nov fgs fitting
DESCRIPTION
NOV Fiber Glass System FittingTRANSCRIPT
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PIPE INSTALLATION HANDBOOK
Matched Tapered Bell & Spigot Joints
REDTHREADII GREENTHREAD SILVERSTREAK F-CHEM
ManualNo.F6000January1,2009
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FIBER GLASS SYSTEMS L. P.PIPE INSTALLATION HANDBOOK
Matched Tapered Bell & Spigot Joints
Thisfabricationmanualisofferedtoassistyouintheproperfabricationand installationprocedureswhenassemblingyourFiberGlassSystems(FGS)pipingsystem.
If you do not find the answer to your questions in themanual,feelfreetocontactusoryourlocalFGSdistributor.
FGSproductsmustbe installedandused inaccordancewithsound,provenpracticeandcommonsense.
The information supplied by Fiber Glass Systems in its literaturemustbeconsideredasanexpressionofguidelinesbasedonfieldexperienceratherthanawarrantyforwhichFGSassumes responsibility. FGS offers a limited warranty of itsproductsintheTerms and Conditions of Sale.Theinformationcontained in the literature and catalogs furnished by FGScannotensure,ofitself,asuccessfulinstallationandisofferedtocustomerssubjecttotheselimitationsandexplanations.
It is the policy of FGS to improve its products continually.Therefore, the company reserves the right, without notice, tochangespecificationsand/ordesignatanytimewithoutincurringan obligation for equipment previously sold. DescriptionscontainedinthiscatalogareforthepurposeofidentificationandneitherlimitnorextendthestandardproductlimitedwarrantysetforthintheTerms and Conditions of Sale and Trade Customs.
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TABLE OF CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iFabrication&InstallationAssistance . . . . . . . . . . . . . . . . . iv
Part IPIPE PRODuCTS
PipeProducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 DescriptionofPipeProducts . . . . . . . . . . . . . . . . . . . . .1 PipeGrades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 FabricationAccessories. . . . . . . . . . . . . . . . . . . . . . . . . .6JoiningSystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Part IISITE CONSIDERATIONS
StorageandHandling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Tools,Equipment,andSupplies . . . . . . . . . . . . . . . . . . . . .10SuggestedCrewSetUp. . . . . . . . . . . . . . . . . . . . . . . . . . .12AdverseWeatherRecommendations. . . . . . . . . . . . . . . . .14BurialRecommendations . . . . . . . . . . . . . . . . . . . . . . . . . .15Anchors,GuidesandSupports. . . . . . . . . . . . . . . . . . . . . .22
Part IIIGENERAL INSTALLATION
ReadThisFirst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24CuttingFGSPipe................................25
Part IVFABRICATION OF RED THREAD II, GREEN THREAD, AND
SILVER STREAK PIPE AND FITTINGS
TaperingFGSPipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26TaperingToolReferenceChart. . . . . . . . . . . . . . . . . . . . . .28JointPrep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29AdhesiveMixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30JointAssembly..................................31 CloseTolerancePiping . . . . . . . . . . . . . . . . . . . . . . . . .31 Take-OffDimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .33 1-6BellxSpigotJoints. . . . . . . . . . . . . . . . . . . . . . . .37 8-24BellxSpigotJoints. . . . . . . . . . . . . . . . . . . . . . .38 T.A.B.Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40JointCure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
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HeatCollars&HeatPacks . . . . . . . . . . . . . . . . . . . . . .42Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
PART VFABRICATION OF F-CHEM PIPE AND FITTINGS
JointPrep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50JointAssembly..................................50JointCure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 HeatBlankets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 TappingintoaLine . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Part VI INSTALLATION CONSIDERATIONS
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63WaterHammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63Flanges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64ConnectingtoOtherSystems. . . . . . . . . . . . . . . . . . . . . . .73PaintingPipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Part VIIHELPFuL INFORMATION
Conversions....................................76DecimalEquivalentsofFractions . . . . . . . . . . . . . . . . . . . .77DefinitionofTerms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78HowToReadFlangedorReducingFittings . . . . . . . . . . . .83
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2005,NATIONALOILWELLVARCO
TrademarkofVarcoI/P,Inc.
RT REDTHREADIIpipingsystemsRTPP REDTHREADIIPerformance Plus pipingsystemsGT GREENTHREADpipingsystemsGTPP GREENTHREADPerformance Plus pipingsystemsSS SILVERSTREAKpipingsystemsFC F-CHEMpipingsystems
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ENER
AL
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RT, G
T, SSFA
BR
ICATIO
NF-C
HEM
FA
BR
ICATIO
NIN
STALLATIO
N
CO
NSID
ERATIO
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HELPFu
L IN
FOR
MATIO
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Standard Abbreviations
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HowToFigurea45Offset . . . . . . . . . . . . . . . . . . . . . . . .84
FABRICATION AND INSTALLATION ASSISTANCE
Installing FGS fiberglass pipe is different from installingcarbon steel, stainless steel, lined steel and even otherfiberglass piping systems. Learning the proper methods toprepareandmake-upbell&spigotjointscanhelpensurethereliabilityandlong-termperformanceofyourpipingsystem.
FGS offers the TQI Plus (ASME B31.3) Fabricationand Assembly certification program. Qualified Field ServiceRepresentativestrainfabricationandassemblycrews,conductandsupervisefabricationwork,andinspectworkinprogress.
For complete information concerning these trainingseminars,contactyourlocalFGSdistributororFGS.
Installationvideosareavailableforviewingonourwebsiteatwww.smithfibercast.comorwww.fgspipe.com.
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SAFETYThissafetyalertsymbolindicatesanimportantsafetymessage.Whenyouseethissymbol,bealerttothepossibilityofpersonalinjury.
CAuTIONAsthispipemaycarryhazardousmaterialand/oroperateatahazardouspressurelevel,youmustfollowinstructionsinthismanualtoavoidseriouspersonalinjuryorpropertydamage. Inanyevent, improper installationcancauseinjuryordamage.Inaddition,installersshouldreadandfollow all cautions andwarnings on adhesive kits, heatpacks, propane torches, etc. to avoid personal injury.Also, observe general safety practices with all saws,tools, etc. to avoid personal injury. Wear protectiveclothing when necessary. Make sure work surfacesare clean and stable and that work areas are properlyventilated.
