corrpro cathodic protection catalogue

EnvironmentEnerg y

Infrastructure

The Complete S ource for Cor rosion Control Mater ial s

COMPANY OVERVIEWCorrpro is the leading North American supplier of corrosion protection and specialty coatings services to the energy and water infrastructure industries. We offer our clients one stop for all their corrosion solution needs including engineering, installation, pipeline integrity, materials, and coating inspection. Furthermore, Corrpro has over 28 offi ces in North America which serve our customers in the oil, gas, pipeline, refi ning, water, above and below ground storage tank, infrastructure, and offshore markets. In essence, no matter where corrosion occurs, Corrpro has a solution.

OUR MISSIONThrough Teamwork and Superior Execution, Corrpro’s Mission is to Deliver Unwavering Quality Services and Materials.

We Value Results

EthicsSafety People

Environment Customer Teamwork

T A B L E O F C O N T E N T S

Corrpro The Complete Source for Corrosion Control Materials

Table of Contents

© 2008 Corrpro Companies, Inc. • All Rights Reserved

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3 | TABLE OF CONTENTS –––––––––––––––––––––––––––––––––––––––––––12 | CORRPRO PARTNERS

14 | CABLE, WIRE, AND SPLICING –––––––––––––––––––––––––––––––––––15 | CABLE15 | Corrpro® HMWPE Direct Burial Cable16 | Corrpro® HALAR® Direct Burial Cable17 | Corrpro® EPR / CSPE Direct Burial Cable18 | TEST LEAD REELS AND WIRE18 | M.C. Miller / AGRA Hand-Held Reel18 | M.C. Miller HYKON Model 9XC 18 | M.C. Miller HYKON Model JL918 | M.C. Miller HYKON Model 15XC18 | M.C. Miller HANNAY Electric Rewind Reel18 | M.C. Miller Test Lead Wire - No. 1818 | M.C. Miller Test Lead Wire - No. 1619 | M.C. Miller Soil Box Test Lead Set19 | M.C. Miller Standard Test Lead Wires19 | M.C. Miller Electrode-to-Banana Plug Adapter19 | M.C. Miller Banana Plugs19 | M.C. Miller Test Clips19 | M.C. Miller Submersible Adapter 20 | SURVEY WIRE20 | Corrpro® Survey Wire21 | SPLICING KITS21 | SCOTCHCAST™21 | Scotchcast™ In-line Resin Splicing Kit: 82A Series, Voltage Rating Up to 5 kV Non-shielded21 | Scotchcast™ Wye Resin Splicing Kit: 82-B1, Voltage Rating Up to 5 kV Non-sheilded21 | Scotchcast™ Flexible Power Cable Splicing Kit: 82-BF1, Voltage Rating Up to 1000V22 | Scotchcast™ Flexible Power Cable Splicing Kits 82-F and 82-BF Series23 | Scotchcast™ Wye Resin Splicing Kit: 90-B1, Voltage Rating Up to 1000V23 | Scotchcast™ Multi-Mold Resin Splicing Kit for Non-Shielded Cable 85 Series, Voltage Rating Up to 1000 V25 | 3M™25 | 3M™ DBY/DBR Direct Bury Splice Kits26 | ROYSTON PRODUCTS26 | Royston SpliceRight™28 | KING INNOVATIONS 28 | DryConn® Waterproof Connections Anode Splice Box28 | DryConn® VisiLock™ with SmartGel™29 | CONNECTIONS29 | BURNDY29 | Split Bolts and Crimpits

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92 | COATINGS, ADHESIVES, AND TAPES –––––––––––––––––––––––––––––CONTINUED - 3M™ TAPES85 | 3M™ Scotchrap™ Pipe Primer85 | 3M™ Temfl ex™ Vinyl Corrosion Protection Tape 1200 85 | 3M™ Insulating and Splicing Tape85 | 3M™ Linerless Electrical Rubber Tape 224285 | 3M™ TemFlex™ Rubber Splicing Tape 215585 | 3M™ Insulating and Splicing Tape85 | Scotch® Electrical Grounding Braid 2585 | Scotch® Electrical Insulating Varnished Cambric Tape 2510 and 252085 | Scotch® Electrical Semi-Conducting Tape 1385 | Scotch® Electrical Shielding Tape 2485 | Scotch® Fire Retardant Electric Arc Proofi ng Tape 7785 | Scotch® Self-fusing Silicone Rubber Electrical Tape 70 85 | Scotch® Self-fusing Silicone Heavy Duty Triangular Electrical Tape 70 HDT86 | Scotch® Electrical Insulating Varnished Cambric Tape 2510 and 252086 | Scotch® Electrical Semi-Conducting Tape 1386 | Scotch® Electrical Shielding Tape 2486 | Scotch® Fire Retardant Electric Arc Proofi ng Tape 7786 | Scotch® Linerless Rubber Splicing Tape 130 C86 | Scotch® Rubber Splicing Tape 2386 | Scotch® Self-fusing Silicone Rubber Electrical Tape 70 86 | Scotch® Self-fusing Silicone Heavy Duty Triangular Electrical Tape 70 HDT86 | 3M™ Mastic Tapes86 | 3M Scotch-Seal™ Mastic Tape 222986 | 3M™ Scotchfi l™ Electrical Insulation Putty Tape86 | Scotch® Electrical Moisture Sealant Pads 0614987 | Scotch® Electrical Moisture Sealant Roll 0614787 | Scotch® Mastic Strip 223087 | Scotch® Rubber Mastic Tape 222887 | Scotch® Vinyl Mastic Pads 220087 | Scotch® Vinyl Mastic Roll 221087 | 3M™ Highland™ Vinyl Electrical Tape87 | 3M™ Tartan™ General Use Vinyl Electrial Insulating Tape 171087 | 3M™ Temfl ex™ Gereral Use Vinyl Electrical Tape 170087 | Scotch® Heavy Duty Vinyl Insulation Tape 2287 | Scotch® Vinyl Electrical Color Coding Tape 3587 | Scotch® Vinyl Electrical Tape 66R88 | 3M™ EPOXY COATING MATERIALS88 | Scotchkote® Electrical Coating 1458388 | 3M™ Internal Linings88 | 3M™ Scotchkote™ Water Base Primer 500N, 42.3 lb.88 | 3M™ Scotchkote™ Fusion Bond Epoxy Powder Coating 206N, Extra Long Gel, 65 lb.



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88 | COATINGS, ADHESIVES, AND TAPES –––––––––––––––––––––––––––––CONTINUED - 3M™ EPOXY COATING MATERIALS88 | 3M™ Scotchkote™ Fusion Bond Epoxy Powder Coating 206N, Long Gel, 65 lb.88 | 3M™ Scotchkote™ Fusion Bond Epoxy Powder Coating 206N, Long Gel, 1700 lb. Supersack88 | 3M™ Scotchkote™ Fusion Bond Epoxy Powdered Coating XC-625988 | 3M™ Scotchkote™ Fusion Bonded Epoxy Coating XC-617188 | 3M™ Scotchkote™ Fusion Bonded Epoxy Powder Coating 625888 | 3M™ Scotchkote™ Liquid Epoxy Coating 32388 | 3M™ Scotchkote™ Liquid Phenolic Primer 345, Drum88 | 3M™ Scotchkote™ Single Layer Powder Coating89 | 3M™ Scotchkote™ Fusion Bonded Epoxy Powdered Coating 226N+89 | 3M™ Scotchkote™ Fusion Bond Epoxy Powdered Coating 226N89 | 3M™ Scotchkote™ Fusion Bonded Epoxy Powder Coating 623389 | 3M™ Scotchkote™ Fusion Bonded Epoxy Powder Coating 625889 | 3M™ Scotchkote™ Fusion Bonded Epoxy Powdered Coating 206N89 | 3M™ Scotchkote™ Dual and Multi Layer Fusion Bonded Epoxy89 | 3M™ Scotchkote™ Fusion Bond Epoxy Powdered Coating 635289 | 3M™ Scotchkote™ Fusion Bonded Epoxy Dual Coating System 625189 | 3M™ Scotchkote™ Fusion Bonded Epoxy Rough Overcoating 207R89 | 3M™ Scotchkote™ Patch Repair / Rehabilitation89 | 3M™ Scotchkote™ Hot Melt Patch Compound 226P, Green89 | 3M™ Scotchkote™ Liquid Epoxy Coating 306, Green89 | 3M™ Scotchkote™ Liquid Epoxy Coating 314, Forest Green90 | BERRY PLASTICS CORPORATION, CORROSION PROTECTION GROUP90 | POLYKEN® 90 | Polyken® Pipeline Coating Products - Over the Ditch Line Coatings90 | Polyken® 1019 Solvent Based Liquid Adhesive for Line Travel System90 | Polyken® 1600 High Temperature Polypropylene System - GoCoat 25090 | Polyken® 1619 Solvent Based Liquid Adhesive90 | Polyken® 1636 High Temperature Joint Wrap91 | Polyken® 2000 High Shear System - GOCoat 20091 | Polyken® 2019 Solvent Based Liquid Adhesive91 | Polyken® 2027 Solvent Based Liquid Adhesive91 | Polyken® 2036 High Temperature / High-shear Resistant Anti-Corrosion Joint Wrap Coating91 | Polyken® 954 Protective Pipeline Outerwrap92 | Polyken® Pipeline Coating Products - Girth Weld Coatings92 | Polyken® 930 Wrap - Cold Applied Tape Coating System92 | Polyken® 932 Wrap - Cold Applied Tape Coating92 | DIN 942/955 Cold Applied Double Faced Tape93 | Polyken® 1019 Solvent Based Liquid Adhesive for Line Travel System93 | Polyken® 1027 Liquid and Spray Adhesive93 | Polyken® 1619 Solvent Based Liquid Adhesive93 | Polyken ®1627 Liquid Adhesive


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COATINGS, ADHESIVES, AND TAPES –––––––––––––––––––––––––––––––––CONTINUED - BERRY PLASTICS CORPORATION, CORROSION PROTECTION GROUP93 | Polyken® 2019 Solvent Based Liquid Adhesive94 | Polyken® Pipeline Coating Products - Liquid Adhesive Products94 | Polyken® 2027 Solvent Based Liquid Adhesive94 | Polyken® P 1033A Low VOC Liquid Adhesive System94 | Polyken® P 1039 VOC Liquid Adhesive System95 | Polyken® Pipeline Coating Products - Coatings for Pipe Fittings, Bends and “T”s95 | Polyken® 4000-35 PCS Primerless Coating System95 | Polyken® 930 Wrap - Cold Applied Tape Coating System95 | Polyken® 932 Wrap - Cold Applied Tape Coating95 | Polyken® 934 Wrap Cold Applied Tape Coating System96 | Polyken® 936 High UV Resistant / High Tack Joint Wrap Tape96 | Polyken® 937/938 Mastic System96 | DIN 942/955 Cold Applied Double Faced Tape97 | Polyken® Pipeline Coating Products - Accessory Products97 | Polyken® 900 General Utility Tape for Hand Application on Small Diameter Pipe Joints and Fittings97 | Polyken® 910 All Purpose Tape System for Field Application in the Oil Patch97 | Polyken® 931 Self-adhering Filler Tape97 | Polyken® 939 Self-adhering Filler Tape98 | Polyken® Pipeline Coating Products Plant Applied Line Coatings98 | Polyken Powercrete®

99 | COVALENCE®

99 | Covalence® Heat Shrinkable Pipeline Coatings - Accessory Products99 | Covalence® EQ Roller - Rollers are specifi cally designed for use with heat shrink products99 | Covalence® S1113 - Adhesive Tape on Rolls With Release Paper for IPEC 99 | Covalence® S1137 - High Viscosity Sealant Based Filler for PERP, PERP 80, PERP60E99 | Covalence® S1113-RI - Adhesive Tape Reinforced with Glass Fiber for RayJoint 99 | Covalence® Torches - Propane Heating Device 100 | Covalence® Heat Shrinkable Pipeline Coatings for Pipe Fittings, Bends and “T”s100 | Covalence® BLOT - Moulded Part to Coat Blocking T’s 100 | Covalence® CPSM/XCSM - Tubular Sleeve with High Shrink Ratio for Couplers101 | Covalence® CSEM-F - Fiber Reinforced Wrap Around Sleeve for Casing End Seals 101 | Covalence® FCTS/FCWS/FCMS/FCWSF - Heat-Shrinkable Moulded Sleeve 102 | Covalence® FLANGESEAL - Fiber Reinforced Wrap Around Sleeve for Flanges 102 | Covalence® FLEXCLAD - Heat Shrinkable Tape for Bends 104 | Covalence® DIRAX - Directional Drill Fiber Reinforced Wrap-around Field-Joint Coating 104 | Covalence® HTLP-PP - 3 Layer Polypropylene Field-Joint Coating System 104 | Covalence® HTLP60 - 3 layer Wrap-around Field-Joint Coating (with epoxy) 105 | Covalence® HTLP80 - 3 Layer Wrap-around Field-Joint Coating (with epoxy) 105 | Covalence® PPS120 - Wrap-around Field-Joint Coating for 3LPP (2 layer) 105 | Covalence® TPS - Tubular Field-Joint Coating (2 layer)



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104 | COATINGS, ADHESIVES, AND TAPES ––––––––––––––––––––––––––––CONTINUED - BERRY PLASTICS CORPORATION, CORROSION PROTECTION GROUP105 | Covalence® WaterWrap - Wrap-around Field-Joint Coating for Large Diameter Water Pipes (2 layer) – Internal Welding 106 | Covalence® WPC - Wrap-around Field-Joint Coating (2 layer) 106 | Covalence® WPC C30 - Heatshrinkable Sleeves 106 | Covalence® WPC C50 - Wrap-around Field-Joint Coating (2 layer) 107 | Covalence® WPC100M - Wrap-around Field-Joint Coating (2 layer) 107 | Covalence® WPC120 - Wrap-around Field-Joint Coating (2 layer) 108 | Covalence® WPC60 - Wrap-around Shrink Sleeve for Pre-insulated Pipe Joint Sealing108 | Covalence® WPC65M - Wrap-around Field-Joint Coating (2 layer) 108 | Covalence® WPCT - Wrap-around Field-Joint Coating (2 layer) 109 | Covalence® WPCZ - Wrap-around Field-Joint Coating (2 layer) for Infi ll Joints 110 | Covalence® Heat Shrinkable Pipeline Coatings - Liquid Epoxy Primers110 | Covalence® S1239 Epoxy Primer - Two Components Epoxy Primer 110 | Covalence® S1301 Epoxy Primer - Two Components Epoxy Primer 110 | Covalence® S1401 111 | Covalence® Heat Shrinkable Pipeline Coatings - Pipe Coating Repair Systems111 | Covalence® PERP - Coating Repair System for HDD 111 | Covalence® PERP Meltstick - Coating Repair System (scratches only) 111 | Covalence® PERP80 - Coating Repair System 112 | Covalence® Heat Shrinkable Pipeline Coatings - Plant Applied Line Coatings112 | Covalence® Rayclad 120 - Plant Applied Heat Shrinkable Pipeline Coating Tape 112 | Covalence® Rayclad 80 - Plant Applied Heat Shrinkable Pipeline Coating Tape 113 | KEMA COATINGS, INC.113 | KEMA Module Sealants (Macro-Polyisobutylene)115 | PROSHIELD 115 | Coiled Rockshield116 | ROYSTON COATING AND WRAP PRODUCTS 116 | Royston Greenline Tape, Tac-Tape, Roybond 747, Roskote 216, Roskote A-51 and R-20117 | Royston Tapecoat® Cold-Applied Tape Coatings117 | Tapecoat® Gray Tapes118 | Tapecoat® HT/ MB118 | Tapecoat® M50 RC Gray 119 | Tapecoat® 6025 Gray High Temperature Tape119 | Tapecoat® T Tape GPE - Cold-Applied Tape Coating 119 | Tapecoat® CT - Cold-Applied Tape Coating 119 | Tapecoat® Grey Pad - Cold-Applied Mesh Backed Tape Coating 119 | Royston One Step Tape 120 | TR Green120 | Tapecoat® HT Sealant 120 | Royston Sealant Tapes120 | Tape A (Mil Thickness)

Partnering to Bring You the Latest in Corrosion Control Materials

C O R R P R O P A R T N E R S O

ur Partners


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CORRPRO PARTNERSCorrpro wishes to thank our Partners for their continued support and contributions to the content of this catalog. Working together, Corrpro and its Partners bring you the latest technology and expertise in Corrosion Control Materials and Cathodic Protection.

3M™

Alnor

American Innovations

Asbury Carbons

Bacharach

Berry Plastics Corporation

Borin Manufacturing

Burndy Connections

Calpico

Central Plastics

Chlor*Test

Continental Industries

(thermOweld)

Cott Manufacturing

Dairyland Electrical Industries

De Nora

Defelsko

Delmhorst

Erico® Products

Fluke

Gerome Manufacturing

Global Thermoelectric

Handley Industries, Inc.

Hanna Instruments

Holloway

Kema Coatings, Inc.

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King Innovations

Kirk Products

Loresco®

M.C. Miller

Metal Samples

Metrotech

Micro-Metrics

Minitest

N.I.S.T.

NTG

Oxbow Calcining

Pikotek®

Pipeline Seal and Insulation, Inc.

Pro-Mark

PTC Thermometers

QuaNix

Raytek

Royston

Safetrack

Scotchcast™

Serdex

STOPAQ AMCORR

Tempscribe

Testex

Tinker & Rasor

Thompson Lightning Protection

Tooke

Universal Rectifi ers, Inc.

U.S. Weather Bureau

CORRPRO PARTNERS CONTINUED

C a t h o d i c P r o t e c t i o nE n v i r o n m e n t • E n e r g y • I n f r a s t r u c t u r e

Cable, Wire, Splicing Materials, Bonding Materials, and Accessories

C A B L E , W I R E , A N D S P L I C I N G C

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CABLE, WIRE, AND SPLICINGCable Corrpro® HMWPE Corrpro® HALAR®

Corrpro® EPR / CSPETest Lead Reels and Wire M.C. MillerSurvey Wire Corrpro®

Splicing Kits Scotchcast™

3M™

Royston King InnovationsConnections Burndy Connections Calpico Continental Industries (thermOweld®) Erico SafetrackAccessories Royston

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C A B L ECorrpro® HMWPE Direct Burial Cable

Multi-Purpose Cathodic Protection Cable Selecting the right cable for connecting anodes, power supplies, and structures is an important part of cathodic protection design. Corrpro makes this selection process easy by offering a cable manufactured specifi cally for the cathodic protection industry. It is composed of copper wire, which is covered by high-molecular weight polyethylene (HMWPE).The copper wire is stranded and annealed to permit extra fl exibility. Because the polyethylene on the cable is approximately twice as thick as on conventional HMWPE wire, it serves as both electrical insulator and mechanical cover for the conductor. This provides Corrpro’s cathodic protection cable with outstanding dielectric strength and moisture resistance. During installation, the cable can withstand considerable mechanical abuse without risk of damage to the copper electrical conductor. The polyethylene cover is also chemically resistant, and protects against most substances.

Corrpro’s HMWPE cable is manufactured according to strict quality control standards. The polyethylene coating is made to meet American Society for Testing Materials Standard D-1248 for plastic molding and extruded materials. In addition, routine tests are performed to ensure that the cable possesses certain mechanical and electrical properties.

ApplicationsHMWPE cable is offered in a variety of sizes. It can be used as a header cable on cathodic protection systems, or to make anode-lead or negative-return connections. The thick polyethylene cover permits direct burial of the cable in native soils or submersion in fresh water. The cable exhibits superior fl exibility and can be bent without risk of notch propagation. It is not recommended for use in environments containing chlorine, hydrochloric acid or petroleum hydrocarbons.

HMWPE Order Information

Wire SizeAWG

Number of Strands

Insulation Thickness Nominal O.D.

in mm in mm

14 7 0.11 2.794 0.299 7.5912 7 0.11 2.794 .031 7.8710 7 0.11 2.794 0.34 8.648 7 0.11 2.794 0.36 9.146 7 0.11 2.794 0.41 10.414 7 0.11 2.794 0.46 11.682 7 0.11 2.794 0.52 13.211 19 0.125 3.175 0.59 14.99

1/0 19 0.125 3.175 0.63 16.002/0 19 0.125 3.175 0.67 17.024/0 19 0.125 3.175 0.78 19.81

COPPER CONDUCTORS

HIGH MOLECULAR WEIGHTPOLYETHLENE

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without risk of damage. Prior to applying the two insulation layers, the copper wire on the HALAR cable is coated with tin. This prevents oxidation from occurring on the wire strands and ensures good electrical conduction over the life of the cathodic protection system.

ApplicationsHALAR cable is designed for making anode lead connections in a wide range of environments. Due to its dual insulation construction, it can be installed directly in native soils or submerged in fresh, brackish or salt waters. The cable is ideal for deep anode bed installations where chlorine and oxygen gases are generated.The HALAR cable will not embrittle at temperatures as low as -105°F (--76°C), and will maintain dimensional stability and dielectric strength at temperatures up to 250°F (121°C).It is also highly resistant to notch propagation.

C A B L ECorrpro® HALAR® Direct Burial Cable

Protection for the Harshest EnvironmentsCathodic protection stops corrosion attack on metallic structures by making a complete electrical circuit. To create a system with high circuit reliability it is important to use a lead wire cable which is rugged enough to withstand the most severe environments. HALAR is just such a cable. It is composed of stranded copper wire covered by two layers of insulation. The outer insulation layer, or protective jacket, is made from high molecular weight polyethylene (HMWPE). It exhibits superior dielectric and tensile strength, and provides mechanical protection to the wire. The material is also resistant to water intrusion. The inner or primary insulation is composed of HALAR, a fl uorocopolymer. This insulating material demonstrates exceptional chemical resistance. In the presence of chlorine, hydrochloric acid, sulfuric acid or other strong oxidizing agents, the material remains stable. Further, it will not deteriorate when exposed to petroleum hydrocarbons which are encountered in numerous cathodic protection applications.

The HALAR cable distributed by Corrpro is made specifi cally for cathodic protection applications. It can withstand considerable abuse during installation

HALAR Order Information

Wire SizeAWG (mm)

Number of Strands

Insulation Thickness

Jacket Thickness Nominal O.D.

in mm in mm in mm8 (10) 7 0.020 0.508 0.065 1.651 0.35 8.896 (16) 7 0.020 0.508 0.065 1.651 0.38 9.654 (25) 7 0.020 0.508 0.065 1.651 0.43 10.922 (35) 7 0.020 0.508 0.065 1.651 0.49 12.45

JACKET– HIGHMOLECULAR WEIGHTPOLYETHYLENETHICKNESS .065

TIN COATED COPPERCONDUCTOR

PRIMARY INSULATION HALAR, E – CTFEFLUORO – COPOLYMOR THICKNESS .020 IN


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C A B L ECorrpro® EPR / CSPE Direct Burial Cable

Flexible Double Insulated CableTo deliver long-life protection to buried or submerged metallic structures you need a cable, which can perform in all types of environments.EPR/CSPE is a double insulated cable, which has been used extensively as an anode lead wire. Ithas demonstrated excellent resistance to acids and petroleum hydrocarbons, and can sustain signifi cant mechanical abuse without risk of damage to theelectrical conductor. The cable is composed of stranded copper wire, which is coated to prevent oxidation. Because a greater number of strands are used which are relatively small in diameter, the EPR/CSPE cable has greater fl exibility than most direct burial cable.

Dielectric protection to the copper wire is furnished through a two-part insulation. The outer portion of this insulation consists of chlorosulfonated polyethylene. The material can be severely stretched without risk of notch propagation. It is also resistant to moisture intrusion and can operate in a wide range of temperatures without becoming deformed. The insulation material directly surrounding the copper wire is made from ethylene propylene. This insulation material is extremely resilient, and shields the copper wire from most organic and inorganic substances.Applications

EPR / CSPE Order Information

Wire SizeAWG (mm)

Number of Strands

Insulation Thickness Jacket Thickness Nominal O.D.

in mm in mm in mm

6 (16) 7 0.045 1.143 0.030 0.762 0.34 8.6410 (50) 19 0.055 1.397 0.045 1.143 0.58 14.73

EPR/CSPE can be installed indoors or out, in wet or dry locations. It is used primarily as a lead wire for cathodic protection systems. While it can withstand most oils, acids, and alkalies, it is important to consult your Corrpro representative to ensure the cable is appropriate for a particular environment.

STRANDED COPPER CONDUCTOR

EPR INSULATION

CSPE JACKET



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T E S T L E A D R E E L S A N D W I R EM.C. Miller

M.C. Miller / AGRA Hand-Held ReelStamped aluminum construction. Capacity:16 AWG wire - 250 ft 18 AWG wire - 1000 ft Weight 1.25 lbs. without wire Cat. #30501

M.C. Miller HYKON Model 9XC Slip Ring Hub for Continuous Operation12” H x 8” x 8.5 Capacity: 16 AWG wire - 500 ft. 18 AWG wire - 2000 ft. Weight 8 lbs. without wire Cat. #30104 Note: Due to manufacturers discontinuation of this model, MCM will only be able fi ll orders while supplies last.

M.C. Miller HYKON Model JL9Rotating Wire End Offset from Center12.5” H x 8.5” x 10” Capacity:16 AWG wire - 500 ft .18 AWG wire - 2500 ft. Weight 7 lbs. without wire Cat. #30002

M.C. Miller HYKON Model 15XCSlip Ring Hub for Continuous Operation21” H s 16” x 11” Capacity:16 AWG wire - 2000 ft. 18 AWG wire - 5000 ft Weight 16 lbs. without wire Cat. # 30206 Note: Due to manufacturers discontinuation of this model, MCM will only be able fi ll orders while supplies last.

M.C. Miller HANNAY Electric Rewind ReelHandles wire for pipeline corrosion & CP testing. Compact, motorized wire reel with slip ring hub, 12 volt DC motor w/push button switch and tubular handles for carrying. Capacity:16 AWG wire - 4500 ft.18 AWG wire - 10000 ft. Weight 70 lbs. without wire Cat. # 30603

M.C. Miller Test Lead Wire - No. 18No. 18 AWG, 41 Strands/ #34 Tinned Copper Wire

Available in 1000 ft. & 2500 ft. spools Red Cat. #31210 Green Cat. #31301 Orange Cat. #31403 Black Cat. #31410

M.C. Miller Test Lead Wire - No. 16No. 16 AWG, 105 Strands/ #36 Tinned Copper

Available in 500 ft. spools:Red Cat. #30807 Green Cat. #30909 Orange Cat. #31006 Yellow Cat. #31108 Black Cat. # 31505

Note: Do :model, o elast.s

M.C. MM C MHandlesa dHandlesCompao pCompacDC motC mDC motcarryinga icarrying

pCapacita ap16 AWG6 W18 AWG8 WWeight WeCat. # 3a #C t # 3#C t # 3


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M.C. Miller Soil Box Test Lead Set(4 Lead Wires Test Set)Cat. #37009 2 ft long 2-black, 2-red banana plug and pointed plug ends.

M.C. Miller Standard Test Lead WiresStraight No. 16 AWG, 6 ft. longRed Cat. #33808 Green Cat. #33910 Orange Cat. #34007 Yellow Cat. #34109 Black Cat. #34903

Coiled Leads, 6 ft. longRed Cat. #32906R Black Cat. #32906B

Coiled Leads, 12 ft longRed Cat. #32912R Black Cat. #32912B

M.C. Miller Electrode-to-Banana Plug AdapterCat. #16300 Converts any MCM reference electrode from a threaded connection to a convenient banana plug jack. (Extremely useful when making multiple tests where constant connection and disconnection of test apparatus is required.)

M.C. Miller Banana PlugsRed Cat. #TER001 Green Cat. #TER002 Orange Cat. #TER003 Yellow Cat. #TER004 Black Cat. #TER005

M.C. Miller Test Clips27-C Test Clip (40-amp) Cat. #34608 25-C Test Clip (75-amp) Cat. #34607 46-C Hippo Clip (75-amp) Cat. #CON064

M.C. Miller Submersible Adapter Converts any MCM electrode for use underwater. Includes your choice of lead length (8’, 25’, 50’, 100’ or 200’) with a banana plug attached. Water tight connection.

Stock lengths: 8 ft. - Cat. #16305 25 ft. - Cat. #16407 50 ft. - Cat. #16509 100 ft. - Cat. #16600 150 ft. - Cat. #16702 200 ft. - Cat. #16804 Special lengths are available upon request.



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C A B L ECorrpro® Survey Wire

The Long Distance Connection The development of hand-held data logging equipment has greatly simplifi ed the performance of close interval surveys on buried gas, oil, and water transmission and distribution pipelines. These surveys take continuous potential readings between test stations, which can be located from one to three miles apart. To permit these long distance tests, Corrpro supplies disposable survey wire. The wire is made from pure copper and is coated with a varnish to prevent oxidation. It is supplied on plastic spools for completing up to 3 miles of close interval survey. The wire can be used with any type of survey backpack or wire dispense and is easily measured using automatic footage counters to take potential measurements as a function of distance. Unlike standard test wire, which is heavy and diffi cult to work with on long distance surveys, Corrpro’s disposable copper wire is lightweight and dispenses easily. It is made from #34 AWG wire, and exhibits superior resilience. The wire does not tangle or break easily, and provides accurate potential readings.

Applications Corrpro survey wire is designed for conducting close interval surveys. It can be used with any type of backpack or wire dispenser and can be used to collect up to 3 miles of data. The wire should be properly discarded after the survey is complete. Because the varnish coating on the wire is not completely free of holidays, the wire is not suitable for use in water.

Survey Wire Order Information

Wire Material

Spool Nominal DimensionsWire Length Total Weight

Ø Height

in mm in mm Miles km lbs kg

#34 AWG (0.02 mm2)Varnished Copper 3 76.2 4 101.6 3 4.9 2 0.9

Also available in #30 and #32 AWG.


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S P L I C I N G K I T SScotchcast™ In-line Resin Splicing Kit:82A Series, Voltage Rating Up to 5 kV Non-shielded, UL 486D Listed, File #EI 02356Use 82A series kits to insulate and moisture-seal single conductor, non-shielded cables through 5kV and multi-conductor cables through 1000V. Each kit contains a snap-together mill body which fi ts around the splice, two funnels, tape for sealing mold ends, and Scotchcast 4 epoxy electrical einsulating resin in a Unipak™ container for clean and easy handling. These kits may be used for above ground or direct buried applications.

Scotchcast™ Wye Resin Splicing Kit: 82-B1, Voltage Rating Up to 5 kV Non-sheilded82-B1 kit insulates and moisture seals wye splices on non-shielded cable through 5 kV and on multi-conductor cables through 1000V. Its rigid two-part transparent molds snap around splices for a tailor-made field splice. Within 30 minutes after the resin is poured, the splice is ready for a long, reliable life. The kit contains Scotchcast 4 electrical insulating resin. This kit may be used for above ground or direct buried applications.

Scotchcast™ Flexible Power Cable Splicing Kit: 82-BF1, Voltage Rating Up to 1000VScotchcast flexible power cable tape splicing kit 82-BF1 is a permanent splice for use on non-shielded portable power cables and cords with copper conductors rated up to 1000V. It can be used on single conductor or multiple conductor cables using a compression “C” tap connector. The kit contains one piece removable mold tape for sealing mold ends, abrasive cloth and Scotchcast 2130 compound in the Unipak™ container for clean and easy handling. The completed splice is designed for use in weather exposed, direct bury or submerged locations.

Product Specifi cations

Product UPC Voltage Rating (Max) Conductor Size Max Cable O.D. Max Conn O.D.

Sleeve Type82-A

25016 5 kV 10 - 2 AWG6 - 30 mm)

0.750”(19 mm)

0.406”(10 mm)

82-A125024 5 kV Up to 2 AWG

(30 mm)0.625”

(16 mm)0.406”

(10 mm)82-A225032 5 kV 2 3/0 AWG

(35 - 80 mm)1.0”

(25 mm)0.625”

(16 mm)

82-A325040 5 kV

3/0 AWG - 400 kcmil

(90 - 200 mm)

1.438”(40 mm)

1.0”(25 mm)


Product UPC Voltage Rating (Max)

Connector Split Bolt (Max)

Connector Crimped (Max) Max Cable O.D.

82-B125057

5kV Single Con1000V Multlipe

Cond4 AWG 2 AWG

(19 mm)0.250” - 0.625”

(6 - 16 mm)


Product UPC Voltage Rating (Max) Connector Size Range Number of

Conductors

82-BF108309

1000 Up to 1/0 AWG (50 mm) 11000 - Multi



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Scotchcast™ Flexible Power Cable Splicing Kits 82-F and 82-BF Series3M™ Scotchcast™ 82-F and 82-BF Series Flexible Power Cable Splicing Kits are a series of fl exible inline and tap splices for use on non-shielded portable power cables and cords. They are designed to be used on single and multiple conductor cables and cords rated up to 1000 Volts (600/2000 Volts mine portable cable rating). The 82-F Series will accommodate a single-conductor cable rated up to 5 kV. The splices will accommodate single-conductor cables sized up to 4/0 AWG for inline splicing and up to 1/0 fAWG for tap splicing. Multi-conductor sizing is based on a cable diameter range of up to 1.2 inches for inline splicing and up to 0.8 inches for tap splicing. The splice kits are based on Scotchcast™ 2130 Compound for toughness, fl exibility, moisture sealing and fl ame retardancy. They are permanent splices as assigned by the Mine Safety and Health Administration (P-l42-5 MSHA). The completed splices are designed for use in weather exposed, direct burial or submerged locations.

