. Joint CureCuretimeisthetimerequiredfortheadhesiveinthe
assembledjointtohardenanddependsontheambienttem-perature.Cure Time for CL-100 Adhesive is 24 hours.Curetimecanbedecreasedandjointstrengthincreasedbyheatingthejointfrom175°Fto225°F.Heatcureisstronglyrecom-mendedforpipingsystemscarryingfluidsattemperaturesabove120°F.
52
ADHESIVE DISPOSAL: Once the adhesive and catalyst havebeenmixedandreacted,nothingcanbeextracted,anditisclassi-fiedasnon-hazardousmaterial.Disposeofinanormalmannerasothersolidwaste.Excessadhesiveandcatalystcanbemixed,al-lowedtoreact,anddisposedofasabove.Ifextracansofadhesiveor tubesof catalysthaveaccumulatedwithout theother compo-nenttomixandreact,contactyourFGSregionalmanager.Cata-lysttubes,whenemptyarenotsubjecttoEPAregulationandcanbedisposedof inanormalmanner.Theseguidelinesarebasedonfederalregulations.Stateandlocalregulationsandordinancesshouldbereviewed.
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INSTRuCTIONS FOR uSING FGS SILICON RuBBER HEAT BLANKET
Caution:ReadOperatingInstructionsBeforeUsing.• Useonlywith120voltpoweroutlet.• Blanketshouldnotbeusedinwetconditions.• Tears,cutsorpuncturesintheblanketcancreatea
potentialsafetyhazard.• Thethermostatmustbewrappedintheblankettoprevent
overheating.
1. Useonlythepropersizeheatblanketforthepipebeingjoined.
2. Aftertheadhesivefillethashardened,wraptheblanketaroundthejointbyfirstplacingthethermostatendoftheblanketagainstthejointwiththethermostatfacingout.Wraptheremainderoftheblankettightlyaroundthepipe.Holditinplaceduringtheheatingprocess.
NOTE:Checkheatblankettemperaturetobesureitis heatingproperly.
3. Avoidexcessflexingoftheblanket.Abnormalflexingcancausebreakageandshortentheservicelifeoftheblanket.DONOTcreasetheheatblanket.
4. Usealuminumfoiltoprotectheatblanketfromadhesive.5. DONOTusecleaningsolvents.Solventspenetratethe
rubberanddamagetheheatingwires.6. DONOTcarryormovetheblanketbyliftingitwiththe
cordalone.Supporttheweightoftheblanketseparatelyfromthecordtoavoidabusingthecord-to-blanketcon-nection.
Impropersizingoruseoftheheatblanketscancauseexcessheatingwhichcandamageboththepipingandheatblankets.
53
TABLE 15. 110 Volt Silicon Rubber Heat Blanket Models(For use with F-CHEM pipe)
PipeSize 4”-8” 10”-14” 16”-20”
Model C D E
F-CH
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TABLE 16. Silicon Rubber Heat Blanket Cure Times for Adhesive Joint Fabrication
NOTE:Heatblanketcuretimereferstothattimewhentheheatsourcecanberemovedandthepipeinstalledandtestedatrecommendedpressures.Heatblankethourspertainto70°-100°Ffabricationenvironment.Curetimeswillbelongerforcoldertemperatures.Fortemperaturesbelow70°F,see"ColdWeatherInstallationTips"onpage14orconsultFGSTechnicalServices.Ifnoheatsourceisavailable,adhesiveswillcureatambienttemperaturesof70°-100°Fin24hours.
54
Piping System/Adhesive Grade
Pipe Size(In.)
B&S Joints(hrs.)
F-CHEMCL-1004-14 1
16-20 4
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REPAIR & MODIFICATIONfor F-CHEM PIPING SYSTEMS
Fiberglasspipingsystemsarerelativelysimpletorepair.Normally,repairmeanscuttingoutafittingoradamagedsec-tionofpipeandreplacingitwithnewmaterial.
Caution:Alwaysdetermineexactlywhatfluidhasbeeninthepipingsystem.Contactmaybeharmfultohumans.Takenecessaryprecautions.
Alwaysusethesamepipegrade,fittings,andadhesivewhenrepairingorreplacingdamagedsections,ormodifyingthesystem.
Ifyouhaveanyquestionsaboutthechemicalservice,pipegradeselection,orsystemoperatingconditions,callyourlocalFGSDistributororFiberGlassSystemsdirect.
NOTE: Whenmakingrepairs,besureallsurfacestobebonded
aredry,cleanandthoroughlysanded.Goodadhesiveconnectionscannotbemadeonwetorcontaminatedsurfaces.
REPLACING DAMAGED PIPEPipeleaksthroughthepipewallarealmostalwaystheresultofphysicaldamagetothepipefromimpact,vacuum,excessivebending,orotherabusiveconditions.Thedam-agedsectionshouldalwaysbereplacedusingthefollowingprocedures:
Flanged Systems:Ifpossible,simplyreplacetheentireflangedlength.Other-wise,cutoutthedamagedsection,thenbondnewflangestotheremainingpipeendsaccordingtorecommendedproce-dures.Next,fabricateanewflange-by-flangespooltothelengthrequired.Boltinthenewpipesection.
Flangedfittingsshouldberemovedfromthesystemwhendamagedandreplacedwithanewfitting
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Tapered Bell & Spigot Systems:Cutoutthesectionofpipewhichleaks,makingsurecutsaresquare.Drythepipeends.Cutanewlengthofpipethesamelengthasthepiecethatwascutout.UsetwoFGSbutt&wrapkitstobondthenewpipeintoplace.RefertoManual No. F6080 for Butt & Wrap Jointdetailedinstructions.
REPLACING DAMAGED FITTINGSIfaleakdevelopsinanF-CHEMfitting,itwillusuallybenecessarytocutouttheleakingpartandreplaceit.UseFGSbutt&wrapkitstobondthenewfittingintoplace.Referto Manual No. F6080fordetailedinstructions.TEMPORARY FIXES, OVERWRAP
ButtWrap ButtWrap
ButtWrapJoint
ProblemFitting
Step1-CutoutSection
Asatemporaryrepair,aleakingfitting,pipeorjointcanbeoverwrappedwitharesinandglasslay-up.Thisrequiresresin,catalyst,fiberglassreinforcement,tools,andaclean,dryworkarea.Manytimesanoverwrapisthepreferredmethod,particularlywhenfittingsareinaclose,complexmanifoldorassembly.Customoverwrapkitsareavailableforeachpipesizeandpressureclassification.ContactFGS.