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PART IPIPE PRODuCTS
DESCRIPTION OF PIPE PRODuCTS
The performance characteristics of a fiberglass pipesystem depend on several important elements including theresinandcuringagent,aswellasthemanufacturingprocessandtypeandthicknessofthepipescorrosionbarrier. FGSpipingsystemsaremanufacturedusingepoxy,vinylester,orisophthalicpolyesterresinsystems.Allareheatcuredfor optimum chemical resistance and physical properties.Match your temperature, pressure and chemical resistancerequirementstothepipingsystem.
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FGS PIPE GRADES
RED THREAD II & RED THREAD II Performance PlusEpoxy pipe grade that provides long service life, lightweightand corrosion resistance. Used for light chemical servicesinsalts,solventsandpH2 to13solutionsup to210Fandpressures to 450 psig.Available in 2-24 pipe sizes.T.A.B.(Threaded and Bonded bell & spigot) is the primary joiningmethodfor2-6diameterpipe.Matchedtaperedbell&spigotjoiningmethodisusedfor8-24pipe.
GREEN THREAD & GREEN THREAD Performance PlusEpoxy pipe with 15-35 mil resin-rich liner that providesexcellent chemical resistance to dilute acids and caustics.Rated for temperatures up to 225F and pressures to 450psig.Matchedtaperedbell&spigotconnectionisprovidedonall1-24pipesizes.
SILVER STREAKCustomfilamentwoundpipeisspeciallydesignedforabrasiveand corrosive services found in flue gas desulfurization. Itis a proprietary blend of epoxy resin and abrasion-resistantadditives. Rated for temperatures to 225F and 225 psig.Availablein2-24pipesizes.
F-CHEM Custom filament wound construction offers more flexibilityin resin systems, corrosion barriers andwall thickness thanourstandardproducts.Rated for temperatures to250Fand150 psig. Let us assist you in selecting the right pipe for aspecific application. Available in 1-72 pipe sizes. Joiningmethodsincludeplainendbuttandwrap,O-ringbell&spigotormatchedtaperedbell&spigot.
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FITTINGS
FGSfittingsarecolorcoded.GREENTHREADfittingsaregreen andmay be usedwithREDTHREAD II andGREENTHREADpipe.SILVERSTREAKfittingsareblack.F-CHEMfittings are color matched to the pipe. Be sure to use thecorrectgradeofpipeandfittingsforyourservice.ConsultFGSFittings&AccessoriesBulletins for pressure rating limits onvariousfittings.Thelowestratedfittingdeterminesthesystempressurerating. Mostcompression-moldedfittingshaveacenterlinedotorcrosswhichwillassistyouinmakingmeasurements.
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ADHESIVES
FGS adhesives are formulated for specific use withthe companion pipe grades. Use only the recommendedadhesivewitheachpipegrade-donotmixsystems!Standardadhesivesareatwo-componentsystem(PartsAandB)whichmustbemixedpriortouse.Detailedinstructionsforadhesivesareprovidedwitheachkit.Readtheseinstructionsthoroughlyandfollowtherecommendedprocedures.Thecuretimeandpot-life of the adhesive is dependent on temperature. Referto the adhesive instructions. Ambient temperatures above100Frequireextracarebythefabricatortoassuresufficientworking time of the adhesive. Refer to Adverse Weather Recommendationsonpage14.
ADHESIVE SELECTION
FGSstandardadhesivekitsaredesignedtobeusedwithspecificpipingsystemsasshowninTable2.
ADHESIVE WORKING LIFE
Workinglifeorpotlifeisthetimeittakesfortheadhesivetohardeninthemixingcan.RefertoTable1below.
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TABLE 1. Fiber Glass Systems Adhesives Estimated Pot Life
NOTE:Potlifeisthetimeavailableforfabrication.Timesmayvarydependingupontemperature,humidity,quantitymixed,etc.
Pipe Resin
Systems Adhesive
Pot Life@ 70F (min.)
(see note)
Pot Life@ 90F (min.)
(see note)
Epoxy 2000 20 12
Epoxy 7000 25 15
Epoxy 8000 15 8
VinylEster CL-100 20 10
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5TAB
LE 2
. Adh
esiv
e Se
lect
ion
R
efer
to B
ulle
tin N
o. D
4000
for
mor
e in
form
atio
n
use
with
thes
e Pi
ping
Sys
tem
sM
ax.
Tem
p.K
itN
br.
Num
ber
of B
onds
per
kit
1"11
/2"
2"3"
4"6"
8"10
"12
"14
"16
"18
"20
"24
"
RTII/G
TPERF.PLU
S20
0F
2014
1815
135
21
1 /2
1 /2
2069
84
32
21
13 /
41 /2
REDTHREADII
(JointsPerCan
)15
0F
7014
2518
106
32
1
7024
96
42
1
7069
84
32
21
REDTHREADII
GREENTHREAD
SILVERSTR
EAK
225F
8014
4527
2115
85
32
11 /2
1 /2
8024
2012
96
42
1
8069
84
32
21
13 /
41 /2
Num
ber
of B
onds
per
kit
14"
16"
18"
20"
24"
30"
36"
42"
48"
54"-
72"
F-CHEM
200F
CL-10
011/2
11/2
11
3 /4
1 /2
1 /3
1 /4
1 /5
Con
tactth
efactory
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FABRICATION ACCESSORIES
Heat Collars and Heat Blankets:FGS offers high temperature heatcollars and silicone heat blanketsfor use in curing of adhesive joints.Theblanketsandcollarshaveapre-set thermostat which controls thetemperature of the unit. See page44 for heat collar page 54 for heatblanket cure times for adhesive jointfabrications.
Heat Guns:Highwattageelectricheat guns are also available toheatF-CHEMadhesivejoints.Theheatgunsare1600wattcapacity.
FGS Heat Packs: A heat pack unit consisting of ties andreactants in a plastic bag attached to foil paper is alsoavailable.Heatpackswillcurejointswithinonehour.
Tapering Tools: FGSmatchedtaperedjointsrequirevarioustools formakingthetaperedspigot in the field(RT,GT,SS).Refer toTable6onpage28 forselectionofproper taperingtool.
Come-Along: Specificallydesigned hydraulic come-alongsare available for 8-24 pipingsystems (RT,GT,SS).Especiallyuseful for long straight runs ofpipe.