Kit ContentsEach kit contains suffi cient quantities of the following materials to make one splice or cable repair (connectors are not included in kit):

One-piece removable moldScotchcast 2130 Compound in Unipak™containerScotch™ 23 Tape, for sealing mold endsAbrasive cloth (80J grit)Comprehensive instructions showing proper installation techniques for splicing non-shielded portable power cables and cords

FeaturesFactory quality “permanent” splice; MSHA accepted equal to shop or factory vulcanizingFlexible compound allows splice to bend with Scotchcast 2130 Compound is self-curing; a cold cure requiring no torch, no heated mold and no cooking timeScotchcast 2130 Compound bonds to common acket materials; neoprene, hypalon, PVC nitrile/PVC, EPR, urethane, 2130 (itself)Scotchcast 2130 Compound forms a splice or repair that is abrasion resistant and flame retardantSmooth tapered splice profile eliminates cable hang-ups and splice end-lifting

ApplicationsTo splice or rejacket non-shielded portable power cable and portable cords:

For inline single-conductor cables rated up to 5 kVFor tap single-conductor cables rated up to 1000 VFor inline and tap multi-conductor cables rated up to 1000 VFor mine portable cable rated 600/2000 V (P-142-5 MSHA)For use with compression inline connectors (82-F) and compression “C” tap connectors (82-BF)For indoor and outdoor applications:Weather exposedDirect burialSubmergedCable reelsFor jacket repairs


Product UPC Voltage Rating (Max) Conductor Size Number of Conductors

Connection Max O.D. (inches)

82-F108307

5000 6 - 1/0 AWG(16 - 50 mm) 1 0.62 connector

1000 (600/2000) - Multi 0.90 connector bundle

82-F208308

5000 2/0 - 4/0 AWG(70 - 95 mm) 1 0.82 connector

1000 (600/2000) - Multi 1.32 connector bundle


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S P L I C I N G K I T SScotchcast™

Scotchcast™ Wye Resin Splicing Kit: 90-B1, Voltage Rating Up to 1000V90-B1 insulates and moisture-seals wye splices made with the split-bolt type connectors on cable rated through 1000V. Each kit contains a snap-together mold body which fi ts around the splice, two funnels, tape for sealing mold ends, and Scotchcast 4 epoxy electrical insulating resin in a Unipak™ container for clean and easy handling. These kits may be used for above ground or dried buried applications

Scotchcast™ Multi-Mold Resin Splicing Kit for Non-Shielded Cable 85 Series, Voltage Rating Up to 1000 VScotchcast 85 Series versatile kits are used to electrically insulate and moisture-seal odd-sized and odd-shaped splices on cables rated through /000V. The fl exible plastic mold forms easily around splices and within 30 minutes after the resin is poured, the splice is ready for direct bury or above ground service.


Product UPC Voltage Rating (Max)

Connector Split Bolt (Max)

Connector Crimped (Max) Max Cable O.D.

90-B125115 1000 1/0 AWG 2/0 AWG

(19 mm)

run 0.50” - 812”(13 - 21 mm)

tap max 0.375”(10 mm)


Product UPC Voltage Rating (Max) Connector Type Max Conductor

Size

85-1011846 1000

Split bolt compressionH or C tap

8 AWG str4 AWG str

85-1211847 1000


1 AWG str2/0 AWG str

85-1411848 1000


2/0 AWG str4/0 AWG str

85-1602403 1000

Inline compression split bolt

750 kcmil str.250 kcmil (run):

2/0 AWG str. (tap)Compression

H or C tap500 kcmil (run)

4/0 AWGH str. (tap)

Single Conductor CableMultiple Conductor, to 1000 Volt Cable



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Scotchcast Ordering Information

Kit Number Typical Use Maximum Conductor SizeAWG (mm)

85-10 Multi-moldOdd Shaped Connections #4 Stranded (25)

85-12 Multi-moldOdd Shaped Connections 2/0 Stranded (70)

85-14 Multi-moldOdd Shaped Connections 4/0 Stranded (120)

85-16 Multi-moldOdd Shaped Connections 750 kcml (400)

82-A1 Inline Splices #2 Stranded (35)82-A2 Inline Splices #2 - 3/0 Stranded (35 - 95)82-A3 Inline Splices 3/0 - 400 kcml (85 - 203)82-B1 Wye Splices #2 Stranded (35)82-B2 Wye Splices 2/0 Stranded (70)


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S P L I C I N G K I T S3M™

3M™ DBY/DBR Direct Bury Splice KitsDBY Wire Range: 2 - 5 #18’s AWG through 2 #12’s AWG / DBR Wire Range: 5 # 16’s AWG through 3 #10’s AWG

Easy to install as 1, 2, 3

Strip wires, apply the Scotchlok Electrical Spring 1. Connector and twist in a clockwise direction

Insert the splice into the gel-fi lled insulator tube. 2. Push past the locking fi ngers to hld the Scotchlok connector in place

Position wires in wire-channels and snap insulator 3. tube cover closed

Saves TimeThe 3M Direct Bury Splice Kite is a real-time saver when installing underground electrical cable systems. Every component for the splice is included in the kit. The insulator tube is pre-fi lled eliminating the chance of the installer using too much or too little sealant. No crimping tools, no waste, no mess. Just quick, reliable underground splices for projects of 30 volts or less.

FlexibleThe DBY splice kit meets a wire range of 2 - 5 #18 AWG through 2 #12’s AWG solid or stranded copper wireThe DBR splice kit meets a wire range of 5 #16’s AWG through 3 #10’s AWG solid or stranded copper wireSealant does not set up hard, allowing splice to be reworked, without cutting wires (new tube required)Application Temperature Range 32°F to 120°F (0°C to 49°C)Storage Temperature 120°F (49°C)

EconomicalInsulating gel is already contained in the tube Long-term electrical properties reduce callbacks and rework

DependableLocking fingers in the tube ensure that the Scotchlok connector stays in positionThe closed tube cover provides strain relief Design protects against corrosion failure

Packaged for Quick Shipment2 splices per kit, 25 kits per carton



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R O Y S T O N P R O D U C T SRoyston SpliceRight™

Royston SpliceRight™The Royston SpliceRight System is designed toinsulate, waterproof and protect low voltage electrical connections. It’s the splicing kit that keeps your Catholic Protection System intact. SpIiceRight’s tacky elastomeric insulatingcompound completely seals and waterproofs, the connection. There’s no mixing heating or pouring. We’ve developed this compound based on Royston’s 60 years of experience in corrosion protection. The SpIiceRight system’s resin-impregnated, moisture-cured fabric bandage can be applied immediately after applying the compound-unlike other methods which require a hardening time. The bandage provides mechanical protection for the sealant, and sets in less than 10 minutes. And the SpliceRight system’s quick installation time allows for immediate backfi ll.

It’s EconomicalThe SpliceRight System is the low-cost way to do the job right. It’s fast, easy and effective, which keeps your labor costs down. And if re-entry to the splice is necessary, the SpIiceRight system can be removed without damage to the cable orthe splice.

One-Size-Fits-AllWith SpliceRight you need to carry only one size kit to the site - there is no need for various-sized kits. The SpIiceRight system’s green sealant fi ts easily around any shape or confi guration quickly and with no mess.

All Season SpliceThe SpliceRight system can be applied in both hot or below freezing temperatures. The green sealant remains pliable, so it will never crack if a cable shifts. The SpliceRight system’s unique rubber encapsulating material maintains its electrical resistance and physical properties without deterioration during long aging or exposure to corrosive underground environments.

It’s Easy-to-useJust cover, wrap and spray.

OrderingRoyston SpliceRight kits are furnished in a carton containing 12 individually packaged kits and one spray bottle for water.

Typical PropertiesEncapsulating compound Specially compounded butyl elastomer

Color GreenQuantity 150 grams

Water absorption 0.01% ASTM D570Percent non-volatile 100%

Service temp -50°F to + 185°F

Protection shell (bandage)

Specially impregnated fabric, hermetically seated in a foil pouch. After custom forming around the splice, the moisture cured urethane responds by

hardening into a tough, damage-resistant shell in a few minutes


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Royston SpliceRight Kit Instructions

* Do not use gloves until after Step 4. Splice and Adjacent Insulation Must Be Clean and Free ofContamination

CoverWith your bare hands, apply the fi rst piece of rubber 1. by pressing and packing it around the splice.

With the second piece of rubber, begin wrapping 2. about the “V” area and use a “stretch and wind” technique around the rest of the splice.

With the third piece of rubber stretch and wind, 3. being sure to cover 1” or more of the insulation of each wire.

Wrap Now, slip on protective gloves. 1. Open the foil pouch by tearing at the notch and 2. remove the bandage.

Wrap the splice with a combination X-wrap” -”fi gure 3. 8” being sure to pass through the “V” area at least once.

Temporarily secure the end with the clip.4.

SprayDampen this area with the spray bottle. 1.

Under normal conditions the bandage should set in 2. less than 10 minutes.



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K I N G I N N O V A T I O N S DryConn® Waterproof Connections Anode Splice Box

DryConn® VisiLock™ with SmartGel™

Features and Benefi tsWaterproof and corrosion proofPre-filled with a non-toxic gel that eliminates hazmat requriementsRe-enterable, semi-transparent, encapsulated splice allows for visible splice examinationIncludes mounting tabs to securely attach housing to structuresLocking mechanism centers splice in boxOne piece for fast, easy installationNo need to abrade cable during installationNo assembly or set up time requiredNo shelf life issues with SmartGelEliminates heat shrinks, primers, tapes and epoxy packsAmperage not to exceed maximum temperature of the conductorDesigned to protect cathodic splices from corrosionFor use in outdoor or direct-burial locationsFor making top or branch splices on insulated cables rated up to 50V

Eliminate these time-consuming steps:Two-part epoxy mixing and messy pouring materialsAmbient temperature issues with epoxy splice methodsAssembly and set-up timeHazmat requirements with transporting materialsHeat shrinks, primers, tapes and epoxy packs

Product Data and Testing Information:Gel is a cross-linked silicone polymerTests conducted

1. 500 Hour Salt Fog 2. Immersion / Heating / Cooling Sequence - 24 hour water immersion → 72 hours at 75°C → 24 hours water immersion → 4 hours at → -18°C → 24 hours water immersion 3. 336 hours of immersion in 10% chlorine solution 4. 336 hours of immersion in 5% salt water solution

DryConn® VisiLock™ with SmartGel™

5. 30 minutes water submersion at 6 feet followed by dielectric at 1000VAC 6. Impact at ambient and following 168 hours at 110°C. 4 hour water immersion following impactNote:

The above tests were conducted with separate sets 1. of samplesDielectrics at 1000VAC and Insulation 2. Resistance at 250 VDC conducted following all 24 hour immersions, chlorine and salt water immersion and impact testing

Product Specifi cations and MeasurementsMax Voltage 50VTemperature Rating -40°C - 90°C (194°F)Wire Range: Main: #8 - 1/0 Tap: #12 - #4

Installation Instructions1. Install electrical connections per connector manufacturer’s instructions2. Lay main conductor into conductor cradle centering electrical connector as show in FIgure A3. Position Tap conductor as shown in Figure A. Note: Tap conductor can be positioned to exit either side of housing4. Install wire ties tightly around main conductor. Cut remaining length of wire tie and discard. Close housing verifying it is securely latched.


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CRIMPIT

L

SPLIT BOLT

B U R N D Y C O N N E C T I O N SSplit Bolts and Crimpits

DescriptionSpliced wire connections are common to both galvanic and impressed current cathodic protection systems. Split bolts and crimpits by Burndy are the mechanical means for making these connections. They are composed of high purity copper and provide superior conductivity for anode leads, negative returns, grounds, or any other type of spliced wire connection. Burndy crimpits are “C” type connectors, which can be used with a wide range of wire diameters, from #14 to 4/0 AWG. Because they are attached under high compression using special crimping tools, they form a permanent bond, which can be electrically insulated with standard encapsulation kits. Split bolts can also accommodate many different conductors. Their free-running threads and easy to grip wrench fl ats ensure maximum pressure and a secure mechanical bond. In addition, they are resistant to cracking and corrosion.

Burndy split bolts and crimpits have a proven track record for long-life performance. They are manufactured under strict quality control standards and meet all the requirements established by Underwriters Laboratories and the Canadian Standards Association.

Applications Mechanical and compression connectors such as split bolts and crimpits are used for making wire splices. They are most often used on run and tap style connections used to join header cables to anode leads. To protect these connections against corrosion and moisture, a wire splice kit or other type of electrical insulating material should be used.

Ordering ProcedureCorrpro is an authorized Burndy distributor. To order the right mechanical connector for your particular application, indicate the connector type, quantity, and order number. Crimpits are attached to structures using specially manufactured crimping tools, which are also stocked by Corrpro. An example is provided to help illustrate this process.

Ordering Procedure ExampleQuantity 50Product Burndy Crimpits

Catalog Number YC2C4



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Burndy Split Bolt Order Information

Catalog Number Range for Equal Run and Tap (AWG)

Min Tap with Max Run (AWG)

Recom Tightening Torque (lbs)

KS90 12 stranded - 10 stranded 16 stranded 80KS15 10 stranded - 8 stranded 14 stranded 80KS17 8 stranded - 6 solid 14 stranded 165

KS17-3 8 stranded - 6 solid 16 stranded 165KS20 8 stranded - 4 solid 14 stranded 165

KS20-3 8 stranded - 4 solid 14 stranded 165KS22 6 stranded - 2 solid 14 stranded 275

KS22-3 6 stranded - 2 solid 14 stranded 275KS23 6 stranded - 2 stranded 14 stranded 275KS25 4 stranded - 1/0 stranded 14 stranded 385KS26 2 stranded - 2/0 stranded 14 stranded 385KS27 1 stranded - 3/0 stranded 8 solid 500KS29 1 stranded - 250 8 stranded 650KS31 1/0 stranded - 350 1/0 stranded 650KS34 2/0 stranded - 500 2/0 stranded 825KS39 4/0 stranded - 750 4/0 stranded 1000KS44 300 - 1000 4/0 stranded 1100

Brundy Crimpit Order InformationCatalog Number Run (AWG) TAP (AWG) Length (in)

YC10C10 12 solid - 10 stranded 12 solid - 10 stranded 0.375YC8C8 8 solid - 8 stranded 10 solid - 8 stranded 0.5YC4C8 6 solid - 4 stranded 8 solid - 8 stranded 0.625YC4C6 6 solid - 4 stranded 6 solid - 6 stranded 0.625YC4C4 6 solid - 4 stranded 4 solid - 6 stranded 0.625YC2C4 2 solid - 2 stranded 8 solid - 4 stranded 0.75YC2C2 2 solid - 2 stranded 2 solid - 2 stranded 0.75YC26C2 1/0 - 2/0 stranded 8 solid - 2 stranded 0.938YC26C26 1/0 - 2/0 stranded 1/0 - 2/0 stranded 0.938YC28C2 3/0 - 4/0 stranded 6 solid - 2 stranded 1.063YC28C26 3/0 - 4/0 stranded 1/0 - 2/0 stranded 1.063YC28C28 3/0 - 4/0 stranded 3/0 - 4/0 stranded 1.063


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B U R N D Y C O N N E C T I O N STerminal Wire Connectors

Cathodic protection relies on a complete electrical circuit to stop corrosion. Burndy terminal wire connectors provide the kind of circuit reliability you need for long-term protection. They are offered in copper, aluminum, and dual-rated aluminum, for both compression and mechanical attachment. Because they are highly conductive and operate cooler than the wire on which they are installed, the Burndy wire connectors can withstand a wide range of electrical and environmental conditions. These include current surges, corrosion, vibration, and high moisture and temperatures. Copper compression connectors manufactures by Burndy are normally tin or lead plated. They can also be coated with Burndy Bright Finish® to provide durable long-lasting corrosion resistance. Aluminum connectors are made from wrought aluminum and designed with a tin plating of suffi cient mass to minimize bimetallic corrosion.

Burndy wire connectors are offered in a wide assortment of styles to address numerous applications. They are manufactured under strict quality control standards and meet the requirements stablished by Underwriters Laboratories and the Canadian Standards Association.

Applications Terminal wire connectors are used to mechanically link anode, structure, power, and test leads to rectifi ers, junction boxes, and test stations. Copper connectors are recommended for copper conductors and aluminum connectors with aluminum conductors. Dual-rated aluminum compression connectors may be used on both copper and aluminum conductors.

Ordering ProcedureCorrpro is an authorized Burndy distributor. To order the right terminal connector for your particular application, indicate that you need a Burndy terminal wire connector and specify the quantity and product number. An example is include to help illustrate this process.

Ordering Procedure ExampleQuantity 25

Product Burndy Wire Connectors

Type KPA4CTPStud Size 1/4 in



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C A L P I C OCalpico T-Caps, Thermite Weld Caps

ComponentsPlastic igloo outer cover Highly adhesive synthetic elastomer backing which adheres to metalAn igloo filled with a soft rubberized compound to flow around the weld and wireOverall thickness: 125 mils

To seal Model T-Caps: Remove the release paper and press it manually over the thermite weld.

Normal size of T-Caps is 4” x 4” square; larger and smaller sizes are also available. Calpico T-Caps are ideal for covering the weld made on jumper cables, or when attaching anode wire to pipes or fi ttings.

Calpico T-Caps can be applied from 20°F to 130°F, with an operating temperature of -40°F to 180°F. It is advisable to apply Calpico #22 Primer before applying the T-Caps.

The Primer comes in 12 oz. aerosol spray cans, as well as in one-quart liquid cans and one-gallon liquid cans.


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C O N T I N E N T A L I N D U S T R I E SthermOweld® Cathodic Protection Process

The thermOweld cathodic connection process is a simple, effi cient method of welding copper to copper or copper to steel. One advantage is that no outside power is required when using the thermOweld exothermic process. The thermOweld process uses high temperature reaction of powdered copper oxide and aluminum. Reaction takes place in a semi-permanent graphite mold. These molds should last for approximately fi fty or more welds if proper care is given. Reaction takes place very rapidly, therefore the total amount of heat applied to the conductors or surfaces is considerably less than that of brazing or soldering. This is important to remember when welding to insulated cable or thin wall pipe.

This system is very fi eld friendly, since it is light and portable and requires no outside power source. It requires very little time or skill to obtain an effi cient, maintenance free connection when using the thermOweld process.

The thermOweld process has been used to weld materials other than copper for electrical purposes. Materials welded include:Stainless Steel Columbium BrassCopperweld® Plain Steel BronzeNichrome V Everdur® NiobiumGalvanized Steel Kama ChromaxSilicon Bronze Steel Rail Cast IronCopper Clad Steel Cor-ten® Monel

When welding to galvanized steel it is recommended to resurface exposed bare steel.

The thermOweld connection is a molecular weld. The weld has the same melting point as copper. This factor along with the increased cross sectional area of the connection and the following insure thermOweld connections will:

Not be affected by a high current surge. Tests have 1. shown that the electrical conductor will melt before the thermOweld connection when subjected to high short circuit current. Consult IEEE Standard 837.

thermOweld connections will not loosen or corrode 2. at the point of weld. There are no contact surfaces or mechanical pressures involved. A thermOweld connection becomes an integral part of the conductor.

thermOweld connections have a current-carrying 3. capacity equal to or greater than that of the conductors.



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Step 4Dump powder into crucible, being careful not to loosen all the starting powder.

Step 5Close lid and place a small amount of starting powder in the ignition pocket. Ignite the starting powder with the Flint Ignitor.

Step 6Remove mold and clean mold before making next connection.

Making a thermOweld Connection

Step 1Clean pipe before making weld.

Step 2Position conductor and mold onto cleaned pipe, after making sure mold is dry, by pre-heating or making a test joint.

Step 3Place metal disc in bottom of mold crucible.

htht RR ddh R d


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CS-32 Type MoldsCable Size Surface Mold

NumberWeld Metal

#14 to #6 Solid

Flat (4” & Larger pipe)3/4” to 3 1/2” pipe

M-100M-101

15CP15CP

#6 Stranded


M-102M-103

15CP15CP

#4 SolidFlat (6” & Larger pipe)

3/4” to 3 1/2” pipe4” to 5” pipe

M-104M-105M-130

15CP15CP15CP

#4 Stranded


4” to 5” pipe

M-106M-107M-108

15CP15CP15CP


1” to 3 1/2” pipe4” to 8” pipe

M-109M-110M-111

25CP25CP25CP

#2 Stranded

Flat (10” & Larger pipe)1” to 3 1/2” pipe

4” to 8” pipe10” to 14” pipe

M-112M-113M-114M-115

32CP32CP32CP32-CP

#1 Stranded

Flat (16” & Larger pipe)1 1/2” to 3 1/2” pipe


M-116M-117M-118M-119

45CP45CP45CP45CP

1/0 Stranded



M-120M-121M-122M-123

65CP65CP65CP65CP

2/0 Stranded



M-124M-125M-126M-127

65CP65CP65CP65CP

CS-32 Type MoldsHorizontal Cable to Horizontal Steel SurfacesCS-32 Type Molds are for connecting copper cable to horizontal steel surfaces. When welding to steel pipe, each mold fi ts a wide range of pipe sizes. When welding to pipe, the cable runs parallel to the pipe.

For sizes not listed, contact Corrpro.Sold complete with frame. If not required, specify MOLD NUMBER followed by suffix “-G”Required Tools; 38-0309-00 - Flint IgnitorOther recommended accessories;

38-3922-00 - Mold Cleaning - Brush 38-0135-00 - Cable - Cleaning Brush 38-0101-00 - Rasp -38-4129-00 - Packing -Material for 1/0 and Larger - Molds

Welding To Ductile Iron Pipe: When welding to ductile iron pipe, useweld metal and molds designated for cast iron.

C O N T I N E N T A L I N D U S T R I E S

For adapter sleeves, refer to table on page 165.



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thermOweld’s NEW thermOcap

Protect your weld...thermOweld’s new thermOcap is designed to cover your exothermically welded connection.

Elongated wire inlet allows the cap to conform easier to the pipeOuter shell designed to prevent crushing Butyl rubber filled dome Easier field application

PropertiesConstruction - Molded plastic dome filled with corrosion resistant compound on a base of thick elastomeric tape.Dimensions: Overall: 4”x 4” Application Temperature: 35° F to 170° FSheet Thickness: 21mils Service -20° F to 225° F Plastic Dome: 15/8”x 5/8” Height: 2 3/4” Wire Way: 3/8” x 1 3/8” Adhesive Thickness: 1/8” Thicker outer shell that prevents crushing during applicationPacked in boxes of 20 Also available pre-primed

Release Paper

Butyle Rubber Fill

ElastomericAdhesive

Crush ResistantVinyl Dome

Extended Dome

Each CP Kit ContainsFlat to 4” and Larger

Pipe3/4” to 3 1/2” & Larger

Pipe(1) M-100 Mold (1) M-101 Mold

(80) 15PS Cartridges (80) 15PS Cartridges(80) Sleeves (80) Sleeves

Flint Gun Flint GunMold Cleaner Mold Cleaner

Part # Part #38-4350-00 38-4351-00

CP Kit

thermOweld’s NEW thermOcap


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CS-34 Type MoldsHorizontal Thru Cable to Horizontal Steel Surface

CS-34 Type Molds are for connecting copper cable to horizontal steel surfaces. When welding to steel pipe, each mold fi ts a wide range of pipe sizes. When welding to pipe, the cable runs parallel to the pipe. For welding to ductile iron pipe, see note below.

38-3922-00 - Mold Cleaning Brush -38-0135-00 - Cable Cleaning Brush -38-0101-00 - Rasp -38-4129-00 - Packing Material for 1/0 & Larger -

Molds

CS-34 Type Molds

Cable Size Surface Mold Number

Weld Metal

#6 Solid

Flat (12” & Larger pipe)3/4” to 2” pipe

2 1/2” to 5” pipe6” to 10” pipe

M-1955M-5666M-3097M-3141

25CP25CP25CP25CP

#6 Stranded


2 1/2” to 5” pipe6” to 10” pipe

M-5661M-5662M-5663M-5664

25CP25CP25CP25CP

#4 Solid


2 1/2” to 5” pipe6” to 10” pipe

M-1956M-1957M-1958M-1966

25CP25CP25CP25CP

#4 Stranded


2 1/2” to 5” pipe6” to 10” pipe

M-6000M-1967M-5501M-5503

25CP25CP25CP25CP

#2 Solid



M-5505M-5507M-5510M-5514

32CP32CP32CP32CP

#2 Stranded



M-5518M-5986M-5605M-5988

45CP45CP45CP45CP

#1 Stranded



M-5519M-5520M-5521M-5523

45CP45CP45CP45CP

1/0 Stranded

Flat (30” & Larger pipe)3” to 4” pipe5” to 6” pipe


M-5524M-5525M-5526M-5527M-5529

65CP65CP65CP65CP65CP

2/0 Stranded

Flat (30” & Larger pipe)3” to 4” pipe5” to 6” pipe


M-6215M-5530M-5531M-5532M-5533




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CS-33 Type MoldsHorizontal Cable to Horizontal Cast Iron SurfaceCS-33 Type Molds are for connecting copper cable to horizontal cast iron surfaces. When welding to cast iron pipe, each mold fi ts a specifi ed pipe size. When welding to pipe, the cable runs parallel to the pipe. For welding to ductile iron pipe, see note below.

CS-35 Type MoldsHorizontal Thru Cable to Horizontal Cast Iron SurfaceCS-35 Type Molds are for connecting copper cable to horizontal cast iron surfaces. When welding to cast iron pipe, each mold fi ts a specifi c pipe size. When welding to pipe, the cable runs parallel to the pipe. For welding to ductile iron pipe, see note below.

CS-33 Type Molds


Weld Metal

#6 Solid Flat (30” & larger pipe) M-156 25Cl

#6 Stranded Flat (30” & larger pipe) M-157 25Cl






CS-36 Type Molds


Weld Metal








DO NOT use Type CS-33 or CS-35 molds on Soil Pipe (ASTM A74-82). A test weld should be made on a section of the pipe being used to determine the possibility of detrimental metallurgical effects.

For sizes not listed, contact CorrproSold complete with frame. If not required, specify MOLD NUMBER followed by suffix “-G”Required Tools; 38-0309-00 - Flint IgnitorOther recommended accessories;

38-3922-00 - Mold Cleaning Brush -38-0135-00 - Cable Cleaning Brush -38-0101-00 - Rasp -38-4129-00 - Packing Material for 1/0 & Larger Molds -

Welding To Ductile Iron Pipe: When welding to ductile iron pipe, use weld metal and molds designated for cast iron.


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CS-36 Type MoldsCable to Vertical Steel SurfaceCS-36 Type Molds are used for connecting copper cable to a vertical steel surface. When welding to steel pipe, each mold fi ts a wide range of pipe sizes. For welding to ductile iron pipe, see note below.

For sizes not listed, contact CorrproSold complete with frame. If not required, specify MOLD NUMBER followed by suffix “-G”Required Tools; 38-0309-00 - Flint IgnitorOther recommended accessories;

38-3922-00 - Mold Cleaning Brush -38-0135-00 - Cable Cleaning Brush -38-0101-00 - Rasp -38-4129-00 - Packing Material for 1/0 & Larger -

MoldsWelding To Ductile Iron Pipe: When welding to ductile iron pipe, use weld metal and molds designated for cast iron.

CS-34 Type Molds


Weld Metal


3/4” to 3 1/2” pipe4” to 10” pipe

M-142M-150M-151

15CP15CP15CP

#6 StrandedFlat (12” & Larger pipe)

3/4” to 3 1/2” pipe4” to 10” pipe

M-144M-152M-153

15CP15CP15CP

#4 Solid



M-145M-186M-187M-188

25CP25CP25CP25CP

#4 Stranded



M-146M-189M-190M-191

25CP25CP25CP25CP

#2 Solid



M-147M-192M-193M-194

25CP25CP25CP25CP

#2 Stranded


2” to 3” pipe4” to 6” pipe8” to 12” pipe

M-148M-195M-196M-197M-198


#1 Stranded



M-6117M-6118M-6119M-6120M-6121


1/0 Stranded

Flat (18” & Larger pipe)2 1/2” to 4” pipe5” to 10” pipe12” to 16” pipe

M-2586M-2587M-2588M-2589

65CP65CP65CP65CP

2/0 Stranded

Flat (18” & Larger pipe)3” to 4” pipe5” to 10” pipe12” to 16” pipe

M-2590M-2591M-2591M-2593

65CP65CP65CP65CP



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CS-37 Type MoldsCable to Vertical Cast IronCS-37 Type Molds are for connecting copper cable to vertical cast iron surfaces. When welding to cast iron pipe, each mold is made to fi t the specifi ed pipe size. When welding to ductile iron pipe, see note below.

DO NOT use Type CS-37 molds on Soil Pipe (ASTM A74-82). A test weld should be made on a section of the pipe being used to determine the possibility of detrimental metallurgical effects.

CB-1 Type MoldsCable to LugCB-1 Type Molds are for connecting copper cable to copper lugs.

For sizes not listed, contact CorrproSold complete with frame. If not required, specify MOLD NUMBER followed by suffix “-G”Required Tools; 38-0309-00-Flint IgnitorOther recommended accessories;

38-3922-00 - Mold Cleaning Brush -38-0135-00 - Cable Cleaning Brush -38-0101-00 - Rasp -38-4129-00 - Packing -Material for 1/0 and Larger Molds -

Welding To Ductile Iron Pipe: When welding to ductile iron pipe, use weld metal and molds designated for cast iron.

CS-37 Type Molds


Weld Metal

#6 Solid Flat (30” & larger pipe) M-2594-S 25Cl







CB-1 Type Molds

Cable Size Lug Size Lug Part Number

Mold Number

Weld Metal

#6 Solid 1/16” x 1/2”

38-4709-00

M-8391-S 25

#6 Stranded 1/16” x 1/2” M-8391 25

#4 Solid 1/16” x 1/2” M-8393-S 25

#4 Stranded 1/16” x 1/2” M-8393 25#2 Solid 1/16” x 1/2” M-8395-S 32

#2 Stranded 1/16” x 1/2” M-8395 32#1 Stranded 1/16” x 1/2” M-8397 321/0 Stranded 1/16” x 1/2” M-8398 45

2/0 Stranded 1/8” x 1” 38-4200-00 M-8399 45


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CS-48 / CS-49 Type MoldsField Made Bond to Horizontal Steel or Cast Iron SurfaceCS-48/CS-49 Type Molds are for connecting fi eld made terminal bonds to horizontal steel or cast iron pipe. See below for hammer die and sleeve part numbers. When welding to steel pipe, each mold fi ts a wide range of pipe sizes. When welding to cast iron pipe, each mold fi ts a specifi ed pipe size. For welding to ductile iron pipe, see note below.

DO NOT use Type CS-48 molds on Soil Pipe (ASTM A74-82). A test weld should be made on a section of the pipe being used to determine the possibility of detrimental metallurgical effects.

Mold Information for Steel Pipe

Surface Mold Number

Weld Metal

Bond Size

4” pipe M-7348 15CP#6 Str6” to 8” pipe M-7344 15CP

10” & larger pipe M-7342 15CP4” pipe M-7346 25CP

#4 Str6” to 8” pipe M-7347 25CP10” & larger pipe M-7345 25CP




4” pipe M-7337 32CP1/0 Str6” to 8” pipe M-134 32CP


2/0 Str6” to 8” pipe M-137 45CP10” & larger pipe M-135 45CP

For sizes not listed contact Corrpro.

Mold Information for Cast Iron Pipe

Surface Mold Number

Weld Metal

Bond Size

4” pipe M-7352-P.S. 25Cl

#6 Str6” to 10” pipe M-7352 25ClReplace P.S. with Pipe Size (Ex. M-7352-4 for 4” Pipe)

4” pipe M-154-P.S. 32Cl

#4 Str6” to 10” pipe M-154 32Cl30” & larger pipe

4” pipe M-175-P.S. 32Cl


4” pipe M-7354-P.S. 45Cl


4” pipe M-5809-P.S. 45Cl

1/0 Str6” to 10” pipe M-5809 45ClReplace P.S. with Pipe Size (Ex. M-5809-4 for 4” Pipe)

4” pipe M-7355-P.S. 45Cl

2/0 Str6” to 10” pipe M-7355 45ClReplace P.S. with Pipe Size (Ex. M-7355-4 for 4” Pipe)



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Shim Stock and Adapter SleevesthermOweld molds designed for larger cable sizes can be used on smaller diameter cables if copper adapter sleeves or shim stock are utilized. The copper shim stock, .0108” x 1-1/2” x 3”, is normally wrapped around cable until the diameter is about equal to the cable opening. A tight fi t is not necessary as the shim stock will unwrap slightly and prevent leakage of weld metal. To order shim stock use part # 38-0329-00. Shim stock comes 100 pieces per box.

Hammer DiesBonds can be made in the fi eld using your own cable, a copper adapter sleeve and a hammer die.

For Use on Cable Size PartNumber

Use In Mold Size

Sleeve Dimensions in Inches

Stranded Solid O.D. I.D. Length

#12, #14 #10, #12, #14 38-0200-00 #6 Str & Sol 0.156 0.111 1.00

#9, #10 #8, #9, #10 38-0208-00 #4 Sol 0.303 0.140 1.00#7, #8, #10 #6, #8 38-0201-00 #4 0.227 0.177 1.00

#6 #5 38-0202-00 #2 0.292 0.198 1.00#4, #5 #3, #4 38-0207-00 #2 0.287 0.246 1.00

#4 #2 38-0204-00 #1 0.340 0.246 1.00#2 #1 38-0208-00 1/0 0.370 0.307 1.00#1 1/0 38-0209-00 2/0 0.420 0.359 1.00

1/0, #1 2/0 38-0205-00 3/0 & 4/0 Sol 0.452 0.389 1.00

2/0, 1/0 3/0 38-0240-00 4/0 0.542 0.437 1.50

Part Number Wire Size Sleeve

38-6020-00 #10, #12, #14 38-0202-00

38-4859-00 #8, #9, #10 38-0204-0038-0310-00 #6, #8 38-0203-0038-0392-00 #5 38-0209-0038-0311-00 #3, #4 38-0205-0038-0312-00 3/0 38-0240-00

p , groro CCCCComCompanpaniiesies II, Incnc. • AllAllAll RiRi Ri htghtght Rs Rs Reseeserverveddds n A R h R e d



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Jumper BondsFactory made jumper bonds have copper sleeves formed on each end. These bonds are most commonly used for bonding pipe joints. Formed ends allow the use of smaller weld metal size.

