rtr - assembly instruction butt-and-wrap lamination joint (16 bars)-bondstrand

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AMLANTIT BONDSTRAND©, LTD. Assembly Instructions Assembly Instructions For Bondstrand® Butt-and-Wrap Lamination Joint (16 Bars) Scope These assembly instructions cover the bull-and-wrap jointing system of Bondstrand® RTR pipes and fittings with plain ends (tapered-joint butt-and- wrapping for 16-bar pressure-rated joints). The procedure applies to pipe sizes 1” (25 mm.) to 40’ (1000 mm.) ND. Description The bull-and-wrap joint typically consists of two plain pipe ends which have been prepared for joining by sanding and tapering the outside surface in the joint area (tapered ends as in Figure 2). These spigots are abutted end to end and aligned on the same centerline, and the joint overwrapped with overlapping layers of resin-impregnated fiberglass fabrics (boat tape and woven roving). Each layer becomes increasingly thicker to provide a laminate or build-up that can accommodate both internal pressure and longitudinal forces. Materials of The butt-and-wrap laminate consists of fiberglass reinforcement materials and Construction an epoxy resin system to impregnate and bind the reinforcement materials. For estimated material requirements per size of joint, please refer to Table I for 16-bar pressure rating. Fiberglass Reinforcement. . Glass Woven Roving Owens-Corning, PPG, 500 gm./ m.2 Carl Freudenberg, etc. Boat Tape Owens-Corning, PPG, 150 gm.lm.2 Carl Freudenberg, etc. Resin System. . Epoxy Resin Shell Epikote 827 or DOW 100 Parts by Weight DER 330 . Hardener (Curing IPD (Isophoronediamine) 24 Parts by Weight Agent) . Adhesive Ameron RP34 Adhesive For Initial Jointing or RP48 Adhesive 1

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

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Page 1: RTR - Assembly Instruction Butt-And-Wrap Lamination Joint (16 Bars)-BONDSTRAND

AMLANTIT BONDSTRAND©, LTD.

Assembly Instructions

Assembly InstructionsFor Bondstrand® Butt-and-WrapLamination Joint (16 Bars)

Scope These assembly instructions cover the bull-and-wrap jointing system ofBondstrand® RTR pipes and fittings with plain ends (tapered-joint butt-and-wrapping for 16-bar pressure-rated joints).

The procedure applies to pipe sizes 1” (25 mm.) to 40’ (1000 mm.) ND.

Description The bull-and-wrap joint typically consists of two plain pipe ends which havebeen prepared for joining by sanding and tapering the outside surface in the jointarea (tapered ends as in Figure 2). These spigots are abutted end to end andaligned on the same centerline, and the joint overwrapped with overlappinglayers of resin-impregnated fiberglass fabrics (boat tape and woven roving).

Each layer becomes increasingly thicker to provide a laminate or build-up thatcan accommodate both internal pressure and longitudinal forces.

Materials of The butt-and-wrap laminate consists of fiberglass reinforcement materials andConstruction an epoxy resin system to impregnate and bind the reinforcement materials.

For estimated material requirements per size of joint, please refer to Table I for16-bar pressure rating.

Fiberglass Reinforcement.

. Glass Woven Roving Owens-Corning, PPG, 500 gm./ m.2Carl Freudenberg, etc.

• Boat Tape Owens-Corning, PPG, 150 gm.lm.2Carl Freudenberg, etc.

Resin System.

. Epoxy Resin Shell Epikote 827 or DOW 100 Parts by WeightDER 330

. Hardener (Curing IPD (Isophoronediamine) 24 Parts by WeightAgent)

. Adhesive Ameron RP34 Adhesive For Initial Jointingor RP48 Adhesive

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Page 2: RTR - Assembly Instruction Butt-And-Wrap Lamination Joint (16 Bars)-BONDSTRAND

Materials Important: Store all fiberglass components in a dry but not too cool area in(Cont...) order to avoid surface condensation when used in warmer conditions outside.

Perform moisture-content checks by weighing samples prior to and after onehour of heating at 115°C. A moisture content higher than 0.2% makes thefiberglass fabric unacceptable for lamination use.

Since the curing agent IPD is hygroscopic, keep it stored in closed containerswhen not in use. Prepare IPD batches shortly before mixing with the resincomponent.