Manual Come-Along: Kit consistsof two manual cable puller come-alongsandonestrapclampkit.Itisamechanicalaidusedtojoinlargerdiameter piping. The come-alongismostuseful for8-16pipesizes
toaidinthealignmentandlandingofthespigotendintothebell.
Strap Clamp Kit: FGS offersStrap Clamp Kits that can beused in conjunction with come-alongsforbonding8-24fittings.
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JOINING SYSTEMS
Bell and Spigot Joint: The adhesive bonded, tapered belland spigot joint is a primary joining method for the followingproducts: 1"-24"GREENTHREADpipingandpipetofittings 2"-24"REDTHREADIIpipingandpipetofittings 2-24SILVERSTREAKpipetofittings 4-72F-CHEMpiping* *Pipetopipejointsalsoavailableinbutt&wrap. Pipe is suppliedwith one endtapered(thespigot)and the other endbelled (integral bellor factory bondedcoupling) to accept a tapered spigot. The joint ismade byapplyingadhesivewhich,whencured, iscompatiblewiththepipingsystemsforjointstrengthandcorrosionresistance.
T.A.B. (Threaded and Bonded) Joint:TheT.A.B.jointisthe primaryjoiningmethodforthefollowingproduct:
2"-6"REDTHREADIIpipingandpipetocou-plings.
The joining sys-tem combinesboth threads andadhesives on thebonding surfaces.The mechanical locking action of these promotes positivemakeup which prevents backout during adhesive curing.Standardtaperedbellfittingsareusedwiththissystem.
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PART IISITE CONSIDERATIONS
STORAGE AND HANDLING
A. Pipe and Fittings Fiberglassreinforcedpipe,fittings,andadhesivesrequirespecial storage and handling. Care should be taken intransporting, unloading, handling, and storing FGS productstopreventimpactandotherdamage. When transportingpipe, thespacersunderandbetweenthe pipe joints must be of sufficient width to avoid pointloading, which could produce cracking or buckling damage.Aminimumoffourspacersshouldbeusedforsupporting14"andlarger40'longpipejoints.Morespacersshouldbeusedforsmallerpipeorifpipeisstackedovereightfeethigh. Due to its light weight, lifting equipment is usually notrequiredfor1"-14"pipe.Whenliftingequipmentisrequired,use nylon slings or chokers. Do not allow chains or cablesto contact thepipeduring transport orhandling. If apipeorfabricationismorethan20feetlong,useatleasttwosupportpoints. For storage, a board (2 x 4minimum) should be placedunder each layer of pipe approximately every five feet. Theintent is to support the pipe and distribute the load evenly.Thepipeshouldalsobebracedoneithersideofthepiperackto prevent unnecessary pipemovement.Avoid placing FGSpipeon sharpedges, narrowsupports, or other objects thatcouldcausedamagetothepipewall.WhenstoringFGSpipedirectlyontheground,selectaflatareafreeofrocksandotherdebristhatcoulddamagethepipe. FGSpipeisfurnishedfactorypackagedincompact,easy-to-handlebundlescompletewithprotectiveendcaps.Leavethesecaps inplaceuntil installation time toprotect thepipeendsaswellas topreventdirtorothermaterial fromgettingintothepipe.Fittingsarepackagedincardboardboxesandshouldbestored inadryarea. If fittingsare removed fromtheboxes,protectmachinedbellsandspigotsfromexposuretodirectsunlight. FGSpipecanbedamagedwhenjointsorbundlesofpipeare dropped during handling or shipping. Severe localizedimpactblowsmayresultindamagetothefiberglassreinforcedstructure in the pipe wall.Before installation, inspect the pipe's outer surface for any damage.DonotusedamagedpipeunlessinspectedandapprovedbyaFGSrepresentative.If impact damage occurs, the damaged areas may be
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recognizedbyastartypefractureonthepipe.Pipethathasbeendamagedshouldhavealengthcutawayapproximatelyonefooteithersideoftheimpactedsite.
Note: weight. straps.
B. AdhesiveFGS vinyl ester adhesives can be damaged by storage inwarm places. FGS recommends that CL-100 adhesive bestoredinadryareawheretemperaturesdonotexceed80F.Refertoadhesiveinstructionsincludedineachkitforstorageliferecommendations.
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Material Safety Data Sheets (MSDS) are available from FGS at http://www.smithfibercast.com
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TOOLS, EQuIPMENT and SuPPLIES REQuIRED FOR INSTALLATION
Formaximumefficiency,thefollowingtoolsandequipmentarerecommendedpriortoanyinstallation:
clampkit HandTools -Level-MarkingPen-TapeMeasure-PipeWrap -Hacksaw(22-28teeth/inch) -Taperingtool(Seepages26-28) RT,GT,SS) PowerTools -Powertaperingtools(Seepages26-28) aluminumoxide,carbideordiamond cuttingblade -Heatgun,heatblanketorcollar -T.A.B.wrenches(for2-6T.A.B.jointpipingsystems) Expendables -Clean,Dry,Lint-FreeShopCloths SS),(30-60gritforF-Chem) -Impermeablegloves -Chemicalsplashgoggles
NOTE: Youmustuse theproper tool for taperingeachsizeandtypeofpipe(seepages26-28).
Equipment for Cool Weather (Below 70F) pipe assembly: Heatsource -Portabletorchwithspreadertip,or -Portableelectricheatlamp,or -Industrialhotairgun Ameansofmaintainingadhesivekitsat70-80F: -Aboxwitha25wattlightbulb,or -Insideofavehicle. Heatassistedcuring -Electricheatingcollarsorblankets -Chemicalheatpacks
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Additional equipment for 8-24 pipe assembly (RT, GT, SS):Hydrauliccome-alongortwocome-alongswithmanilarope ornylonslings(forreducedslippage)StrapclampkitSledgehammer,12-16lbs.,anda4x4blockofwood
Additional equipment for applying saddles:Powersanderwith30-60gritsandingdisc(preferred for6andlargersaddles).Hoseclamps
SuGGESTED LABOR TIMES FOR FGS BELL X SPIGOT PIPING SYSTEMS
Table 2.1(1)Placinginhangersfiguresarebasedonone-workeroperationfor1"-4";twoworkersfor6"-10";threeworkersfor12"-24".Totaltimesshouldbefiguredbymultiplyingfiguresgivenbyworkersneededperoperation.(2)2000seriesPowerTools
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PipeSize
Placingin
Hangers(Min/Ft)
(1)
SetUp(Min.)