Factory made jumper bonds with pigtails are used bonding across Dresser Style Couplings.

Bond Information

Size Length Catalog Number

#4 Str18” 27-6623-1824” 27-6623-24

#2 Str18” 27-6378-1824” 27-6378-24

End Viewof Bond

Bond Information

Bond Size Pigtail Size Length Catalog Number

#2 Strand #12 Solid 24” 27-6412-00


Surface Mold Number

Weld Metal

Bond Size






Surface Mold Number Weld Metal Bond

Size

4” pipe M-154-P.S. 32Cl

#4 Str6” to 10” pipe M-154 32ClReplace P.S. with Pipe Size

(Ex. M-156-4 for 4” Pipe)

4” pipe M-175-P.S. 32Cl

#2 Str6” to 10” pipe M-175 32ClReplace P.S. with Pipe Size

(Ex. M-156-4 for 4” Pipe)



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Mold for Pigtail to Steel

Pipe

Surface Mold#

Weld Metal

Mold #

Weld Metal

Bond Size

4” pipe M-7336 25CP M-100 15CP

#2 Str

6” to 8” pipe M-131 25CP M-100 15CP

10” & larger pipe

M-129 25CP M-100 15CP


Mold for Pigtail to Cast

Iron Pipe

Surface Mold # Weld Metal Mold # Weld

MetalBond Size

4” to 24” pipe

M-175-P.S. 32Cl M-156-

P.S. 25Cl

#2 Str30” & larger pipe

M-175 32Cl M-156 25Cl

Replace P.S. with Pipe Size (Ex. M-7352-4 for 4” Pipe)


Jumper Bonds (Continued)

.250

24”

1.000 #2 AWG HMWPE CATHODIC CABLE

#12 SOL THN X 12” LG PIGTAILSFACTORY FORMEDSLEEVE (EACH END)



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Strap BondsThe strap bond is a method of bonding across joints. It is particularly suited for providing electrical contact across Dresser® Couplers. The strap is made of a soft copper strip available in size equivalent to 1/0 str. copper and supplied to desired length. Soft copper allows easy hand forming of the strap to the coupler contour. Normal application requires 5 welds, 2 on the pipe and 3 on the coupler. Welds are made with mold M-128 sold complete with handle, cleaning tool and fl int gun. Requires #15CP cartridge for each weld.

Copper Strap BondsCoupling Size Catalog # # of Holes A B C D

5” & larger size pipe style 38 27-0180-00 4 1” 3 3/4” 5 1/4” 20”




Under 5” and light pattern style 38 27-0184-00 4 1” 3 1/4” 4 1/4” 17”




For all style 40 couplings use (2) 27-0188-00 bonds 27-0188-00 3 1” 3 3/4” - 9 1/2”

For sizes not listed contact Corrpro.Current capacity of the copper strap bonds is equivalent to 1/0 strand copper cable.

Use mold M-128 to attach bonds with #15 cartirdge.



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Accessories

Tool Kit38-0302-00 Tool Kit with Tools Shown, except Rasp38-0302-02 Kit with Tools Shown and Rasp38-0303-00 Box Only

Tools38-0304-00 8” File38-0305-00 Wire Brush38-0306-00 Card Cloth Brush38-0307-00 Crimping Ttool38-0308-00 6” Screwdriver38-0309-00 Flint Ignitor38-3922-00 Mold Cleaning Brush

38-0101-00 RASPThis tempered steel, curved rasp is recommended for removing rust and mill scale from steel and cast iron surfaces. The blade is replaceable. Specify part # 38-0101-01. Not recommended for use on galvanized surfaces.

38-0904-00 Flint Ignitor ExtensionThe 38-0904-00 Flint Ignitor Extension allows the installer to stand 36” from the mold. Flint Ignitor not included.

38-0309-00 Flint IgnitorThe 38-0309-00 Flint Ignitor is used to ignite the starting powder. Each mold that is sold with a frame has a Flint Ignitor included. Replacement fl ints are available upon request. Part #38-0309-01.

Packing MaterialPacking material is used to prevent the molten weld metal from leaking out of the mold. When cable opening becomes worn from heavy use, the packing material may be used to prolong mold use. It is also used around 7 strand cable to prevent leaking. Packing material comes in a 1 lb or a 5 lb package.

Note: This packing material to be used on outside of mold only. If packing gets into weld cavity, gassy weld will result.

38-0904-00 Flint Ignitor Extension

38-0101-00 RASP

C O N T I N E N T A L I N D U S T R I E SthermOweld® Accessories


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Trouble Shooting Tips

Insuffi cient metal to make weld.

Worn mold resulting in leaking weld metal. Replace mold or if only worn around conductor opening, use duct seal around conductor. Do not get duct seal into mold cavity.

Wrong size cartridge for mold. Check ID plate for mold and compare with number on bottom of cartridge.

Too much spillage when dumping powder. Carefully open lid while holding over crucible and dump.

Wrong mold for conductor being used. Replace with correct mold. In some applications, shim stock or adapter sleeves can be used to enlarge cable to fi t mold.

Mold does not close tightly causing weld

metal to leak out.

Handle clamps not properly adjusted. Remove set screw between the handles of the mold and adjust handle tension by backing out the eye bolt.

Dirt or slag stuck in parting line of mold. Clean mold thoroughly between connections.

Bent or out-of-round cable. Straighten or cut out bad section of cable.

Handle clamps will not lock

closed.Handle clamps not properly adjusted. Remove set screw between the handles of the mold and adjust handle tension

by backing out the eye bolt.

Excessively high weld,

bubbly or gassy appearance, poor

weld.

Moisture in mold. Pre-heat mold to above 220˚ F with a propane torch.

Oil, grease, moisture or foreign material on conductors.

Pre-heat conductors with propane torch then use a clean wire brush on conductor to remove any residue left on conductors. If welding to cast iron or

steel surface, weld area must be cleaned down to bright metal.

Duct seal in weld cavity. take special precautions to keep duct seal out of weld cavity.

Weld powder has gotten wet. Replace with fresh, dry weld powder.

Weld metal blows out top of mold.

Mold worn or chipped around disc seal allowing powder to leak into mold cavity. Replace mold.

Forgot to use steel disc or did not seat it properly at bottom of crucible.

Make sure disc is seated at bottom of crucible before pouring the powder into crucible.

Cannot ignite powder.

Insuffi cient starting powder in ignition pocket on mold lid. Place at least half of starting powder in ignition pocket of mold lid.

Flint ignitor not shooting enough spark. Clean fl int ignitor according to directions on box or replace fl int ignitor.

Starting powder lumped together. Break up starting powder on lid with edge of powder tube.

Mold wearing out to fast.

Improper cleaning of mold. Use mold cleaner, soft natural bristle brush or clean rag to clean mold between shots. Do not use wire brush or screwdriver on molds.

Bent or out of round cable causes chipping and premature wear of the mold.

Use caution when closing mold. Do not force mold shut around bent, twisted or out of round conductors.

Poor weld to ground rod.

Weight of mold not supported during reaction causing mold to slip when cable melts.

Use locking pliers on ground rod under mold to support the weight of the mold during the reaction.

Moisture or contaminant on cable or ground rod. Pre-heat conductors with propane torch then use a clean wire brush on conductors to remove any residue left on conductors.

Weld will not stick to steel surface.

Improperly cleaned area on steel. An area larger than the weld area should be cleaned down to bright clean metal.

Moisture or contaminant on cable or steel surface.

Pre-heat conductors with propane torch then use a clean wire brush on conductors to remove any residue left on conductors.

Cable is improperly positioned in mold, blocking the fl ow of weld metal.

Position cable in mold in accordance with directions for mold. If directions are not available, position top of cable in the center of where the liquid weld metal

hits the steel.

Weld will not stick to cast iron

surface.

All of the causes listed under welding to steel surface also apply to this section.

Not using CI (Cast Iron) powder. Specify “CI” behind cartridge when order powder (i.e. 25 CI).

Cable pulls out of mold when it is

fi red.Cables are either twisted or under tension. Use 38-0330-00 cable clamp or other method to remove tension. Cut out

severely twisted cable.



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Type CAHA

Conductor Size Surface Welder Part Number Welder Price

Welder Metal

#14-10 solid, or #8 solid

or stranded, or #6 solid

Flat (4” & larger pipe)3/4” to 3-1/2” pipe

CAHAA-1GCAHAA-1GA CAA CA15

6 Stranded Flat (4” & larger pipe)3/4” to 3-1/2” pipe

CAHAA-1HCAHAA-1HA CAA CA15

4 SolidFlat (6” & larger pipe)

3/4” to 3-1/2” pipe4” to 5” pipe

CAHAA-1KCAHAA-1KACAHAA-1KB

CAA CA15

4 StrandedFlat (6” & larger pipe)

3/4” to 3-1/2” pipe4” to 5” pipe

CAHAA-1LCAHAA-1LACAHAA-1LB

CAA CA15

2 SolidFlat (10” & larger pipe)

1” to 3-1/2” pipe4” to 8” pipe

CAHAA-1TCAHAA-1TACAHAA-1TB

CAA CA25

2 Stranded

Flat (16” & larger pipe)1” to 3-1/2” pipe


CAHAA-1VCAHAA-1VACAHAA-1VBCAHAA-1VC

CAA CA32

1 Stranded



CAHAA-1YCAHAA-1YACAHAA-1YBCAHAA-1YC

CAA CA45

1/0 Stranded

Flat (20” & larger pipe)2-1/2” to 3-1/2” pipe


CAHAA-2CCAHAA-2CACAHAA-2CBCAHAA-2CC

CAA CA65

1/0 Stranded

Flat (20” & larger pipe)2-1/2” to 3-1/2” pipe


CAHAA-2GCAHAA-2GACAHAA-2GBCAHAA-2GC

CAA CA65

CAHA -Cable to Horizontal Steel Piple CAHA -Cable on surface

E R I C O P R O D U C T SCadweld® Cable Connections for Cathodic Protection


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Connections to SteelType CAHC - through conductor to top of horizontal steel pipe or fl at surface

Type CAHC


Welder Metal



Flat (12” & larger pipe)3/4” to 2” pipe

2 1/2” to 5” pipe6” to 10” pipe

CAHCA-1GCAHCA-1GACAHCA-1GBCAHCA-1GC

CAA CA25

6 Stranded


2 1/2” to 5” pipe6” to 10” pipe

CAHCA-1HCAHCA-1HACAHCA-1HBCAHCA-1HC

CAA CA25

4 Solid


2 1/2” to 5” pipe6” to 10” pipe

CAHCA-1KCAHCA-1KACAHCA-1KBCAHCA-1KC

CAA CA25

4 Stranded


2 1/2” to 5” pipe6” to 10” pipe

CAHCA-1LCAHCA-1LACAHCA-1LBCAHCA-1LC

CAA CA25

2 Solid



CAHCA-1TCAHCA-1TACAHCA-1TBCAHCA-1TC

CAA CA32

2 Stranded



CAHCA-1VCAHCA-1VACAHCA-1VBCAHCA-1VC

CAA CA45

1 Stranded



CAHCA-1YCAHCA-1YACAHCA-1YBCAHCA-1YC

CAA CA45

1/0 Stranded

Flat (30” & larger pipe)3” to 4” pipe5” to 6” pipe8” to 10” pipe12” to 28” pipe

CAHCA-2CCAHCA-2CACAHCA-2CBCAHCA-2CCCAHCA-2CD

CAA C65

2/0 Stranded

Flat (30” & larger pipe)3” to 4” pipe5” to 6” pipe8” to 10” pipe12” to 28” pipe

CAHCA-2GCAHCA-2GACAHCA-2GBCAHCA-2GCCAHCA-2GD

CAA CA65

CAHC -Cable on surface



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E R I C O P R O D U C T SCadweld® Cable Connectionsfor Cathodic Protection

Connections to SteelType CAVS - tap conductor to vertical steel pipe or fl at surface

Type CAVS


Welder Metal




4” to 10” pipe

CAVST-1GCAVST-1GACAVST-1GB

CAT CA15

6 StrandedFlat (12” & larger pipe)

3/4” to 3-1/2” pipe4” to 10” pipe

CAVST-1HCAVST-1HACAVST-1HB

CAT CA15

4 Solid



CAVST-1KCAVST-1KACAVST-1KBCAVST-1KC

CAT CA25

4 Stranded



CAVST-1LCAVST-1LACAVST-1LBCAVST-1LC

CAT CA25

2 Solid



CAVST-1TCAVST-1TACAVST-1TBCAVST-1TC

CAT CA25

2 Stranded



CAVST-1VCAVST-1VACAVST-1VBCAVST-1VCCAVST-1VD

CAT CA32

1 Stranded


3” to 4” pipe5: to 10” pipe

12” to 16” pipe

CAVSP-1YCAVSP-1YACAVSP-1YBCAVSP-1YCCAVSP-1YD

CAP CA45

1/0 Stranded

Flat (18” & larger pipe)2-1/2” to 4” pipe


CAVSP-2CCAVSP-2CACAVSP-2CBCAVSP-2CC

CAP CA45

2/0 Stranded

Flat (18” & larger pipe)2-1/2” to 4” pipe


CAVSP-2GCAVSP-2GACAVSP-2GBCAVSP-2GC

CAP CA65

CAVSCAVS - Cable on surface


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Connections to Cast IronType CAHB - tap conductor to top of horizontal cast iron pipe or fl at surface

Type CAHB

Conductor Size Surface Welder Part Number Welder Price Welder Metal



Flat (30” & larger pipe)4” to 24” pipe

CAHBA-1GCAHBA-1G-P.S. CAA CA25-XF-19

6 Stranded Flat (30” & larger pipe)4” to 24” pipe

CAHBA-1HCAHBA-1H-P.S. CAA CA25XF-19

4 Solid Flat (30” & larger pipe)4” to 24” pipe

CAHBA-1KCAHBA-1K-P.S. CAA CA45XF-19


CAHBA-1LCAHBA-1L-P.S. CAA CA45XF-19


CAHBA-1TCAHBA-1T-P.S. CAA CA45XF-19


CAHBA-1VCAHBA-1V-P.S. CAA CA45XF-19


CAHBA-1YCAHBA-1Y-P.S. CAA CA65XF-19

Do not use Type CAHB on soil pipe (ASTM A74-82). A test weld should be made on a section of the pipe being used to determine possibility of detrimental metallurgical effects.

Type CAHB Tap conductor to top of horizontal CAST IRON pipe or flatsurface.



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Connections to Cast IronType CAHE - through conductor to top of horizontal cast iron pipe or fl at surface

Type CAHE





CAHEA-1GCAHEA-1G-P.S. CAA CA32XF-19


CAHEA-1HCAHEA-1H-P.S. CAA CA32XF-19


CAHEA-1KCAHEA-1K-P.S. CAA CA45XF-19


CAHEA-1LCAHEA-1L-P.S. CAA CA45XF-19


CAHEA-1TCAHEA-1T-P.S. CAA CA45XF-19


CAHEA-1VCAHEA-1V-P.S. CAA CA45XF-19


CAHEA-1YCAHEA-1Y-P.S. CAA CA65XF-19

Do not use Type CAHE on soil pipe (ASTM A74-82). A test weld should be made on a section of the pipe being used to determine possibility of detrimental metallurgical effects.

Type CAHE Through conductorto top of horizontal CAST IRONpipe or flat surface.


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Connections to Cast IronType CAVH - tap conductor to vertical horizontal cast iron pipe or fl at surface

Type CAHE





CAVHT-1GCAVHT-1G-P.S. CAA CA25XF-19


CAVHT-1HCAVHT-1H-P.S. CAA CA25XF-19


CAVHT-1KCAVHT-1K-P.S. CAA CA32XF-19


CAVHT-1LCAVHT-1L-P.S. CAA CA32XF-19


CAVHT-1TCAVHT-1T-P.S. CAA CA45XF-19


CAVHT-1VCAVHT-1V-P.S. CAA CA45XF-19


CAVHT-1YCAVHT-1Y-P.S. CAA CA65XF-19

Do not use Type CAVH on soil pipe (ASTM A74-82). A test weld should be made on a section of the pipe being used to determine possibility of detrimental metallurgical effects.

CAVH

Type CAVH Tap conductorto vertical CAST IRONpipe or flat surface.



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Type CASSSplice of conductors

Type CATAType CATA connections are availabe for any combination of run and tap conductor sizes. For small size taps, the Type CAPC is recommended.


Connections to Ground Rods

Style CAGR Top conductor to the top of a ground rod

Style CAGTThrough conductor to the top of a ground rod.

Connections of Cable to Cable

Type CAPCTap cable to a through cable.

Type CAPCTap cable to a through cable.Also See Type CATA

Style CAGR Tapconductor to thetop of a ground rod.

Style CAGT Throughconductor to the topof a ground rod.

Type CASSSplice of conductors

Type CATA connections are available for any combination of run and tap conductor sizes. For small size taps, the Type CAPC is recommended.


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Type CALACable terminals (lugs)

Contact Corrpro for additional product information and sizes for products listed on this page. 1-866-CORRPRO.

W

G

W

G

W

1 3/4”

1 3/4”

1 3/4”G

H

T

E

5/8”

Type CALACable terminals (Lugs) The Cadweld Process...

Cadweld connections are the accepted method of attaching cathodic protection leads to pipes (steel or cast iron), tanks and structures.

Cadweld connections weld conductors to the object to be protected. Therefore, no galvanic corrosion can occur at the interface. (With mechanical connections, surface contacts are present, and can corrode, resulting in an ineffective current path.)

Cadweld connections for cathodic protection use a special alloy to provide minimum heat effect on the steel, especially important on thin wall, high stress pipes.

Cadweld connections are also used for header cable taps, conductor splices and terminations, and ground rod connections.

A Cadweld Connection...Has current carrying capacity equal to that of the conductor Is permanent - cannot loosen or corrode to cause a high resistance connectionUses lightweight, inexpensive equipment Requires no external source of power or heat Requires no special skills Can be easily checked for quality

Permanent, Welded ConnectionsCadweld connections are made with a semi-permanent graphite mold, which holds the conductors to be welded. Weld metal (a mixture of copper oxide and aluminum) is dumped into the top of the mold. The mold is covered and the weld metal ignited. The exothermic reaction produces molten copper, which produces a permanent, high conductivity connection.



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Cadweld® Formed Terminal Bonds

Factory Made BondsBonds with terminals formed on the ends are often used for bonding pipe joints and fi ttings. The formed terminal allows a smaller weld metal size to be used.

Field Made BondsFormed Terminal Bonds may be made in the fi eld using sleeves (one per conductor end) and forming them in the hammer dies listed.

Welders for Formed Terminal Bonds

Conductor Size Insulated Bond Part Number

Bare Bond Part Number

#2 CAF1 - 1V - Length in inches CAF2 - 1V - Length in inches1/0 CAF1 - 2C - Length in inches CAF2 - 2C - Length in inches2/0 CAF1 - 2G - Length in inches CAF2 - 2G - Length in inches

Conductor Size

Sleeve Part Number

Hammer Die Part Number

#4 CAS-20-F JD11#2 CAS-09-F JD091/0 CAS-05-F JD052/0 CAS-03-F JD03

Type CAFS Welders for Steel Pipe Type CAFC Welder for Case Iron Pipe***

Surface Welder Part Number †

Welder Price

Weld Metal

Conductor Size Surface Welder Part

NumberWelder Price Weld Metal

Flat (10” & larger pipe)

4” pipe6” to 8” pipe

CAFSA-1LCAFSA-1LACAFSA-1LB

CAACAACAA

CA25CA25CA25

#4Flat (30” &

larger pipe) 4” to 24” pipe

CAFCA-!LCAFCA-!L-

P.S.*

CAACAA CA32XF-19

CA32XF-19



CAFSA-1VCAFSA-1VACAFSA-1VB

CAACAACAA

CA25CA25CA25

#2Flat (30” &


CAFCA-1VCAFCA-1V-

P.S.*

CAACAA CA32XF-19

CA32XF-19



CAFSA-2CCAFSA-2CACAFSA-2CB

CAACAACAA

CA32CA32CA32

1/0Flat (30” &


CAFCA-2CCAFCA-2C-

P.S.*

CAACAA CA45XF-19

CA45XF-19



CAFSA-2BCAFSA-2GACAFSA-2GB

CAACAACAA

CA45CA45CA45

2/0Flat (36” &


CAFCA-2GCAFCA-2G-

P.S.*

CAACAA CA65XF-19

CA65XF-19

* Indicate Pipe Size† Replacement molds (graphite portion)are available by ordering

Welder Part Number “M”

***Do not use on soil pipe. (ASTM A74-82). A test weld should be made on a section of the pipe being used to

determine possibility of detrimental metallurgical effects.

Type CAFS Weldersfor STEEL pipe.

Type CAFC Weldersfor CAST IRON pipe.


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Terminal Welder Pigtail Welder

Bond Pipe Size Welder Part Number † Welder Price Welder Metal Welder Part

Number †Welder Price

Welder Metal

Type CADS Welders for Steel Pipe

CAD1-1V(#2)

4” pipe6’ to 8” pipe10” & larger

pipe

CADSA-1VACADSA-1VBCADSA-1V

CAACAACAA

CA25CA25CA25

CAHAA-1G CAA CA15

CAD1-2C(1/0)

4” pipe6’ to 10” pipe12” & larger

pipe

CADSA-2CACADSA-2CBCADSA-2C

CAACAACAA

CA32CA32CA32

CAHAA-1D CAA CA15

Type CADS Welders for Cast Iron PipeCAD1-1V

(#2)CAD1-2C

(1/0)

4” to 24” pipe30” & lager

pipe

CADCA-1VA-P.S.*

CADCA-1V

CAACAA

CA32XF-19CA32XF-19

CAHBA-1G-P.S.*CAHBA-1G

CAACAA

CA25XF-19CA25XF-19

CAD1-2C(1/0)

4” to 24” pipe30” & lager

pipe

CADCA-2C-P.S.*

CADCA-2C

CAACAA

CA45XF-19CA45XF-19

CAHBA-1D-P.S.*CAHBA-1D

CAACAA

CA25XF-19CA25XF-19

* Add pipe size. Example CADca-1V-12 for 12” Pipe.† Welder Part Number includes mold frame. If mold only (less frame) is required. order - Welder part Number “M”

† For factory made bonds listed above

BondsFormed Terminal with Pigtails

Factory Made Bonds with Pigtails for “Dresser Type” Pipe CoatingsInsulated, formed terminal bonds with insulated pigtails are used to bond across the joint and to bond both the middle ring and follower ring of Dresser Type Couplings.

Type DC Welders for Cast Iron PipeDo not use on soil pipe (ASTM A-74-82). A test weld should be made on a section of the pipe being used to determine possibility of detrimental metallurgical effects.

Conductor Size

Pigtail Size Bond Part Number

#2 #12 solid CAD1-1V - length in inches

1/0 8 solid CAD1-2C - length in inches

Length in inches

2 3/8”

Type CADS Welders for Steel Pipe



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Cadweld Welders and MoldsWhen making a Cadweld connection, an accurate control of the Cadweld process is accomplished by using a semi-permanent graphite mold. Control is exercised over the direction and speed of the molten Cadweld weld metal fl ow and fi nal shape. The graphite used in a Cadweld mold is a high temperature type that lasts for an average of 50 to 100 Cadweld connections under normal usage.

*Welder Part Number includes mold frame. If mold only (less fram) is required, order Welder Part Number “M”.

Cadweld Weld MetalWeld metal is a mixture of copper oxide and aluminum packaged by size in plastic tubes. Each tube contains the starting material at the bottom on the plastic tube, with the Weld Metal on top. These materials are not explosive and not subject to spontaneous ignition. These containers are packaged in boxes along with metal disks. Each weld uses one disk.

Two Types of Cadweld Weld Metal Are Used for Cathodic Protection Connections:

F-33 alloy is used for all connections of cable to 1. cable and cable to steel or stainless steel pipe. The F-33 weld metal containers have green caps.XF-19 alloy is used for all connections to cast iron. 2. XF-19 weld metal containers have orange caps.

Packed PerSize Box** Std PkgCA15 20 100

CA25 20 100

CA32 20 100

CA45 20 100

CA65 20 100

* XF-19 Alloy packed in same quantities. XF-19 Alloy not available in 15 size. ** Disks not included.

Ductile IronTests by Erico, Inc. indicate that connections to ductile iron pipe can be made using the Cadweldmolds and weld metal designated to be used on steel pipe. However, some reports from the fi eld suggest that all ductile iron is not the same. In some cases, the material for steel will not work. In such cases, the molds and weld material for cast iron do work. Therefore it is suggested: Whenever possible, make tests on the ductile iron pipe being used to determine if the material for steel can be used. Or use the material for cast iron. It will make satisfactory connections on all ductile iron.


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Cadweld Bonding Straps for Pipe ThawingIn colder climates, water distribution pipes occasionally freeze in the winter. To thaw the ice, a high current (for example, from a welding machine) is applied to heat the pipe and thaw the ice. To accomplish this, each pipe joint must be effi ciently bonded to control the electrical path and to prevent burning the pipe gaskets. 1/1 6” x 3/4” copper bonding straps, welded to the pipe with Cadweld connections, provide the necessary bond or current path across the pipe joints. The bonding straps have been tested at over 500 amperes. The straps may also be used to provide continuity for cathodic protection or grounding systems.

Cadweld “Punched Strap” Bond for Steel PipeThe Cadweld “Punched Strap” Bond allows bonding across joints of steel pipe with a bond of approximately 1 /0 AWG size using a CAl5 Weld Metal. This allows larger size bonds on steel pressure pipe covered by ANSI/ASME B31. The Punched Strap bond is fabricated from 1/16” x 1-1/4” soft copper, allowing easy hand forming over the pipe coupling.

The 5-hole model is used on “Dresser Type” pipe couplings with two welds to the pipe and three to the coupling, made through the holes. A 2-hole model is used across standard mechanical joints or across “Dresser Type” joints when the coupling does not have to be bonded.

CADWELD

Bond Strap

Bond BeforePlacing Riser

JointBonding

TeeBonding

1” 1”A AB B

5 - Hole Bond

1” 1”A

2 - Hole Bond

Steel

CADWELL Bond

A. BOND;

B. CADWELD BOND;

C. CADWELD WELD METAL;

CAB496A _ B _

“B” dimension“A” dimension

in fourthsof an inch

1 3/8”min.} }

Example: a) 5 - hole bond A = 3-3/4” (15 fourths) B = 6-1/4” (25 fourths) P/N CAB496A15B25

b) 2 - hole bond A = 16” (64 fourths) B = 0” (0 fourths) P/N CAB496A64B0

a) Mold with frame/Handle P/N CAHAA-AFb) Replacement Mold ONLY P/N CAHAA-AFM

CA15



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Tools and Materials

Cadweld Wrap Sleeve CAB140ACadweld wrap sleeve is wrapped around the cable until the diameter is about the same as the cable opening in the mold

Mold CleanerCAB-136-AMold cleaners are useful for removing the slag from CAA molds after making a Caldweld connection.

Adapter SleevesSmall conductors may be built up to fi t the opening of larger size welders using either adapter sleeves or shim stock.

Cadweld Sleeve Kit

Cable Size Use Adapter Sleeve Part

Number

Use in Mold for Conductor Size

Stranded Solid Stranded Solid

#12, 14 #10, 12, 14 CAB-133-1H #6 #6

10 8, 10 CAB-133-1K - 47, 8, 10 6, 8 CAB-133-1L 4 -

6 5 CAB-112 2 -Adapter sleeves can be used when a limited number of connectors are to be made with a

smaller conductor in a larger welder.

T427 IncludesProduct Number Quantity Product

Number Quantity

BI33IH 25 B1132L 8BI331L 25 B1132Q 12B112 18 B140A 10

B1331V 10 B117A 20BI331Y 10 B117B 10B1332C 9 B117C 10B1332G 10 T320A 10



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Tool Boxes and ToolsItem Part Number

TOOL BOX ONLY CAT-396COMPLETE KIT BOX AND TOOLS CAT 343†

RASP CAT 321Replacement blade for Rasp CAT-321-A

Flint ignitor CAT-320Screw driver CAT-305Wire brush CAT-336

Crimping tool CAT-335Disk Container CAT-328

Card Cloth Brush CAT-313File and Handle CAT-329

Mold Sealer CAT-403Tools are available separately.

† Uses tool box CAT-396

Brush CAT-313The card cloth brush is used to clean all types of copper conductors. Its short stiff bristles provide for easy removal of oxides.

Mold Sealer CAT-403Mold Sealer is required around the cable on outside of the Caldweld mold for Types CAHA, CAHB, CAHC and CAHE. 2# Package

Surefi re™CAT-111Self-igniting propane torch head. Squeeze the control knob for an instant fl ame. Release and it’s out. No fl ame adjusting. And, the burn tip remains cool during normal use. Operates on its side or upside down. Can withstand 60-MPH winds without fl ameout. Saves fuel. Safe to use. Fits all standard 14 and 16 oz propane cylinders.

Extension Flint Ignitor

Vertical Pipe Clamp CAB-319Holds the welder to a vertical pipe while the Caldweld connection is made. Fits all CAN, CAP or CAT price welders and pipes to 6 inches.

Horizontal Pipe Clamp CAB-320Holds the welder to a horizontal pipe while the Caldweld connection is made. Fits all CAA price welders and pipes to 6 inches.

CatalogNumber Description

CAB-321-30 Extension including fl int ignitor (30 inches long)

CAT-320 Replacement fl int ignitor onlyCAT-320-A Replacement fl ints

CAB-322 Lead holding clip - fi ts all CAA Price Welders



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Regulated Pipelines

The American Society of Mechanical Engineers* 1. (ASME) publishes codes relating to the design and installation of pressure piping systems:

1.1 ANSI/ASME B31.8-1992, Gas Transmission and Distribution Piping Systems.

1.2 ANSI/ASME B31.4-1992, Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia, and Alcohols.

In both, under Corrosion Control, the code allows 1. the attachment of electrical leads using exothermic welding but limits the size of the weld metal used to:

2.1 CAl5 for steel pipe. 2.2 CA32XF1 9 for cast, wrought and Ductile Iron pipe.

These restrictions allow for the welding of #4 AWG 1. and smaller wire to steel pipe using CADWELD Cathodic Type CAHA connections and #6 AWG and smaller to cast, wrought, and ductile iron using Type CAHB connections. When larger sized conductors must be attached to pressure piping systems covered by these codes, several alternative solutions are available:

3.1 Using a Formed Terminal Bond, a #2 AWG can be welded to cast, wrought and ductile iron with a CA32XF1 9.

3.2 Using a CADWELD Bonding Strap, a 1/16” x 1” copper strip (equivalent to slightly smaller than a #1 AWG) can be welded to a cast, wrought and ductile iron pipe with a CA32XF19.

3.3 The “Punched Strap” Bond (1/16” x 1-1/4” copper, equivalent to slightly less than a 1/0 AWG) can be welded to steel pipe using a CAl5. The 5-hole model is used for “Dresser Type” couplings and the 2-hole model for standard joints.

3.4 The strands of a larger 7 strand conductor can be spread and each strand welded separately as noted in the following table:

* Available from: The American Society of Mechanical Engineers, United Engineering Center, 345 East 47th St.,

New York, NY 10017

Conductor 7 Strand

Welder for Each Strand for Steel Pipe

Weld Metal

4/0 CAHAA1H CA153/0 to #1 CAHAA1G CA15#2 to #4 CAHAA1G with sleeve Bl331H CA15

Thermite welding of larger7 STRAND cable to pipeline

PipeCALDWELD CAHA

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Satetrack’s Pinbrazing method is a unique patented braze method to apply electrical connectors to steel constructions. A special brazing pin with a silver solder (melting temperature 650°C/1200°F) is melted down in the cable lug hole and creates a brazed Silver Connection® between the cable wires itself and to the piece of steel.

Safetrack Pinbrazing is used to solve the problem with mechanical methods where you have higher and higher transition resistance caused by temperature changes during the year; propane gas brazing methods that take a very long time and gives a weak bond because the copper becomes brittle; welding methods where you melt the rail together with the copper cable during very high temperature; or to achieve a Silver Connection®

with an extremely low transition resistance during the whole life time.

Advantages of Pinbrazing

Low transition resistance - silver bonding method High mechanical strength

Binding strength is about 490Nmn - 2 (50 kp/mm2

Shear strength is about 245N/mm - 2 (25 kp/mm2

Low brazing temperature - braze material melts at 650°C (1200°F)Very quick method - braze takes 2 seconds. A bond with grinding and brazing takes less than two secondsEasy to use Quick to learn Safe for the operator and work place Works in all kinds of weather Battery driven -- no need for external power source

Advantages of Safetrack’s Patented Electronic Pinbrazing Method

Electronically controlled energy amount A uniform and safe brazing result -Safe for the pipe -No overheating -

Automatic adjusted gun No wearing parts -Self adjusted. Always correct lift level -Braze current directly to the pin -Lightweight -Angle device as an accessory -Extension set -One gun fi ts all Safetract units -

Under-voltage protection Brazing pins without fuse wire

No misfi red brazing pins. -Easy to handle, no fuse wire. -

Battery capacity indicator Separate battery units

Increasing the brazing capacity -Charge one while the other is in use -Sealed maintenance free high power batteries -

Rubber wheels (S101) Foldable -Easy to transport -

Pinbrazing UnitsWhich Pinbrazing unit you need depends on how many brazings per charge you need to do.