Application Procedure:Beforemakingtheover-wrap,readtheseinstructionscarefully.1. Sandthesurfaceareathoroughlyforanequaldistance
oneachsideoftheleak.Thesandedsurfaceshouldextendatleast1/2”beyondthewidestlayerofglasssup-pliedwiththekit.Removeallsurfaceglazes,paint,oil,grease,scale,moisture,orotherforeignmaterialtoen-sureproperbondingoftheresinmaterialtothesurface.
2. Usetheapplicatorbrushtoremovealldustfromthesandedarea.
3. Ifrepairingabell&spigotpipejoint,usetheWELDFASTadhesiveputtysup-pliedinthekittoformataperedbeadasshowninthissketch.Thebeadwillprovideasmoothtransitionfromfittingtopipe.
4. Layouttheprecutfabmatandsurfacingveilonaflat,clean,drysurface(i.e.,cardboard,plywood,etc.).
5. AddcontentsofPart"B"tube(s)tocontainerofPart"A"(resin).Usingoneofthewoodenstirrers,mixthecontentsthoroughlyforatleastoneminute.
6. Usetheapplicatorbrushtoapplyaliberal,evencoatingoftheresinmixturetotheentiresandedsurface.
7. Usingthe3"roller,thoroughlysaturatethefabmatlaidoutonyourworkingsurface.Applywet-outfabmattothejointtobeoverlaidplacingthematsidedown.Usingthe3"roller,continuetorolloutthematerialuntilallentrappedairhasbeenrolledoutandthefabmatiscontouredsmoothlytothesurface.
8. Forjointsizes4"andlarger,repeatStep#7above.
57
TaperedWeldfastBead
Veil &FabmatOverlay
SpigotEnd
BellEnd
F-CH
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9. Placesurfacingveiloverthefabmatand,againusingthe3"roller,applyaliberalamountofresinandworkoutallairasinStep#7.
Be sure that the pipe surface is thoroughly wet out with catalyzed resin.
Some guidelines on the overwrap are:1. Theoverwrapshouldbeequallyspacedoneachsideof
thepointoftheleak.2. Theoverwrapshouldbearoundtheentirecircumference
ofthepipeorfitting.3. Thepressureratingandpipediameterwilldeterminethe
overwrapthickness.ConsultFGStechnicalservicestodeterminespecificinformationaboutdesignoftheover-wrap.
4. Theresinsystemoftheoverwrapshouldbecompatiblewiththeresinsystemoftheexistingpipeorfittings.
5. Curetheoverwrapcompletelybeforepressuretesting.
RefertoManualNo.F6080Butt & Wrap Joint Sectionfordetailedinstructions.
TAPPING INTO AN F-CHEM LINEThemostcommonmethodfor
addingabranchortappingintoanexistingF-CHEMlineistheuseofaT-Miter.Forcompleteinstruc-tions,seeBulletin Nos. D4235, D4240 or D4242,suppliedwitheachT-Miterkit.
Application of a T-Miter:1. Cuttheendofthenewbranchpipewithacontourto
matchtheexistinglinepipeoutsidediameter.2. Trialfitthebranchpipetothelinepipetoensureminimal
gapsandmarkfortheholeinthelinepipe.3. Cutaholeinthelinepipethesamediameterasthe
branchpipeinsidediameter.4. Sandbothpipeswitha36-60gritabrasivetocomplete
roughenthebondingsurface1/2”beyondthewidestlayeroffiberglasstobeapplied.
5. Usetheadhesivesuppliedinthekittosealtheedgesofthepipeandbondthebranchtotheexistingpipe.
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6. Mixtheresinsuppliedinthekitandwetoutthesandedpipesurfacesandsuppliedfiberglass.
7. ApplythefiberglasstothepipejointaccordingtotheinstructionssuppliedintheT-Miterkit.
8. Curethefiberglasslayup.
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PART VIINSTALLATION CONSIDERATIONS
TESTING RECOMMENDATIONS
THESE PROCEDuRES MuST BE FOLLOWED IN OR-DER TO AVOID SERIOuS PERSONAL INJuRY OR PROP-ERTY DAMAGE. FAILuRE TO DO SO WILL RESuLT IN LOSS OF WARRANTY, AND BuYER, INSTALLER, OR ANY EMPLOYEE, AGENT, OR REPRESENTATIVE THEREOF, ASSuMES THE RISK OF ANY DAMAGE OR INJuRY TO PERSON OR PROPERTY.
NOTE:Followallapplicablelocalcodesandprudentengineeringpractices.
HYDROSTATIC TESTINGWhereverpossible,FGSpipingsystemsshouldbehydro-
staticallytestedpriortobeingputintoservice.Careshouldbetakenwhentesting,asinactualinstallation,toavoidwaterhammer.Locatealltestequipmentawayfromtheendofthepipingsystem.
AboveGround:Allanchors,guidesandsupportsmustbeinplacepriortotesting.
BuriedSystems:Beforetesting,makesurethepipingsys-temissecureintheditchwithcompletebeddingunderthepipeandenoughbackfillmaterialinthemiddleofthepipetoholdthepipeinplace.Jointsshouldbeleftopenforvisualinspectionduringtest.
Tohydrostaticallytesttheline,observethefollowing:Watershouldbeintroducedatthelowestpointinthesystemandtheairbledoffthroughapartiallyopenvalveorlooseflangeatallthehighpoints.Slowlyclosethevalve,andbringthesystemgraduallyuptothedesiredpressure.