(10)
Scribe&Cutting(Min/Jt)Hand/power
HandTapering(Min/Jt)
PowerTapering(Min/Jt)
JointMakeup(Min)(7/8)
1" .7 3.0 1.33/1.25 1.0 .25(2) 1.0
11/2" .7 3.0 1.33/1.25 1.5 .25(2) 1.0
2" .7 3.0 1.50/1.25 2.0 .25 1.5
3" .7 3.0 2.0/1.33 3.0 .25 2.0
4" .8 4.0 5.0/2.5 4.0 .25 3.0
6" 1.0 5.0 7.0/3.0 5.0 2.5 (3) 4.08" 1.2 7.0 4.5/3.5 22.0 8.0(4,5,9) 5.0
10" 1.4 7.0 NA/5.0 35.0 10.0(9) 6.0
12" 1.7 8.0 NA/5.0 40.0 12.0(9) 8.0
14" 2.3 9.0 NA/5.0 NA 12.0(5,9) 10.0
16" 2.3 10.0 NA/6.0 NA 12.0(9) 12.0
18" 2.5 12.0 NA/8.0 NA 25.0(6,9) 14.0
20" 3.0 12.0 NA/8.0 NA 28.0(6,9) 16.0
24" 3.0 14.0 NA/10.5 NA 30.0(6,9) 20.0
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(3)2"-6"HandTaperingTool(4)IndividualTaperingTool(5)8"-16"Taper/ScarfTool(6)18"-24"TaperTool(7)Eachjointmakeupcalculationincludescleaning,sand-ing,applyingadhesiveandproperengagement.Allowthreeminutesformixingadhesive.(8)Theunits(time)listedabovearebasedonusingexperi-encedcrewsonfittingintensiveruns.Forstraightrunpipe,contactyourlocalFGSrepresentative.(9)TimedoublesforPerformancePlusproducts.(10)Includessetupforhydraulicormanualcome-alongandsettingpipestandlevels.
These numbers are based on installations using experi-enced crews in typical installation conditions. They do not include extreme weather conditions, time used for gathering supplies and tools, break time, manpower is-sues, etc. Assume 6 hours of productive labor for every 8 hours worked. Adjustment factors should be applied to these base units to compensate for prevailing production and job conditions. Because of all the variables involved, Fiber Glass Systems is not responsible for any differen-tial between these numbers and actual results.
SuGGESTED CREW SET-uP AND ASSEMBLYManpowerrequirementschangedependingonwhether
theinstallationissimple,consistingoflong,straightruns,orcomplex.Italsodependsonpipesize,installationtem-perature,andothersimilarinfluences.Followingaresomegeneralguidelinesthatareapplicabletomostinstallations.Ifyouhaveanyquestions,pleasecontactanFGSrepresenta-tiveforinformation.
A. Suggested Crew Size for 1 - 6 straight run pipe (long runs)
Athree-workercrewistheminimumrecommendedcrewsize.Afour-workercrewissometimesmoreefficient,evenwheninstalling1-6diameterpipe.
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Man # Crew Description #1 Clean/prep/align
Removesendcaps,sandsandcleansjointandalignspipeforbonding.
#2 Adhesive mixer/bonder Mixesadhesiveandappliestobellandspigot.
#3 Assembly man Helpsmakeupjointandchecksforlockup.
#4 Pre-heat/prep/supplies
(optional through 4"; recommended on 6) Pre-heatsjointsandhelpskeeppipealigned.Alsoapplies
heatcollarsduringcoolweather.(Allhelpinmovingsup-pliesandequipmentfromjointtojoint.)
B. Suggested Crew Size for 8 - 48 straight run pipe (long runs)
Asixorsevencrewmembersisrecommended.
Man # Crew Description #1 Clean/prep/align
Removesendcaps,sandsandcleansjointandhelpsalignjointforinsertion.
#2 Adhesive mixer/bonder
Mixesadhesiveandappliestobellandspigot.Marksinsertiondepthanddetermineswhenjointislockedup.Assistswithcome-along.
#3 Adhesive mixer/Bonder
Helps#2withadhesiveandassistswithcome-along.
#4 Pre-heat/alignment man Pre-heatsjoints,helpsalignjointsandassistswithcome-
along.
#5 Alignment man Setslevelofpipeandalignsjointforproperinsertion;
directstractordriver.
#6 Truck driver/Supply man (optional) Drivessupplytruckandassistswithallaspectsofinstal-
lation.Alsocoordinatesheatcollarsduringcoolweatherandicechestduringhotweather.
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#7 Tractor Operator Operatessideboomtractor,trachoeorbackhoe. (Allhelpinmovingsuppliesandequipmentfromjointto
joint.)
C. In more complex pipe assemblies,thecrewsizewilldependontheamountoftaperingandprefabricationneeded.Inmostcases,athree-workercrewisthemini-mumforanysizepipinginstallation.Insomeinstances(smalljobswithonlyafewjoints)onlyoneortwocrew-menwillberequired.
RECOMMENDATIONS FOR FABRICATION IN ADVERSEWEATHER CONDITIONS
FGSpipingcanbeinstalledinadverseweathercondi-tionswhenthenecessaryprecautionsaretaken.
Actualworkwilloftenbemorequicklycompletedinhightemperatureconditions.Lowtemperaturescanincreasetheworktime20%-35%overnormalshopconditions.Asimilarincreaseiscommonforhighmoistureconditions.
Hot Weather Installation TipsHotweatherconditions,temperaturesabove90F,will
greatlyreducetheworkingtimeoftheadhesive.Thefollow-ingstepsarerecommendedwhenfabricatinginhotweatherconditions:1. Avoiddirectsunlightonthejoiningsurfaces.2. Storeadhesiveinacoolarea.3. KeepF-CHEMadhesiveinicechestpriortomixing.4. Keepmixedadhesiveinanicechestwithsealedbagof
iceoricepack.4. Refertothefieldfabricationinstructionssuppliedinthe
adhesivekitfortheproperamountofcatalystinCL-100.
Cold Weather Installation TipsAdhesivecuretimeisdirectlyrelatedtothetemperature.
Coldertemperaturesresultinlongercuretimes.Thefollowingstepsshouldbeusedwhenfabricatingin
coldertemperatures:1. Adhesivekitsshouldbeplacedinawarmroomforsixto
twelvehoursbeforeapplicationinordertoreachtempera-turesof80F-100F.Thiswillmakemixingmucheasierandspeedcuretimes.Oruseaboxwitha25-wattlightbulbtowarmadhesivekits.