S30 XC 40-60 Brazings per charge S101 60-100 Brazings per charge X250 400 Brazings per charge S300 For connecting to welding machines

S A F E T R A C K ®

Pinbrazing



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S6 SAFE 9102 Automatic Pinbrazing GunPinbrazing guns have, until now, been equipped with a manual mechanism to set the lift height of the brazing pin in order to compensate for the different sizes of pins, lugs and ferrules. The lift height has to have a certain dimension to give the optimum brazing arc. The S4 gun sets the correct lift height automatically when the gun is brought to the material to which the connection is to be made. The new gun only weighs about 1.1 kg.Advantages of the self adjusting gun:

Eliminates operator error Consistant braze quality Quick and simple operator training Automatic adjustment of height Quick couplings for cables

S30X/C Electronic Pinbrazing UnitS30X/C is a small hand bearable pinbrazing unit made specially for maintenance work on railways and cathodic protection installations. S30X/C is electronically steered, driven by three 12 volt batteries which are easily exchangeable with a cassette system. Handy SAFE 9361. Braze pins with fuse wire are used.

Advantages of the S30X/CS4 automatic gun Constant energy Very fast method - 2 second brazing time Easy to use Separate battery boxes High operator safety

S101S101 makes up to 100 brazings per charge.The patented S101 is a lightweight, easily transported pinbrazing unit adapted for brazing electrical contacts to railway lines. S101 is delivered with a patented pistol - S4. S101 has both rubber transport wheels and insulated rail guide wheels.

The transport wheels act as a stabilizor. S101 is powered by 3 piece maintenance free, sealed, high powered batteries in a cassette.

Exchange cassettes can be fi tted to increase capacity, these can also be charged separately. S101 uses brazing pins without fuse wires.

Advantages of S101S4 automatic gun Constant energy Very fast method - 2 second brazing time Easy to use Separate battery cassettes High operator safety Weight 50 kg Dimension W 350 mm x H 380 mm x L 800 mm Voltage 36 V DC

Easy to ua t uSeparatee r eHigh opeg o eWeight 5e h 5Dimensiom n oVoltage 3g 3

S30X/C Electronic Pinbrazing Unit

Ca

S101


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X-250 Pinbrazing and SAFEBOND® UnitX250 Makes 400 brazings per charge.The patented X250 is for large production of Pinbrazing and SAFEBOND connectors. For example the manufacturers of switch panels, pipe industry or large construction sites.

X250 makes 400 Pinbrazings per charge or 200 SAFEBOND connections. But the built-in 15A charger makes it possible for continous use. The included Heavy Duty gun, S6 for Pinbrazing and SB6 for Safebonding is made for the toughest use. Pinbrazing and SAFEBOND Battery driven unit for larger production of Pinbrazing and SAFEBOND connections. Allows to do up to 400 Pinbrazings in one charge or 200 SAFEBONDs. When connecting the built-in and included digital 15A/230VAC charger one can make bondings continuously. The new digital electronic in X-250 allows to SAFEBOND as large as 70mm² copper cables. The batteries, 3x42Ah, are sealed and maintenance free. Weight: X-250: 74.5 kg (164 lb). The unit is equipped with 3x42Ah sealed batteries.

S300 Electronic Pinbrazing Unit for Use with Welding MachineWhen a large number of brazings is needed for applications such as pipe coating yards, lay barges, offshore etc. then the S300 unit can be used.

The unit is simply connected to a standard welding machine. Delivered with: S5 Automatic pin brazing gun, electronic unit, grounding device and 3M plus/minus cables. The equipment is designed for use with welding machines with an open maximum circuit voltage of approximately 80V. Advantages Compared to Fuse Wired Systems

Automatic pin brazing gun, S5 Use of brazing pins without fuse wire No “waste” of brazing pins Low maintenance required

ConsumablesTo make a pin brazing connection one must use some consumables. These are made especially for the Pinbrazing method.

Brazing Pins - the patented “bullits” that you insert in the gun; the only melting part in the process is silver Ferrules - prevent the gun not to be soldered to the work piece And a large assortment of different Jumper Bonds or cable lugs, brazing sleeves etc.

ronic Pinbrazing Unit for Use witho c P b a n n


Pinbrazing



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Brazing PinsThe Pinbrazing system use a special patented silver containing brazing pin with a melting temperature of 650°C (1200°F). The special pin brazing technique ensures that it is only the solder material that melts, never the steel structure. Brazing pins for use within Cathodic Protection and Grounding systems:

FerrulesFerrules are used when Pinbrazing to prevent the gun from becoming stuck to the work piece and also for evenly distributing the oxygen.

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Cable LugsCable Lugs - Field Made BondsIt is possible to make your own bond with a special cable lug made for Pin Brazing. It is very important that this lug is exactly manufactured for the brazing method to secure a perfect bond. You crimp the cable to the lug with a crimping tool. The lugs are supplied in a kit with brazing pins and ferrules so there is no risk of mixing the material.

Cable Lugs for Pinbrazing to the CableWhen using a special brazing lug where you pin braze the cable with the lug and also to the work piece you achieve the lowest possible transition resistance as you do with a pre-manufactured Jumper Bond. This cable lug is also Pinbrazed to the cable and no crimping tool is needed. The cable is inserted in the lug which is fl attened and the cable is then brazed to the lug by placing the brazing pin in the fl attened hole.

Brazing Pins

SAFE Number Dimension in mm Qty/Pack

10051 Ø 8 10010301 Ø 8 extra 10010191 Ø 9.5 100

10381

M8, threaded brazing pin,

L=16 50

10401


L=24 50

10421


L=24 50

FerrulesSAFE Number BV. Number Dimension

SAFE 2003 0624680 Ø 8 mmSAFE 2009 - Ø 9.5 mmSAFE 2012 - Ø 12 mm

CaWBrazing Pins and Ferrules


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Pinbrazing

Brazing SleevesWith these you can pinbraze your cables together without using mechanical pressing tools...and you get a long lasting Silver Connection® between the cable wires itself.

Jumper Bonds - ConnectorsThe SAFETRACK® Jumper Bonds / Connectors have special cable lugs made for pin brazing in both ends. The bonds are produced in a special way so that it is the actual wire itself in the cable that is silver brazed. This unique design ensures an extremely low transition resistance and a long life bond that withstand corrosion extremely well.

ToolsDescription Part Number8 Inch File 38-0304-00Wire Brush 38-0305-00

Card Cloth Brush 38-0306-00Crimping Tool 38-0307-00

6 Inch Screwdriver 38-0308-00Flint Igniter 38-0309-00

Mold Cleaning Brush 38-3922-00Tool Kit with Tools Listed Above

Except Rasp 38-0302-00

Tool Kit with Tools Listed Above And Rasp 38-0303-02

Tool Box Only 38-0303-00Rasp - Tempered steel,

curved rasp is recommended for removing rust and mill scale from steel and cast

iron surfaces. The blade is replaceable.

38-0101-00

Replaceable Blade for Rasp 38-0101-01Flint Igniter Extension - Allows the installer to stand 36” from

the mold. Flint Ignitor not included.

38-0904-00

Flint Ignitor - Used to ignite the starting powder. Each mold that is sold with a frame has a Flint Ignitor included. Replacement

Flints available.

38-0309-00

Flint Ignitor Replacement Flints 38-0309-01Packing Material - Used to

prevent the molten weld metal from leaking out of the mold.

When the cable opening becomes worn from heavy use,

the packing material may be used to prolong mold use. It is

also used around 7 strand cable to prevent leaking. Packing

material comes in a 1 lb or 5 lb package. Note packing material to be used on outside of mold only. If packing gets into weld cavity, gassy weld will result.



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Accessories for Pinbrazing UnitsDescription Part Number

Battery Charger 3A SAFE 8052Battery Charger 5A SAFE 8049

Battery Charger for Car Use SAFE 8055High Power Batteries 13 AH (S30XC) SAFE 8092High Power Batteries 16AH (S30XC) SAFE 8903High Power Batteries 26 AH (S101) SAFE 8036

Ground Magnet Standard SAFE 8067Ground With Super Magnet For Cathodic Protection SAFE 8069

Ground Clamp SAFE 8070

Grinding Wheel, Silicon Free SAFE 8025Carbide Burr SAFE 8014

Handy 2, Rail Trolley (S30XC) SAFE 9361

Separate Battery Box for 16 AH (S30XC) Excluding Batteries With Lid and Handle SAFE 9320

Separate Battery Box for 13 AH (S30XC) Excluding Batteries With Lid and Handle SAFE 9321

Battery Adapter for Charging (S30XC) of Separate Battery Box SAFE 9318

Angle Device for S4 Gun SAFE 9232

Pin Holder 8-9, 5 SAFE 9211Pin Holder M8 SAFE 9213Pin Holder M10 SAFE 9215Pin Holder M12 SAFE 9217

Ring Holder 8-9,5 SAFE 9202Ring Holder M8/M10/M12 SAFE 9204

Extension Set for S4 / 8-9,5 SAFE 9227Extension Set Threaded Pins SAFE 9229


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Safety Vests on the Construction Site

At the construction site, the visibility of fl aggers is key to their safety. Construction safety vests are not only ideal, but can fulfi ll a requirement from the Occupational Safety and Health Administration OSHA. According to OSHA, garments for fl aggers can be a variety of fl uorescent colors, including orange, yellow or yellow green. These garments can be construction safety vests, shirts or jackets. Flaggers working at night should wear construction safety vests or comparable garments with a retro refl ective material. The retro refl ective material can be numerous colors, including orange, yellow, white, or a fl uorescent color. OSHA requires that the refl ective material be visible to a distance of 1,000 feet away.



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R O Y S T O N P R O D U C T SRoyston Tapecoat Handy Caps™

Royston Tapecoat Handy Cap IP Exothermic Weld Grounding Connection

No Liquid Primer Needed Easy Field-Applied Corrosion Protection Ideal for Keyhole ApplicationsDome and Tunnel Provide Easy AccessTapecoat Gray Adhesive Eliminates Liquid PrimerElastomeric Compound Encases Weld Profile Serrations Conform to Small Diameters

Handy Cap IP is a prefabricated assembly designed to provide quick, fi eld-applied corrosion protection to anode and test lead wire welds on metal pipe and tanks. This economical product is ideal for use in limited access applications. New Handy Cap IP now adds the innovative technology of Tapecoat Gray Adhesive to its unique design. The integration of a primer in Tapecoat Gray makes fi eld application of Handy Cap IP easier and more economical.Tapecoat Gray Adhesive bonds the tough outer shell of the Handy Cap IP to the bare metal weld area and surrounding plant applied coating. Innovative Tapecoat Gray incorporates an integrated primer in its adhesive and provides exceptional bonding without the costly application of liquid primer. A protective compound within the dome molds itself over the irregular welded profi le and encases the exothermic connection.

Application InformationClean all mud, dirt, grease, oil and other 1. contaminants from the metal surface and mill coating which is to be covered. The Handy Cap IP incorporates an integrated primer in its Tapecoat Gray Adhesive and does not require the use of a liquid primer prior to application.

Remove the release paper from the bottom of the 1. Handy Cap IP. Bend the plastic sheet inward at the serrations when applying to small diameter pipe. Position and place the Handy Cap IP on the welded area with the tunnel over the lead wire.

Push the dome of the cap fi rmly into the weld area. 1. Lift the lead wire away from the pipe and squeeze the adhesive compound completely around and

underneath the wire. Push the lead wire back down on the pipe and press the elastomeric compound into fi rm contact with the pipe over the entire area.

No further protection is required when the Handy Cap IP covers the entire exposed metal area. Uncovered areas should be protected with primerless Tapecoat or Royston tapes. Remove the narrow plastic release fi lm to accommodate tool use for keyhole applications.

Typical PropertiesConstruction - Molded plastic dome filled with corrosion resistant compound on a base of thick elastomeric tape.Dimension:Overall: 4” x 4” Plastic Sheet: 2.75” x 4” (serrated) Sheet Thickness: 10 mils Plastic Dome: 1.625” diameter/ .8” height Adhesive Thickness: 165 mils Weight: 2.8 oz Application Temperature: - 20˚F to 120˚F (-29˚C to 49˚C)Service Temperature: -40˚F to 150˚F (-40˚C to 66˚C) Shelf Life: Rotate yearly

Royston Handy Cap XL IPExothermic Weld Grounding Connection Handy Cap XL IP Handy Cap XL IP is a prefabricated assemblydesigned to provide quick, fi eld-applied corrosionprotection to anode and test lead wire welds onmetal pipe and tanks. This economical product isideal for use in limited access applications. NewHandy Cap XL IP now adds the innovativetechnology of Tapecoat Gray Adhesive to its unique design. The integration of a primer in Tapecoat Gray makes fi eld application of Handy Cap XL IP easier and more economical.


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Application InformationClean all mud, dirt, grease, oil and other 1. contaminants from the metal surface and mill coating which is to be covered. The Handy Cap XL IP incorporates an integrated primer in its Tapecoat Gray Adhesive and does not require the use of a liquid primer prior to application.Remove the release paper from the bottom of the 2. Handy Cap XL IP. Bend the plastic sheet inward at the serrations when applying to small diameter pipe. Position and place the Handy Cap XL IP on the welded area with the tunnel over the lead wire.Push the dome of the cap fi rmly into the weld area. 3. Lift the lead wire away from the pipe and squeeze the adhesive compound completely around and underneath the wire. Push the lead wire back down on the pipe and press the elastomeric compound into fi rm contact with the pipe over the entire area. No further protection is required when the Handy Cap XL IP covers the entire exposed metal area. Uncovered areas should be protected with primerless Tapecoat or Royston tapes. Remove the narrow plastic release fi lm to accommodate tool use for keyhole applications.

Typical Properties

Royston Tapecoat Handy Cap Standard

The Royston Tapecoat Handy Cap™ is a 4” x 4” prefabricated assembly designed for cathodic protection of leads to pipes and tanks. When pressed by hand into position over the anode lead wire weld, it forms a thick, highly resistant electrical insulation seal over the weld, the end of the lead wire and the surrounding area of the pipe or tank.

Royston Tapecoat Handy Cap is easily applied and economical. It may be used on all anode lead wire and test wire weld areas. It is especially useful for welds on mill coated pipe where only a small part of the coating has been removed to permit installation of the thermite grounding connections. It is ideal for use in limited access situations, because it can be manipulated easily and applied at arm’s length.

The Handy Cap requires use of the Royston Roybond 747 Primer.

A top plastic sheet formed with an igloo shaped dome and entry tunnel for the lead wireA special elastomeric compound in the plastic dome, which is firm enough to resist flow at all normally encountered application and operation temperatures, but soft enough to mold itself around and completely cover the irregular welded profile On either side of the dome are a double row of parallel, flexibilizing serrations to assist with conforming around small diameter pipe A base of Royston Tac-Tape, a black unbacked elastomeric tape with exceptional adhesive properties, for bonding firmly to the metal surface, when used with Royston Roybond 747 primer.

Application Clean all mud, dirt, grease, oil and other 1. contaminants from the metal surface and any part of the mill applied coating which is to be covered. Apply a coat of Royston Roybond 747 Primer and allow to dry to a non-glossy appearance, which will take about 5 minutes, depending on humidity and temperature.Remove the release paper from the bottom of the 2. Royston Tapecoat Handy Cap. Bend the plastic sheet inward at the serrations when applying to small diameter pipe. Position and place the Handy Cap on the welded area with the tunnel over the lead wire.



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Push the dome of the cap fi rmly into the weld 3. area. Now lift the lead wire away from the pipe and squeeze the black rubber compound completely around and underneath the wire. Then push the lead wire back down on the pipe and press the elastomeric compound into fi rm contact with the pipe over the entire area.

No further protection is necessary when Royston Tapecoat Handy Cap covers the entire exposed metal area. Uncovered areas should be protected by applying tape or mastic, such as Royston Blue Max Water Pipe Line Tape CP or Royston Roskote Mastic.

When coating or wrapping the Royston Tapecoat Handy Cap, remove the narrow strips of plastic release fi lm on the top of the cap. This will assure maximum protection by effecting a positive waterproof seal.

Typical PropertiesConstruction molded plastic cap filled with corrosion resistant compound on a base of thick elastomeric tapeDimensions overall: 4” x 4” Plastic sheet: 2.75” x 4” (serrated) Sheet thickness: 10 mils Plastic dome: 1.625” dia, 0.8” height Adhesive thickness: 165 mils Weight 2.1 oz Application temperature -20 to +120°F Service temperature -40 to + 185°F Shelf life: Rotate annually

Royston Caps and Sealers

Caps and Sealers For Truly Sound Connections Strong wire connections are important for all cathodic protection systems. To create reliable connections that will last for many years, Corrpro supplies easy-to-use weld caps and sealers. These include Royston Handy Caps, thermite weld caps, and Kop-Coat® bitumastic.

Royston Hand Caps are the complete weld-connection sealers. They are designed to fi t any welded connection, and are installed simply by pressing fi rmly into place. The four-inch-square base of the cap is made from 125-mil Tac-Tape®. Because the tape possesses exceptional adhesive properties, it will strongly bond to a wide variety of substrates without the use of a primer. It is also resistant to moisture and weathering, and will not shrink, crack, or harden at temperatures below 0° Fahrenheit. Contained in a plastic dome on the Handy Cap is an elastomeric compound. The compound forms a highly resistant insulation around the thermite weld. This material is soft enough to mold to irregular-shaped welds, but fi rm enough to remain stable at normally encountered installation temperatures.

As an alternative to the Handy Cap, Corrpro also distributes weld caps and bitumastic. The caps re made from high-density polyethylene, and can be used to protect most types of thermite welds. A shield against corrosion and moisture is created by fi lling the caps with a cold-applied bitumastic, such as Kop-Coat. The Kop-Coat sealer bonds to any clean metal surface without the use of a primer, and forms a thick, tough coating around wire connections. It will not oxidize, alligator, or crack, and is resistant to moisture, chloride ions, and corrosive atmospheric fumes. Applications Handy Caps and weld caps with bitumastic seal protect anode and test lead welded connections. They are designed for buried applications, and are ideal for welds on mill-coated pipe, where only a small portion of coating has been removed. The caps should not be used in areas that have direct contact with potable water. Kop-Coat bitumastic is considered a corrosive solid, and must be shipped according to established safety regulations.


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Ordering Procedure Corrpro stocks Royston Handy Caps, weld caps, and Kop-Coat bitumastic. To order the right connection sealer for your particular application, indicate the type and the quantity of cap desired. The Kop-Coat bitumastic coating is sold separately, and is packaged in one- and fi ve-gallon containers. Each gallon will fi ll between 175 and 200 weld caps.

Ordering Procedure ExampleItem Example

Quantity 800Product Weld capsQuantity 4 gallonsProduct Kop-Coat Bitumastic

Kop-Coat Order Information

Standard Unit Package Weightlbs (kg) Standard Carton

1 gallon (3.8 L) 12 (5.4) 4 gallons (15.1 L)5 gallons (18.9 L) 60 (27.2) -

ENCAPSULATIONCOMPOUND

LEAD WIRE

THERMITE WELDCONNECTION

PIPELINE

HANDY–CAP

TAC–TAPE


Impressed Current, Water Storage, and Hydrocarbon Leak Detection

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CATHODIC PROTECTION SYSTEMSImpressed Current Corrpro® Tank-Pak® Corrpro® The Grid™

Water Storage Corrpro® Permanode® Water Storage Tank System

Hydrocarbon Leak Detection SensorComm TLD 5000 SensorComm TT5000 Sensor Cable


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I M P R E S S E D C U R R E N TCorrpro® TANK-PAK® Impressed Current System for Underground Storage Tanks

Protection For Underground Storage Tanks Meeting EPA corrosion control requirements for underground storage tanks can be costly and frustrating. To address this problem, Corrpro developed TANK-PAK, an impressed-current cathodic protection system that can upgrade an existing storage tank for less than 10% of the cost of replacement. The system is based on characteristics common to most fueling systems, but also contains the fl exibility to meet site-specifi c requirements. A custom TANK-PAK system is created for a particular location by using soil samples and diagrams of existing tanks and piping. Installation of the system requires only minor drilling. The TANK-PAK system consists of anodes, lead wire, a junction box, and a rectifi er. The anodes provided are packaged in Corrpro’s Spira-Pak® canisters, and are surrounded by metallurgical coke breeze backfi ll. The backfi ll provides the anodes with a uniform environment for low-resistance contact to the earth and extended life. To install the anode canisters, openings are cut into the pavement, and an auger is then used to drill holes for anode placement. Once the anodes are in place, lead wires are slot cut into the pavement and connected to Corrpro’s standard fi berglass junction box. The box is NEMA Type 4X rated, and provides superior

protection from all types of weather conditions. Power for the system is furnished by a specially manufactured rectifi er, which is air cooled. Corrpro engineers design each TANK-PAK system to deliver optimum corrosion protection. To ensure that this protection level is achieved, it is recommended that the system is installed either by a certifi ed tank installer, or Corrpro’s own construction crews. Regardless of which option is selected, Corrpro technicians will energize and test the system once the installation is complete. The minimum design life for the TANK-PAK system is 20 years.

Applications TANK-PAK is designed to protect existing underground storage tanks. It prevents corrosion attack on both the steel tanks and piping, and can be installed while a service station remains open for business.

Ordering ProcedureThe TANK-PAK system is custom made to satisfy design specifi cations. To learn how the system can be used to effectively protect your UST system, contact your local Corrpro representative.

VENTS

UNDERGROUND TANKS

RECTIFIER

PRODUCT PIPING

DISPENSER

ANODES

Please Note:Vent Liners are typically fi berglass and connection is made to the tank, sub-pump, or one of the tank risers.

C AT HODIC P ROT E C T ION SYST E M S


Cathodic Protection System

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Corrpro® The Grid™ Impressed Current System for Aboveground Storage Tank Bottoms

Protection For Aboveground Storage Tank Bottoms Cathodic protection is an economical method for controlling corrosion on the bottoms of aboveground storage tanks. While sacrifi cial systems can be used, impressed current systems have proven to be more effective and easier to install. For new storage tanks with secondary containment liners and older tanks retrofi tted with an additional tank bottom, Corrpro offers The Grid, an impressed current system with a design life of 20 to 50 years, depending on project requirements. The system is comprised of ribbon anodes evenly spaced in a parallel confi guration typically on 5 ft. centers. Through resistance welding, the anodes are attached to multiple distributor bars to create a grid shaped pattern. The close anode spacing and redundant electrical connections created by this design ensure uniform current distribution to all areas of the tank bottom.

The ribbon anodes used in this system are made from a titanium substrate, which is coated with a mixed metal oxide catalyst. Because the titanium substrate is naturally protected by an oxidizing fi lm, the ribbon anode remains dimensionally stable over the life of the system. Direct current transfer is accomplished through the mixed metal oxide catalyst, which is highly conductive and fully oxidized so that higher current outputs are possible.

On new tank installations, the anodes are placed in a layer of sand above the secondary containment liner. For older tanks that are being retrofi tted with a secondary tank bottom, the anodes are again placed above the liner in a layer of sand, and may be covered with a plastic isolation mesh to protect against shorting to the tank bottom. No fi eld splices are necessary with The Grid system. The connection between the lead wire and the main power distributor bar is made at the factory. It is encased in an epoxy tube, and is totally water tight. Reference cells used in the system include Corrpro’s Permacell Plus, a copper/copper sulfate cell. Junction boxes are offered with either cast aluminum cases, for areas requiring explosion-proof equipment, or in fi berglass cases, which are NEMA Type 4X rated. Rectifi ers are provided to meet specifi c project requirements.

The Grid Impressed Current System forAboveground Storage Tank Bottoms

Typical Applications The Grid system is designed for protection of aboveground storage tank bottoms. It may be used on new tank installations with secondary containment liners, or existing tanks retrofi tted with or without a double bottom. The system can be installed by Corrpro’s trained technicians or Corrpro certifi ed installer.

Ordering Procedure Corrpro’s tank bottom system is custom made to satisfy design specifi cations. To learn how the system can be used to effectively protect your structure, contact your local Corrpro representative.


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TITANIUM ANODE RIBBON

CONDUCTOR BAR

REFERENCE ELECTRODES

POWER FEEDPOINT TO MAINCONDUCTOR BAR

JUNCTION BOX

JUNCTION BOX

REFERENCE ELECTRODE

TANK WALL

TANK BOTTOM

COMPACTED SANDBACKFILL

8”

LEAD WIRE

RING WALL

CONDUIT

CROSS SECTIONPLAN VIEW

TITANIUM ANODERIBBON

SECONDARY CONTAINMENTMEMBRANE

Please note: This drawing is a typical schematic representation of installation.




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Continuous Protection for Tank Interiors Water storage tanks are extremely susceptible to corrosion attack. Cathodic protection is a proven method for combating this attack and preventing unexpected service interruptions and costly repairs. Since 1948, Corrpro has designed, installed, and serviced cathodic protection systems on water storage tanks. Today, Permanode, an innovative impressed-current cathodic protection system, can be used on all types of water tanks in accordance with AWWA and NACE standards.

In areas where icing is a problem, the system is installed by suspending anodes horizontally. The anodes used in this system are made from a precious-metal wire or rod. They are lightweight and provide even current distribution to all areas of the tank. To support the anodes, fl exible tethered supports are used. Because the supports allow extra movement, the anodes can adjust slightly to avoid damage from ice. At least two permanent reference cells are included with the system, which are also attached to the tethered supports. Reference cell and lead wire connections are completed in Corrpro’s standard fi berglass junction box, which is placed on the outside of the tank opposite a watertight pressure fi tting. For tanks that are not susceptible to icing, the anodes in the Permanode system may be suspended horizontally or vertically. On the vertically suspended systems, the

anodes are supported from the roof of the tank, and are kept taught by weights attached to their opposite end. Like the tank icing system, the non-icing vertical system also contains at least two Corrpro Permacell™ copper/copper sulfate reference cells. Lead wires for the cells are attached to the tank’s roof, but the cells themselves are located near the lower bowl or base of the tank. Both confi gurations of the Permanode system are installed by trained Corrpro technicians. These same technicians are also available for routine maintenance and repairs. Power is provided to the tank system through an electronically controlled rectifi er. The unit automatically adjusts to meet established protection levels, ensuring optimum performance.

Applications Corrpro’s impressed-current cathodic protection system can be used to stop the corrosion attack on both elevated and ground level water storage tanks. It can be used in conjunction with coatings, and is designed to deliver a minimum of 20 years of protection. The system also can be used to halt corrosion on other water and wastewater treatment equipment.

Ordering ProceduresCorrpro’s Permanode tank system is custom made to satisy design specifi cations. To learn how the system can be used to effectively protect your structure, contact your local Corrpro Waterworks representative.

W A T E R S T O R A G ECorrpro® Permanode® Water Storage Tank System

STEEL ANCHORS WELDEDTO SIDE WALL

SUPPORT SYSTEM BOLTED TOROOF FOR ANODES AND REFERENCE ELECTRODES

POLYESTER ROPE SUPPORTS

SUBMERGED ANODE SUPPORTSYSTEM

PRECIOUS METAL ANODE



CONDUIT AND CABLESTO TOP OF TANK

REFERENCE CELL


RECTIFIER

RECTIFIERPRESSURE FITTING

REFERENCE CELL

REFERENCE CELL

REFERENCE CELL

ICING CONFIGURATION NON – ICING CONFIGURATION

ANSI & NSF 61 Compliant for potable water applications.


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H Y D R O C A R B O N L E A K D E T E C T I O NSensorComm TLD 5000

FeaturesContinuous MonitoringLow CostNo False AlarmsNo Monitoring FeesNo Testing Down TimeNo Probe CleaningBattery Operated

SensorComm TLD 5000

ApplicationsAboveground Fuel Storage TanksBuried ValvesManifoldsDouble Wall Sumps and UST’sBuried Pipelines and Piping

Buried Valve Monitoring

Buried Double Wall Tanks And Sumps




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SensorComm TT5000 Sensor Cable The Corrpro-SensorComm leak detection system represents the industry's most dependable and cost effective system in use today. These leak detection systems have already been installed under hundreds of above ground storage tanks, providing continuous, around-the-clock monitoring of active leaks which may occur. The Corrpro-SensorComm leak detection system represents state-of-the art technology, with a zero false alarm rate at an attractive price.

TT5000 Sensor Cable The cable is about 3/8” in diameter. It is sensitive to liquid hydrocarbons (e.g. jet fuel, gasoline, diesel, crude oil, naphtha, etc.) at any point along its length. The cable can be installed in lengths as short as 0.5 meters or as long as necessary (the longest pipeline installation to date is 35 km). The cable operates by absorbing small amounts of fuel escaping into the soil around a buried pipeline, buried valve fl ange, under an tank fl oor or accumulations of free liquid in a sump. As the fuel is absorbed, the specially formulated conductive polymer jacket of the sensor cable swells and thickens. The conductive wall material contacts two electrode wires in the core of the cable and activates the alarm and location circuitry. The cable uses less that 0.5 mA of current at less than 5 volts to perform detection and leak location measurements. (The cable is considered intrinsically safe at these low energy levels and is approved for installation in all hazardous areas.) The cable and instrumentation systems have the ability to locate the point of liquid contact to within about +/- 1 meter along the cable length providing a high degree of accuracy for effi cient leak investigation and remediation while the incident is still in its earliest stages. Response time of the sensor cable depends on the ground and fl uid temperature and upon the volatility of the leaking fuel. It may take anywhere form a few minutes (20C gasoline) to more than an hour for the cable to respond (cold diesel). However, since the cable responds to the fi rst edge of the plume of fuel in the soil, the dominate factor in the overall leak response is time it takes for the fuel leak to spread through the soil to the cable location.

Cross-section of sensor cable prior to contact with liquid hydrocarbon fuel.

Cross-section of sensor cable after fuel contact. Note thicker wall and conductive path from one electrode

to the opposite electrode.


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Typical 120’ Diameter Leak Detection Installment


Coatings, Adhesives, and Tapes

COATINGS, ADHESIVES, AND TAPESC

oatings, Adhesives, and Tapes


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COATINGS, ADHESIVES, AND TAPESCentral Plastics STAC Coating System

3M™ 3M™ Tapes

3M™ Epoxy Coating Materials

Berry Plastics Corporation Polyken® Covalence®

KEMA Coatings, IncProshield Royston CoatingsSTOPAQ® AMCORR


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C E N T R A L P L A S T I C SSTAC Coating System

The STAC Coating System is a petrolatum based, multilayer barrier designed to isolate all metal surfaces. STAC systems were developed for long term protection of metal surfaces in the most severe atmospheric, buried and submerged environments.

The STAC Coating System is not a form of paint but rather a foolproof, multi-purpose, hand-applied membrane wrap system. STAC coatings are applied over wire-brushed surfaces so no abrasive blasting is required.

The STAC Coating System consists of: STACprime, STACfi ll, STACwrap and STACguard.

Features Non-toxic and non-combustiveChemically inertContains no VOC’sDoes not polymerize and hardenDoes not crack or peelAccomodates vibrations and movement of the substrate over a wide temperature range

C O A T I N G S , A D H E S I V E S , A N D T A P E S


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3M™ T A P E SCorrosion Protection Tape, Insulating and Splicing Tape, Mastic Tape, Vinyl Electric Tape

3M™ Scotchfi l™ Electrical Putty TapeThis black electrical grade, rubber-based, self-fusing insulating putty is supplied in tape form.

3M™ Scotchfi l™ Electrical Insulation TapeAn electrical grade, rubber-based, elastic-type putty in tape form. Use it as a build-up compound on highly irregular surfaces, such as fi ttings and valves, to provide a smooth, waterproof taping surface.

Scotch® Linerless Rubber Splicing Tape 130 CA highly conformable linerless ethylene propylene rubber (EPR) high-voltage insulating tape that provides excellent chemical dissipation of splice heat.

Scotch® Rubber Splicing Tape 23A highly conformable, self-fusing Ethylene Propylene Rubber (EPR) based high-insulating voltage tape. Schotch 23 has a “snakeskin” liner that is easily removed as the tape is applied.

3M™ Vinyl Electrical TapeSince inventing the fi rst vinyl electrical tape, 3M has continued to improve tape technology and offers a 3M™ or Scotch® Electrical Tape for nearly every application.

Vinyl tapes from 3M provide high dielectric strength as well as resistance to moisture, UV rays, abrasion, corrosion, alkalies and acids. The aggressive pressure-sensitive rubber-based adhesive performs well over

a range of temperatures. Fade-resistant colored vinyl tapes ensure fast identifi cation of electrical phases, leads, piping and safety areas. Vinyl tapes provide primary electrical insulation up to 600 volts and can be used in jacketing application for high-voltage cables and wire harnessing.

Scotch® Premium VInyl Electrical Tape Super 88Black, 8.5 mil heavy duty, premium grade all-weather vinyl electrical insulating tape that maintains conformabilitiy for cold weather applications.

Scotch® Super 33+ Vinyl Electrical TapeBlack, 7 mil premium grade all-weather vinyl electrical insulating tape with an aggressive adhesive and elastic backing that enables it to easily conform to irregular surfaces to water-resistant electrical and mechanical protection.

Scotch® Vinyl Electrical Tape 33A quality, general purpose PVC electral insulating tape that can provide excellent mechanical protection with minimum bulk.

3M™ Corrosion Protection Tapes3M Corrosion Protection products can help provide protection on pipes, conduits, fi ttings and joints, etc.

™ Scotchfil™ Electrical InE c i a n

Scotchfi l ElectricalPutty Tape

otch® Rubber SplicingS c n®

Scotch Linerless Rubber Splicing Tape

130 C

Scotch Premium Vinyl Electrical Tape Super 88

Corrosion ProtectionC rrosion Protectionrosion Protectionosion Protectioosion Protectio

Scotch Vinyl Electrical Tape 33


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Scotch® Electrical Grounding Braid 25A fl at, all-metal woven electrical grounding braid that is compatible with all power cable insulations and high-voltage splicing and terminating materials.

Scotch® Electrical Insulating Varnished Cambric Tape 2510 and 2520Straight weave cotton cambric fabric tape, oil primed and coated with high-grade yellow electrical insulating varnish for quality electrical insulating.

Scotch® Electrical Semi-Conducting Tape 13A highly conformable, semi-conducting Ethylene Propylene Rubber (EPR) based high-voltage splicing tape which elongates easily to conform to irregular shapes and retains its conductivity when stretched.

Scotch® Electrical Shielding Tape 24An all-metal, fl at, open-weave shielding braid that is compatible with power cable insulations and all high-voltage splicing and terminating materials.