Equipment Check El HacksawList El Abrasive Cutting Disc (Diamond Grit or Carborundum)

ci Pipe Supportsci White MarkerEl Wrap-Aroundci Flapper-Wheel Sanders (Grit-60)ci Drilling Machineci Balance (Weighing Scale)ci Air-Relieve Rollers (1.5” through 0.375” Diameter)ci Infra-Red Burners or Hot-Air Gunsci Heating Blanketsci Resin Mixerci Paint Brush, 4”-Wideci Rubber Scraper Plate

Pipe End Preparation Pipe Culling.Note: This initial step shall be applicable only if a factory-prepared pipe endneeds to be cut and replaced, or a pipe length requires field adjustment. Markthe pipe section to be cut using a wrap-around and a white marker.

Cut the pipe using a hacksaw or a cutting disc.; make sure that a proper squarecut has been made see Figure I - Step I.

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

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

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

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

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

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

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Page 3: RTR - Assembly Instruction Butt-And-Wrap Lamination Joint (16 Bars)-BONDSTRAND

Prepare all equipment and construction materials required for the joint Laminationlamination — see Table 1 for estimated material requirements per joint size. Do Procedurenot use humid or damp fiberglass materials; use hot-air guns or oven-dry thefiberglass fabrics before use.

Start the lamination of the filled sections within two hours after sanding ortapering; re-sanding of the lamination area shall be required if the waiting periodexceeds two hours. Remove any possible dew by slightly heating the pipe endsfrom the inside by a heating blanket.

Prepare the resin mix using the correct mixing ratio Resin 100 Parts byWeight; Hardener 24 Parts by Weight. Take note of the pot life after mixing. Theamount of the mixture depends on the diameter. Several batches could be useddepending on the weather, temperature and gelling time.

Be sure that the curing agent is carefully mixed with the resin. The temperatureof the resin and curing agent mixture should not exceed 25°C.

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

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

Make sure that each applied layer of boat tape or woven roving is thoroughlyimpregnated with the resin mixture.

Apply the layers in a circumferential direction onto the pipe-joint ends — seeFigure 1 Steps 4 and 5.

During the wrapping process, tension must be applied so that the resin underthe layer being laid could be pressed out.

Avoid air getting into the laminate by using the air-relieve rollers continuously.

To give the finishing touch, apply one final layer of boat tape spirally wrappedonto the whole surface of the laminate. Use air-relieve rollers to avoid airenclosures.

After the final boat tape layer, smooth out the resin from the exterior of thelaminate, using a rubber scraper, to leave a resin-rich surface.

Before curing, use a heat source (hot-air blower, flood light etc.) to allow thelaminate to gel.

Use heating blankets, to cure the buff-and-wrap joint laminate. Curing and Finishing

Check if the heating blanket is working properly. Temperatures in excess of120 C should be easily achieved if the heating blanket works properly. Thesurface contact between the heating blanket and the laminate should be as largeas possible; fit the blanket as snugly as possible to the joint.

Cure the laminate for 4 hours’ minimum. Wherever possible, apply a heatingblanket on the inside as well and close the pipe ends to avoid drafts.

In cold weather, insulate the heating blanket to trap the heat, but do not coverthe blanket’s thermostat housing.

After curing, use sandpaper to remove the rough edges of the laminate and togenerally smooth out the extemal surface.

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Page 4: RTR - Assembly Instruction Butt-And-Wrap Lamination Joint (16 Bars)-BONDSTRAND

LaminationProcedure(Figure 1...)

Figure 1. Tapered Ends Jointing (16-Bar Pressure Rating)

STEP 1: PIPE CUTTING

STEP 2: SANDING/GRINDING

S I NDd

STEP 4: LAMINATION

L

2L

L

STEP 3: FIT LAYER

STEP 5 LAMINATION

Page 5: RTR - Assembly Instruction Butt-And-Wrap Lamination Joint (16 Bars)-BONDSTRAND

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

Note: LL

Figure 2.

2L

ND

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

Adhesive Laminate Material Requirement

. Ameron RP-34 “Wit’ - 1PDNominal or Boat Woven Epoxy CuringDiameter Ameron RP-48 Tape Roving Resin Agent

(In.) (mm.) 3-oz. Kit 6-oz. Kit (Kg.) (Kg.) (Kg.) (Kg.)