14
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2. Whenpossible,pipingshouldbebondedindoorsintosubassemblies.Thewarmerconditionsoftheseareaswillallowfastercuretimes.
3. Pre-warmbondingsurfacesto80F-100Fwhentempera-turefallsbelow70F.
4. Refertothefieldfabricationinstructionssuppliedintheadhe-sivekitfortheproperamountofcatalystforvinylesterkits.
5. Aheatgun,collarorblanketmaybeusedtoobtainafastercuretime.Applyalayeroffiberglassinsulationoraweldingblanketaroundtheheatcollarsorblanketswheninstallationtemperaturesarebelow50F.
Extreme Moisture
Adhesive Joints Iffittingsorpipehavemoistureonthebondingsurface,
wipethemdrypriortosanding. Sandpipeorfittingsimmediatelybeforeapplyingthe
adhesivetobondthejoint.Sandsurfacesuntilafresh,drysurfaceispresent,thenremovedustwithacleandrycloth,andapplyadhesive.
Cureperthepreviousrecommendationsfornormal,ex-tremeheatorextremecoldtemperatures.
BuRIED INSTALLATIONS
Thesearegeneralguidelinesonly.FormoredetailsseeFGSEngineeringandPipingDesignGuideE5000.Forinstal-lationsusingULlistedREDTHREADIIApipingseespecialinstructionscontainedinManualNo.B2160.
15
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16
Offset Bending Allowance for GREEN THREAD & RED THREAD II Pipe
Size(In)
X (Ft)(straight run)
Y (Ft)(offset from straight
run)
2
10 0.820 3.730 9.040 18.1
3
10 0.520 2.530 5.940 11.1
4
10 0.420 1.930 4.440 8.2
6
20 1.230 2.940 5.450 8.6
8
20 0.840 4.060 9.480 17.5
10
20 0.740 3.260 7.580 13.8
12
20 0.640 2.760 6.380 11.6
14
20 0.540 2.460 5.580 10.0
16
20 0.4640 2.1060 4.8080 8.80
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* Basedon1000psisoilmodulus.Contactthefactoryfordetailedinformationforyourspecificapplication.
** F-CHEMisdesignedforspecificburialapplicationsac-cordingtoAWWAC950.
A. Burial Depth1. MinimumBurialDepth Minimumdepthinunpavedareasforpipesubjected
tovehicularloadsdependsonpipegrade,pipesize,vehicleaxleweight,andthebeddingmaterial.Withastandardlegalaxleloadof34,000lbs.,themini-mumdepthofcover(fromthetopofthepipetothe
17
Size(In)
X (Ft)(straight run)
Y (Ft)(offset from straight
run)
18
20 0.440 1.960 4.380 7.9
20
20 0.340 1.760 3.980 7.1
24
20 0.340 1.460 3.280 5.9
TABLE 3. Burial Depths*
Product Minimum (Ft.)Maximum
(Ft.)1"-4"REDTHREADII 2 15
6"-24"REDTHREADII 3 15
1"-12"GREENTHREAD 2 15
14"-24"GREENTHREAD 3 15
1"-12"SILVERSTREAK 2 15
14"-24"SILVERSTREAK 3 15
F-CHEMCustomPiping** 3-5 12-20
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surface)formoderatelycompactednon-claybearingsoilsisshowninTable3.
Thepipeshouldalwaysbeburiedbelowthefrostline.
2. MaximumBurialDepth Maximumburialdepthisdependentonthebackfill
material.Formoderatelycompactedsoilsthatdonotcontainlargeamountsofhighlyexpansiveclays,themaximumburialdepthisshowninTable3.
B. Trench Preparation Finalbeddingofthetrenchmustbeasuniformandcon-
tinuousaspossible.Beforebackfilling,fillallgapsunderthepipewithproperbeddingmaterial.Avoidsharpbendsandsuddenchangesinslope.Itisimportanttoremoveallsharprocks,cribbage,orotherforeignobjectsthatcouldcomeincontactwiththepiping.
C. Bedding Requirements Fiberglasspipecanbedamagedbypointcontactorwear
withthetrenchbottomandwalls,improperbeddingmate-rials,oradjacentpipe.Userecommendedbeddingmate-rialaminimumof6inchesthickatthebottom,sides,andtopofthepiping(refertoTable4).Adjacentpipesshouldbespacedthegreaterof6inchesoronepipediameter.Thepipingcanbelaiddirectlyontheundisturbedtrenchbottomifthenativesoilmeetstherequirementsofarecommendedbeddingmaterial(refertoTable4).Neverlayfiberglasspipingdirectlyagainstnativerockorshale.Alwaysusedry,unfrozenbeddingmaterialsthatdonotcontainforeignobjectsordebris.Neverusewaterfloodforcompaction.Slurriescanbeusedthatareintendedforburialofflexiblepipingsystems.Whenusingslurries,caremustbetakentopreventfloatingordeformationofthepiping.
18
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D. Pipe Support Fiberglasspipeisflexibleandrequiresthesupportofthe
beddingmaterialtokeepthepiperoundinburialapplica-tions.Itisveryimportantthatarecommendedbeddingmaterialisproperlycompactedaroundtheentirecircum-ferenceofthepipe.(RefertoTable4)Tampthebeddingmaterialunderthebottomhalfofthepipingtopreventvoidsorareasoflowcompaction.Vibratoryorsimilartampingequipmentcandrivesmallstonesordebrisintothepipewalliftheyarepresentinthebeddingmaterial.Avoidstrikingthepipewithtampingequipmentasthepipemaybefractured.
19
CompactedNativeFill
Backfill
Bedding
Areasamustfirmlysupportpipehaunches
TABLE 4. Recommended Bedding MaterialsBeddingMaterial CompactionProctor
Density
Crushedrockorpeagravel3/4maximumsize
NotRequired
Coarse-grainedsandorsoilwithlittleornofines
75-85%
Coarse-grainedsandorsoilwithmorethan12%fines
85-95%
Sandorgravelwithmorethan30%coarse-grainedparticles
85-95%
Sandorgravelwithlessthan30%coarse-grainedparticles
Greaterthan95%
6" Min.