Scotch® Fire Retardant Electric Arc Proofi ng Tape 77Designed to protect all types of electrical cables where exposed to potential failures of other high voltage cables or exposed to other high energy cables.

Scotch® Self-fusing Silicone Rubber Electrical Tape 70 A high-temperature, arc-and-track resistant tape composed of self-fusing inorganic silicone rubber with an easy-tear and easy-strip line.

Scotch® Self-fusing Silicone Heavy Duty Triangular Electrical Tape 70 HDTA high-temperature, arc-and-track resistant tape with a triangular tapered edge profi le and a blue guideline to make half-taping application easier.

3M™ Scotchrap™ All-Weather Corrosion Protection Tape 50This 10 mil tape with PVC backing is all -weather performance and corrosion resistant and has a high quality adhesive. Apply this tape over a wide temperature range and is resistant to impact, abrasions and punctures.

3M™ Scotchrap™ All-Weather Corrosion Protection Tape 51This 20 mil tape with PVC backing is all-weather performance and corrosion resistant and has a high quality adhesive. Apply this tape over a wide temperature range and is resistant to impact, abrasions and punctures.

3M™ Scotchrap™ Pipe PrimerA quick-drying, no-sag rubber base primer that permeates metal surface irregularities, preparing the surface for tape application

3M™ Temfl ex™ Vinyl Corrosion Protection Tape 1200This 20 mil vinyl corrosion protection tape is a general purpose corrosion resistant tape

3M™ Insulating and Splicing TapeA variety of tapes are available from 3M to meet your insulating and splicing requirements. For example, Scotch Linerless Rubber Splicing Tape 130C is a highly conformable, linerless, high voltage insulating tape that provides excellent thermal dissipation of splice heat and meets industry specifi cations.

3M™ Linerless Electrical Rubber Tape 2242A highly conformable, linerless ethylene propylene rubber (EPR) base tape

3M™ TemFlex™ Rubber Splicing Tape 2155An economical low voltage rubber vinyl insulating tape that is self-fusing.

Scotch Electrical Grounding Braid 25



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3 M ™ T A P E SCorrosion Protection Tape, Insulating and Splicing Tape, Mastic Tape, Vinyl Electric Tape

Scotch® Electrical Insulating Varnished Cambric Tape 2510 and 2520Straight weave cotton cambric fabric tape, oil primed and coated with high-grade yellow electrical insulating varnish for quality electrical insulating.

Scotch® Electrical Semi-Conducting Tape 13A highly conformable, semi-conducting Ethylene Propylene Rubber (EPR) based high-voltage splicing tape which elongates easily to conform to irregular shapes and retains its conductivity when stretched.

Scotch® Electrical Shielding Tape 24An all-metal, fl at, open-weave shielding braid that is compatible with power cable insulations and all high-voltage splicing and terminating materials.

Scotch® Fire Retardant Electric Arc Proofi ng Tape 77Designed to protect all types of electrical cables where exposed to potential failures of other high voltage cables or exposed to other high energy cables.

Scotch® Linerless Rubber Splicing Tape 130 CA highly conformable linerless ethylene propylene rubber (EPR) high-voltage insulating tape that provides excellent chemical dissipation of splice heat.

Scotch Linerless Rubber Splicing Tape

130 C

Scotch® Rubber Splicing Tape 23A highly conformable, self-fusing Ethylene Propylene Rubber (EPR) based high-insulating voltage tape. Schotch 23 has a “snakeskin” liner that is easily removed as the tape is applied.

Scotch® Self-fusing Silicone Rubber Electrical Tape 70 A high-temperature, arc-and-track resistant tape composed of self-fusing inorganic silicone rubber with an easy-tear and easy-strip line.

Scotch® Self-fusing Silicone Heavy Duty Triangular Electrical Tape 70 HDTA high-temperature, arc-and-track resistant tape with a triangular tapered edge profi le and a blue guideline to make half-taping application easier.

3M™ Mastic TapesMastic and rubber tapes from 3M can help provide an effective moisture and environmental seal.

3M Scotch-Seal™ Mastic Tape 2229Designed for quick and easy insulating, padding and sealing of electrical connections

3M Scotch-Seal Mastic Tape 2229

3M™ Scotchfi l™ Electrical Insulation Putty TapeAn electrical grade putty in a tape form. It offers excellent electrical properties, and will not dry out.

Scotch® Electrical Moisture Sealant Pads 06149Self-fusing, rubber based thin insulating mastic compounds laminated to a fl exible, all-weather grade PVC backing and are designed for moisture sealing of electrical connections up to 600 volts.


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Scotch® Electrical Moisture Sealant Roll 06147Self-fusing, rubber based thin insulating mastic compounds laminated to a fl exible, all-weather grade PVC backing and are designed for moisture sealing of electrical connections up to 600 volts.

Scotch® Mastic Strip 2230Short lengths of thin mastic with a removable liner on each side.

Scotch® Rubber Mastic Tape 2228A conformable self-fusing rubber electrical insulating and sealing tape.

Scotch Rubber Mastic Tape 2228

Scotch® Vinyl Mastic Pads 2200(125 mil) a self-fusing, rubber-based insulating compound laminated to a fl exible, all-weather grade PVC backing.

Scotch® Vinyl Mastic Roll 2210(90 mil) a self-fusing, rubber-based insulating compound laminated to a fl exible, all-weather grade PVC backing.

Scotch Vinyl Mastic Roll 2210

3M™ Highland™ Vinyl Electrical TapeA fl ame-resistant, conformable, general purpose, 7-mil thick vinyl insulation tape. It can be used for protective jacketing and harnessing.

3M™ Tartan™ General Use Vinyl Electrial Insulating Tape 1710A good quality and economical general purpose vinyl insulating tape with excellent resistance to abrasion, moisture, alkalies, acid and varying weather conditions (including sunlight).

3M™ Temfl ex™ Gereral Use Vinyl Electrical Tape 1700Black, 7 mil vinyl tape is the economical solution for less demanding indoor jobs.

Scotch® Heavy Duty Vinyl Insulation Tape 22Black, 10 mil tape that is one of 3M’s thickest vinyl electrical tapes. It seals in all kinds of weather and provides moisture-tight electrical and mechanical protection with fewer wraps than thinner tapes.

Scotch® Vinyl Electrical Color Coding Tape 357 mil premium grade electrical vinyl tape that stretches to conform to virtually any shape that requires color-coded insulation. Available in nine fade resistant colors.

Scotch® Vinyl Electrical Tape 66RConformable 10 mil thick vinyl electrical tape designed to perform in a continuous temperature environment up to 220°F (105°C). This is a made to order item.



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Scotchkote® Electrical Coating 14583A fast-drying coating that provides extra protection to splices where moisture, oil and corrosive conditions can cause problems. Helps prevent cable and connector damage due to corrosive vapors from battery outgassing.

3M™ Internal Linings3M™ Scotchkote™ Epoxy Coatings are designed for coating the interior girth weld of line pipe. Not only do they provide excellent corrosion protection but they also offer increased fl ow effi ciency.

3M™ Scotchkote™ Water Base Primer 500N, 42.3 lb.3M™ Scotchkote 500N primer is a water-based metal treatment designed to increase adhesion of fusion bonded epoxy coatings. Properly applied to blast-cleaned steel, it provides protection for metal surfaces and a uniform bonding base for increased coating performance. 42.3 pound.

3M™ Scotchkote™ Fusion Bond Epoxy Powder Coating 206N, Extra Long Gel, 65 lb.Gel time @ 450°F/232°C: 40-60 seconds

3M™ Scotchkote™ Fusion Bond Epoxy Powder Coating 206N, Long Gel, 65 lb.Gel time @ 423°F/217°C: 30-45 seconds

3M™ Scotchkote™ Fusion Bond Epoxy Powder Coating 206N, Long Gel, 1700 lb. SupersackGel time @ 423°F/217°C: 30-45 seconds

3M™ Scotchkote™ Fusion Bond Epoxy Powdered Coating XC-62593M™ Scotchkote™ Fusion Bond Epoxy Powdered Coating XC-6259 is a one-part, heat curable, thermosetting, powdered epoxy coating designed for coating the interior girth weld of line pipe.

3M™ Scotchkote™ Fusion Bonded Epoxy Coating XC-61713M™ Scotchkote™ Fusion Bonded Epoxy Coating XC-6171 is a one-part, heat curable, thermosetting, powdered epoxy coating designed for coating the interior of production tubing, line pipe, and fi ttings. When applied over a primer, XC-6171 FBEC meets Saudi Aramco seawater and sour gas service requirements. 3M™ Scotchkote™ Fusion Bonded Epoxy Powder Coating 62583M™ Scotchkote™ Fusion Bonded Epoxy Coating 6258 is a one-part, heat curable, thermosetting epoxy coating designed for corrosion protection of pipe. 3M™ Scotchkote™ Liquid Epoxy Coating 3233M™ Scotchkote™ 323 Liquid Epoxy Coating is a two part system designed to protect steel Pipe and other metal surfaces from the harsh affects of corrosion. It can be used as a patch material, a girthweld coating, a stand alone coating for pipe rehabilitation, and in a wide variety of other fi eld applications where corrosion protection of metal is required. 3M™ Scotchkote™ Liquid Phenolic Primer 345, Drum3M™ Scotchkote™ Liquid Phenolic Primer 345 is a one-part phenolic base primer designed specifi cally for application to metal surfaces prior to topcoating with Scotchkote Fusion Bonded Epoxy Coating. When properly applied, Scotchkote 345 primer and topcoat system provide excellent resistance to CO2, H2S, CH4, petroleum distillates and brine at elevated temperatures and pressures. 3M™ Scotchkote™ Single Layer Powder Coating3M Scotchkote Pipeline coatings meet the toughest test of all time. Introduced more than 40 years ago, Scotchkote Fusion Bonded Epoxy Coating (FBEC) has performed superbly, protecting steel pipe from corrosion and mechanical damage.

3 M ™ E P O X Y C O A T I N G M A T E R I A L S3M™ Scotchkote™ Product Line


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3M™ Scotchkote™ Fusion Bonded Epoxy Powdered Coating 226N+3M™ Scotchkote™ Fusion Bond Epoxy Powdered Coating 226N+ is an one-part, heat curable, thermosetting epoxy coating powder designed for corrosion protection of pipe. The 226N+ also provides excellent damage resistance while handling.

3M™ Scotchkote™ Fusion Bond Epoxy Powdered Coating 226N3M™ Scotchkote™ Fusion Bond Epoxy Powdered Coating 226N is an one-part, heat curable, thermosetting epoxy coating powder designed for corrosion protection of pipe. 3M™ Scotchkote™ Fusion Bonded Epoxy Powder Coating 62333M™ Scotchkote™ Fusion Bonded Epoxy Coating 6233 is a one-part, heat curable, thermosetting epoxy coating powder designed for corrosion protection of pipe. 3M™ Scotchkote™ Fusion Bonded Epoxy Powder Coating 62583M™ Scotchkote™ Fusion Bonded Epoxy Coating 6258 is a one-part, heat curable, thermosetting epoxy coating designed for corrosion protection of pipe. 3M™ Scotchkote™ Fusion Bonded Epoxy Powdered Coating 206N3M™ Scotchkote™ 206N, has been a pipe coating standard since 1974. It is available in a wide variety of gel/cure time ranges for automatic or manual application to external and internal surfaces of pipe, associated appurtenances and fi eld joints. The coating exceeds all industry pipe-coating standards.

3M™ Scotchkote™ Dual and Multi Layer Fusion Bonded EpoxyWith advanced coating systems, it’s important to select a supplier that can provide service to match the level of technology. 3M provides this service through its extensive laboratories and its global network of subsidiaries and applicators.

3M™ Scotchkote™ Fusion Bond Epoxy Powdered Coating 63523M™ Scotchkote™ Fusion Bonded Epoxy Dual Coating System 6352 is a hard, mechanically strong top coating for all Scotchkote fusion bonded pipeline corrosion protection coatings.

3M™ Scotchkote™ Fusion Bonded Epoxy Dual Coating System 62513M™ Scotchkote™ Fusion Bonded Epoxy Dual Coating System 6251 is a unique, cellular, fusion bonded epoxy top coating for all Scotchkote fusion bonded epoxy coatings (Scotchkote 206N, 226N).

3M™ Scotchkote™ Fusion Bonded Epoxy Rough Overcoating 207R3M ™ Scotchkote™ 207R Fusion Bonded Epoxy Rough Overcoating is a one-part, heat-curing, thermosetting fusion bonded epoxy coating.

3M™ Scotchkote™ Patch Repair / RehabilitationFor patches, repairs, and rehabilitation. 3M™ Scotchkote™ Hot Melt Patch Compound 226P, GreenScotchkote 226P Green is matched to Scotchkote 226N and 6233 coating. 3M™ Scotchkote™ Liquid Epoxy Coating 306, Green3M™ Scotchkote™ 306 Liquid Epoxy Coating is an ambient temperature cure, two-part thermosetting and 80% solids liquid epoxy coatings designed to protect metal, concrete and other surfaces from corrosion and deterioration. 3M™ Scotchkote™ Liquid Epoxy Coating 314, Forest Green3M™ Scotchkote™ 314 Liquid Epoxy Coating is an ambient temperature cure, two-part thermosetting 80% solids liquid epoxy coating designed to protect metal, concrete and other surfaces from corrosion and deterioration.



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B E R R Y P L A S T I C S C O R P O R A T I O N , C O R R O S I O N P R O T E C T I O N G R O U P Polyken® Pipeline Coating Products - Over the Ditch Line Coatings

Corrpro® is an authorized distributor of Covalence Polyken products Polyken, the leader in Pipeline Protection TechnologyThe Polyken brand has been synonymous with pipeline corrosion protection systems worldwide for more than 50 years. Whether in the extreme heat of the Middle East or the forbidding cold of Russia or the more moderate climate of the United States, Covalenace CPG is there with the most advanced anti-corrosion pipeline coatings for the oil, gas, water and coal slurry industry.

Pipeline Coating Products include:Over the ditch line coatingsGirth weld coatingsLiquid adhesive systemsCoatings for pipe fi ttings, bends and t’sAccessory productsPlant applied line coatingsReconditioning / rehabilitiation coating systems

Polyken 1019 Solvent Based Liquid Adhesive for Line Travel SystemDescriptionPollyken 1019 liquid adhesive is recommended primarily for machine application to new or smooth pipe surfaces.

FeaturesExcellent adhesiionExcellent cathodic disbondment resistanceConforms to local and national standardsNon-pollutingNon-toxicManufactured at ISO 9002 facilityMaximum temperature 100°C -212°F

Polyken 1600 High Temperature Polypropylene System - GoCoat 250DescriptionPolyken 1600 -30 is one of the components of the Polyken GoCoat 250 System. Applications

Designed for the corrosion protection of new or operating pipeline with a maximum operating temperature of 250°F (121°C).

FeaturesUser freindly applications to new or operating pipelinesShear resistant at elevated temperatures Retains long term fl exibility Manufactured at ISO certifi ed facility plant or in-fi led applicationMaximum temperature 250°F (121°C)

Polyken 1619 Solvent Based Liquid AdhesiveDescriptionPolyken 1619 liquid adhesive system is recommended primarily for machine application to new or smooth pipe surfaces.

ApplicationsThermally activated solvent based primer designed for machine, spray, or hand brush applications to mechanically cleaned new or reconditioned pipe.

FeaturesExcellent adhesion Excellent cathodic disbondment resistance Conform to local and national standards Non -polluting Non-toxic Manufactured at ISO 9200 facility Maximum temperature 248°F (120°C)

Polyken 1636 High Temperature Joint WrapDescriptionJoint wrap for a one-component coating system which when applied to pipe in half-tap confi guration, provides up to 250°F (120°C) continuous operating temperature protection.

Features


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Includes a polymeric alloy capable of withstanding high temperaturesIncludes adhesive with bonds tenaciously to primed steelResists soil stress Can be used at temperatures at which most adhesives softenMaximum temperatures not applicable

Polyken 2000 High Shear System - GOCoat 200DescriptionPolyken 2000 -25 is a component of the Polyken GoCoat 200 system. The Polyken GoCoat 200 System is designed for in-fi eld application on pipe where soil stress conditions exist and with a maximum operating temperature of 200°F.

ApplicationsDesigned for in-fi eld application on pipe where soil stress conditions exist and with a maximum operating temperature of 200°F (93°C).

FeaturesShear resistant up to 200°F (93°C) Thermally stable polymeric backing Incorporated SCC inhibitors Established in-ground history New construction or reconditioning of existing pipelinesMaximum temperature 199°F (93°C)


ApplicationsHigh shear primer designed for machine, spray, or hand brush applications to mechanically cleaned pipe surfaces.

FeaturesExcellent adhesion Excellent cathodic disbondment resistance Conform to local and national standards Non-polluting Non-toxic Manufactured at ISO 9002 facility Maximum temperature 100°C -212°F

Polyken 2027 Solvent Based Liquid AdhesiveDescriptionPolyken 2027 liquid adhesive system is recommended primarily for machine application to rough, reconditioned or grit-blasted pipe surfaces. ApplicationsHigh shear primer designed for hand brush applications to mechanically cleaned pipe surfaces.

Features Excellent adhesion Excellent cathodic disbondment resistance Conform to local and national standards Non-polluting Non-toxic Manufactured at ISO 9002 facility Maximum temperature 100ºC - 212ºF

Polyken 2036 High-temperature / High-shear Resistant Anti-Corrosion Joint Wrap CoatingDescriptionPolyken 2036 is a primary anti-corrosion joint wrap designed for use in fi eld coating applications.

FeaturesSuperier bond strength to primed steel Continuous operating service temperature up to 200°FExcellent conformability when applied to pipe

Polyken 954 Protective Pipeline OuterwrapDescriptionProtective pipeline joint outerwrap that is used where a complete bond of outerwrap to tape is specifi ed.

FeaturesTough polyethylene backing provides excellent mechanical protection to anti-corrosion joint wrapsAdhesive assures complete bond Eliminates need for tie downs on the outerwrap Designed for hand application over primary joint wrapMaximum temperature not applicable



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Polyken 930 Wrap - Cold Applied Tape Coating SystemDescriptionPolyken 930 is a cold applied tape coating system designed for the corrosion protection of fi eld joints, fi ttings and specialty piping.

ApplicationsHeavy duty joint wrap tape for hand wrapping in applications where higher shear properties are required. Designed without release liner for less waste and ease of use.

FeaturesHeavy duty adhesiveConformabel to irregular shapesNo release linerEstablished in-ground historyComplies with AWWA C-209 StandardCompatible with generic plant coating systemsMaximum temperature -151°F (66°C)

Polyken 932 Wrap - Cold Applied Tape CoatingDescriptionCold applied tape coating system designed for the corrosion protection of fi eld joints, fi ttings and specialty piping.

ApplicationsCold applied tape system with an elevated high-tack adhesiveProvides excellent conformability when hand applied to fi eld joints, fi ttings and specialty piping

B E R R Y P L A S T I C S C O R P O R A T I O N , C O R R O S I O N P R O T E C T I O N G R O U P Polyken® Pipeline Coating Products - Girth Weld Coatings

FeaturesSuper high tack adhesiveConformabel to irregular shapesHand or machine applicationEstablished in-ground historyComplies with AWWA C-209 StandardCompatible with generic plant coating systemsMaximum temperature -122°F (50°C)

DIN 942/955 Cold Applied Double Faced TapeDescriptionThe Polyken 942/955 EN System is a multilayer coating system designed for the corrosion protection of girth weld fi eld joints as well as complete line coatings of steel pipelines in highly corrosive environments and exposed to high mechanical stresses.

ApplicationsThe Polyken double faced tape coating system is designed for the corrosion protection of girth weld fi eld joints, fi ttings, fabricated pipe sections, and the repair of main line coatings.

FeaturesDeveloped and manufactured in ISO certifi ed facilitiesConformable to irregular shapesHand or machine applicationEstablished and proven in-ground historyCompatible with most generic plant coating systemsCertifi ed to DIN 30672 Class C at 50°C


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Polyken 1019 Solvent Based Liquid Adhesive for Line Travel SystemDescriptionPolyken 1019 liquid adhesive is recommended primarily for machine application to new or smooth pipe surfaces.

FeaturesExcellent adhesiionExcellent cathodic disbondment resistanceConforms to local and national standardsNon-pollutingNon-toxicManufactured at ISO 9002 facilityMaximum temperature -212°F (100°C)

Polyken 1027 Liquid and Spray AdhesiveDescriptionPolyken 1027 liquid adhesive system is ideal for slower machine appliction to rough, reconditioned or grit-blasted pipe surfaces.

ApplicationsSolvent based primer designed for machine, spray, or hand brush applications to mechanically cleaned pipe surfaces.

FeaturesExcellent adhesionExcellent cathodic disbondment resistanceConform to local and national standardsNon-pollutingNon-toxicManufactured at ISO 9002 facilityMaximum temperature - 212°F (100°C)


ApplicationsThermally activated solvent based primer designed for machine, spray, or hand brush applications to mechanically cleaned new or reconditioned pipe.

FeaturesExcellent adhesion Excellent cathodic disbondment resistance Conform to local and national standards Non -polluting Non-toxic Manufactured at ISO 9200 facility Maximum temperature 248°F (120°C)

Polyken 1627 Liquid AdhesiveDescriptionLiquid adhesive system is ideal for slower machine or hand application to or grit-blasted pipe surfaces.

FeaturesMaximum temperature not applicable

Polyken 2019 Solvent Based Liquid AdhesiveDescriptionPolyken 2019 liquid adhesive system is recommended primarily for machine application to new or smooth pipe surfaces

ApplicationsHigh shear primer designed for machine, spray, or hand brush applications to mechanically cleaned pipe surfaces

FeaturesExcellent adhesion Excellent cathodic disbondment resistance Conform to local and national standards Non-polluting Non-toxic Manufactured at ISO 9002 facility Maximum temperature -212°F (100°C)

B E R R Y P L A S T I C S C O R P O R A T I O N , C O R R O S I O N P R O T E C T I O N G R O U P Polyken® Pipeline Coating Products - Liquid Adhesive Products



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Polyken 2027 Solvent Based Liquid AdhesiveDescriptionPolyken 2027 liquid adhesive system is recommended primarily for machine application to rough, reconditioned or grit-blasted pipe surfaces. ApplicationsHigh shear primer designed for hand brush applications to mechanically cleaned pipe surfaces.

Features Excellent adhesion Excellent cathodic disbondment resistance Conform to local and national standards Non-polluting Non-toxic Manufactured at ISO 9002 facility Maximum temperature - 212ºF (100ºC)

Polyken P 1033A Low VOC Liquid Adhesive SystemDescriptionPolyken 1033A is a VOC liquid adhesive system that complies with federal and state clean air requirements.

ApplicationsPolyken liquid adhesive systems consist of elastomers blended with polymeric resins dissolved in an organic solvent system. They can be used for machine or hand applications, are non-toxic, non-polluting and conform to local and national standards. In addition to excellent adhesion to the pipe substrate and cathodic disbondment resistance, the pipe surface is protected against stress corrosion cracking with industry proven SCC inhibitors.

The newly reformulated Polyken 1033A is a low VOC liquid adhesive system that complies with federal and state clean air requirements. The VOC content is 103 lbs/gal (0.859g/ltr). The newly reformulated 1033A is not only environmentally clean, but also highly effective in protecting against corrosion. It is easy to apply and fast drying. Used in conjunction with the recommended Polyken coating systems, the 1033A will provide the

same longterm performance as the other Polyken liquid adhesvie systems.

FeaturesExcellent adhesion Excellent cathodic disbondment resistance Conform to local and national standards Non-polluting Non-toxic Manufactured at ISO 9002 facility Maximum temperature 100°C -212°F

Polyken P 1039 VOC Liquid Adhesive SystemDescriptionPolyken P 1039 is a zero VOC Liquid adhesive system that complies with federal and state clean air requirements.

ApplicationsThe liquid adhesive systems consist of elastomers blended with polymeric resins dissolved in an organic solvent system. They can be used for machine or hand applications in environmentally sensitive areas, are non toxic, non-polluting, and conform to local and national standards. In addition to excellent adhesion to the pipe substrate and cathodic disbondment resistance, the pipe surface is protected against stress corrosion cracking with industry proven SCC inhibitors. Used in conjunction with the recommended Polyken coating systems, the 1039 will provide the same long-term performance as the other Polyken liquid adhesive systems. Warning Polyken liquid adhesive systems are fl amable mixtures. Caution: Store away from heat source.

FeaturesExcellent adhesion Excellent cathodic disbondment resistance Conform to local and national standards Non-polluting Non-toxic Manufactured at ISO 9002 facility

B E R R Y P L A S T I C S C O R P O R A T I O N , C O R R O S I O N P R O T E C T I O N G R O U P Polyken® Pipeline Coating Products - Liquid Adhesive Products


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Polyken 4000-35 PCS Primerless Coating SystemDescription4000-35 PCS is a cold applied coating system designed for the corrosion protection of fi eld joints, fi ttings and specialty piping.

FeaturesLabor saving applications Eliminates VOC emissions Eliminates dangers associated with a hazardous productCompatibility with generic plant coating systems Can be used as a one coat system Heavy duty / high tack adhesive ensures a strong bond and impervious sealExcellent adhesion Comformable to irregular shapes Above and below ground use Superior resistance to cathodic disbondment Meets AWWA C209 standard Maximum temperature - 122°F (50°C)

Polyken 930 Wrap - Cold Applied Tape Coating SystemDescriptionPolyken 930 is a cold applied tape coating system designed for the corrosion protection of fi eld joints, fi ttings and specialty piping.

ApplicationsHeavy duty joint wrap tape for hand wrapping in applications where higher shear properties are required. Designed without release liner for less waste and ease of use.

FeaturesHeavy duty adhesive Conformabel to irregular shapes No release liner Established in-ground history Complies with AWWA C-209 Standard Compatible with generic plant coating systems Maximum temperature -151°F (66°C)

Polyken® Pipeline Coating Products - Coatings for Pipe Fittings, Bends and “T”s

Polyken 932 Wrap - Cold Applied Tape CoatingDescriptionCold applied tape coating system designed for the corrosion protection of fi eld joints, fi ttings and specialty piping.

ApplicationsCold applied tape system with an elevatedhigh-tack adhesiveProvides excellent conformability when hand applied to fi eld joints, fi ttings and specialty piping

FeaturesSuper high tack adhesive Conformable to irregualr shapes Hand or machine application Established in-ground history Complies with AWWA C-209 Standard C ompatible with generic plant coating systemsMaximum temperature -122°F (50°C)

Polyken 934 Wrap Cold Applied Tape Coating SystemDescriptionPolyken 934 wrap is a cold applied tape coating system designed for the corrosion protection of fi eld joints, fi ttings and specialty piping.

ApplicationsCold applied tape system with an elevated high-tack adhesiveUsed as a patch/repair system and as the primary corrosion protection system fi eld joints, fi ttings and specialty piping

FeaturesHigh-tack adhesive Conformable to irregular shapes Hand or machine application Established in-ground history Complies with AWWA C-209 Standard Compatible with generic plant coating systems



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Polyken 936 High UV ResistantHigh Tack Joint Wrap TapeDescription Polyken 936 is a long-term UV resistant high tack joint wrap for above or below ground use. This unique product is easily applied to fi eld joints, fi ttings, tees and ells. The polyolefi nic backing has excellent conformability, and built-in resistance to environmental stress cracking (ESCR).

FeaturesProven optimum corrosion protectionStrong bondVersatileEasy to applyConformableEnvironmentally stableMaximum temperature: - 151ºF (66ºC)

Polyken 937/938 Mastic SystemDescriptionThe Polyken family of mastics are cold applied coatings designed to protect underground piping such as valves, T’s, ells and couplings. Once applied, the Polyken mastics for a tough monolithic coating, which resists cracking, crazing or checking.

FeaturesHigh solidsTwo gradesEasy fi led applicationEstablished in-ground historyConforms to irregular shapesMaximum temperature not applicable

B E R R Y P L A S T I C S C O R P O R A T I O N , C O R R O S I O N P R O T E C T I O N G R O U P

DIN 942/955 Cold Applied Double Faced TapeDescriptionThe Polyken 942/955 EN System is a multilayer coating system designed for the corrosion protection of girth weld fi eld joints as well as a complete line coatings for steel pipelines in highly corrosive environments and exposed to high mechanical stresses.

ApplicationsThe Polyken double faced tape coating system is designed for the corrosion protection of girth weld fi eld joints, fi ttings, fabricated pipe sections, and the repair of main line coatings.Features

Developed and manufactured in ISO certifi ed facilitiesConformable to irregular shapes Hand or machine application Established and proven in-ground history Compatible with most generic plant coating systems Certifi ed to DIN 30672 Class C at 50°C


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B E R R Y P L A S T I C S C O R P O R A T I O N , C O R R O S I O N P R O T E C T I O N G R O U P Polyken® Pipeline Coating Products - Accessory Products

Polyken 900 General Utility Tape for Hand Application on Small Diameter Pipe Joints and FittingsDescription General utility tape for hand application on small diameter pipe joints and fi ttings.

FeaturesEstablished and proven performanceConformable to irregular shapesHand or machine applicationExceeds LT 1512-A, LT-0077, and MIL I-7798 specifi cationsCompatible with most generic plant coating systems Maximum temperature: - 151ºF (66ºC)

Polyken 910 All Purpose Tape System for Field Application in the Oil PatchDescription All purpose tape system for fi eld application in the oil patch.

ApplicationsGeneral utility tape for hand application on small diameter pipe, joints, and fi ttings.

Features Established and proven performanceConformable to irregular shapesHand or machine applicationExceeds LT 1512-A, LT-0077, and MIL I-7798 specifi cationsCompatible with most generic plant coating systemsMaximum temperature - 151ºF (66ºC)

Polyken 931 Self Adhering Filler TapeDescription Polyken 931 Filler Tape is designed as an underlying fi ller material prior to the application of Polyken coating systems such as 908, 930 and 980.

ApplicationsSelf-adhering Used to fi ll voids and crevices around joints, fi ttings, and specialty piping

Features Flexible under various fi eld conditions Conformable and moldableEasy and simple application Compatible with Polyken coating systems Maximum temperature: - 250ºF (121ºC)

Polyken 939 Self Adhering Filler TapeDescription Polyken 939 Filler Tape is designed as an underlying fi ller material prior to the application of Polyken coating systems.

ApplicationsThick mastic-like butyl rubber fuller designed to fi ll and smooth transition areas.

Features Flexible under various fi eld conditionsEasy and simple applicationConformable and moldableCompatible with Polyken coating systems Maximum temperature not applicable



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B E R R Y P L A S T I C S C O R P O R A T I O N , C O R R O S I O N P R O T E C T I O N G R O U P Polyken® Pipeline Coating Products Plant Applied Line Coatings

Polyken Powercrete®DescriptionSince 1980, Powercrete epoxies have demonstrated strength and integrity as revolutionary liquid coatings for corrosion prevention in the pipeline industry. Leading scientists and researchers have further developed the Powercrete line in response to application demands. Today owners and contractors choose Powercrete because they are confi dent in the dependable and reliable performance.

Choosing Powercrete means you are selecting the leading liquid epoxy that has set the standard for the industry. Powercrete provided superior adhesion and abrasion resistance to protect valuable assets. Powercrete is impervious to soil stress and is compatible with FBE and CTE line coatings.

Powercrete coatings are fi eld fi eldly, easy to apply and cost effective. All Powercrete formulations can be spray, roller or brush applied and are available in a variety of colors.

ApplicationsCorrosion Prevention Coatings

Ideal for coating girth welds, bends, fi ttings and -elbows

New high-build , fast setting - formulationsIID coatings for fl ow effi ciency -Cost effective joint coating for FBE coated pipe -

Directional Drill Coatings Abrasion resistenat overlay (ARO) applied over -

FBEExtremely high adhesion to the FBE mainline -

coatingsExceptional abrasion and impact resistanc -Flexible application in the fi eld or in the plant -

Rehabilitation Coatings Bell hole rehab long or short pipe sections -Cost effective recoating solution -Field friendly and easy to apply -World class manufacturer’s Applicator Certifi ca- -

tion Program

Offshore Coatings Risers and spans for offshore structures -Pile and splash zone protection against me- -

chanical damageLong life alternative to traditional marine paints -High speed manual and spray application -Proven performance in harsh marine environ- -

mentsWater, Wastewater and Tank Coatings

OD water pipe - for exceeds AWWA C210 and -C222

ID water pipe - NSF 61 approval, potable water -formulations

High build in a single pass -Chemical resistant and non leachable -


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B E R R Y P L A S T I C S C O R P O R A T I O N , C O R R O S I O N P R O T E C T I O N G R O U P Covalence® Heat Shrinkable Pipeline Coatings - Accessory Products

Covalence EQ Roller - Rollers are specifi cally designed for use with heat shrink productsDescription Rollers are specifi cally designed for use with heat-shrink products.

ApplicationsTo remove entrapped air in the adhesive layer around weld bead or in the overlap area.

Features Silicon rubber roller 7 mm thick silicone Aluminum body Ø: 31 mm W: 120 mm Maximum temperature not applicable

Covalence S1113 - Adhesive Tape on Rolls With Release Paper for IPEC Description S1113 is an adhesive tape on rolls with release paper for IPEC.

ApplicationsUsed in combination with CCS-DHEC and DHEC. Can be sold seperately in case leak detection wires have to be brought out when installing CCS-DHEC or DHEC.

Features Easy to use release linerIncluded in group packaging of IPECDouble wrap of sealing strip is applied on the pipe before shrinking of IPEC Maximum temperature - 266ºF (130ºC)

Covalence S1137 - High Viscosity Sealant Based Filler for PERP, PERP 80, PERP60EDescription S1137 is a high viscosity sealant based fi ller material delivered in rolls.

ApplicationsS1137 is used as a fi ller material with PERP, HTTE, and STTE. Filler tape is used to fi ll the holiday thus restoring the mill applied coating thickness of the pipe.