A. Test Procedures (RT, GT, SS) Thenormalrecommendedprocedureistoconducta
cyclicpressuretest.Thepipingsystemissubjectedto10pressurizationcyclesat11/2timestheanticipatedordesignoperatingpressure.Pressureisthenkeptonthesystemfor1-8hourswhilethelineisinspectedforleaks.Whenhighertestpressuresaredesired,thetestpressureshouldnotexceed11/2timesthemaximumratedcyclicpressureforthelowestratedcomponentinthesystem.Forlowpressureapplications,suchasdrainlines,thecyclictestmaybereplacedbyasteadypressuretest.Linesthatcanbesubjectedtoseveretemperaturecycles,suchas
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steamcondensatelines,hotwaterlines,andcoldwaterlines,shouldbetestedusingthecyclictestprocedureat11/2timesthecyclicpressurerating,evenifthesystemistooperateatrelativelylowpressure.Vacuumorexternalpressuretestingmustnotexceedtheexternalpressurerating.
B. Test Procedures (F-CHEM) Testpressureshouldnotbemorethan1-1/2timesthe
workingpressureofthepipingsystem,andneverexceed1-1/2timestheratedoperatingpressureofthelowestratedcomponentinthesystem.Whentestingiscomplet-ed,openalloftheairbleedsbeforedrainingthepiping.Thiswillpreventvacuumcollapseofthepipe.
WARNINGS:Air Testing:Hydrostatictestshouldbeusedinsteadofairorcompressedgasifpossible.Whenairorcompressedgasisusedfortesting,tremendousamountsofenergycanbestoredinthesystem.Ifafailureoccurs,theenergymaybere-leasedcatastrophically,whichcanresultinpropertydamageandpersonalinjury.Incaseswheresystemcontaminationorfluidweightpreventstheuseofhydrostatictest,airtestmaybeusedwithextremecaution.Toreducetheriskofairtesting,usethetablebelowtodeterminemaximumpressure.Whenpressurizingthesystemwithairorcompressedgas,theareasurroundingthepipingmustbeclearedofpersonneltopreventinjury.Holdairpressureforonehour,thenreducethepressuretoonehalftheoriginal.Personnelcanthenentertheareatoperformsoaptestofalljoints.Again,extremecautionmustbeexercisedduringairtestingtopreventpropertydam-ageorpersonnelinjury.If air or compressed gas testing is used, FGS will not be responsible for any resulting injury to personnel or damage to property, including the piping system.Airorcompressedgastestingisdoneentirelyatthediscretionandriskofmanagementatthejobsite.
Forlargerdiameters,contactFiberGlassSystems.
61
Pipe Diameter 1” 11/2” 2” 3” 4” 6” 8” 10” 12” 14” 16”
psig 25 25 25 25 25 25 14 9 6 5 4
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C. Test Frequency It is strongly suggested that pressure tests be per-
formed on small sections of the installation as they are completed to assure that the installation tech-niques are satisfactory.
•READ THIS CAREFuLLY•
D. SAFETY PRECAuTIONS Asinanysystemwherepressureisemployed,adequate
safetyprecautionsshouldbeexercised. Locatepressuregaugesincloseproximitytothepressurizingequipment,notdirectlyonthepip-ingsystem.Stayawayfromtheendsofthepipeline.Donotstraddlepipe.Useofapressuregauge,withthetestpressureatmid-scale,isrecommended.
Inburiedapplications,itissuggestedthatlongpiperunsbepartiallybackfilledatvariouspointstosecuretheminplace.Alljointsandconnectionsshouldbeleftexposedforinspection.
Inexposedpipesystems,standardpipeguidesandhang-erswillnormallybesufficienttorestrainthepipeduringtesting.
62
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SYSTEM STARTuP
Onanypressurizedpipingsystem,theinitialstart-upshouldbegradualtopreventexcessiveloadsandpressuresurgeswhichmaydamageorweakenthepiping.
Onemethodistoslowlyfillthesystemwhilebleedingoffallairbeforestartinganypumpsoropeningvalvesintopres-surizedpiping.Analternatemethodistostartthecentrifugalpumpagainstaclosed,adjacentvalve;thenslowlyopenthevalvetograduallybuildupsystempressure.Theairshouldbebledoffwhilethelineisfillingasinthefirstmethod.
Forpositivedisplacementpumps,consultFGSEngineer-ingforrecommendations.
WATER HAMMER - AVOIDING PROBLEMS
WaterHammerisatermgenerallyusedtodescribesitu-ationswhereapressuresurgeinthepipingsystemcausesviolentmovementofthesystem.Usuallythispressuresurgeiscausedbyasuddenvalveclosing,electricaloutage,pumpfailure,orsomeotherout-of-theordinarysituation.Thepres-suresurgeisusuallybrief,butdamagecanbesevere.InFRPpiping,waterhammerusuallyresultsinfailedfittingsduetopipesystemmovementcausedbypressure.Insufficientsys-temanchors,guidesandsupportsallowexcessivemovementofthepipingandcreatesfittingfailures.
Installingslowoperatingvalves,apumpbypassorsurgeprotectorsinthesystemisrecommended.
Airinasystemcanalsocausewaterhammer.Besuretobleedairoutofthepipingpriortofullpressureoperation.Anypipesystemwhichmovessuddenly,createsalotofnoise,orisunstableissusceptibletowaterhammer.
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FIBERGLASS FLANGES
Beforebondingtheflangeontothepipe,makesuretheboltholeslineupwiththematingboltholesontheothersys-tem.Donotbolttheflangebeforebonding,unlessinsertiondepthofthespigotispreviouslycheckedtobecertainthatthespigotdoesnotbottomoutorextendthroughtheflange.Theuseofflatwashersonallnutsandboltsisrequired.ThemaximumallowabletorqueisindicatedoneachflangeandisalsoshowninTable6.3.
FGSflangesaredesignedtomeetANSIB16.5,Class150boltholestandards.Full-facegasketingmaterials,1/8"thick,withaShoreAhardnessof60to70durometer,arerecom-mendedforfiberglassflanges.GasketsmadefromTeflon®andPVCusuallyhavehighdurometerratingsandarenotacceptable.
ConnectingtoFlat-FaceFlanges:Fiberglassflangesmaybejoinedtoflat-faceflangesattherecommendedtorquelevels(SeeTable6.3)whenusingpropergasketingmaterial.