6" Min. SITE C
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Consult the factory if the pipe will be subject to vacuum or high water tables.
E. Road Crossings Whenlayingfiberglass
pipeunderroadcross-ings, itmaybeneces-sary to pass the pipethroughconduittopro-tect the pipe. Pad thepipetopreventrubbingor point loads againsttheconduit.
F. Wall Penetrations Wherethepipegoesthroughorpassesunderaconcrete
structure,precautionsmustbetakentopreventbendingorpointloadingofthepipeduetosettling.Aminimum2"thickpadofresilientmaterialshouldbewrappedaroundthepipetoprovideflexibilityandpreventcontactwiththeconcrete.Ifboltsareusedintheresilientmaterial,careshouldbetakenthatthebolts,nuts,orwasherscannotcomeintopointloadcontactwiththepipe.Beddingdepthunderthepipeshouldbeincreasedtoaminimumof12"oronepipediameter,whicheverisgreater,foronepipejointlengthawayfromtheconcrete.
20
Proper Bedding Improper Bedding
EnsureFirmCompaction
NoVoids
SelectBedding
ThickPadofRe-silientMaterial
ORingBell&Spigot
ThickProtectiveLayerofResilientMaterial
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G. Timing Testandcoverthepipeassoonaspossibletoreducethe
chanceofdamagetothepipe,floatingofthepipeduetoflooding,orshiftingofthelineduetocave-ins.
H. Two Point Lifting of Red Thread II
ThistableprovidesinformationconcerningsafeliftpointsforRTIIduringinstallation.Thefollowingtablehasbeencompiledfortwoliftpointsandthemaximumlengthofpipethatmaybesafelyliftedandthecriticallocationoftheliftpoints.
21
TABLE 4.H
NominalSize(In)
PipeLengths(Feet)
CantileverLength(Feet)
Mid-SpanLengths(Feet)
Number Length Min. Max. Min. Max.
8 3 120 24 26 68 72
10 3 120 20 28 64 80
12 3 120 22 31 58 76
14 3 120 22 31 58 76
16 3 120 20 35 50 80
18 3 120 19 36 48 82
20 4* 160 31 37 86 98
24 4* 160 29 40 80 102
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ANCHORS, GuIDES AND SuPPORTS
A. Pipe Hangers Pipehangerssuchasthoseshownareoftenusedto
supportFGSpipeinbuildingsandpiperacks.However,theuseoftoomanyhangersinsuccessioncanresultinanun-stablelinewhencontrolvalvesoperate,andduringpumpstart-upandshutdown.Toavoidthiscondition,thedesignershouldincorporateauxiliaryguidesperiodicallyinthelinetoaddlateralandaxialstability.
B. Pipe Guides Guidesarerigidlyfixedtothesupportingstructureand
allowthepipetomoveintheaxialdirectiononly.Properguideplacementandspacingareimportanttoensurepropermovementofexpansionjointsorloopsandtopre-ventbucklingoftheline.
Theguidingmechanismshouldbeloosesoitwillallowfreeaxialmovementofthepipe.Ubolts,double-nuttedsotheycannotbepulleddowntight,areoftenutilizedforguides.
Primaryandsecondaryguides,i.e.,thoseimmediatelyadjacenttoexpansionjoints,arespacedmorecloselythanintermediateguides.RefertoFGSManualNo.E5000,Engineering & Piping Design Manual, fordetails.
Pipingenteringexpansionjointsorexpansionloopsre-quireadditionalguides.RefertoFGSManualNo.E5000, Engineering & Piping Design Manualfordetails.
C. Pipe Supports: PipingsupportsforFGSpipeshould
bespacedatintervalsasshownintheproductbulletins.
22
1/16Min.-1/8Max.clearanceperside
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NOTE:Properlyspacedsupportsdonotalleviatetheneedforguidesasrecommendedintheprecedingsection.Supportsthatmakeonlypointcontactorthatprovidenarrowsupportingareasshouldbeavoided.Somemeansofincreasingthesupportingareashouldbeused;sleevesmadefromhalfofaFGScouplingorpipearesuitable.Supportpumps,valvesandotherheavyequipmentindependentofthepipe.Refertopumpandvalveconnectioninstructionsonpage74.
D. Pipe Anchors: Pipeanchorsdivideapipelineintoindividualexpandingsections.Inmostapplications,majorpiecesofconnectedequipment,suchaspumpsandtanks,functionasanchors.Additionalanchorsareusuallylocatedatvalves,nearchangesindirectionofthepiping,atblindendsofpipe,andatmajorbranchconnections.Provi-sionsforexpansionshouldbedesignedintoeachoftheindividualpipesec-tions.
Caution: Donotinstallmorethanoneexpansionjointbe-tweenthesametwoanchorsinanystraightpipesection.
DonotanchorFGSpipebyapplyingexternalpres-sureaspointloads,suchasa"U"-bolt,directlytothebarepipe.RefertoFGSManualNo.E5000,Engineering & Piping Design Guide,forathorough
discussiononsupports,anchorsandguides.
23
!
AnchorSleeves
Clamp,snugbutnottight
WeldorBoltAnchortosupportmember
Snugfit
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PART IIIGENERAL INSTALLATION
INSTRuCTIONS
Beforebeginningtheactualassemblyprocedures,readandmakesureallinstallersthoroughlyunderstandthefollow-inginstructions.
All bonding surfaces must be clean, dry and factory fresh in appearance before applying adhesive.Whenendcapshavebeenlost,surfaceswillweatherandresultinlossofbondstrengthWhensurfacesareweathered,re-taper(RT,GT,SS)spigots.SandbellsandF-CHEMspigotstoachieveafactoryfreshappearance.(Note:T.A.B.couplingsthathaveweatheredmustbereplaced.)
Matching tapered bell and spigot joints require a very thin adhesive bond line for maximum strength and du-rability. Theadhesiveusedwithtaperedjointsisverystrongwhenusedinbondlinesafewthousandthsofaninchthick.Thesameadhesivemaybebrittleinthicksectionsresult-inginpoorbondstrength.Toachieveathinbondline,thematchedtaperedanglesofthejointaredesignedtomechani-callylock-upwhenwedgedtogether.
using mechanical force assures lock up and a thin bond line. Hammeringawoodenblockplacedagainstthebellendofpipe,orusingmechanicaldevicessuchascome-alongsshouldbeusedtolockupthejoint.