FeaturesHigh viscosity sealant-based fi llerDelivered on rolls Maximum temperature - 176ºF (80ºC)

Covalence S1113-RI - Adhesive Tape Reinforced with Glass Fiber for RayJoint Description RayJoint is a cross-linked, heat-shrinkable, tubular, all-in-one joint with superior performance. It is a complete system offering both casing pipe continuation and permanent sealing of the joint area.

ApplicationsThe mastic is used in combination with RayJoint. The mastic is wrapped around the jacket ends of the pre-insulated pipe during installation of the RayJoint casing. The RayJoint is placed centrally over the joint and the ends are heated with a gas torch.

Features Acrylic set fi berglass meshHDPE release fi lmS1113 adhesive Maximum temperature - 122ºF (50ºC)

Covalence Torches - Propane Heating Device Description The torch assembly is a propane heating device for fast and effi cient installation of heat-shrinkable pipeline coatings.

FeaturesTorch assemblies are designed for installation of heat-shrinkable products in the gas and water, construction or district heating markets Maximum temperature - 86ºF (30ºC)



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B E R R Y P L A S T I C S C O R P O R A T I O N , C O R R O S I O N P R O T E C T I O N G R O U P Covalence® Heat Shrinkable Pipeline Coatings for Pipe Fittings, Bends and “T”s

Covalence BLOT - Moulded Part to Coat Blocking T’s Description BLOT is a heat-shrinkable molded part, specially developed for blocking t’s, consisting of a saddle and a separate cap provided with a tightly fi tting plug cover.

BLOT blocking tee coating.Construction: Two-layer system:

First layer: High-viscosity, high strength mastic (collar and fl ap) High performance copolymer (cap)Second layer: Thick-walled, radiation cross- linked, high density polyethylene.

BLOT is a heat-shrinkable, two-piece molded part kit pre-shaped to encapsulate blocking tees in gas distribution networks and thus protect from corrosion. The BLOT components are fabricated from a special compound, that fi t the contours of the metal t-pieces. BLOT consists of a “saddle” (a ± 30 mm (1.25”) high collar provided with a square fl ap) and a separate cap provided with a tightly fi tting plug cover.The ‘“saddle” is internally coated with a high-viscosity, high-strength mastic to secure the bond to the pre-coated pipe. This also makes the installation easy. The high performance copolymer coating of the cap ensures an excellent bond to the bare steel of the tee-piece.

BLOT is installed using regular propane gas torches. The installation is carried out directly on the cleaned and preheated substrate surface. The BLOT “saddle” is fi t over the t-piece and shrunk to fi rmly adhere onto the service pipe and the t- base. Then the BLOT cap is put onto the blocking “t” and, beginning from the plug, shrunk tightly around. During recovery, the adhesive softens and fl ows to form a tight bond with the substrate. The bond strength builds up during cool down and is fully retained after completion of the job.

Features No primer required

No drying time and easy application -Pre-shaped mold system

Makes installation easy -Provides accurate protection -

Controlled high wall thicknessProvides accurate and reliable protection -

Small number of sizes for a large number of applicationsReduced inventory and logistics costsSpecially formulated sealant

Ensures a strong bond and reliable - protectionProvides high peel and shear values - after

installationNo special equipment or skills required

Makes installation fast and easy -Keeps installation costs low -

Maximum temperature - 122ºF (50ºC)

Covalence CPSM/XCSM - Tubular Sleeve with High Shrink Ratio for CouplersDescription CPSM, XCSM are thick-wall, high expansion heat-shrinkable tubular sleeves remarkable for their high shrink ratio allowing awkward, irregular shapes to be coated easily.

CPSM, XCSM fi ttings & mechanical coupler coating and sealingConstruction: Two-layer system:

First layer: Visco-elastic mastic sealant.Second layer: Thick-walled, radiation cross-linked, high density polyethylene.

CPSM, XCSM are thick-wall, high expansion heat-shrinkable tubular sleeves remarkable for their high shrink ratio allowing awkward, irregular shapes to be coated easily. This makes them specifi cally useful for corrosion prevention and sealing of screw, or other mechanical couplers in distribution networks. CPSM, XCSM are typically used for small diameters and high percentage transitions. CPSM, XCSM can also be used on small diameter bends, like riser bends. The installation is carried out directly on the cleaned and dried (pre-heated) coupler and pipe surface without any primer being required. CPSM/XCSM is positioned on the pipes prior to coupling them together and, after installation of the coupler, slid centrally over the joint to be protected. When heated, the CPSM/XCSM sleeve shrinks and the sealant melts, encapsulating mechanical couplings and straight pipes with a strong


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impervious seal. While the sleeve conforms to the shape of the coupling or pipe, the melted sealant is forced into all surface irregularities providing a permanent environmental seal.

Features No primer required

No drying time and easy application -Low preheat sensitivity and proven functionality

Allows easy application combined with - high functional performance

Highly resistantTrustful as CPSM/XCSM resists - bending,

impact, abrasion, penetration, corrosive gases or fl uids, disbonding and long-term storage

Remains user-friendly (even at low tempera- -tures)

Copes with diffi cult shapesMakes installation and protection a - child’s playSaves time and money -

Specially formulated sealantsEnsures a strong bond and impervious - seal

Self-healing effect - Saves extra intervention steps (Sealing adhe-

sive automatically fl ows and seals off minor me-chanical damages)

Copes with relatively high transitions (high shrink ratio)

Minimizes inventory, thus economical -No special equipment or skills required

Makes installation fast and easy -Keeps installation costs low -

Maximum temperature - 86ºF (30ºC)

Covalence CSEM-F - Fiber Reinforced Wrap Around Sleeve for Casing End Seals Description CSEM-F/CASEAL (US) is a heat-shrinkable, wrap-around sleeve with a very high shrink ratio, specially developed for casing/service pipe sealing. CSEM-F/ CASEAL (US) casing/carrier step-down sealing.Construction: Two-layer system:

First layer: Visco-elastic mastic sealantSecond layer: Fiberglass reinforced, radiation cross-linked, polyethylene backingAdditional kit component: Non-shrinkable, polypropylene support sheet.

CSEM-F/CASEAL (US) is a heat-shrinkable, wrap-

around sleeve with a very high shrink ratio, specially developed for casing/service pipe sealing. The special adhesive inside the thick-wall CSEM-F/CASEAL(US) assures an excellent bond between the sleeve and bare or pre-coated pipes. The fi berglass reinforced woven and laminated backing gives the CSEM-F/CASEAL(US) sleeve a high mechanical resistance as well as a high recovery capacity. A zipper closing system allows a simple and fast installation. In addition to the CSEM-F/CASEAL(US) sleeve, a support sheet is supplied which provides a smooth step-down in the transition area to ensure a tight closure and enhances the mechanical strength. CSEM-F/CASEAL(US) is installed using standard gas torches. After pipe surface preparation and preheating, the support sheet is wrapped around the transition to be sealed followed by the heat-shrinkable sleeve. The sleeve is zipper-closed, forming a tube, and shrunk in place tightly fi tting around the substrate. During recovery, the adhesive softens and fl ows to form a tight bond. The bond strength builds up during cool down and is fully retained after completion of the job.

Features Installation is carried out directly on the cleaned and prepared pipe surface. No primer is required. The system can also be used when the service pipe is not concentric with the casing. Maximum temperature - 86ºF (30ºC)

Covalence FCTS/FCWS/FCMS/FCWSF - Heat-Shrinkable Moulded Sleeve Description Heat shrinkable corrosion protection sleeve specifi cally developed for installation on fl anges or mechanical couplings that are already in place. FCMS/FCWS fl ange/pipe sealing and protectionConstruction: Two-layer system:

First layer: Visco-elastic sealant Second layer: Thick-walled, radiation-cross-linked, high density polyethylene

FCWS and FCMS are available in a variety of fl ange sizes. Both products eliminate the need for molding and fi lling compounds or jellies. The visco-elastic properties of adhesives in the installed product protect against pipe stresses caused by ground movement. The wall thickness of the installed product offers additional


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Covalence HTLP80 - 3 Layer Wrap-around Field-Joint Coating (with epoxy) Description Covalence’s three-layer fi eld-joint coatings (HTLP) are the toughest fi eld-applied coating systems. ApplicationsCompatible with all commonly used pipe coatings, including PE, coal tar enamel, coal tar epoxy, and fusion-bonded epoxy.

Features Fully resistant to shear forces induced by soil and thermal movements Sleeve applied over wet epoxy, with no curing or waiting timesSuperior cathodic disbondment performance and hot water immersion resistance Fully reconstructs three-layer coating at all girth welds for continuous and homogeneous performance on pipelines coated with 3LPE Low preheat requirementsMaximum temperature - 176ºF (80ºC)

Covalence PPS120 - Wrap-aroundField-Joint Coating for 3LPP (2 layer) Description PPS120 with PCI (Permanent Change Indicator) is a 4-component fi eld-joint coating system for high temperature, polypropylene coated pipelines operating up to 248°F (120°C) temperature.

ApplicationsPPS120 is normally used for girth weld protection of steel pipes coated with polypropylene. PPS120 may be cut to appropriate length to cover all pipe diameters. The system is designed to be applied with special and user-friendly preheating methods.

Features Dimpled backing provides a “Permanent Change Indicator” (PCI) for application of heatAvailable as a one-peice wrap-around unit or in roll form Specially designed application tools usable for all diametersHigh shear resistanceHigh operating temperature rating Maximum temperature - 248ºF (120ºC)

Covalence TPS - Tubular Field-JointCoating (2 layer) Description TPS(M) are heat-shrinkable, tubular sleeves which prevent corrosion of welded pipe joints in distribution lines for sizes up to 8.625”/DN200. ApplicationsCompatible with standard pipe coatings including PE, FBE, tape and coal tar.

Features Installation is carried out directly on the cleaned and dried (pre-heated) pipe surface No primer is required to promote adhesion. Compatible with standard commercial mill- applied coatings In the event of mechanical damage, the sealing adhesive fl ows and seals off the damaged area (self-healing effect) No special tools needed, leading to low installation costs Continuous, tubular design means no closure patch is necessary (tubes must be slid over the pipe prior to welding the joint) The thick-walled structure of the cross-linked heat- shrinkable material gives it high impact strength and penetration resistance (TPSM-C30)Maximum temperature - 86ºF (30ºC)

Covalence WaterWrap - Wrap-aroundField-Joint Coating for Large Diameter Water Pipes (2 layer) – Internal Welding Description TWDB is a hot applied duct sealing tape composed of heat-shrinkable backing with a heat resistant pressure sensitive, non-drip adhesive and a closure patch. ApplicationsWaterWrap is a wrap-around heat-shrinkable, ready-to-fi t assembly for the corrosion protection of fi eld girth weld joints in water distribution and transportation systems. WaterWrap is compatible with standard pipe coatings. It can also be used for coating bare, replacement pipe sections & large radius bends.


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The installation is carried out directly on the cleaned and prepared pipe surface without any primer. During installation, FLEXCLAD(-II) is to be wrapped spirally around the bend with a 50% overlap. The carrier is heated and shrinks tightly around the substrate; at the same time, the sealing adhesive melts and is forced into all surface irregularities, forming a thorough coating and a complete bond with the substrate.

Features Different mechanical devices

Provides options to the customer and allows -cost savings

Highly FlexibleEasy to apply at both low or high temperatures -

and on pipes of small diameterCompatible with varying pipe diameters

Minimizes inventory, thus saving money -Self-tensioning, heat-shrinkable backing

Easy to use. Saves time -No Special equipment required

Keeps installation costs low -Maximum temperature 50°C - 122°F



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Features

Ensures correct application of heat and allows easy post-heat inspection. Reliable inspectability at any timeSaves money by keeping inventory and logistics costs lowMakes installation fast and easy. Keeps installation costs lowProvides high functional performance and safety Top performance in demanding conditions Has enhanced resistance to cracking at elevated temperatures Maximum temperature not applicable

Covalence HTLP60 - 3 Layer Wrap Around Field-Joint Coating (with epoxy) Description Wrap-around heat-shrinkable sleeve which replicates the structure and performance of mill-applied three-layer PE coatings. ApplicationsCompatible with all commonly used pipe coatings, including PE, coal tar enamel, coal tar epoxy, and fusion-bonded epoxy.

Features Fully resistant to shear forces induced by soil and thermal movements Sleeve applied over wet epoxy, with no curing or waiting timesSuperior cathodic disbondment performance and hot water immersion resistance Fully reconstructs three-layer coating at all girth welds for continuous and homogeneous performance on pipelines coated with 3LPE Low preheat requirements Maximum temperature - 149ºF (65ºC)

B E R R Y P L A S T I C S C O R P O R A T I O N , C O R R O S I O N P R O T E C T I O N G R O U P Covalence® Heat Shrinkable Pipeline Coatings - Girth Weld Coatings

Covalence DIRAX - Directional Drill Fiber Reinforced Wrap Around Field-Joint Coating (with epoxy and leading edge) Description A high performance fi berglass reinforced sleeve specifi cally designed for girth weld corrosion protection.

ApplicationsThe sleeve is used for corrosion protection of girth welds on coated pipes used for horizontal or directional drilling.

Features Highly resistant to shear and peel forces induced by soil and thermal movements. The DIRAX is tough!DIRAX offers abrasion and wear resistance at pull-through comparable to mill coatings Provides a monolithic coating systemWear cone protects leading edge of sleeve against pull-through forces. Provides additional strength and security---increases reliabilitySleeve applied over wet epoxy---there are no curing or waiting times / formation of strong mechanical and chemical bonds Allows fast application---saves time! Ensures high performance!Superior cathodic disbondment and hot water immersion resistance. Offers the optimum barrier protection against corrosionPre-attached closure patch. Allows fast and easy applicationLow preheat requirements. Makes installation faster and saves timeMaximum Temperature -122ºF (50ºC)

Covalence HTLP-PP - 3 Layer Polypropylene Field-Joint Coating System for Polypropylene Coated Pipelines Operating up to 120°C TemperatureDescription HTLP-PP is a wrap-around, polypropylene based heat-shrinkable sleeve and is designed for corrosion prevention and sealing for polypropylene coated pipelines, operating at temperatures up to 120°C .


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Covalence HTLP80 - 3 Layer Wrap-around Field-Joint Coating (with epoxy) Description Covalence’s three-layer fi eld-joint coatings (HTLP) are the toughest fi eld-applied coating systems. ApplicationsCompatible with all commonly used pipe coatings, including PE, coal tar enamel, coal tar epoxy, and fusion-bonded epoxy.

Features Fully resistant to shear forces induced by soil and thermal movements Sleeve applied over wet epoxy, with no curing or waiting timesSuperior cathodic disbondment performance and hot water immersion resistance Fully reconstructs three-layer coating at all girth welds for continuous and homogeneous performance on pipelines coated with 3LPE Low preheat requirementsMaximum temperature - 176ºF (80ºC)

Covalence PPS120 - Wrap-aroundField-Joint Coating for 3LPP (2 layer) Description PPS120 with PCI (Permanent Change Indicator) is a 4-component fi eld-joint coating system for high temperature, polypropylene coated pipelines operating up to 248°F (120°C) temperature.

ApplicationsPPS120 is normally used for girth weld protection of steel pipes coated with polypropylene. PPS120 may be cut to appropriate length to cover all pipe diameters. The system is designed to be applied with special and user-friendly preheating methods.

Features Dimpled backing provides a “Permanent Change Indicator” (PCI) for application of heatAvailable as a one-peice wrap-around unit or in roll form Specially designed application tools usable for all diametersHigh shear resistanceHigh operating temperature rating Maximum temperature - 248ºF (120ºC)

Covalence TPS - Tubular Field-JointCoating (2 layer) Description TPS(M) are heat-shrinkable, tubular sleeves which prevent corrosion of welded pipe joints in distribution lines for sizes up to 8.625”/DN200. ApplicationsCompatible with standard pipe coatings including PE, FBE, tape and coal tar.

Features Installation is carried out directly on the cleaned and dried (pre-heated) pipe surface No primer is required to promote adhesion. Compatible with standard commercial mill- applied coatings In the event of mechanical damage, the sealing adhesive fl ows and seals off the damaged area (self-healing effect) No special tools needed, leading to low installation costs Continuous, tubular design means no closure patch is necessary (tubes must be slid over the pipe prior to welding the joint) The thick-walled structure of the cross-linked heat- shrinkable material gives it high impact strength and penetration resistance (TPSM-C30)Maximum temperature - 86ºF (30ºC)

Covalence WaterWrap - Wrap-aroundField-Joint Coating for Large Diameter Water Pipes (2 layer) – Internal Welding Description TWDB is a hot applied duct sealing tape composed of heat-shrinkable backing with a heat resistant pressure sensitive, non-drip adhesive and a closure patch. ApplicationsWaterWrap is a wrap-around heat-shrinkable, ready-to-fi t assembly for the corrosion protection of fi eld girth weld joints in water distribution and transportation systems. WaterWrap is compatible with standard pipe coatings. It can also be used for coating bare, replacement pipe sections & large radius bends.



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Features Offers two Permanent Change Indicators (PCI) A low preheat of only 68°F still yields excellent results, even over the weldNo special equipment or skills requiredLow application preheatHigh modulus of elasticity backingHigh impact and penetration resistanceHigh shrink forceContains no asphaltAdhesive remains tacky and strongAdhesive remains in place Maximum temperature -122ºF (50ºC)

Covalence WPC - Wrap-around Field-Joint Coating (2 layer) Description WPC is a heat-shrinkable ready-to-fi t assembly. The WPC elevated temperature with PCI (Permanent Change Indicator) is a two-layer fi eld-joint coating system for pipeline operating at ambient and elevated temperature.

Features Dimpled backing provides a “permanent change” indicator for application of heatEnsures correct application heat and allows easy post-heat inspectionReliable inspectability at any timeLow preheat sensitivity and proven functionalityInstallation friendly in combination with high functional performanceAvailable as all-in-one unit or roll formSaves money by keeping inventory and logistics costs lowHigh shear resistance. WPC offers “safer protection”Covers a wide range of operating temperature ratingsOffers a solution for nearly every applicationNo special equipment (standard gas torch and a roller) or skills requiredMakes installation fast and easyKeeps installation costs lowMaximum temperature - 86ºF (30ºC)


Covalence WPC C30 - Heatshrinkable Sleeves Description WPCT, WPC/B, WPC B30, WPC C30 sleeves are heat-shrinkable ready-to-fi t assemblies for the corrosion protection of piplines.

ApplicationsDesigned for the corrosion protection of welded joints. Compatible with standard pipe coatings – including PE, CTE, CT, FBE, PP and asphalt-based coatings.

Features These products are available on rolls or as unisleeves Installation is carried out directly on the cleaned and dried (pre-heated) pipe surface No primer is required No special tools are needed leading to low installation costs The thick-walled structure of the cross-linked heat-shrinkable sleeve gives the material high impact strength and high penetration resistance (WPC C30) Compatible with standard mill-applied coatings In the event of mechanical damage, the sealing adhesive fi lls and seals off the damaged area (“self-healing” effect) Maximum temperature - 86ºF (30ºC)

Covalence WPC C50 - Wrap-around Field-Joint Coating (2 layer) Description WPC B50, WPC C50, WPC 80, WPC100M and WPC120 sleeves are especially suitable for higher soil stress conditions.

ApplicationsThese products are based on a two-layer system and are normally used for PE-coated steel pipe, and may be used for girth-weld protection or to re-coat (rehabilitate) long pipe sections and large radius bends.


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Features The wrap-around pipe sleeve for fi eld girth weld corrosion protection (WPC) is a heat-shrinkable wrap-around sleeve, closed with a patch closure that may be supplied separately or preattached to one sleeve end. The WPC sleeves are available with different constructions and adhesives Wide range of operating temperature ratings Higher shear resistance than ambient temperature sleeves Simple installation requiring only a torch and a roller Maximum temperature - 140ºF (60ºC)

Covalence WPC100M - Wrap-around Field-Joint Coating (2 layer) Description WPC B50, WPC C50, WPC 80, WPC100M and WPC120 sleeves are especially suitable for higher soil stress conditions. ApplicationsThese products are based on a two-layer system and are normally used for PE-coated steel pipe, and may be used for girth-weld protection or to re-coat (rehabilitate) long pipe sections and large radius bends.

Features The wrap-around pipe sleeve for fi eld girth weld corrosion protection (WPC) is a heat-shrinkable wrap-around sleeve, closed with a patch closure that may be supplied separately or preattached to one sleeve end. The WPC sleeves are available with different constructions and adhesives Wide range of operating temperature ratings Higher shear resistance than ambient temperature sleeves Simple installation requiring only a torch and a roller Maximum temperature - 212ºF (100ºC)

Covalence WPC120 - Wrap-around Field-Joint Coating (2 layer) Description WPC B50, WPC C50, WPC 80, WPC100M and WPC120 sleeves are especially suitable for higher soil stress conditions.

WPC120 fi eld-joint coatingConstruction: Two-layer system:

First layer: High shear-strength copolymer adhesive Second layer: Radiation cross-linked, high density polyethylene with PCI (Permanent Change Indicator)

WPC120 is a wrap-around, heat-shrinkable sleeve designed for corrosion prevention and sealingon various types of piping systems (oil, gas, water, pipe-type cable, etc.), which operate at temperatures up to 120°C (248°F). WPC120 is specially suited for higher stress conditions caused both by elevated temperatures and by soils with severe contraction between wet-dry cycles. WPC120 is normally used for girth weld protection of steel pipes coated with Covalence Rayclad120 heat shrinkable tape. WPC120 may be cut to appropriate length to cover all pipe diameters.The system is designed to be applied with minimum preheating of the pipe. While installing, WPC120 is wrapped around the joint, a closure patch is then installed (already pre-attached if Uni-sleeve) forming a tube, and the sleeve is shrunk in place. No epoxy primer is required. Upon heat exposure, the sleeve starts shrinking from its expanded size to form a tight fi t around the substrate. During recovery, the copolymer adhesive softens and fl ows to form a perfect bond with the pipe surface providing pipe protection against corrosion. The radiation cross-linked outer layer forms a durable barrier to moisture and mechanical damage. Features

Dimpled backing provides a “permanent change” indicator for application of heatEnsures correct application heat and allows easy post-heat inspectionReliable inspectability at any time Available as a one-piece wrap-around unit or in roll formSaves money by keeping inventory and logistics costs lowHigh shear resistance provides high functional performance and safetyHigh operating temperature rating Top performance in demanding conditions No special equipment (standard gas torch and a roller) or skills requiredMakes installation fast and easy Keeps installation costs low Maximum temperature - 248ºF (120ºC)



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Covalence WPC60 - Wrap-around Shrink Sleeve for Pre-insulated Pipe Joint SealingDescription WPC 60 heat-shrinkable wrap-around sleeves are designed for the insulation and sealing against moisture penetration of joint areas on preinsulated piping system. WPC 60 sleeves have a thick radiation-crosslinked polyolefi n backing coated with a high-shear-strength-thermoplastic hot-melt adhesive. During installation the adhesive melts and fl ows, fi lling all surface irregularities, bonds. Features

Rugged and mechanically strong. WPC 60 sleeves resist abrasion, impact and penetration, yet remain fl exible even at very low temperatures. No rock-shield is requiredResists adverse enviroments. WPC 60 sleeves resist temperature cycling, soil stresses and hydrostatic pressure. They demonstrate high resistance to ultraviolet light, fungus, cathodic disbondment and chemical attack by common fl uids and solventsVersatile. WPC 60 sleeves are compatible with Rayclad 60, fusion-bonded epoxy, polyethylene, polypropyelene and most other high performance pipe coating and jackets. The product has a long shelf-life and is unaffected by typical storage conditions Maximum temperature - 149ºF (65ºC)

Covalence WPC65M - Wrap-around Field-Joint Coating (2 layer) Description WPC B50, WPC C50, WPC65M, WPC100M and WPC120 sleeves are especially suitable for higher soil stress conditions.

ApplicationsThese products are based on a two-layer system and are normally used for PE-coated steel pipe, and may be used for girth-weld protection or to re-coat (rehabilitate) long pipe sections and large radius bends.


Features The wrap-around pipe sleeve for fi eld girth weld corrosion protection (WPC) is a heat- shrinkable wrap-around sleeve, closed with a patch closure that may be supplied separately or pre-attached to one sleeve end. The WPC sleeves are available with different constructions and adhesives Wide range of operating temperature ratings Higher shear resistance than ambient temperature sleeves Simple installation requiring only a torch and a roller Maximum temperature - 149ºF (65ºC)

Covalence WPCT - Wrap-around Field-Joint Coating (2 layer) Description WPCT, WPC/B, WPC B30, WPC C30 sleeves are heat-shrinkable ready-to-fi t assemblies for the corrosion of pipelines. Applications

Designed for the corrosion protection of welded jointsCompatible with standard pipe coatings – including PE, CTE, CT, FBE, PP and asphalt-based coatings

Features These products are available on rolls or as unisleeves Installation is carried out directly on the cleaned and dried (pre-heated) pipe surface No primer is required No special tools are needed leading to low installation costs The thick-walled structure of the cross-linked heat- shrinkable sleeve gives the material high impact strength and high penetration resistance (WPC C30) Compatible with standard mill-applied coatings In the event of mechanical damage, the sealing adhesive fi lls and seals off the damaged area (“self-healing” effect) Maximum temperature - 86ºF (30ºC)


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Covalence WPCZ - Wrap-around Field-JointCoating (2 layer) for Infi ll Joints Description WPCZ is a heat-shrinkable wrap-around sleeve specially engineered for use on offshore, weight-coated pipelines incorporating hot marine mastic pour or other infi ll systems at the girth weld. Applications

Designed for corrosion protection of welded jointsCompatible with standard pipe coatings – including PE, CTE, CT, FBE, PP and asphalt-based coatings

Features Products are available on rolls or as uni-sleeves Installation carried out directly on cleaned and dried (pre-heated) pipe surface No primer is required No special tools are needed leading to low installation costs The thick-walled structure of the cross-linked heat-shrinkable sleeve gives the material high impact strength and high penetration resistance (WPC C30) Compatible with standard mill-applied coatings In the event of mechanical damage, the sealing adhesive fi lls and seals off the damaged area (“self-healing” effect) Maximum temperature - 122ºF (50ºC)



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B E R R Y P L A S T I C S C O R P O R A T I O N , C O R R O S I O N P R O T E C T I O N G R O U P Covalence® Heat Shrinkable Pipeline Coatings - Liquid Epoxy Primers

Covalence S1239 Epoxy Primer - Two Components Epoxy Primer Description Epoxy primer which consists of resin Part A and hardener part B. Primer is available in bulk packages. ApplicationsDesigned for machine, spray, or hand brush applications to mechanically cleaned pipe surfaces.

Features Excellent adhesion Excellent cathodic disbondment resistance Conform to local and national standardsMaximum temperature 65ºC - 149ºF

Covalence S1301 Epoxy Primer - Two Components Epoxy Primer Description Epoxy primer which consists of resin Part A and hardener part B. Primer is available in bulk package ApplicationsDesigned for machine, spray, or hand brush applications to mechanically cleaned pipe surfaces.

Features Excellent adhesion. Excellent cathodic disbondment resistance. Conform to local and national standards.Maximum temperature 80ºC - 176ºF

Covalence S1401 S1401 Primer is a Specially Formulated 100 Volume Solids (solventless) Two Component Epoxy Description As a epoxy primer in a 3 layer polyethylene coating system for superior corrosion protection of fi eld welded joints of steel pipes. S1401 can be used with Covalence 3 layer coating systems : HTLP80-HB, HTLP60-HB, DIRAX-HB, RPS as the initial anti-corrosion layer or as wear cones in the PPS120 system. ApplicationsAn epoxy in a 3 layer polyethylene coating system for superior corrosion protection of fi eld welded joints of steel pipes, S1401 can be used with Covalence 3 layer coating systems.


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B E R R Y P L A S T I C S C O R P O R A T I O N , C O R R O S I O N P R O T E C T I O N G R O U P Covalence® Heat Shrinkable Pipeline Coatings - Pipe Coating Repair Systems

Covalence PERP - Coating Repair System for HDD Description Repair system for damaged mill-applied PE coating. ApplicationsPERP is designed to repair the damaged areas on line coatings, mainly two or three-layer.

Features The PERP Repair System resists high shear forces and shows excellent adhesion to commercial polyethylene-based, mill-applied coatings Specifi c repair system, and therefore highly economical Maximum temperature 60ºC - 140ºF

Covalence PERP Meltstick - Coating Repair System (scratches only) Description PERP Meltstick is a heat-sensitive, PE copolymer-based stick used for small superfi cial, damage (scratches) to PE-coatings where the damage does not extend to the bare metal. ApplicationsPERP Meltstick is designed to repair the damaged areas on line coatings, mainly two or three-layer.

Covalence PERP80 - Coating Repair System Description The system consists of two components:

PERP fi ller PERP repair patch

ApplicationsPERP is designed to repair damaged areas in mill-applied PE coating on steel pipes and ductile cast iron pipes.

Features The PERP Repair System resists high shear forces and shows excellent adhesion to commercial polyethylene-based mill-applied coatings Specifi c repair system, and therefore highly economical Maximum temperature 80ºC - 176ºF



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B E R R Y P L A S T I C S C O R P O R A T I O N , C O R R O S I O N P R O T E C T I O N G R O U P Covalence® Heat Shrinkable Pipeline Coatings - Plant Applied Line Coatings

Covalence Rayclad 120 - Plant Applied Heat Shrinkable Pipeline Coating Tape Description Rayclad 120 hot-applied product coatings are designed to provide a continuous, holiday-free, permanent barrier, which affords long-term protection for high-temperature pipelines operating both on and offshore. ApplicationsRayclad hot-applied product coatings are designed to provide a continuous, holiday-free, permanent barrier which affords long-term protection for high-temperature pipelines operating both on and offshore.

FeaturesExtremely high shear resistance provides the strength required to soil-anchor hot pipelinesEase of installation. Rayclad is supplied as a complete coating ready to install May be transported with minimum damage, and resists backfi ll compaction and soil stresses without a rock shield Wide handling and operating temperature range Rayclad 120 may be handled at temperatures down to –40°C (–40°F) and comes in ormulations for pipelines operating to 80°C (176°F) and 120°C (248°F) Rayclad may be stored without shelf-life or gel-time limitationsHighly resistant to U.V. light, fungus and cathodic disbondment Maximum temperature 120ºC - 248ºF

Covalence Rayclad 80 - Plant Applied Heat Shrinkable Pipeline Coating Tape Description Rayclad 80 hot-applied product coatings are designed to provide a continuous, holiday-free, permanent barrier, which affords long-term protection for high-temperature pipelines operating both on- and offshore. ApplicationsRayclad 80 is designed to be applied as line coating on bare steel pipes to coat the entire pipe circumference.

Features Extremely high shear resistance provides the strength required to soil-anchor hot pipelines Ease of installation. Rayclad is supplied as a complete coating ready to install May be transported with minimum damage and resists backfi ll compaction and soil stresses without a rock shield Wide handling and operating temperature range. Rayclad 80 may be handled at temperatures down to –40°C (–40°F) and comes in formulations available for pipelines operating to 80°C (176°F) and 120°C (248°F). Rayclad may be stored without shelf-life or gel-time limitationsHighly resistant to UV light, fungus and cathodic disbondment Maximum temperature 80 ºC - 176ºF


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K E M A C O A T I N G S , I N C .Module Sealants (Macro-Polyisobutylene)

KEMA Module Sealants(Macro-Polyisobutylene)DescriptionKEMA Module Sealants are safe, easy-to use, long lasting, corrosion-resistant barrier coatings.

They are packaged in roll form and can be either wrapped onto the pipe, fi tting and assembly or cut into strips for fl at application to a clean substrate.

The aggressive bond of the adhesive is a result of the proprietary macro-polyisobutylene formulation that is further improved with the addition of special raw material enhancements.

The fi nished elastomeric adhesive comound exhibits very high tensile strength and a strong resistance to both cold fl ow and shear.

All Module Sealants are UV-resistant and well-suited for both above and below grade installations.

They are immune to the attck of anaerobic bacteria commonly found in soils worldwide and do not breakdown even after lengthy immersion.

KEMA Module Sealants offer the user a barrier coating that is resistant to a wide range of acid and alkali solutions as well as gases.

They are offered as either sealants or tapes in a variety of roll lengths, widths and thicknesses. The tapes are completed with a polyethylene (PE) fi lm bonded to one side. The PE fi lm is currently available in 5 mils. (127 ums) or 12 mils (304.8 ums) fi lm thicknesses.

KEMA Module Sealants are at work in the ice and snow of the Canadian North, the dry deserts of the Middle East and in the moist, humid coastal regions of Africa.

CharacteristicsColor: BlackV.O.C. Content: 0 (Zero)Viscosity: 99% Solid

Flash Point (min.): 204°C (400°F)Specifi c Gravity: 1.1 @ 25°C (77°F)

Shelf Life: 36 months unopened; Store indoors at 5°C - 38°C (41°F - 100°F)

Interleaf: Comprised of treated paper that is 1/2 inch / 12.7 mm wider that the tape wrap it protects. Biodegradable.

Primer: The use of a pre-approve liquid primer is recommended on all bare metal surfaces only. Contact Corrpro representative for more information.