ConnectingtoRaised-FaceSteelFlanges:Whenconnectingtoaraised-facesteelflange,oneofthefol-lowingmustbeutilized:
a.Usefilamentwoundfiberglassflanges,
b.Usemoldedfiberglassflangesandmachinethesteelflangefaceuntilitisflatoruseametalspacerringtofillthevoidbetweentheraised-facesteelflangeandthefiberglassflat-faceflange(normallymoredifficultthanmachiningthesteelflangeface).Ifmetalspacerringsarenotavailable,itisacceptabletousespacerringsmadefrommaterialsthatareatleastashardasthefiberglassflange.
c.Usemetalback-upringsbehindmoldedfiberglassflanges(SeeFigs.8.4and8.5).
ConnectingtoLugorWaferValves:MostlinedvalvesneedaflatsurfacetosealagainstandasealingsurfacethatisclosetotheirownI.D.toproperlyseatthelining.Unlinedvalveswithsealingcomponentsinthefaceareinthesamecategoryaslinedvalves.Sometimesthe
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FIGuRE 8.3
sealingridgesonthevalvefacecanfallinthewrongplaceforthegroovesinfiberglassflangefaces,ortheycanbetooclosetotheI.D.toseal.Whenconnectingtovalveswithotherthanflat-facedflanges,followtheserecommendations:1)Forunlinedlugandwafervalveswithoutintegralseals,
usefilamentwoundflangeswithnoback-upringsormoldedflangeswithmetalback-uprings.(SeeFig.8.3,8.4,and8.5)
2)Forlugandwafervalvesthatarelinedorhaveintegralseals,usea¼"steelspacerplatewithanI.D.equaltoSchedule40steelorasrequiredbythevalvemanufacturer.(SeeFig.8.6)
SUMMARY• FGSmolded flanges aredesignedtobeusedagainstflat-faceflanges.Whenjoiningtoraised-faceflangesandlugorwafervalves,steelback-upringsshouldbeused,orspacersfabricatedfromanymaterialcapableofpreventingtheflangefacefrombending.•FGSfilament wound flangesmaybematedtoraised-faceflangesandlugorwafervalveswithnoback-upringsorspacersifthebolttorquelimitsshowninTable6.4arenotexceeded.• Whenusinglugandwafervalveswithintegralseals,itmaybenecessarytousea¼"thicksteelflangebetweenthevalveandthefiberglassflangetoachieveaproperseal.A⅛" thick full-face gasket should be used between the steel flangefaceandthefiberglassflange.• Whenusingsmooth-face flanges (non-standard)forpressuresabove25psig,itisnecessarytogluea0.20"toa0.35"diameter,80durometerO-ringtothefull-facegasket.AcompositeretainerO-ringgasketmayalsobeusedtosealsmooth-faceflanges.
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FIGuRE 8.4 FIGuRE 8.5
Back-upRingThicknessPipeSize RingThickness
1"-8" 1/2"10"-12" 3/4"
FIGuRE 8.6
66
STANDARD BOLTING CONDITIONSFGSflangesaredesignedtomeetANSIB16.5Class
150boltholestandards.For RT, GT & SS,full-facegasket-ingmaterials,1/8"thick,withaShoreAhardnessof60to70durometer,arerecommended.F-CHEM flangesrequirefull-facegasketingmaterial1/4"thickorO-ringsealsdependingonpressureratings.RefertoTable17.
FlatgasketsmadefromTeflon®andPVCusuallyhavehighdurometerratingsandarenotacceptable.
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TABLE17.Gasket&O-RingRequirementsforF-CHEMStubFlanges&FlangedFittings
PipeSize(In.)
PressureRating(psig)
Gasket(1)I.D.O.D.(In.)(In.)
O-Ring(2)CrossI.D.Section
14 50-100125-150
143/16-
21-
-.275
-15.475
16 50-100125
163/16-
23½-
-.275
-17.455
18 50-100125
183/16-
25-
-.275
-19.455
20 50-75100
203/16-
27½-
-.275
-21.629
24 50-75100
243/16-
32-
-.275
-26.129
30 50-75100
303/16-
38¾-
-.375
-31.975
36 50-75100
363/16-
46-
-.375
-36.180
42 5075-100
423/16-
53-
-.375
-44.620
48 5075-100
481/16-
59½-
-.500
-50.680
54 50-75 - - .500 56.770
60 50-75 - - .750 62.590
72 50-75 - - .750 75.340
(1)UseANSI16.5Class150lb.drillinggasketwithahardnessof50to70durometerontheShoreAscale.(2)Use O-ring with a hardness of 50-70 durometer on theShoreAscale.
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TABLE 18. Bolt, Washer & Torque Requirements forRT,GT,SSFlanges&FlangedFittings(1)
(1) Most flanged fittings are available with molded flanges.Filamentwoundflangesareavailableonrequest.(2) Bolt lengths are nominal. When joining FGS flanges toflanges of other material or manufacturers products, boltlengthmustbecalculated.(3) 1"-24" flanges are ANSI B16.5 Class 150 lb. bolt holestandard.
NOTE:Washersarerequiredwithallnutsandbolts.
Recommended Bolt Torquing Sequencefor FGS Flanges Before bonding the flange onto the pipe, make sure thebolt holes line up with the mating bolt holes on the othersystem.Donotbolttheflangebeforebondingunlessinsertiondepthofthespigotispreviouslycheckedtobecertainthatthespigotdoesnotbottomoutorextendthroughtheflange.ThemaximumallowabletorqueisindicatedoneachflangeandisalsoshowninTables18,20,and21.
FlangeSize(In.)
Numberof
Bolts(3)
MachineBolt(2)Size
StudBolt(2)Size
MaximumAllowableTorqueinFt.Lbs.