Note:ForT.A.Bjoints,specialT.A.B.wrenchesarerequiredtoachievethemechanicallockupinthejoint.
Adverse weather conditions require special precau-tions when bonding pipe.(Seepage14,Recommendations for Fabrication in Adverse Weather Conditions)Theadhesiveisveryviscous(thick)whencoolorwhenappliedtocoolpipe.Thethickadhesivecanactuallybestiffenoughtopreventjointlockup.Whentheadhesiveishotorwhenitisappliedtohotpipe,theavailableworkingtimemaybesignificantlyreduced.
Matched tapered bell and spigot joints that are not locked up can fail prematurely.
24
IMPORTANT READ THIS FIRST
RT,
GT,
SS
FAB
RIC
ATIO
N
-
CuTTING FIBERGLASS PIPE
FGSpipeshouldbecutusingoneofthemethodsreferredtounderToolsandEquipmentonpage10.
1. Measurepipe,rememberingtoallowforspigotandfittingdimensions.
2. Scribeacuttingguidearoundthepipetoensureaper-pendicularcutforproperfit.
3. Holdthepipefirmlybutnottothepointofcrushing.Ifchainvisesorothermechanicalholdingdevicesareused,careshouldbetakentopreventcrushingorpointloadingofthepipe.Topreventdamagetothepipe,180degreesectionsofFGSpipecanbeusedforprotectivecovers.
4. Sawthepipeassmoothlyaspossible.Thepipeendsshouldbesquarewithin1/8inch.
PART IV
25
Note:Forintegraljoint(IJ)bellends,thebellendmustbecutoffbeforetapering.MeasuretheO.D.ofthepipenearthebellenduntilyouseetheO.D.starttogetlarger.Cutthepipeatthispoint.Dependingonpipesizethedistancefromtheendofthebellcanvaryanywherefrom12"to36".
RT, G
T, SS FA
BR
ICATIO
N
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FABRICATION OF RED THREAD II, GREEN THREAD AND SILVER STREAK PIPE AND FITTINGS
TAPERING FGS PIPEVarioustoolsareavailablefromFGSformakingtheta-
peredspigotinthefield.Toreproduceastandardtaper,thetaperingtoolmustbe
markedoradjusted.Theprocessvariesdependingonthetoolbeingusedandtheproductbeingtapered.Pleaserefertoindi-vidualtoolinstructionsfortapering.
RefertoTable6onpage28forspecificbulletinnumberandpropertaperangleforeachsizeandtypeofpipe.
Do not taperoverthebellendofintegraljointpipe.Seepage25forcuttinginstructions.
A. 1"-6" Tool (Bulletin F6600)-Ahand-heldtoolthatcanbeadaptedforpowerwhenalargenumberoftapersisnecessary.Differentpipingsystemsrequiredifferentmandrels.
B. Model 2100/ 2102 Tool (Bulletin F6625/ F6624) -PowertoolfortaperingandscarfingREDTHREADIIandREDTHREADIIApiping.
C. Model 2300 Tool (Bulletin F6627)-Powertoolespeciallydesignedfortapering1-4GREENTHREADpiping.
D. 8", 10", or 12" Tapering Tool (Bulletin F6608 or F6612)-Thesetoolsaredesignedformanualorpower(i.e.,Ridgid300or700powerdriveorequal)operation;thereisatoolforeachsizepipe.
26
RT,
GT,
SS
FAB
RIC
ATIO
N
-
E. 2"-12" Remote Power Tool (Bulletin F6601)-Tapers2"-12"pipe.Mustchangeanglefor8"andlargerpipe.Recommend-edforall6"tapers.
Additional material will be needed: 1.Sturdyworkbench(preferablywithametaltop)orstandtoholdthetool2.Two20"longpiecesof1"diametersteelpipe.Mounttheseontopofthebenchparalleltoeachother,ona2-footcenter,extendingoffthebench12".3.Twoadjustablepipestandswithhardrubberrollersat90degreeangletopipe,i.e.thestandmustallowthepipetorotate.4.Thistoolrequiresapproximately3,000wattsof115vacpowerforoperation(30ampbreaker).Werecommend5,000watts(50ampbreaker).Asthelengthofextensioncordsin-creases,thepowerlostinthecordincreases.Table5showsmaximumallowablelengthsforvarioussizecords:
F. 8"-16" Taper/Scarf Tool (Bulletin F6622)-Thisisanelectricallypoweredtaperingtool.Thetoolcomeswithdifferentsizemandrelstotaper8"-16"pipe.
G. 18"-24" Tapering Tool (Bulletin F6621)-Thisisanelectricallypow-eredtaperingtool.Thetoolcomes
withdifferentsizemandrelstotaper18"-24"pipe.
Note: Sometoolsmaybeusedwithotherpipesystemswithspecial-ordertooling.Inthesecases,supplementaltoolinstruc-tionsarealsoavailable.Besuretospecifywhichpipesystemyouwillbetaperingwhenorderingtools.
JOINT PREP forRED THREAD II, GREEN THREAD and SILVER STREAK
27
TABLE 5. Extension Cord LengthWire Size
(AWG)Suggested Length
(Ft.)Maximum Length
(Ft.)12 20 22
10 30 36
8 50 57
RT, G
T, SS FA
BR
ICATIO
N
-
28
TABLE 6. Tapering, Scarfing and Cutting Tool Reference Chart
Tool
Prod
uct
Tool
Tap
er A
ngle
Bul
letin
#C
omm
ents
1"-6"Han
dTape
ring
RT
GT
1"=3;1
1 /2=21/2
2"-6"=13/4
F660
0Spe
cifyprodu
ctto
receivecorrectm
andrels.Orderscarfing
ad
apterk
itfors
ec.con
t.Pow
erada
ptersep
arate.UsesRidg-
id700
ore
quivalen
tpow
erdrivewithaRidgid77
4ad
apter.
2100
Pow
erRT
13/4
F662
5Tape
rs2&
3;Scarfs
3&
4
2102
Pow
erRT
13/4
F662
4Tape
rs2-4
;Scarfs
3
2300
Pow
erGT
13/4
F662
7Tape
rs2-4
,
2700
Pow
erSS
13/4
F663
2Tape
rs2"-4"SilverStre
ak8"Tap
eringor
Scarfing
Too
lRT/GT
GTMOS
0or1
0F6
608Tape
rF6
609Scarf
Tape
rsand
scarfs
.Orderscarfing
ada
pterkitforS
.C.U
ses
Ridgid70
0orequ
ivalen
tpow
erdrivewithaRidgid77
4ad
apter.