Recommended UsesThermite welds on pipelines and tanksPipeline girth weldsStainless steel band weld coatingPipeline rehad coating transitionsGeneral pipeline coating repairTie-insNew pipeline coatingTemporary highway island transitionsAsphalt/concrete crack / gap repairsAdhesive strips for plastic film bondingInsulated spacers



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Standard Sizes and Part Numbers - 250 mils / 6.4 mm thick sealantItem Description Part Number

KEMA 250 4 in / 10 cm wide 752GHA760KEMA 250 6 in / 15 cm wide 752GHE760

KEMA 250-12 4 in / 10 cm widec/w 12 mils / 304.8 ums

PE fi lm on 1 sideKEMA 250-12 6 in / 15 cm wide

c/w 12 mils / 304.8 umsPE fi lm on 1 side

752GHA1760

Standard Sizes and Part Numbers - 60 mils / 1.5 mm thick sealantKEMA Series 60 4 in / 10 cm wideKEMA Series 60 6 in / 15 cm wideKEMA Series 60 4 in / 10 cm wide

c/w 5 mils / 127 umsPE fi lm on 1 side

KEMA Series 60 6 in / 15 cm widec/w 5 mils / 127 ums

PE fi lm on 1 sidePhysical Properties

Dielectric Breakdown VoltageASTM D149-97a (2004)

>20.000V Wet>10,000V Dry

Peel AdhesionCSA Z245.21 M98

Clause 12.4

22.7N

Cathodic DisbondmentCSA Z245.21 M98

Clause 12.3

0 (Zero)

Chemical Resistance1. Aqueous inorganic salts

2. Mineral acids including hydrofl uoric3. Sulfuric, Phosphoric and mixed acids

4. AlkalisService Temperature Ranges ASTM D1000

Above Grade Service -29°C - 121°F-20°C - 249°F

Below Grade Service -29°C - 90°F-20°C - 194°F

Application -7°C - 49°F-19°C - 120°F

CompatabilityBoth the KEMA 250 - 12 w/PE fi lm and the DEMA Series 60 w/PE fi lm can be used as topcoats over the KEMA

250 and the KEMA Series 60 sealants. They can also be used on all prepared metal surfaces. Aggressively bonds to itself, coal tar, asphalt, urethane, polyethylene, polypropylene, tapes, fusion bond epoxy and liquid

epoxy coated surfaces. Please contact Corrpro if your existing coating is not mentioned here.


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P R O S H I E L D Coiled Rockshield

The Best Coil Rockshield Protection for Steel or Plastic Pipe

FeaturesFlow through design does not impede cathodic protectionBest coil rockshield protection and support on the marketASTM G14 tested and proven

AvailabilityStock Sizes 1/4” Thickness

20” x 50’ 36’ X 50’25” x 50’ 44” x 50’32” x 50’ 48” x 50’

3/8” Thickness36” x 30’ 48” x 30’

Call Corrpro for specifi c sizes for your project.

ProShield Coil Rockshield is available in two thicknesses: 3/8” (left” and 1/4” right



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For Quality Pipeline Coating RepairsCathodic protection, combined with a quality coating, is the best defense for combating corrosion on buried pipelines. When anode and test leads are thermite welded to coated pipe, a small portion of the coating must be removed and should be repaired. To ensure these weld areas are properly recoated, Corrpro supplies proven Royston products. They include primers, mastics and repair tapes and wraps.

Royston Roybond® primers are the fi rst line of defense for pipeline repairs. They form a strong mechanical bond to steel and create an excellent base for a variety of coatings and tapes. Made from phenolic, synthetic resin, rubber and elastometic bases, the primers can withstand acids, alkalies and many corrosive chemicals.

For high dielectric protection Royston manufactures Roskote® mastics. Cold-applied and extremely moisture resistant, these mastics form a coating on pipelines that will not oxidize, alligator or crack. They are also formulated with superior mechanical properties to defend against abrasion.

When a thick corrosion resistant barrier is needed, Royston tapes and wraps should be used. They are

R O Y S T O N C O A T I N G A N D W R A P P R O D U C T S Royston Greenline Tape, Tac-Tape, Roybond 747, Roskote 216, Roskote A-51 and R-20

offered in a wide range of widths and are supplied with and without plastic laminated backings. Royston’s Tac-Tape® is a soft repair tape which is ideal for molding around irregular contours such as thermite welded connections.

Typical ApplicationsAny exposed metal area on a coated pipe can cause accelerated corrosion attack. Royston primers, mastics, tapes and wraps seal these areas to ensure buried pipelines are properly coated. They are designed for easy fi t applications and have a history of delivering long-life protection.

Ordering ProcedureCorrpro is an authorized Royston Distributor. To order the right Royston product for your particular application, indicate the product type, order number and quantity. An example is included to illustrate this process.

Ordering Procedure ExampleQuantity 4 GallonsProduct Royston Primer

Product Name Roybond 747

Royston Ordering InformationProduct Type of Material Unit Packaging Size Standard Order

QuantityGreenline® Tape Tape 2”, 4” and 6”

(50.8, 101.6m 152.4 mm)-

Tac-Tape® Tape 2” (50.8 mm)Wide Rolls 10 ft (15.2 mm)

8 rolls/ctn

Roybond® 747 Primer 16 oz (0.42 L)Spray Quarts and 1, 5, 55 Gallons

(3.8, 18.9, 208 L)

6-16 oz (0.15 - 0.42 L)Spray/ctn

6 Quarts (5.7 L)/ctn4 Gallons (15.1 L)/ctn

Roskote® 216 Mastic Coating 1 Gallon (3.8 L) Containers 4 Gallons (15.1 L/ctnRoskote® A-51 Mastic Coating 1, 5, and 55 Gallon

(3.8, 18.9, 208 L) Containers

4 Gallons (15.1 L)/ctn

R-28 Rubberized Mastic 1, 5, and 55 Gallon(3.8, 18.9, 208 L)

Containers

4 Gallons (15.1 L)/ctn


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R O Y S T O N C O A T I N G A N D W R A P P R O D U C T S Royston Tapecoat® Cold-Applied Tape Coatings

Tapecoat Gray TapesProtect Pipeline and Infrastructure from Corrosion

Tapecoat Gray coatings are innovative cold-applied tapes that exceed all previous performance criteria for the protection from corrosion of above and below ground pipelines, girth welds and fi ttings. Tapecoat incorporates a patented integrated primer into these protective tapes and eliminated the dangers of emissions and hazardous waste associated with the application of liquid primers. Tapecoat Gray can be applied over a wide range of ambient temperatures for the protection of most metal surfaces

Features Integrated Primer:

Replaces fl ammable and hazardous liquid primersEliminates VOC emissionsEliminates dangers of a toxic material spillEliminates need to dispose of hazardous wastesLabor-saving applicationAggressive tack gives consistent applicationSuccessfully tested by independent labs

Adhesive Coating:Aggressive bond to steel and other metal substratesCohesive strength as well as fl exibilityExcellent resistance to cathodic disbondment

MAF® Backing:(H35 Gray/ H50 Gray)

Pulls tight around fi ttings and irregular shapesFormulated for durabilityThermally stableAbrasion resistantUV resistant

Tapecoat H50 Gray cold-applied above and below ground coating in tape form with an integrated primer. Tapecoat H35 Gray and Tapecoat H50 Gray are designed to protect above and below ground metal surfaces from corrosion and electrolysis. They are used for coating pipe, girth welds, fi ttings, couplings, tanks, pipetype cable, conduit, tie rods, elevator casings and other metal surfaces. Their unique MAF® backing has been specially formulated to provide strength that allows it to be pulled tightly around fi ttings and other

irregular shapes with minimal pull back due to memory. Tapecoat H35 Gray and Tapecoat H50 Gray employ an integrated primer and are resistant to UV rays, thermal expansion, impact and abrasion. Both tapes can be applied over a wide range of ambient temperatures.

CompositionTapecoat H35 Gray and Tapecoat H50 Gray are composed of a Gray specially formulated MAF backing with a synthetic elastomeric adhesive. Impregnated into the adhesive is an integrated primer.

Technical DataColor: GrayShelf life: Rotate stock yearlyStandards: AWWA C-209Recommended for use with: Coal Tar, Extruded Polyethylene, FBE, 3 Layer Systems, Coal Tar and Urethane Plant CoatingsLow temp fl ex: ExcellentBacteria resistance: ExcellentThickness: H35 35 ± 2 milsH50 50 ± 2 milsTests: ASTM D1737, ASTM G22,ASTM D1000, ASTM G8.

Surface PreparationSurface must be clean and dry. SSPC-SP3 Power Tool Cleaning is recommended to remove any loose rust and scale, dust or dirt. A “Tack Cloth” for removal of fi ne dust particles is provided in each carton. Oil, grease and all other residue are to be removed from pipe surface per SSPC-SP1 Solvent Cleaning. SSPC-SP6 Commercial Blast Cleaning is optional.

Tapecoat H35 Gray and Tapecoat H50 Gray are impregnated with an integrated primer.

Tape ApplicationSpiral Wrap: Tapecoat H35 Gray and Tapecoat H50 Gray are hand applied by removing the release liner and spiral wrapping with a continuous overlap of tape. Tension in wrapping should be enough to obtain conformability to the surface being coated.



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Cigarette Wrap: Pre-cut strips of Tapecoat H35 Gray or Tapecoat H50 Gray to a length equal to the circumference of the pipe plus a minimum of 4”. Follow general tape applications described above.

Option: Tape wrapping machines available upon request.

Tapecoat® HT/ MBHigh Temperature Mesh Fabric Coating

Tapecoat HT/MB High Temperature Coating exceeds all performance criteria for prevention of corrosion of buried pipelines, pipe joints/fi ttings, and other metal surfaces.

Tapecoat HT/MB and TC 7030 are recommended for use on high-temp pipelines with a maximum constant operating temperature of up to 310° F (154 °C).

Tapecoat HT/MB works best when used with high-temp TC 7000 Epoxy Primer.

Tapecoat HT/MB is a 40 mil coating, applied with a 50% overlap, for below grade application. Tapecoat HT/MB is a cold-applied, self-adhering coating that is impermeable to water and salt. An aggressive high temperature adhesive is laminated to the HT/MB polypropylene mesh backing. The woven mesh backing gives the coating added strength against soil stress. Appropriate for coating below grade pipe with operation temperatures up to 300oF. Use TC OMNIPRIME primer when operation temperatures will not exceed 180°F; use TC 7000 EPOXY as a primer for operation temperatures to 300°F.

Tapecoat® M50 RC Gray A heavy-duty below ground pipeline recoating material in tape form with an integrated primer. Tapecoat M50 RC Gray is designed to protect below ground metal surfaces from corrosion and electrolysis. It is used for coating pipe, girth welds, fi ttings, couplings, tanks, pipe type cable, conduit, tie rods, elevator casings and other metal surfaces. Tapecoat M50 RC Gray is resistant to thermal expansion, impact and abrasion and employs an integrated primer.

Technical Specifi cations

CompositionTapecoat M50 RC Gray is a pre-formed, cold-applied coating. The adhesive is manufactured from specially formulated elastomer and resins bonded to a woven highly puncture-resistant polymer. Impregnated into the adhesive is an integrated primer.

Technical DataColor: GrayShelf life: Rotate stock yearlyStandards: AWWA C-209Recommendedfor use with: Coal Tar, Extruded Polyethylene, FBE, 3 Layer Systems, Coal Tar and Urethane Plant CoatingsLow temp fl ex: ExcellentBacteria resistance: ExcellentThickness: 50 ± 2 milsTests: ASTM D1737, ASTM G22, ASTM D1000, ASTM G8.

Surface PreparationSurface must be clean and dry. SSPC-SP3 Power Tool Cleaning is recommended to remove any loose rust and scale, dust or dirt. A “Tack Cloth” for removal of fi ne dust particles is provided in each carton. Oil, grease and all other residue are to be removed from pipe surface per SSPC-SP1 Solvent Cleaning. SSPC-SP6 Commercial Blast Cleaning is optional.

Tapecoat M50 RC Gray is impregnated with an integrated primer.

Tape ApplicationSpiral Wrap: Tapecoat M50 RC Gray is hand applied by removing the release liner and spirally wrapping with a continuous overlap of tape. Tension in wrapping should be enough to obtain conformability to the surface being coated.

Cigarette Wrap: Pre-cut strips of Tapecoat M50 RC Gray to a length equal to the circumference of the pipe plus a minimum of 4”. Follow general tape applications above.


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Tapecoat 6025 Gray High Temperature TapeCold-applied coating, in tape form, for use in high temperature pipeline Tapecoat 6025 Gray High Temperature tape with a MAF backing is designed to protect above and below ground pipe, pipe-type cable, girth welds, fi ttings, tanks, insulated steam lines, and other metal surfaces from corrosion and electrolysis over a wide range of in-service temperatures up to as high as 250°F (121°c) in constant or peak load operating conditions. Tapecoat 6025 Gray and TC Omniprime may be applied to new pipelines and to pipelines in service operating at elevated temperatures.

CompositionTapecoat 6025 Gray is composed of a specifi cally formulated MAF backing and a synthetic elastomeric, temperature resistant coating.

Technical DataService temp: -30°F to 300°F (-35 to 125°C)Application temp: -30 to 185°F (-35 to 85°C)Total thickness: 25 mils (0.63 mm)Adhesion (primed steel): 250 oz/inch width (2.79 kg/cm width)Elongation: 300%Tensile strength: 50 lb/inch width (8.95 kg/cm width)Dielectric strength: Exceeds 12 KVSalt crock test: PassInsulation resistance: 106 megohmsWater vapor trans rate: 0.01-0.20 g/100 inch2/24 hr (0.15-3.10 g/m2/24 hr)Tests: ASTM G6, ASTM G20, ASTM G42, ASTM G14, ASTM G11, ASTM D1000.

Surface PreparationSurface must be clean and dry. SSPC-SP3 Power Tool Cleaning is recommended to remove any loose rust and scale, dust or dirt. Oil, grease and all other residue are to be removed from pipe surface per SSPC-SP1 Solvent Cleaning. SSPC-SP6 Commercial Blast Cleaning is also acceptable.

Priming: If operating temperatures do not exceed 180°F (85°C) TC Omniprime is the primer of choice. TC 7000 Epoxy has been developed specifi cally for use with Tapecoat 6025 Gray when service temperatures are between 180°F and 300°F (85-125°C). Either

primer may be hand applied by brush or roller. Let TC Omniprime or TC 7000 Epoxy dry to the touch before applying Tapecoat 6025 Gray.

Tape ApplicationTapecoat 6025 Gray is applied by hand, with the Tapecoat Hand Wrapster #3, or by plant or over-the-ditch tape wrapping methods. Tapecoat 6025 Gray is spirally wrapped in two layers. Wrapping tension is to be maintained to obtain conformability of the tape to the surface being coated.

Tapecoat T Tape GPE - Cold-Applied TapeCoating A 65 mil coating with a 3 mil polyethylene backing and 62 mils of adhesive for ambient temperature, below grade application. The 62 mil adhesive provides T Tape with a high degree of conformability. Appropriate for coating tees, bends and other irregular confi gurations, such as weld beads, wire connections, thermite welds and all smaller diameter piping.

Tapecoat CT - Cold-Applied Tape Coating TAPECOAT CT - a 35 mil cold-applied tape coating with a 7 mil polyethylene fi lm backing and 28 mils of adhesive, for ambient temperature below grade application. Appropriate for coating small to moderate size pipe with a single layer; a 50% overlap may be preferred when coating larger diameter pipe.

Tapecoat Grey Pad - Cold-Applied Mesh Backed Tape Coating A 65 mil coating, packaged in 6 X 6 pads, with a polypropylene mesh fi ber backing and pressure sensitive adhesive; used for easy application as a protective coating on small holidays, wire splices and thermite welds.

Royston One Step Tape A 35 mil, primerless, cold-applied tape coating with a 6 mil UV resistant polyethylene fi lm backing for ambient temperature above and below grade application. Color: Green.

R O Y S T O N C O A T I N G A N D W R A P P R O D U C T S Royston Tapecoat® Cold-Applied Tape Coatings



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TR Green A 35 mil cold-applied tape with a fl exible plastic backing and an elastomeric adhesive, for ambient temperature below grade application. Greenline Tape has a leading adhesive edge to secure the lap seal and guide in spiral wrap applications. Color: Green.Compatible primer: ROYSTON ROYBOND 747.

Tapecoat HT Sealant A conformable water tight coating for irregular surfaces which may be subjected to temperatures up to 300 degrees F (150 degrees C).

Royston Sealant TapesA moldable synthetic elastomeric adhesive that is specially formulated with different degrees of tack and pliability to accommodate the particular application need such as for sealant, caulking, insulation or waterproofi ng.Compatible primer: ROYSTON ROYBOND 747.

Tape A (Mil Thickness) A sealant tape with a moderate degree of tack and pliability.

Tape C (Mil Thickness) aka. TAC-TAPE at 125 mils- a sealant tape with a high degree of` tack and pliability.

Special coatings and repair kits:

Handy Cap Standard A 4” X 4” exothermic weld coating system used in conjunction with ROYSTON Roybond 747 Primer. 747 Primer is available in aerosol dispensers or standard size liquid containers.

Tapecoat Reinforcing Scrim A polypropylene cloth material used as an optional reinforcing wrap to increase the impact resistance of liquid coatings. Packaged in rolls 2”, 4” and 6” x 100’.

Tapecoat TC Flo-Coat - Petrolatum Wax System A corrosion preventive coating paste to fi ll and coat irregular contours.

Tapecoat TC Mastic A thixotropic brush applied coal tar coating for ambient temperature, below grade application. Appropriate for coating fi ttings, fl anges, valves, mechanical couplings and other irregular confi gurations.

Tapecoat TC Mastic 2000 A brush or spray applied bituminous coating for temperatures up to 250°F, below grade application. Appropriate for coating fi ttings, fl anges, valves, mechanical couplings and other irregular confi gurations. Tapecoat TC Aluminum Mastic A brush or spray applied aluminum pigmented bituminous coating for ambient temperature, above or below grade application. Appropriate for coating fi ttings, fl anges, valves, mechanical couplings and other irregular confi gurations. Operation temperature ambient to 250°F. Royston Roskote A51 A hydrocarbon resin base mastic coating system for ambient temperature, below grade application. Appropriate for coating fi ttings, fl anges, valves, tanks, mechanical couplings and other irregular confi gurations.Compatible primer: ROYSTON RAPID RED

Roskote 201 A coal tar epoxy coating is a cold-applied, 2 component, polyamide cured, coal tar epoxy for above and below ground protection in severely corrosive environments. Through chemical cross linking, forms a tough adhesion resistant coating to withstand physical damage, impact, temperature variations and underground soil stresses.

Accessories

Tapecoat Hand WrapsterA cold tape hand operated application tool, which can assist the operator in wrapping tape with the proper tension and overlap for piping 4” OD and above.


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R O Y S T O N C O A T I N G A N D W R A P P R O D U C T S Royston Hot-Applied Tape and Epoxy Coatings

Heat Application ToolPropane Torch KitThe Magnum Torch with self-contained torch ignition is a wide mouth propane torch for applying hot applied tapes and sleeves. The kit comes complete: 16” handle torch with igniter, burner head, regulator and 33’ long hose.

TC® 7000 High Temperature EpoxyTwo Applications in One ProductTC 7000 Epoxy is a surface tolerant two component 100% solids material that replaces VOC base primers. It is manufactured to be used as a one coat wet or dry primer with Tapecoat hot and cold-applied tapes.

TC 7000 can also be applied as a stand alone coating for use on metal surfaces. This coating offers exceptional fl owability with self leveling attributes. This product can be used above or below ground.

Use as a primer prior to wrapping with Tapecoat hot or cold-applied tapes.

As a coating use alone as a coating on metal surfaces or use with our new polyethylene scrim wrap, which adds reinforcement and impact resistance.


Technical DataColor: RedPot Life: 15 to 20 minutes @ 70°F (121°C) and 50% relative humidity (R.H.)

Max. Constant Operating Temperature 250°F (121° C)VOC’s: ZeroMix Ratio: 3.54:1 by volumeNo Red Label required

Application Parameters:Environment: Use only when the surface to be coated is above 40°F (4°C) and the relative humidity (R.H.) is less than 90%.

Application Surface Temperature: 40°-250°F (4°-121°C). Surface temperature must be 5°F (3°C) above the dew point to avoid condensation.

Cure Time: 60 to 90 minutes @ 70°-80°F (21°-27°C) and 50% R.H. Cure time can be accelerated by preheating the metal surface to 100°-200°F (38°-93°C).

ApplicationSurface must be clean and dry. Commercial blast to SSPC-SP6. Remove oil and grease with suitable solvent. Salt and other contaminants may be removed by high pressure fresh water cleaning.Pour entire contents of Part B Curing Agent (small container) into Part A Resin (large container) and mix thoroughly, approx. 3-5 minutes.Do not alter the amounts of A and B in the mixture. Apply epoxy by brush, pad, roller or spray.Primer should be dry to touch before applying Tapecoat hot-applied tapes or sleeves. As a stand alone coating, TC 7000 Epoxy provides superior corrosion protection above and below ground.Specially selected Tapecoat reinforcing scrim can be applied over wet epoxy. After scrim is applied, apply a second application of TC 7000 Epoxy.

Recommended CoverageAs a 1 coat primer: 6-10 mils thickness, with a coverage of 220 sq. ft. per mixed gallon (m2/liter=5.4 m2/liter). As a single coat stand alone coating: 20 mils (.5mm) thickness, with a coverage of 80 sq. ft. per mixed gallon (m2/liter=1.96 m2/liter). As a 2 coat stand alone coating, with scrim: 16-30 mils (.41-.76 mm) thickness (2 coats of 8-15 mils (.20-.38 mm) each).

TC® 7030 High Build High Temperature EpoxyProtect Pipelines Joints and FittingsA one coat, stand alone protection that exceeds all performance criteria for prevention of corrosion of above and below ground metal surfaces. This tough coating can be used for any general application including high temperature pipelines with a maximum constant operating temperature of up to 250°F (121°C).



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TC 7030 is an environment-friendly two component, 100% solids material that provides up to 30 mils of high build thickness for tough abrasion resistance to backfi ll and soil stress damage. This surface tolerant epoxy provides exceptional corrosion prevention for reconditioning pipelines, protecting joints, patching pipeline coatings, and covering irregular fi ttings and metal surfaces.


Technical DataColor: Red. Additional colors available upon request.Pot Life: 15 to 20 minutes @ 70°F (121°C) and 50% relative humidity (R.H.)Max. Constant Operating Temperature 250°F (121° C)VOC’s: ZeroMix Ratio: 3.6:1 by volumeNo Red Label required

ApplicationSurface must be clean and dry. Commercial blast to SSPC-SP6. Remove oil and grease with suitable solvent. Salt and other contaminants may be removed by high pressure fresh water cleaning.Pour entire contents of Part B Curing Agent (small container) into Part A Resin (large container) and mix thoroughly, approx. 3-5 minutes.Do not alter the amounts of A and B in the mixture. Apply epoxy by brush, pad, roller or spray.Primer should be dry to touch before applying Tapecoat hot applied tapes or sleeves. As a stand alone coating, TC 7030 Epoxy provides superior corrosion protection above and below ground.Specially selected Tapecoat reinforcing scrim can be applied over wet epoxy. After scrim is applied, apply a second application of TC 7030 Epoxy.

Application ParametersEnvironment: Use only when the surface to be coated is above 40°F (4°C) and the relative humidity (R.H.) is less than 90%.Application Surface Temperature: 40°-250°F (4°-121°C). Surface temperature must be 5°F (3°C) above the dew point to avoid condensation.

Cure Time: 60 to 90 minutes @ 70°-80°F (21°-27°C) and 50% R.H. Cure time can be accelerated by preheating the metal surface to 100°-200°F (38°-93°C).

Recommended Coverage: A single coat stand alone coating: 30 mils (.76mm) thickness, with a coverage of 53 sq. ft. per mixed gallon (m2/liter=1.23 m2/liter)

TC® 7100 Wet Bond Gray Epoxy Corrosion Protection for Fresh Water Wet Surfaces. TC® 7100 Wet Bond Gray Epoxy is a surface tolerant epoxy developed for coating metal and concrete above and below fresh water.

TC 7100 provides an exceptional anti-corrosion coating for protecting bare steel, welded joints on factory-coated pipe, irregular fi ttings and surfaces. This innovative coating can be applied underwater for the repair of damaged coatings on steel transmission pipes; steel, concrete, and sheet pilings; and lateral supports.TC 7100 is ideal for above and below ground protection of metallic surfaces on pipes and compressor / pumping stations that endure splashes, condensation, or humidity.

TC 7100 Wet Bond Gray Epoxy (Color Gray) - a two part liquid epoxy system. Used on damp, wet or dry metal surfaces as a one-coat stand-alone protective coating system for above and below grade application. Technical Specifi cations Wet Surface ApplicationTC 7100 is an environment-friendly two component, 100% solids material. A single application to a wet surface can provide in excess of 20 mils of high build thickness for tough abrasion resistance. This wet bond epoxy can be fi eld-applied as a single or multiple coating above and below fresh water with a paint brush or roller after normal surface preparation.

Basic UseTC 7100 Wet bond-Gray is a corrosion preventive epoxy coating developed for coating metal and concrete surfaces above and below the water line. It is used to repair pipeline coatings, for coating irregular fi ttings and surfaces and is suitable for above and below ground as well as underwater applications.

CompositionTC 7100 Wet Bond-Gray is a unique modifi ed amine cured epoxy coating with a 100% solids content.


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TC Wet Bond Flexible Epoxy Mastic®Corrosion Preventive Coating for Wet SurfacesTC Wet Bond Flexible Epoxy Mastic® is a corrosion preventive epoxy coating developed for coating metal and concrete surfaces above and below the water line. This protective epoxy is also suitable for wet surfaces above and below ground and for underwater applications in fresh water environments.

It can be used to repair pipeline coatings, for coating irregular fi ttings and surfaces, and to perform general maintenance coatings repair in regulator vaults. TC Wet Bond Flexible Epoxy Mastic is ideal for the repair of damaged plant-applied coatings including coal tar enamel.


CompositionTC Wet Bond-Flexible Epoxy Mastic is a unique modifi ed amine cured epoxy coating with a 100% solids content.

Technical Data (at 40 mils)VOC: O lbs /gal (kg/L)Solids: 100% by volumeCoverage: 40ft2/gal (40 mils) ( m2/liter)=1.0 m2/liter (1.0mm)Color: Gray or BlackCuring time @ 70°F: 4 to 8 hoursApplication temp: 40-120°F (4-49°C)Operating temp: -40-165°F (-40-74°C)Thickness: 40 mils (10 mm)Weight per gallon: 10.6 lbsResin: 11.2 lbs / (kg)=5.0 kgHardener: 8.3 lbsShore A-2 Durometer: 90 to 100

Surface PreparationRemove all contaminants that would impede bond. Use effective cleaning procedures to remove: rust, dirt, oil and grease. This may include the use of high-pressure fresh water cleaning, using suitable solvents or detergents to SSPC-SP 1 or abrasive blast to SSPC-SP 6.

ApplicationEnvironment: Use only where application and curing can proceed at temperatures above 40ºF (4ºC). The temperature of the surface and that of the coating itself must also be within these limits. Apply only on a clean surface. (See detailed Field Specifi cations for complete instructions.)Mixing: Pour entire contents of hardener container into the resin container and mix thoroughly until homogeneously mixed, approx. 3-5 minutes.Application Method: Apply epoxy by brush or pad.

TC® 7010 Fast Set Epoxy Field Applied Joint Epoxy for Plant Coated Pipe TC® 7010 Fast Set Epoxy is a high-build, surface tolerant coating that exceeds all performance criteria for the protection from corrosion of above and below groundpipelines.

TC 7010 provides exceptional corrosion prevention for protecting joints, patching pipeline coatings, and covering irregular fi ttings and metal surfaces. This innovative product can be used in conjunction with all factory and fi eld coatings, such as cold and hot-applied tape, coal tar enamel, extruded polyethylene, and fusion bonded epoxy.

TC 7010 Fast Set Epoxy is a two part liquid epoxy system. Used as a one-coat stand-alone protective coating system for above and below grade application on dry substrates.Tapecoat 7010 Fast Set Gray Epoxy eliminates the complex and lengthy application process required for fi eld-applied powder epoxy coating of welded joints.

TC 7010 is an environment friendly two component, 100% solids material that provides up to 30 mils of high-build thickness for tough abrasion resistance to backfi ll and soil stress damage. This fast-set epoxy also decreases lengthy fi eld application by accepting backfi ll after only 2 hours of cure time.




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Technical Specifi cation Basic UseTC 7010 FS-Gray is a corrosion preventive epoxy coating developed for coating joints, patching pipeline coatings and coating irregular fi ttings and surfaces; suitable for above and below ground applications.

CompositionTC 7010 FS-Gray Epoxy is a modifi ed amine cured epoxy coating with 100% solids content.

Technical Data: (at 20 mils)VOC: 0 lbx/gal (0 kg/l)/(.5mm)Solids: 100% by volumeCoverage: 80 ft2/gal (20 mils)/(1.96 m2/liter) (.5mm)

Color: GrayCuring time @ 70°F: 2 hours to backfi llApplications temp: 40-120°F (4--49°C)Operating temp: -40 to 165°F (-40 to 740C)Thickness: 20 mils (.5 mm)Weight per gallon: 12 lbs. (5.4kg)

Surface PreparationRemove all contaminants that would impede bond. Use effective cleaning procedures to remove: moisture, salts, rust, dirt and dust, oil and grease. This may include the use of high pressure fresh water cleaning, using suitable solvents or detergents to SSPC-SP-1 or abrasive blast to SSPC-SP-6.

ApplicationEnvironment: Use only where application and curing can proceed at temperatures above 40°F (40°C). The temperature of the surface and that of the coating itself must also be within these limits. Apply only on a dry and clean surface with a temperature above the dew point to avoid condensation. Relative humidity maximum is 90% preferably between 40-60% (See detailed fi eld specifi catons for complete instructions.)

Mixing: Pour entire contents of Part A and Part B into a separate container (furnished in the kit) and mix thoroughly until homogenously mixed, approx. 2-3 minutes.

Application Method: Apply epoxy by brush, pad or roller.

Royston Black TackA fast drying (under 5 minutes) rubber-resin base adhesive, carried in petroleum solvents. It is used as a

corrosion resistant adhesive for bonding Royston Quick Seal Tape Wrap to steel pipe.Black Tack provides a strong bond between Quick Seal Tape Wrap and all of the various surfaces commonly encountered in underground service. It increases adhesion or pressure-sensitive polyethylene tapes.

Where to use it:Royston Black Tack is recommended for use with commercially available pressure sensitive tapes used for corrosion protection of buried piping systems. It is formulated to provide superior performance in its intended use. Black Tack is specifi cally formulated for bonding Quick Seal Tape Wrap. Its suitability with other tape and wraps should be tested prior to use.

How to use it:Handling Precautions: Royston Black Tack is a fl ammable mixture which should be kept away from heat and open fl ame. Prohibit welding sparks and smoking. Contains aliphatic and aromatic solvents. Avoid prolonged or repeated breathing of vapors or fumes. Avoid contact with skin. Harmful or fatal if swallowed. If swallowed do not induce vomiting. Call physician immediately. Keep out of reach of children.

MixingThe only mixing required is thorough agitation prior to use. This is necessary to insure adequate redispersion.Surface Preparation: Surfaces should be dry and cleaned of all rust, scale, soil, mud, oil, grease and other contaminants by wire brushing, blasting or other methods. Mil applied coatings and pipe wraps should be dry and free from mud, soil, dust and oil.

ApplicationRoyston Black Tack may be applied by brush, spray or roller without thinning. Brushes my be cleaned in mineral spirits or xylene. Tape applications may be made as soon as the surface is dry to the touch.

CoverageCoverage of Black Tack on metal surfaces is 308 square feet per gallon at 1 mil dry fi lm thickness. Allowances must be made for rough surfaces and application losses which will reduce coverage.

Physical PropertiesColor: Black Solids %: By weight: 24.5% By Volume: 19.2% Weight: 6.7 lbs. per gallonViscosity: Approx. 380 cps@ 77˚F VOC: 607 g/l or 5.06 #/gal Shelf Life: Over 6 months


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Test Data: NA

Ordering Information: - Royston Black Tack is available in one-gallon cans, packaged 4 per carton.

Royston Roybond 747An elastomer-resin based formulation used as a corrosion resistant adhesive for adhering Royston Greenline Accessory Wrap to both metallic and non-metallic surfaces for underground service.

What it does:Royston Roybond 747 provides a strong bond between Greenline Wrap and all of the various surfaces commonly encountered in underground service. Its high degree of corrosion resistance enhances salt crock performance and maintains excellent adhesion under adverse environmental conditions. Its heavy consistency retards settling in the container yet allows easy brush-on for thin fi lm coverage.

Royston Roybond 747 should be used to adhere Greenline Accessory Wrap to the following substrates commonly used underground:

Steel and galvanized metalExtruded polyethylene and polypropyleneCoal tar and asphalt enamels - Micro crystalline waxThermoplastic and thermoset thin fi lm coatingsLaminated and extruded pipe wraps

Royston Roybond 747 is formulated for bonding Royston Greenline Wrap. Its suitability with other tapes and wraps should be tested prior to use.

Roybond 747 settles very slightly on standing. If there is an accumulation of solvent at the top of the container, stir lightly to reach a smooth, creamy consistency.

Surface PreparationSurfaces should be dry and cleaned of all rust, scale, soil, mud, oil, grease and other contaminants by wire brushing, blasting or other methods. Mil applied coatings and pipe wraps should be dry and free from mud, soil, dust and oil.

Application:Roybond 747 may be applied by brush or roller without thinning. It must be brushed out to a thin fi lm not more that 1 1/2 mils dry thickness. Do not apply too thick Roybond 747 will brush out readily to the desired thin fi lm.

Application Temperature:Pipe heated by welding should be allowed to cool to 120˚ to 140˚F before applying Roybond 747. Application may be made at temperatures below 0˚F, but condensation of moisture must be guarded against at low temperatures.

Drying Time:For rapid bond development Roybond 747 should be allowed to dry to a non-glossy appearance before applying Greenline. This will require only one to fi ve minutes depending on variable application conditions Bond development over semi-dried Roybond 747 is delayed somewhat, and over wet Roybond 747 is delayed as much as 24 hours.

Coverage:Coverage of Roybond 747 on metal surfaces is 300 to 400 square feet per gallon at 1 to 1 1/2 mil dry fi lm thickness. Allowances must be made for rough surfaces and application losses which will reduce coverage.One gallon of Roybond 747 to three squares of Greenline is a good rule of thumb.