1 4 ½-13x3 ½-13x4 25
1½ 4 ½-13x3 ½-13x4 25
2 4 ⅝ - 11x3 ⅝ - 11x4 30
3 4 ⅝ - 11x4½ ⅝ - 11x5½ 30
4 8 ⅝ - 11x4½ ⅝ - 11x5½ 30
6 8 ¾-10x5½ ¾-10x6 30
8 8 ¾-10x5½ ¾-10x6½ 100
10 12 ⅞ - 9x6 ⅞ - 9x7½ 100
12 12 ⅞ - 9x6 ½ ⅞ - 9x7½ 100
14 12 1-8x7 1-8x8 100
16 16 1-8x7 1-8x8 100
18 16 1⅛ - 7x7½ 1⅛ - 7x8¾ 100
20 20 1⅛ - 7x7½ 1⅛ - 7x8¾ 100
24 20 1¼-7x7¾ 1¼-7x9½ 100
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TABLE 20. Bolt, Washer & Torque Requirements for RTPP and GTPP Van Stone-Type Flanges(2)
Flange Machine Stub Maximum Allowable Size No. of Bolt (3) Bolt Torque in Ft. Lbs. (in.) Bolts Size Size RTPP, GTPP
8 12 7/8-9x11 7/8-9x12 100 10 16 1-8x12 1-8x13 100 12 16 11/8-7x131/2 11/8-7x15 100 14 20 11/8-7x15 11/8-7x161/2 100 16 20 11/4-7x171/2 11/4-7x19 100 18 24 11/4-7x201/2 11/4-7x22 200 20 24 11/2-6x23 11/2-6x25 200 24 24 11/2-6x27 11/2-6x281/2 200
(1) On3”,14”and16”45°flangedelbowsandonall8”,10”and12”flangedfittings,fourholesarerecessedforclearanceduringassembly.Studsarerecommendedforassembly.Studlengthisdependentonadjacentflange.(2) FlangesareANSIB16.5Class300-lb.boltholestandard.(3) Boltlengthsarenominal.WhenjoiningFGSflangestoflangesofothermaterialormanufactures,boltlengthmustbecalculated.
Note:Washersarerequiredwithallnutsandbolts.
TABLE 19. Recessed Bolt Hole Data for RT, GT, SS(1)
Flange Stud Recess Washer No. Size Size Depth O.D. of (In.) (In.) (In.) (In.) Studs
3 5/8 1/4 15/16 4 8 3/4 1/2 11/2 4 10 7/8 5/8 13/4 4 12 7/8 3/4 13/4 4 14 1 1/2 2 4 16 1 1/2 2 4
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TABLE 21. Bolt, Washer & Torque Requirements for F-CHEM Flanges & Flanged Fittings
(1)Usetwowasherswitheachbolt.UseSAEstandardwashersunderallnutsandboltheadsupto48”size.UseUSSwroughtwashersfor54”andlargersizes.(2)Boltlengthsarenominal.Whenjoiningflangestoflangesofothermaterialormanufacturer,boltlengthmustbecalculated.Note:Specialboltlengthsarerequiredforblindflanges.
Pipe Pressure No. of Machine Stub Size Rating Bolt Bolt Bolt (in.) (psig) Holes Size Size (Nom) (Max) 14 50 12 1-8x41/2 1-8x6 75 100 75 12 1-8x5 1-8x6 85 110 100 12 1-8x5 1-8x7 90 120 125 12 1-8x51/2 1-8x7 50 100 150 12 1-8x6 1-8x7 50 100 16 50 16 1-8x41/2 1-8x6 75 100 75 16 1-8x5 1-8x6 85 110 100 16 1-8x51/2 1-8x7 90 120 125 16 1-8x6 1-8x7 50 100 18 50 16 11/8-7x5 11/8-7x6 75 100 75 16 11/8-7x51/2 11/8-7x7 85 110 100 16 11/8-7x6 11/8-7x7 90 120 125 16 11/8-7x61/2 11/8-7x8 50 100 20 50 20 11/8-7x5 11/8-7x7 90 120 75 20 11/8-7x51/2 11/8-7x7 105 140 100 20 11/8-7x6 11/8-7x8 75 125 24 50 20 11/4-7x51/2 11/4-7x7 90 120 75 20 11/4-7x6 11/4-7x8 105 140 100 20 11/4-7x61/2 11/4-7x8 75 125 30 50 28 11/4-7x6 11/4-7x8 105 140 75 28 11/4-7x61/2 11/4-7x8 120 160 100 28 11/4-7x7 11/4-7x9 75 125 36 50 32 11/2-6x61/2 11/2-6x9 105 140 75 32 11/2-6x71/2 11/2-6x9 120 160 100 32 11/2-6x8 11/2-6x10 100 150 42 50 36 11/2-6x7 11/2-6x9 120 160 75 36 11/2-6x8 11/2-6x10 100 150 100 36 11/2-6x81/2 11/2-6x10 100 150 48 50 44 11/2-6x71/2 11/2-6x9 120 160 75 44 11/2-6x8 11/2-6x10 100 150 100 44 11/2-6x9 11/2-6x11 100 150 54 50 44 13/4-5x8 13/4-5x10 100 175 75 44 13/4-5x9 13/4-5x11 100 175 60 50 52 13/4-5x81/2 13/4-5x11 100 175 75 52 13/4-5x91/2 13/4-5x12 100 175 72 50 60 13/4-5x91/2 13/4-5x11 125 200 75 60 13/4-5x11 13/4-5x13 125 200
Bolt Torque(ft.lbs.)
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Recommended Bolt Torquing Sequence for FGS Flanges
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CONNECTING TO OTHER SYSTEMSItisoftennecessarytoconnectafiberglasspipingtoanotherpipingsystemormakeaconnectionthatwillnotbepossibleusingflanges.Twotypesofadaptersareavailable:bellorspigotbygroovedendsandbellorspigotbythreadedends.
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ADAPTERSNote:Whenusingadapterswithspigotends,itmaybenec-essarytocutoffaportionofthefactorypipebellifthegrooveorthreadsarenotfullyexposed.
A. Grooved Adapters RT,GT,SSProduct:Do
notusecouplingsdesignedforplasticorcement-linedsteelastheycanleakduetoadifferenceingroovedimensions.GroovedadaptersaremachinedtoESdimensions.Usestandardhighpressure(VictaulicStyle77)couplingorequivalent.
B. Threaded Adapters Whenusingthreaded
adapters,threadthemintotheothersystembeforebondingontoFGSpipe.Otherwise,unlessaunionisused,itmaybeimpossibletoturntheadapterintothematingthread.Usesoftset,nonmetallicthreadlubricantortwowrapsofTeflontape.Caution:Donotovertighten.Tightentheadaptersasiftheywerebrassorothersoftmate-rial.
NOTES:1. TheuseofFGSadhesivetobondasteelormetalpipe
intoafiberglassflangeisnotrecommended.2. Ifmatingafiberglasssystemtosteel,thepreferred
methodiswithflanges.TerminatetheoldsystemwiththeirflangeandbolttheFGSflangeonthenewsystem.