1 25 1 - 0.15 - 0.12 0.03

1% 40 1 - 0.21 - 0.17 0.04

2 50 1 - 0.24 - 0.19 0.04

3 80 1 - 0.35 - 0.27 0.07

4 100 1 - 0.10 0.37 0.38 0.09

6 150 1 - 0.15 0.81 0.77 0.19

8 200 - 1 0.19 1.34 1.24 0.30

10 250 - 1 0.33 2.11 1.96 0.47

12 300 - 1 0.47 3.63 3.30 0.80

14 350 - 2 0.60 5.17 4.65 1.11

16 400 - 2 0.98 7.46 6.80 1.64

18 450 - 2 1.21 10.23 9.24 2.21

20 500 - 3 1.50 14.00 12.50 3.00

24 600 - 3 2.59 23.87 21.34 5.12

28 700 - 4 3.65 40.84 35.89 8.61

30 750 - 4 4.88 49.83 44.13 10.59

32 800 - 4 5.56 60.30 53.11 12.75

36 900 - 5 7.01 85.98 74.99 17.99

40 1000 - 6 9.92 118.20 103.32 24.79

L L

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Page 6: RTR - Assembly Instruction Butt-And-Wrap Lamination Joint (16 Bars)-BONDSTRAND

2o R,9~5Table 2. Recommended Layering Sequence

for the Laminate Structure: 16-Bar Pressure Rating i~.,-. —0/ —~

t~≤

‘.~ 2’~x~

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

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ND:InchND:mm.

LaminationLength(mm.)

LaminationThickness

(mm.)SequenceNumberofLa ers

123456789101112131415161718192021222324252627282930313233343536

-r

40

1000

500

35.6

BTBT

WRWRWRWRWRBT

WRWRWRWRWRBT

WRWRWRWi?WRBT

WRWRWRWRWRBT

Wi?WRWRWi?Wi?BT

Wi?WRWRBT

Note: 1. BT = Boat Tape, 2’ or 4” Wide; WR = Woven Roving.

2. L = Lamination Length; 2L = Total Length of Joint Lamination.

Page 7: RTR - Assembly Instruction Butt-And-Wrap Lamination Joint (16 Bars)-BONDSTRAND
Page 8: RTR - Assembly Instruction Butt-And-Wrap Lamination Joint (16 Bars)-BONDSTRAND

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

Quality Assurance For the design, manufacture and QC testing of Bondstrand RTRP systems,lSO900l Bondstrand Ltd. has established a quality management system which conforms to

both national and international standards. Bondstrand Ltd.’s quality system wasaudited in June 1994 by TUV-CERT. The successful audit furnished proof andcertification that requirements according to DIN !S09001 EN 29001 BS 5750 Part Ihave been fulfilled.

Important Notice This product literature and the recommendations for usage it contains are basedon test data reasonably believed to be reliable. It is intended that this literaturebe used by personnel having specialized training in accordance with currentlyaccepted industry practice and normal operating conditions. Variations inenvironment, changes in operating procedures, or extrapolation of data maycause unsatisfactory results. We recommend that your engineers verify thesuitability of this product for your intended application. Since we have no controlover the conditions of service, we expressly disclaim responsibility for the resultsobtained, or for any consequential or incidental damages of any kind incurred.

Amiantit Marketing and Sales OfficesCentral Province Western Province Eastern Province Export DivisionP.O. Box 1029 P.O. Box 2140 P.O. Box 589 P.O. Box 589Riyadh 11431 Jeddah 21451 Dammam 31421 Dammam 31421

TeL #01-465-8153 TeL #02-651-5676 TeL #03-857 1160 TeL #03-857-1160Fax #01-463-1389 Fax #02-651-6149 Fax #03-857-1156 Fax #03-857-8824Tlx. #401008 AwIuA Si TIx. #6OI43JAWJEDSJ Tix. #803401 AwEPMSJ Tix. #8OJO84APSJDAMSi

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

P.O. Box 589, Dammam 31421, Saudi Arabia

Phone #009663-8571160Fax #009663-8577540

#802958 CCPDAMSJ

Accredited FirmManufacturing Plant: First Industrial City,

Dammam, Kingdom of Saudi A abia.

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

Bondstrand Catalog No. BLAS 05 - April 1997. Revised II Januaiy 1999Printed in the Kingdom ofSaudi Arabia

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