Physical Properties:Composition: Elastomer-resin based formulation in blended solvent system Color: Black Viscosity: 8500 cps typical Weight: 8.1 +/- 0.02 lbs per gallon Specifi c Gravity: 0.97 Percent Solid: By Volume: 29% By Weight: 38.7% +/- 1% Flash Point: 38˚F Seta Flash Closed Cup Shelf Life: At least one year

Test Data: N/A




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Ordering Information:Royston Roybond 747 is available in one quart and one gallon metal cans, in fi ve gallon steel pails and in fi fty-fi ve gallon steel drums. Quart cans are packaged six per carton and gallons four per carton. It is also available in a 16 ounce (by weight) aerosol Spray-Pac, packaged 12 per carton.

TC® 7025 Ez Flow EpoxyField Applied Joint Epoxy for Plant Coated PipeTC® 7025 Ez Flow Epoxy is a versatile liquid epoxy for the protection of pipe and metal structures from corrosion in both above and below grade environments.

TC 7025 serves as an outstanding corrosion preventive coating for reconditioning pipelines, coating joints, coating repairs, and coating irregular bends and fi ttings. It can be applied to a dry, properly prepared surface, either manually or with the use of a power spray unit designed for such purpose.

This two part liquid epoxy system can be used as a one-coat stand-alone protective coating, isolating the metal substrate from the detrimental effects of electrolysis. An environmentally friendly,100% solids coating that contains no VOC’s, (volatile organic compounds).TC 7025 provides a thickness up to 25 mils providing a tough resistant barrier when exposed to backfi ll and soil stress. EZ FLOW EPOXY provides an EZ alternative to the complex and lengthy application process of fi eld-applied powder epoxy coatings.


Basic UseTC 7025 is a versatile liquid epoxy for the protection of pipe and metal structures from corrosion in both above and below grade environments.

Composition:TC 7025 is a modifi ed amine cured epoxy coating with 100% solids content.

Technical Data:VOC: 0 lbx/gal (0 kg/l)/(.5mm)Solids: 100% by volumeCoverage: 64 ft²/gal (25 mils)/(1.57 m2/liter) (.635mm)Color: Charcoal Gray

Curing time @ 70°F:3 to 4 hours to backfi llApplications temp: 40° to 120°F (4° to 49°C)Operating temp: -40° to 165°F (-40° to 74°C)Thickness: 25 mils (.635mm) Weight per gallon: 13.6 lbs. (6.16 kg)

Surface Preparation:Use effective cleaning procedures remove all contaminants that would impede bond, to include moisture, salts, grease and any loose material. This may include the use of high pressure fresh water cleaning, using suitable solvents or detergents.

The surface must have a 2.5 to 4 mil surface profi le. This can best be accomplished using a SSPC-SP-6 abrasive blast or better.

Environment: Use only where application and curing can proceed at temperatures above 40°F (4°C). The temperature of the surface and that of the coating itself must also be within these perimeters. Apply only on a dry and clean surface with a temperature above the dew point to avoid condensation. Relative humidity maximum is 90% preferably between 40-60%.

Mixing: Mix the entire contents of the hardener into the resin container and mix thoroughly until thoroughly mixed (approx. 2-3 minutes).Application Method: Apply epoxy by pad, brush or roller. TC 7025 is also available in a spray grade.

Tapecoat® Reinforcing Scrim A polypropylene cloth material used as an optional reinforcing wrap to increase the impact resistance of liquid coatings. Packaged in rolls 2’, 4’ and 6’ x 100’

Tapecoat® Enviroshield® Series R The TC Enviroshield Series R module is designed for the maximum protection of offshore platform risers and lateral beams from the harsh marine environment. This easy fi eld-applied modular system provides abrasion and corrosion protection of existing and new marine structures. A tough outer abrasion-resistant jacket activates an encapsulating environmentally-safe petrolatum with the tensioning of an easy-installation closure system. The TC Enviroshield allows for quick reinspection and easy accommodation of lateral braces, peripheral beams and weld-attached anodes. This easy fi eld-applied protection can be installed in and out of the water on a wet or dry minimally prepared surface.


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The TC Enviroshield Series R module is an easy fi eld-applied maximum marine protection system. The Series R module provides proven corrosion protection, re-inspection capability, aesthetic appearance, accommodation for lateral braces and environmental sensitivity.

Factory assembled for fi eld installation Install on minimally prepared surface Apply to wet, dry, or underwater surface Inner petrolatum mat encapsulates and seals substrateTough multi-layer urethane outer jacket Composite tensioning closure system forces petrolatum into pores of surfaceNo metal components No hand tapping or exterior bands Re-inspectable Available in 5 ft. and 2.5 ft. length with a 3 in. overlap for longer requirements




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R O Y S T O N C O A T I N G A N D W R A P P R O D U C T S Royston Petrolatum Wax Systems

Tapecoat® Envirotape®TC Envirotape is a prefabricated petrolatum coating in tape form designed to protect wet or dry irregularly shaped metal surfaces. Ideal for valves, fl anges, fi ttings, vaults, manholes and tunnels or other areas where continuous moisture levels make normal coating material diffi cult or impractical to apply. Recommended for use with: bare metal, wood and concrete. Compatible with asphalt, coal tar, polyethylene, polypropylene, FBE and urethanes

Technical Information StandardsANSI/AWWA C-217Color: Grayish brownThickness: 50 mils minimumBacteria resistance: ExcellentLow temperature (ASTM D-1737): ExcellentOperating temperature: 150°F (65°C)Operating temperature HT: 200°F (93°F)Shelf life: Rotate stock yearly

ApplicationTape is wrapped around the irregular shape and hand molded to conform to the shape of the surfaces being coated. The fi nished coating will be over wrapped with TC Stretch Outerwraps for below ground or TC Enviro-Hardcoat for above ground applications.

® ®

PackagingPackaged in bulk cartons containing 200 square feet in widths of 2”, 4” or 6”. Also available in special TC Enviro-packs which contain 50 square feet plus 1 pint of TC Enviroprime, gloves, 1 pint of TC Enviro-Hardcoat and 1 roll 4” x 200’ of TC Stretch Outerwrap.

Envirocoat® System Enviroprime® Tapecoat Enviroprime is a petrolatum based primer that exhibits preferential wetting capabilities to readily coat wet or dry surfaces and cavities prior to the application of TC Envirocoat products.

Technical Information Standards: ANSI/AWWA C-217Color: YellowSpecifi c gravity: 0.8 - 0.9Thickness: Apply to 2 mils minimum

ApplicationApply by hand to assure preferential wetting of the surface above or below the water line to a minimum thickness of 2 mils (.002”).

PackagingPacked in cartons of 2 or 4 one gallon cans, 12 one quart cans or in 5 gallon pails.

Envirocoat® System Envirostretchwrap®Tapecoat Envirostretchwrap is a clear fl exible plastic fi lm designed to provide extra mechanical protection for surfaces coated with TC Envirotape. It may be used below ground in industrial and commercial settings such as refi neries, petrochemical plants, pulp mills and gas and water utilities.

Technical Information Standards ANSI/AWWA C-217Color: ClearThickness: 1 mil (.001”)Application temperature: Above 20°F (-6°C)Operating temperature: -40 to 165°F (-40 to 73°C)


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ApplicationApply to conform to TC Envirotape-wrapped surface for additional mechanical strength prior to back fi lling.

PackagingAvailable in rolls of 4” and 6” widths in 200’ or 1,000’ lengths.

TC Enviroseal Mastic®TC Enviroseal Mastic is a specially formulated polymer emulsion that provides a protective outer shell or top-coating suitable for both industrial and commercial settings. Recommended for above-ground applications in refi neries, petrochemical plants, pulp mills, gas and water utilities, and other facilities where TC Envirotapes are used.

Technical Information StandardsANSI/AWWA C-217Color: Grayish brownThickness: 50 mils minimumBacteria resistance: ExcellentLow temperature (ASTM D-1737): ExcellentOperating temperature: 150°F (65°C)Operating temperature HT: 200°F (93°F)Shelf life: Rotate stock yearly

ApplicationTape is wrapped around the irregular shape and hand molded to conform to the shape of the surfaces being coated. The fi nished coating will be over wrapped with TC Stretch Outerwraps for below ground or TC Enviro-Hardcoat for above ground applications.

PackagingPackaged in bulk cartons containing 200 square feet in widths of 2”, 4” or 6”. Also available in special TC Enviro-packs which contain 50 square feet plus 1 pint of TC Enviroprime, gloves, 1 pint of TC Enviro-Hardcoat and 1 roll 4” x 200’ of TC Stretch Outerwrap.

Tapecoat TC® Flo-CoatTapecoat TC® Flo-Coat Petrolatum Wax System – a corrosion preventive coating paste to fi ll and coat irregular contours.

Envirocoat® System FlangeCoat®TC Flangecoat is a thixotropic material designed to protect fl ange faces and bolts from atmospheric corrosion. This fi eld-proven Tapecoat product may be applied to new or worn fl ange surfaces and is ideal for use in natural gas regulator stations and oil transmission pipeline terminals.

TC® Flangecoat® TC Flangecoat is an environmentally-safe, 100% solids material with no harmful solvents that cause drying, cracking or shrinking over time. This innovative product can be easily applied under most fi eld conditions and allows for easy re-entry for fl ange maintenance.

Technical Information StandardsANSI/AWWA C-217Color: GraySpecifi c gravity: 1.3Solids content: 100%Application temperature: Above 20°FOperating temperature: -40 to 180°FShelf life: Rotate stock yearly

ApplicationTrim the cartridge tip for desired bead and puncture seal. Apply TC Flangetape around edges of fl ange. Punch insert/exit holes between all fl ange bolts. Insert cartridge tip through hole and pump TC Flangecoat until coating fl ows over bolts on both sides. Repeat procedure until the space between the fl anges is fi lled. Remove TC Flangetape and smooth out TC Flangecoat. Cover the fl ange edges with Tapecoat H35 Gray or TC Envirotape if the entire fl ange area is to be coated.

PackagingAvailable in 12 ounce cartridges packed 12 per carton, 29 ounce cartridges packed 6 per carton with TC Flangetape, and in 5 gallon pails.

R O Y S T O N C O A T I N G A N D W R A P P R O D U C T S Royston Petrolatum Wax Systems



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Tapecoat TC Moldable Sealant

Water Tight Coating for Metal, Fiberglass, and Wood.

Tapecoat TC Moldable Sealant is a specially formulated, 100% solids, conformable water tight coating. Its tape form allows for a greater surface coverage in a single application.

Moldable Sealant is ideal for sealing aluminum, steel, fi berglass, and plywood. Because it is a 100% solids product, it will never become brittle and crack, leaving avenues for moisture to migrate through and reach the surface intended to be protected. Moldable Sealant is a 60 mil highly conformable gray dielectric putty in tape form for ambient temperature below grade application. Use with TAPECOAT TC OMNIPRIME primer on all bare metal substrates.

Appropriate for use as a seal and dielectric fi ller for step downs, bell and spigot joints and other irregular confi gurations, such as weld beads, wire connections and thermite-welds. Often used as an under coating with an over wrap of one of TAPECOAT’s other cold applied tape products.


Composition:TC Moldable Sealant is a 100% solids formulation of thermoplastic elastomeric and synthetic resins.

Technical Data:Color: GrayService temp: -30 to 120°F (-35 to 49°C)Application temp: Above -10°F (-23°C)Total thickness: 40 and 60 mils (1 and 1.52 mm)Adhesion: 165 oz/in widthFlexibility: .5” radius @ -20°F; no crackingDielectric strength: Exceeds 12 kVCathodic disbonding: Pass (ASTM G-8)Insulation resistance: 106 megohmsWater absorption: Less than .05%

Surface Preparation:Surface must be clean and dry. Moisture, dust, dirt, rust, or any type of debris should be removed. Remove oil, grease, or any other contaminant with suitable cleaner.

Sealant Application:Remove the release liner from one side of the Moldable Sealant and apply the product to the properly prepared surface. The remaining release liner can be utilized as an aid while molding the product until all voids and crevasses have been fi lled. Then remove the remaining release liner and apply to target surface.

Tapecoat® HT Sealant A conformable water tight coating for irregular surfaces which may be subjected to temperatures up to 300 degrees F (150 degrees C).

TC® OmniprimeTC Omniprime is a universal, solvent-based primer that meets 1996 federal standards for health and environmental safety, while demonstrating tough fi eld-applied performance. This versatile primer can be used with cold or hot applied tapes and heat shrinkable sleeves for the corrosion protection of metal surfaces such as pipes, valves and fi ttings. Successful laboratory and fi eld testing show TC Omniprime, with an Oxsol 100 solvent base, meets or exceeds performance criteria for previous Tapecoat primers and pending government air pollution regulations.

Tapecoat TC Omniprime is a liquid primer containing no known carcinogens, no hazardous air pollutants (HAP), compliant with all state and US federal volatile organic compound (VOC) regulations. Requires no Red Label Hazard warning for storage. This primer can be used with all TAPECOAT cold and hot-applied bonded tape systems, and with TAPECOAT 6025 high temperature tape when operating temperatures do not exceed 180° F. Application Parameters:Operating temp: -20°F (-29°C) to 200°F (93°C)Application temp: -20°F (-29°C) to ambientViscosity: 130 to 150 cps; Flash Pt.: 109°F (43°C)Film thickness: 5 mil. WFT, 1 mil. DFTPractical coverage: 300 sq. ft. /gallon

R O Y S T O N C O A T I N G A N D W R A P P R O D U C T S Royston Sealants, Primers and Mastics


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Packaging:Available from stock in 1, 5, and 55 gal. containers. Net weight per gallon is approx. 10 lbs.

Application:Surface must be clean and dry. Remove moisture, dust, dirt, rust and other foreign material by scraping or wire brushing to a SSPC-SP3 standard. Optional: SP6 commercial blast cleaning. Remove oil and grease with a suitable solvent. Remove all loose or incompatible coatings from previously coated surfaces. Slight stirring of the product may be required prior to use. Apply with a brush, pad, roller or spray.

Tapecoat TC® Mastic A thixotropic brush applied coal tar coating for ambient temperature, below grade application. Appropriate for coating fi ttings, fl anges, valves, mechanical couplings and other irregular confi gurations.

Tapecoat TC® Mastic 2000 A brush or spray applied bituminous coating for temperatures up to 250°F, below grade application. Appropriate for coating fi ttings, fl anges, valves, mechanical couplings and other irregular confi gurations.

Tapecoat TC® Aluminum Mastic A brush or spray applied aluminum pigmented bituminous coating for ambient temperature, above or below grade application. Appropriate for coating fi ttings, fl anges, valves, mechanical couplings and other irregular confi gurations. Operation temperature ambient to 250°F.

Tapecoat® Reinforcing Scrim A polypropylene cloth material used as an optional reinforcing wrap to increase the impact resistance of liquid coatings. Packaged in rolls 2”, 4“ and 6” x 100’.

Royston Roskote R28 Rubberized MasticA cold-applied coating with high electrical resistivity designed to protect underground steel pipes, tanks and other structures against corrosion.

R28 Rubberized Mastic bonds fi rmly to clean steel surfaces without use of a primer and also to coal tar and hot applied asphalt. It forms a thick, tough coating which will not oxidize, craze, alligator, crack, check, loosen or scale. It provides a high degree of electrical resistivity and shows excellent performance in cathodic protection or stray current situations. It withstands soil stresses and resists attack by alkalis, acids, salts and moisture.

R28 Rubberized Mastic should be used as a general purpose coating for underground protection of all fabricated steel products, such as pipes, conduits, valves, fi ttings, tank, hydraulic cylinder castings and structural steel. For fi eld coating joints of mill coated pipe, it can be used in conjunction with reinforcing fabric such as Royston Glas-Wrap.

In certain areas in or near petroleum refi neries, gasoline bulk plants, service stations, oil producing fi elds and similar locations, Roskote A-51 Plus which is resistant to both oil and gasoline should be used.

Handling Precautions: R28 Rubberized Mastic is a solvent based material which should be kept away from heat or open fl ame and should be used only with adequate ventilation. Repeated or prolonged contact with the skin should be avoided.

Surface PreparationSurfaces should be dry for maximum adhesion. Remove rust, scale, soil, mud, oil, grease and other contaminants in the fi eld by wire brushing. Sand blasting or chemical treatment may be more convenient for in-plant surface preparation. No adhesive is required except on newly galvanized surfaces which should be coated with a suitable phosphate wash primer prior to mastic application.

StirringR28 Rubberized Mastic should be stirred thoroughly before using.

ThinningThinning is not required except for cold spray at temperatures below 60˚F. If excess thickening occurs because of solvent evaporation from opened containers original viscosity may be restored by adding Royston Thinner 11 (Toluene).



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ApplicationRoyston Roskote R28 Rubberized Mastic is applied bold by brush, spray, fl ow coat, dip or rubber glove. Apply two coats of Royston Roskote R28 Rubberized Mastic at the proper thickness, allowing the fi rst coat to dry to the touch before applying the second. When brushing Royston Roskote R28 Rubberized Mastic, it should be applied liberally with a generous amount on the brush at all times. It should never by brushed thin.For spray application, booster type spray equipment is required because of Royston Roskote R28 Rubberized Mastic’s heavy consistency. At temperatures above 60˚F Royston Roskote R28 Rubberized Mastic may be sprayed as received without thinning or heating, but blow 60˚F it is usually necessary to thin with one quart of thinner to each fi ve gallons of Royston Roskote R28 Rubberized Mastic, or to use an in-line heater set at 120˚F maximum. Either air types or airless spray equipment commercially available from several manufacturers may be used. The following equipment and procedures have provided satisfactory results, but alternates may be equally successful.

Air Type Spray:Pump: Graco 8:1 ratio minimum or equivalent President or Bulldog 10:1 ratio recommended Hose: Atomization - 3/8” to 1/2” D Material - 3/4” to 1” D Gun: Heavy material gun Spray Tips: 3/16” minimum. External Wing Air Cap Pressure: Will vary with temperature and pump output Airless Spray:

Pump: Graco Bulldog or equivalent. Pump must be capable of an output of three gallons per minute Hose: Material hose 1/2” minimum, for lengths over 25 feet use 3/4” I.D. Use high pressure, wire braid hose. Gun: Use mastic type airless spray gun, Graco Hydra mastic Gun or equivalent Spay Tip: .031” maximumTypical PropertiesComposition: A pyrobituminous resin processed by homogenization with inhibitive pigments and aromatic solvents. Color: Black Volume Resistivity: 2.12 x 103 ohms cm3 Application Temperature: 32˚F to 120˚F Service Temperature: 0 to 250˚F Shelf Life: At least one year Weight per Gallon: 9.42 lbs Specifi c Gravity: 1.13 Percent Solids: By Volume - 5.6% By Weight - 69.5% +/- 2% Flash Point: 44˚F Seta Closed Cup

R O Y S T O N C O A T I N G A N D W R A P P R O D U C T S Royston Sealants, Primers and Mastics

For Use With Reinforcing WrapUsing with a reinforcing woven mesh such as Royston Glas-Wrap, the fi rst step is to apply one coat of Royston Roskote R28 Rubberized Mastic an allow to dry to the touch, This amount of drying is necessary before proceeding further to prevent the wrap from pulling through the coating to the metal surface. From this point there are two alternate procedures in common use.1.) Apply the wrap and then put on a second coat of Royston Roskote R28 Rubberized Mastic.2.) Apply the second coat of Royston Roskote R28 Rubberized Mastic and then wrap either while the Mastic is still wet or after it has dried to the touch. Wrap tightly to embed the mesh in the coating.

Drying TimeRoyston Roskote R28 Rubberized Mastic usually dries to the touch in approximately 20 minutes. In 1-1/2 hours it is suffi ciently dry form light handling and backfi lling. If it is necessary to backfi ll while it is still wet or soft, apply pipeline felt to protect against damage to the coating.

CoverageEach coat of Royston Roskote R28 Rubberized Mastic should be applied at a coverage rate of 75-80 square feet per gallon, which will provide a dry fi lm thickness of about 12 mils.

Holiday DetectionThe suggested setting for holiday detector instruments is 125 volts for each mil of dry fi lm thickness. The coating must be thoroughly dry before testing. Allow at least 24 hours of complete solvent evaporation.Ordering InformationRoyston Roskote R28 Rubberized Mastic in 1-Quart cans, 1-Gallon Cans, 5-Gallon cans and 55-Gallon drums. One-Gallon cans are packaged 4 per carton.


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Royston Thick ‘N’ Quick MasticA cold-applied, air drying, hydrocarbon resin base coating designed for underground protection of all fabricated steel products such as pipes, tanks, valves, conduits, and structural steel.

Thick ‘N’ Quick is compatible with a wide range of commonly used pipe coatings and construction materials. It offers improved physical properties, and is compound to provide better resistance to water penetration than conventional cold applied mastics. When applied over our Raid Red Synthetic Primer, the resulting Thick ‘N’ Quick coating system shows maximum resistance to the disbonding effects of cathodic protection as determined by A.S.T.M. Test No. G8-85T. This is premium grade mastic. Smooth coats of uniform thickness may be obtained.

It should be used as a general purpose coating for corrosion protection of underground steel pipeline systems, buried storage tanks, valves, fi ttings, etc. Also suitable for a wide range of additional industrial and construction purposes.

Handling PrecautionsThick ‘N’ Quick is a fl ammable mixture which should be kept away from heat and open fl ame. Prohibit welding sparks and smoking. Use with adequate ventilation. Contains aliphatic and aromatic solvents, avoid prolonged or repeated breathing of vapors or fumes. Avoid contact with skin. Harmful or fatal if swallowed. If swallowed do not induce vomiting. Call physician immediately. Keep out of reach of children.

Surface Preparation: Surfaces should be dry and cleaned of all rust, scale, soil, mud, oil, grease and other contaminants in the fi eld by wire brushing. Sand blasting or chemical treatment may be more convenient for in-plant surface preparation. For best results surface should be coated with Rapid Red Synthetic Primer.

ApplicationThick ‘N’ Quick is applied by brush, spray, roller or gloves. Two coats are recommended, apply evenly. Each coat may be up to 1/32” thick (wet fi lm). Thick ‘N’ Quick comes ready to use. First coat should be dry to the touch before application of the second coat. The second coat should be dry before backfi lling. Royston Glas-Wrap may be used for mechanical reinforcement between fi rst and second coats.

Physical PropertiesColor: Semi Gloss Black Coverage: 84 sq. ft. per gallon 20 mils wet, 11 mils drySolids %: By weight: 72% By volume: 57.6% Weight per Gallon: 10.17 lbs. per gallonFlammability: Red Label VOC: 342 grams/liter - 2.85 #/gal VOC

Resistance to:Moisture: Excellent Weather: Good Alkalis: Excellent Acids: Excellent Soil: Excellent

Test DataN/A

Ordering InformationThick ‘N’ Quick is available from inventory in 1-Gallon Cans, 5-Gallon pails and 55-Gallon drums. One-Gallon cans are packaged 4 per carton.



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R O Y S T O N C O A T I N G A N D W R A P P R O D U C T S Tapecoat Rocksheilds

TC 2025-1 (Terrashield) Extra Protection for Buried PipelinesTC 2025-1 rock shield is the ideal protection where pipeline coatings are subjected to rocky terrain, mountain handling, excessive abrasion and damaging backfi lls. This easy applied Tapecoat product cushions pipelines against abrasion, impact and penetration, so protective coatings remain intact to fi ght corrosion.

This protective material consists of a of a 3/8” closed cell polyethylene foam laminated to a 25 mil backing with 1/4” perforations 1 1/4” off center. Protecting the pipe coating by cushioning the impact of the backfi ll as it is reintroduced into the ditch and keeping harmful rock and debris from direct contact with the coating during and after the ditch has been closed.

The Tapecoat rock shield provides superior performance and is only 25% of the weight of conventional rockshields. By readily conforming to the pipe surface, it also can be easily applied by spiral, longitudinal or cigarette wrapping. The result is a fast, trouble-free installation with a minimum of labor and equipment. TC 2025-1 is available with both a perforated or solid material in approximately 60” diameter rolls.

Tapecoat Terra PadTapecoat Terra Pad is a 1/5” rockshield comprised of a diamond mesh and a geotextile felt pad heat-bonded together. The mesh net keeps large stones and backfi ll from contact with the pipe coating. The geotextile felt pad protects the coating by cushioning impact and minimizing intrusions of small, sharp or abrasive material. Entrapment of such harmful material can scrape and damage the coating even after backfi ll. Because Terra Pad allows the fl ow of liquid and gases, it becomes a complementary part of the cathodic protection system.

Pipesaver 200Flexible polyethylene diamond mesh rockshield with a fl at side for contact with pipe. 3.5 diamonds per inch, easy to apply longitudinally or by cigarette wrap method.

Strapping TapeRockshield should be held in place with nonmetallic banding material. Tapecoat offers a fi ber reinforced, self-adhesive strapping tape for this purpose. Package 1” X 180’ rolls, 36 rolls per case.


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STOPAQ Coat Wrap CZ STOPAQ Coat Wrap CZ is a unique approach to solving corrosion problems in the long run. STOPAQ Coat Wrap CZ is a coating in a wrap form based upon synthetic a-polar polymers. The wrap makes it easy to apply with little preparation. The coating formulation gives no failures during overlap, coating the entire surface and creating an excellent corrosion barrier.

FeaturesEasy to apply Excellent adhesion to steel, FBE, coal tar, etc. Long-term protection Highly specifi c electrical resistance No cathodic disbondment Weather/salt resistant -60°F to 185°F No voids Non-toxic Compatible with current coatings available on the marketing todayPatented technology

ApplicationsSoil/air interface Field joints Spot repair existing coating Rehabilitiation Pipe supports Splash zone River and bridge crossings

STOPAQ Coat Wrap CZ has been tested and approved according to:ASTM G8 ASTM G14 ASTM B117 ASTM D1000 DIN 30672 ASTM D570EN12068 VNIIMostroy KIWA TUV TNO OVGWRUG INTEVEP

STOPAQ AMCORR EZ Wrap STOPAQ AMCORR EZ Wrap is a unique approach to solving waterproofi ng problems in the long run. It is usable for encapsulation of asbestos or other, waterproofi ng, and for sealing the base at storage tanks. It is a sealant in a roll-form based upon synthetic a-polar polymers. The roll makes it easy to apply with little preparation. It is the latest technology in waterproofi ng. The product remains fl exible and allows movements due to weather or fl exing of the fl oor plate. STOPAQ AMCORR EZ Wrap has been used and approved in different countries throughout the world. It is proudly manufactured in the USA.

FeaturesTank chime seal (fl oor, concrete ring interface) Encapsulation of asbestos and lead base paint Seam sealant for manholes roof penetrations Prevention of infi ltration Bridge crossings

S T O P A Q ® A M C O R R P R O D U C T SSTOPAQ Coat Wrap CZ, STOPAQ AMCORR EZ Wrap, STOPAQ FN 4200 Flange Filler, STOPAQ Waterplug



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ApplicationsEasy to apply Excellent adhesion to steel, FBE, coal tar, concrete, sheet metal, brick, etc.Long-term protection Highly specifi c electric resistance Weather/salt resistant -60°F to 185°F Open mesh and fabric, not shielded Non-toxic Compatible with current coatings available on the market todayPatent pending Paintable Reinforced with polyester fabric and mesh

STOPAQ AMCORR EZ Wrap has been tested and approved by many oil, gas and water companies, governments, cities and districts.

STOPAQ FN 4200 Flange Filler STOPAQ FN 4200 Flange Filler is a coating based upon synthetic a-polar polymers. The paste form makes it easy to apply with little preparation. The visco-elastic formulation allows the material to fl ow into gaps and voids, creating an excellent seal against corrosion.

FeaturesEasy to apply Excellent bonding to steel, FBE, PU, PE Long-term protection Highly specifi c electric resistance Weather/salt resistant -60°F to 185°F Patented technology Helps block H 2S gasFills the complete space Non-toxic

Compatible with current coatings available on the market todayTested according to latest specifi cations Removable/reusable

ApplicationsAbove/below grade fl anges/valves Voids/spaces where water can accumulate Bolts and threads

STOPAQ WaterplugSTOPAQ Waterplug is a unique approach to solving water leakage. It is easy to use and can be applied in almost any situation on below grade concrete structures. STOPAQ Waterplug even stops water during leakage, creating an ultimate seal.

s, Adhesives, and Tapes

FeaturesEasy to apply Can be applied in wet environment Long term protection Non-toxic Weather/salt resistant Max temp 104°F Patented technology Cables/pipes can be removed Environmental friendly Can be applied for multiple cables Compatible with current coatings available on the market todayTested according to latest specifi cations Removable/reusable

ApplicationsPipe and cable entries Prefabricated joints Leak repair


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S T O P A Q ® A M C O R R P R O D U C T SSTOPAQ Coat Wrap CZ, STOPAQ AMCORR EZ Wrap, STOPAQ FN 4200 Flange Filler, STOPAQ Waterplug

STOPAQ Product Specifi cationsSTOPAQ Coat

Wrap CZSTOPAQ EZ Wrap STOPAQ FN4200

Flange FillerSTOPAQ Waterplug

Form Wrap/roll Wrap/roll Caulk CaulkApplication Corrosion

Prevention of above and below ground objects

Waterproofi ng lead and asbestos

encapslation sealant at tank base “wall fl oor”

Corrosion prevention of above

and below grade fl anges, small

crevices

Waterproofi ng prevents water

infi ltration at cable and pipe entries

Temperature -76°F to 184°F -76°F to 176°F -76°F to 184°F -30°F to 104°FUV Resistance Yes, cover with

autowrapYes, paintable Covered application Below grade

applicationConsistence Synthetic polyolefi n

reinforcement + PE fi lm

Synthetic polyolefi n fi berglass mesh + open weave cloth

Synthetic polyolefi n Polyolefi n + hydrofi lic

componentsTest Data ASTM G8: Pass

Salt Spray: PassSubmits to EN

12068Nationally Accredited

Salt Spray: PassPerm Rating: 0.001

MilesAdhesion Tests:

Polyethylene: PassConcrete: Pass

PVC: Pass

Salt Spray: PassPerm Rating: 0.001

MilesAdhesion Tests:

Polyethylene: PassConcrete: Pass

PVC: Pass

Adhesion Tests: Polyethylene: Pass

Concrete: PassPVC: Pass

NSF 61 Approval Yes No No YesToxicity Non toxic Non toxic Non toxic Non toxic

Environmental Issues

Environmental Friendly




Water Intake 0 0 0 20% (swell effect)Adhesion to West

SurfaceNo No No Yes

pH Neutral Neutral Neutral NeutralShelf Life Unlimited (dry/cool) Unlimited (dry/cool) Unlimited (dry/cool) Unlimited (dry/cool)



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STOPAQ FN 3000STOPAQ FN3000 is a versatile and economical product intended for a wide range of structural applications both above and below ground where water infi ltration is a problem. STOPAQ FN3000 provides for a quick and economical method of installation with excellent caulking properties. This single grade material may be caulked, knifed or troweled during times when only a clean dry surface is present. It adheres to most structural surfaces without priming. STOPAQ FN3000 is non-toxic and environmentally friendly. There is no cure or set up time required. The material remains permanently pliable, is easy to remove and is re-usable in many applications. STOPAQ FN3000 is storage stable (dry/cool) with an unlimited shelf life.

STOPAQ Casing FillerThe most suitable method for the fi lling of pipeline casings is the STOPAQ Corrosion Preventative System for Casings. In relation to the effectiveness of this system, in which STOPAQ Casing Filler is injected as a casing fi ller material, it is far superior to any other coating system in the market. This system combines the excellent corrosion preventative properties and the visco-elastic behavior of STOPAQ. All materials are non-toxic, environmental friendly and easy to install. They stay fl exible forever sealing the object. Cathodic protection current fl owing through the casing on to the carrier pipe is stopped. STOPAQ Casing Filler will protect the casing itself from corroding. Pinholes have occurred in the walls of casings as the cathodic protection current leaves the inner surface of the casing and fl ows through casing water to the carrier pipe.

STOPAQ Casing Spacer “Eurospacer” insulating spacers are the last generation of metal-free patented products made of synthetic resin. The aim of insulating spacers is positioning,

supporting and electrically insulating carrier pipes from casing in the crossings of roads, highways, railways and waterways. It can be used for gas pipelines, oil pipelines, water pipelines and district heating where carrier pipes are made of one of the following materials: polyethylene, PVC, steel, coated steel, cast iron, and plastic reinforced by fi ber glass.

STOPAQ Fiberbond Fiberbond is a UV curing reinforced fi berglass on a roll. Fiberbond cures in sunlight, creating a strong impermeable shield. For protection of insulated pipe, coated pipe, chemical protection, and to reinforce existing pipe and structures

S T O P A Q ® A M C O R R P R O D U C T SSTOPAQ FN 3000, Casing Filler, Casing Spacer, Fiberbond


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Outdoor Electrical Safety

When participating in outdoor, overhead activities, consumers should take the following precautions:

Keep all objects - including masts, poles, ladders, tools and toys - far away from power lines at all times

If you are taking down or moving an antenna, be aware of new power lines that have been put up since the antenna was fi rst installed

Never assume that an overhead power line is electrically insulated; always assume that contact with any line can be lethal

Never place a ladder anywhere near an electrical power line Position non-metal ladders (such as fi berglass) at a height and location that prevents the possibility of you or it contacting a power lineKeep the distance from an antenna or pole to the power line at least 11/2 times the height of the antenna or pole Properly ground all masts in accordance with electrical codes Be aware that you can be electrocuted by touching a power line directly or by touching a

conductive material (such as a metal ladder, antenna, pipe, kite) and, at the same time, the earth or any grounded item (such as metal siding or a downspout)

Keep away from all downed power lines. A power line that touches the ground can shock or kill you even if you do not touch it. The electrical current can travel through the ground and into your body

The Complete S ource for Cor rosion Control Mater ial s

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