3. Besuretochecktheanchors,guides,andsupportsofanexistingsystemtoavoidtransferofanystressesorthermalexpansionloadsintothefiberglasssystem.
4. Donottrytothreadpipeorfittings.
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Threaded Adapters
Grooved Adapters
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SPECIAL BOLTING CONDITIONSItisoftennecessarytomatefiber-glassflangeswithothercompo-nentswhichdonothaveafullflat-facesurfacesuchasraisedfaceflanges,butterflyorcheckvalveshavingpartiallinerfacings,andVanStoneflangehubs.Theaddi-tionofahardspacerringorsteelback-upringplacedbetweentheraisedfaceandtheouteredgeoftheflangetoformafullflatfaceonthematingflangeisrecommended.Thepurposeofthespaceristofillthegapoutsidetheraisedfacetopreventboltloadsfrombendingandbreakingthefiberglassflange.
Pump & Equipment ConnectionFiberglasspipeconnectionstopumpsorotherequipmentthatinvolvevibration,shockloadsorothermechanicalmove-mentsshouldincludeflexibleconnectors.Theseflexiblecon-nectorsallowfortheabsorptionofvibrationandeliminatetheplacingofunduestrainonthepipeandfittings.Abellows-typeexpansionjointisrecommended.
PAINTING PIPEAllpipingO.D.surfacesshouldbecleananddrybeforepaint-ing.Useafast-dryingsolventsuchasacetoneortrichloroeth-ylenetocleantheO.D.ofRT,GT,orSS.Forlongerlastingresults,andforF-Chempipe,theO.D.shouldbethoroughlysandedorsandblasted.Ifsandblasting,becarefulnottocutorgroovethepipeO.D.withanaggressivespray.FGSpipecanbepaintedwithanygoodqualityepoxyetherortwo-partepoxypaint.Contactyourlocalpaintsupplierforadetailedrecommendation.
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MetricUnits U.S.EquivalentsLengths 1millimeter . . . . . . . . . . .0.03937inch 1centimeter. . . . . . . . . . .0.3937inch 1meter . . . . . . . . . . . . . .39.37inchesor1.094yards 1kilometer . . . . . . . . . . . .1093.61yardsor0.6214mileAreas 1squaremillimeter . . . . .0.00155squareinch 1squarecentimeter. . . . .0.155squareinch 1squaremeter . . . . . . . .10.764squarefeet or1.196sq.yards 1squarekilometer 0.3861squaremile
Volumes 1cubicmillimeter. . . . . . .0.000061cubicinch 1cubiccentimeter . . . . . .0.061cubicinch 1liter. . . . . . . . . . . . . . . .61.025cubicinches 1cubicmeter . . . . . . . . . .35.314cubicfeet or1.3079cubicyardsCapacities 1milliliter(0.001liter) 0.0338U.S.fluidounce 1liter. . . . . . . . . . . . . . . .2.1134U.S.liquidpints 1liter. . . . . . . . . . . . . . . .1.0567U.S.liquidquarts 1liter. . . . . . . . . . . . . . . . .0.2642U.S.gallonWeights 1gram . . . . . . . . . . . . . . .0.03527avoir.ounce or15.4324grains 1kilogram(1000grams). .2.2046avoir.pounds
u.S. System units Metric EquivalentsLengths 1inch 25.4millimeters or2.54centimeters 1foot. . . . . . . . . . . . 0.3048meter 1yard. . . . . . . . . . . . 0.9144meter 1mile . . . . . . . . . . . . 1.6093kilometersAreas 1squareinch . . . . . . 645.16squaremillimeters or6.452squarecentimeters 1squarefoot...... 0.0929squaremeter 1squareyard. . . . . . 0.8361squaremeter 1squaremile . . . . . . 2.59squarekilometersVolumes 1cubicinch. . . . . . . 16,387.2cubicmillimeters or16.3872cubiccentimeters 1cubicfoot . . . . . . . . 0.02832cubicmeter 1cubicyard . . . . . . . 0.7646cubicmeterCapacities 1U.S.fluidounce . . 29.573milliliters 1U.S.liquidpint . . . 0.47317liter 1U.S.liquidquart . . 0.94633liter 1U.S.gallon . . . . . . 3.78533liters
Weights 1grain. . . . . . . . . . . 0.0648gram 1avoir.ounce . . . . . . 28.35grams 1avoir.pound . . . . . 0.4536kilogram 1Troyounce. . . . . . 31.1035grams
PART VIIHELPFuL INFORMATION
CONVERSIONS
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Inches DecimalofanInch Inches DecimalofanInch
DECIMAL EQuIVALENTS OF FRACTIONS
1/64 .015625 1/32 .03125 3/64 .046875 1/20 .05 1/16 .0625 1/13 .0769 5/64 .078125 1/12 .0833 1/11 .0909 3/32 .09375 1/10 .10 7/64 .109375 1/9 .111 1/8 .125 9/64 .140625 1/7 .1429 5/32 .15625 1/6 .1667 11/64 .171875 3/16 .1875 1/5 .2 13/64 .203125 7/32 .21875 15/64 .234375 1/4 .25 17/64 .265625 9/32 .28125 19/64 .296875 5/16 .3125 21/64 .328125 1/3 .333 11/32 .34375 23/64 .359375 3/8 .375 25/64 .390625 13/32 .40625 7/16 .4375
29/64 .453125 15/32 .46875 31/64 .484375 1/2 .5 33/64 .515625 17/32 .53125 35/64 .546875 9/16 .5625 37/64 .578125 19/32 .59375 39/64 .609375 5/8 .625 41/64 .640625 21/32 .65625 43/64 .671875 11/16 .6875 45/64 .703125 23/32 .71875 47/64 .734375 3/4 .75 49/64 .765625 25/32 .78125 51/64 .796875 13/16 .8125 53/64 .828125 27/32 .84375 55/64 .859375 7/8 .875 57/64 .890625 29/32 .90625 59/64 .921875 15/16 .9375 61/64 .953125 31/32 .96875 63/64 .984375 1 1.0 H
ELPFuL
INFO
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DEFINITION OF TERMS
ADAPTER–Afittingusedtojointwopiecesofpipe,ortwofittings,whichhavedifferentjoiningsystems.ADHESIVE–Amaterialformulatedtobondtogetherpipeandfit-tingsresultinginhighstrengthandcorrosionresistantfabrications.ANCHORS–Devicetopositivelyrestrainthemovementofthepipeagainstalllateralandaxialforces.BELL AND SPIGOT–Ajoiningsysteminwhichtwotrun-catedconicalsurfacescometogetherandbondadhesively.Thebellisthefemaleend.Thespigotisthemaleend.BuSHING–Afittingusedtojointwodifferentsizesofpipebyreducingthesizeofthefemaleendofthejoint.Jointsmaycomethreadedortapered.CATALYST–Seehardener.COLLAR–Seecoupling.COMPRESSIVE FORCE–Theforcethatoccurswhenop-posingloadsactonamaterial,crushing,orattemptingtocrushit.Inpipe,circumferentialcompressiveforcesresultfromexternalcollapsepressure,actualcompressiveforcesfromheatingofanend-restrainedfiberglasspipe.COMPRESSION MOLDING–Aprocessformakingfittingsinwhichamoldingcompoundisformedandcuredintothefinishedpartconfigurationthroughpressureandheatinadie.CONCENTRIC REDuCER–Apipefittingusedtojointwodiffer-entsizesofpipewhilemaintainingthesamecenterline.CONTACT MOLDING–Aprocessformakingfittingsinwhichcutpiecesoffiberglassreinforcementarelaidonamold,saturatedwithresin,andcuredtothefinishedpartshape.COuPLING (collar)–Ashortheavywallcylindricalfittingusedtojointwopiecesofthesamesizepipeinastraightline.Thecouplingalwayshasfemaleconnectionendswhichcanbebell,threadedoramechanicaljoiningmethod.CuRE–Thehardeningofathermosetresinsystembytheactionofheatorchemicalaction.CuRE STAGES–Stagesdescribethedegreetowhichathermosetresinhascrosslinked.Threestages,inorderofincreasingcrosslinking,includeB-stage,gelled,fullycured.CuRE TIME–Thetimerequiredforathermosetmaterialtoreactanddevelopfullstrength.Thetimeisdependentuponthetemperatureofthematerial.
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CuRING AGENT–Seehardener.CuT AND MITERED FITTINGS–Fittingsmanufacturedbycutting,assemblingandbondingpipesectionsintoadesiredconfiguration.Theassembledproductisthenoverwrappedwithresin-impregnatedrovingorglasscloth,toprovideaddedstrength.EPOXY RESIN–Athermosettingresin,usuallymadefromBisphenolAandepichlorhydrin,curedbyavarietyofagentssuchasanhydridesandamines.Theseresinscontaincyclicethergroups.Seethermoset.FRP–FiberglassReinforcedPlastic.FILAMENT WOuND –Amanufacturingmethodforpipeandfittingsinwhichresinimpregnatedcontinuousstrandrovingwrapsaroundamandreltoachievehighreinforcementcon-centrationandprecisefilamentplacement.FILLERS(extender,pigments,inerts;i.e.,sand,etc.)–Materialsaddedtoaresinwhichdonotaffectthecureoftheresinbutmayinfluencethephysicalpropertiesoftheresinsystem.FITTING TYPES–Theclassificationoffittingsbythemethodofmanufacture;i.e.,molded,cutandmitered,filamentwound,contactmolded.GEL TIME –Thetimeittakesforaresinsystemtohardentoarubber-likestate.GuIDE– Devicethatallowsfreeaxialmovementofthepipe,butrestrainslateralmovement.HAND LAY-uP–Theformingofresinandfiberglassintofin-ishedpipeproductsorfittingsbymanualprocedures.Theseproceduresincludeoverwraptechniques,contactmolding,handmoldingandothers.HARDENER(accelerator,catalyst,curingagent,promoter)–Chemicalsaddedtotheresin,singleorincombination,whichspeedupthehardeningprocess,orcausehardeningtooccur.HEAT BLANKET or HEAT COLLAR–Anelectricaldeviceusedtoheatafabricationtoreducecuretime.HYDROSTATIC TEST–Apressuretestofacompletedfab-ricationtoconfirmgoodquality.Typically,thesystemisfilledwithwaterandheldattheselectedpressurewhilecheckingforleaks.
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IMPACT RESISTANCE–Theabilityofaparttoabsorbastrikingblowwithoutdamage.JOINING(connectingsystems)–Anyofavarietyofmethodsforconnectingtwoseparatecomponentsofapipingsystemtogether.Includedarebellandspigot,threadedandcoupled,mechanicaldevices,etc.JOINT–Atermusedtodescribeanindividuallengthofpipeortheactualjoiningmechanism;i.e.,adhesivebondedbellandspigot,threadedandcoupled,etc.)LINER–Agenerictermusedtodescribetheinteriorsurfaceinpipe.Generally,linersareresin-richregionsfrom0.005to0.100in.thick.Linersmaybereinforcedwithfibrousmate-rialsuchasveilormat.Linerscanprovideextracorrosionprotectionforseverechemicalservice.Theyalsoformaleakbarrier(elastomerbladder).Themanufacturermayaddalinerbefore,during,orafterconstructionofthepipewalldepend-ingonthemanufacturingprocess.LOCK-uP–Abellandspigotjointengagedsufficientlytoeliminatepivotactioninthejoint.MATRIX–Thematerialusedtobindreinforcementandfillerstogether.Thismaterialmaybethermoplasticorthermosettinganddictatestoalargeextentthetemperatureandchemicalserviceconditionsallowableforapipeorfitting.MECHANICAL FORCE–Physicalexertionofpowerusedtoachievelock-upintaperedbellandspigotjoints.MOLDED FITTINGS–Pipefittingsformedbycompressingresin,choppedfiberandotheringredientsinamoldunderheatandpressure.MOLDING –Anyofseveralmanufacturingmethodswherepressureorcompressionmoldingshapesresinandreinforc-ingmaterialsintofinalproducts.POLYESTER RESIN–Anyofalargefamilyofresinswhicharenormallycuredbycrosslinkingwithstyrene.Thephysi-calandchemicalpropertiesofpolyesterresinsvarygreatly.Somehaveexcellentchemicalandphysicalpropertieswhileothersdonot.Vinylestersareaspecifictypeofpolyesterresin.Otherpolyesterresinswithpropertiessuitableforuseinthemanufactureoffiberglasspipeinclude:isophthalicBisphenolAfumarateandHETacidpolyesters.Eachtypeofresinhasparticularstrengthsandweaknessesforagivenpipingapplication.POT LIFE–Thetimeavailabletousethermosetadhesivesafterthereactivematerialshavebeenmixed.
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PRESSuRE RATING–Themaximumanticipatedlongtermoperatingpressureamanufacturerrecommendsforagivenproduct.Alsoreferredtoasworkingpressure,pressureclassordesignpressure.REINFORCEMENT–Typically,fibersofglass,carbonorsyntheticmaterialusedtoprovidestrengthandstiffnesstoacompositematerial.Thetypeoffiberusedasreinforcementplaysamajorroleindeterminingthepropertiesofacomposite,asdoesthefiberdiameterandthetypeofsizingused.Termsrelatingtothephysicalformofthereinforcementinclude:
ChoppedFiber-Continuousfiberscutintoshort(0.125to2.0-in.)lengths.Filament-Asinglefiberofglass;e.g.,amonofilament.Mats-Coarsefabricsheetsmadefromchoppedstrandsrandomlyplacedandheldtogetherbyresinbinders.MilledFibers-Glassfibers,groundormilled,intoshort(0.032to0.125-in.)lengths.Roving-Acollectionofoneormorefilamentswoundintoacylindricalpackage.Thetypicalformofglassfiberusedinthemanufactureoffilamentwoundpipe.Veil-Surfacingmatofporousfabricmadefromglassorsyntheticfilaments.Usedtoprovidearesinrichlayerorliner.Yarn-Glassfiberfilamentstwistedtogethertoformtextile-typefibers.Yield-Thenumberofyardsofmaterialmadefromonepoundoftheproduct.Resin(polymer)-Asappliedtofiberglasspipe,resinisthepolymerorplasticmaterialusedtobindtheglassfiberstogether.
RESIN–Thepolymer(liquidplastic)materialwhichhardenswithcuretoprovideasolidform,holdingthefiberglassrein-forcementinplace.ResinsprovidethecorrosionresistanceinFRPparts.SADDLE–Afittingwhichisbondedtotheexteriorofapipetomakeabranchconnection.SHELF LIFE–Thestoragetimeforamaterialuntilitbe-comesunusable.SOCKET JOINT–Ajoiningsysteminwhichtwostraightcylindricalsurfacescometogetherandbondadhesively.SPACERS–Woodenstripsusedtosupportpipeduringstor-ageandhandling.
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STRESS–Theforceperunitofcrosssectionalarea.Mea-suredinpoundspersquareinch(psi).Thisshouldnotbeconfusedwithhydraulicpressures,measuredaspsigorpsia,whichcaninducestress.SuPPORT SPACING(span)–Therecommendedmaximumdistancebetweenpipesupportstopreventexcessivepipedeformation(bending).SuRGE PRESSuRE–Atransientpressureincreaseduetorapidchangesinthemomentumofflowingfluids.Waterham-merisonetypeofsurgepressure.Rapidopeningorclosingofvalvesoftenresultinasurgepressureorwaterhammer.THERMAL CONDuCTIVITY–Therateatwhichamaterial(pipe)transmitsheatfromanareaofhightemperaturetoanareaoflowertemperature.Fiberglasspipehaslowthermalconductivity.THERMAL EXPANSION–Theincreaseindimensionsofamaterial(pipe)resultingfromanincreaseintemperature.Adecreaseintemperatureresultsinthermalcontraction.THERMOSET–Apolymericresincuredbyheatorchemicaladditives.Oncecured,athermosetresinbecomesessentiallyinfusible,(cannotbere-melted)andinsoluble.Thermoset-tingresinsusedinpipegenerallyincorporatereinforcements.Typicalthermosetsinclude:•Vinylesters •NovolacorepoxyNovolac•Epoxies •UnsaturatedpolyestersTHRuST FORCES–Commonlyusedtodescribetheforcesresultantfromchangesindirectionofamovingcolumnoffluid.Alsousedtodescribetheaxialorlongitudinalendloadsatfittings,valves,etc.,resultantfromhydraulicpressure.TORQuE–Usedtoquantifyatwistingmoment(torsion)inpipe.Torqueismeasuredasaforcetimesthedistancefromtheforcetotheaxisofrotation.Torqueisexpressedinfoot-pounds(ft-lb)orinch-pounds(in-lb).TWO HOLING–Amethodofaligningflangesontopipeorfit-tingssothattheboltcirclewillmatewiththeadjoiningflange.VINYL ESTER–Apremiumresinsystemwithexcellentcorro-sionresistance.Vinylesterexhibitshighversatility,tempera-tureresistanceandexcellentcorrosionresistancetoacids.WATER HAMMER–Pressuresurgesinapipingsystemcausedbysuddenchangeinfluidvelocity,suchasoperationofavalve,pump,orothercomponent.WORKING LIFE –SameasPOTLIFE.
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HOW TO READ FLANGED OR REDuCING FITTINGS
Theabovesequenceshouldbeusedwhendescrib-ingfittingoutlets.Drawingsorsketchesshowingoutlettypes,locations,sizesanddimensionalrequirementsarerequiredformorecomplicatedfittingconfigurations.
TEE
RunxRunxBranch
LATERALRunxRunxBranch
CROSSRunxRunxBranchXBranch
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HOW TO FIGuRE A 45° OFFSET
˚
OffsetLength
OffsetLength
TrueLength
45
TrueLength=offsetx1.414Offset=truelengthx.707
EXAMPLES:IF:offset=12"
12"x1.414=16.968=1'-5"truelength=1'-5"(tonearest1/16")
IF:truelength=24"24x.707=16.968=1'-5"
offsetlength=1'-5"(tonearest1/16")
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2700W.65thStreetLittleRock,AR72209-8592
Phone:(501)568-4010•Fax:(501)568-4465
25S.MainStreetSandSprings,OK74063
Phone:(918)245-6651•Fax:(918)245-7566
http://www.fgspipe.com
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