10"&12"Tap
erorScarfing
Too
lRT/GT
GTMOS
0or1
0F6
612Tape
rF6
613Scarf
Tape
rsand
scarfs
.Orderscarfing
ada
pterkitforS
econ
dary
Con
tainmen
t.UsesRidgid70
0orequ
ivalen
tpow
erdrivewith
aRidgid77
4ad
apter.
6"-12"CERAM
CORE
CERAM
CORE
Non
eF6
620
Scarfs
6"-12
"Ceram
Core
8"-16"Single
PointTap
erToo
l8"-16"RT,
GT,M
OS
0or1
F662
2Tape
rsors
carfs
8"-16
"RT,GT,SS.Scarfs
8"-12
"GTMOSor
8"-16"secon
darycon
tainmen
t.
2"-12"Rem
ote
Pow
erToo
lRT,GT,SS
2"-6"-13/4
8"-12"-1
F660
1Tape
rs2"-12
"pipe
.Mustcha
ngean
glefor8
"an
dlargerpipe.
Recom
men
dedfora
ll6"Tap
ers.
18"-24
"Tape
rTool
RT,GT,SS
GTMOS
011/4
F662
1Tape
r18"-24"
-
JOINT ASSEMBLY forRED THREAD II, GREEN THREAD and SILVER STREAK
A. Close Tolerance Piping ThetaperedbellandspigotsystememployedbyFGScanbereadilyusedtoachievedimensionalaccuracywhererequiredbyaparticularpipelayout.Aswithanymatchedtaper,minorvariationsintoleranceinthebellorspigotwillaf-fecttheinsertiondepth.Inapplicationswherethefinalmake-uplengthofanassemblyisnotcritical,thesevariationsareofnoconsequence.However,whentheinstallationissuchthatclosetolerancesmustbemaintained,youmustcompensateforthesevariations.Itispossibletoaccuratelyreproducetapers(spigots)inthefieldwiththefieldtaperingtools.Thisprovidesameansofachievingdimensionalaccuracy.Calculation to Achieve a Desired Length
Mostclosetoleranceinstallationsaremadetoprintscall-ingoutCLtoCL(centerlinetocenterline)dimensions.
Whenfabricatingtothesedimensions,followthesepro-ceduresperthefigurebelow.1. Obtainthecenterlinetofacedimension(A)offittings
tobeusedfromTables8or9onpages33-36.2. Createaninsertiongaugebycuttingashortsection
ofpipe;12longforsmalldiametersand18longforlargerdiameters.Taperthepipeusingtheinstruc-tionssuppliedwitheachtool.Checkdryinsertion.Theinsertionlengthshouldbewithin+1/8ofafactoryspigotinsertion.
3. Obtaininsertionlength(IL)byinsertingthegauge(madewiththetoolbeingused)intoafittingandmeasuring.(Note:Measureeachendofeachfitting,becausetheinsertionmayvaryforeachbell.)Youcanprepareanduseashortnippleasastandardinsertion
29
RT, G
T, SS FA
BR
ICATIO
N
-
gauge.(Note:Youmustprepareanewgaugeifyouchangetaperingtoolsormakeanychangestothetoolyouareusing.)Alwaysaddamake-updimension(refertoTable7)tothismeasurement,sincetheadhesivewillactasalubricantandallowgreaterpenetrationthanwhenthesurfacesaredry.TABLE 7. Approximate Make-up Dimensions (M)*
Pipe Diameter (In.) Approximate Make-up Dimensions* (In.)1and11/2 1/16
2 1/83and4 3/16
6 1/48 3/8
10and12 5/814 3/416 118
Usefielddevelopeddimensions2024
4. ToachieveaspecifiedCLtoCLdimension,thelengthofpipetocutisequaltotheCLtoCLdistanceminusthesumofthecenterlinetofacedimensionofthefittings(Adimension)plusthesumofthemeasured
insertionlengths(IL)plusthesumofthemake-upallowance(M),or
LengthofPipetoCut=(CLtoCL)-(A+A)+(IL+IL)+(M+M)
Note:Eachbellofeachfittingmayhaveaslight-lydifferentinsertiondepthwithastandardtaper.Eachbellofeachfittingshouldbechecked
withastandardtaperandmarked.
ConsultFGSFittingsBulletinsNo.A1350orA1355forcompletefit-tingdimensions.
30
*CAUTION:Make-updimensionsdependonthetightnessofthedryfit.Ifthefielddevelopeddimensionsvary,usefielddevelopeddimensions.
RT,
GT,
SS
FAB
RIC
ATIO
N
-
JOINT PREP forRED THREAD II, GREEN THREAD, and SILVER STREAK
Allbondingsurfacesmustbecleananddrybeforebonding. ForT.A.B.joints,cleanwithanacceptablesolventand
cleanrag.WirebrushesmayalsobeusedforcleaningT.A.B.surfaces;however,theymustbecleanandfreeofoilycontaminates.
Forsmoothtapers,sandpaperorsolvent(orboth)maybeused.Sandjustlightenoughtoremoveanycontami-nates.
Usecautionasoversandingcanchangethetaperangleorenddimension,andcreateflatspotsonthespigot.
Whensurfaceshaveweathered,sandorretaperspigotsandsandbellstoachieveafactoryfreshappearance.Cutatleast1fromspigotsbeforeretapering.T.A.B.couplingsmustbereplaced.
Bondingsurfacesmustbedry,sobesureallsolventhasevaporatedbeforeapplyingadhesive.
Note: use of a solvent as a cleaning method is optional.Somealternatecleaningsolventsareacetone,methylenechloride,andmethylethylketone.Aftercleaning,besureanyresidualsolventhasevaporatedbeforeapplyingadhesive.DONOTUSESOLVENTSTHATLEAVEANOILYFILMONTHEBONDINGSURFACES.
WARNING: Somedegreasersandsolventsareextremelyflammable.Donotsmokeorusenearanopenflame.Weareyeprotection.Besuretoreadwarninglabelsoncontainers.
Neverusegasoline,turpentine,ordieselfueltocleanjoints.
Solventcontainersmaybeunderpressure.Usecautionwhenremovinginnerseals,especiallyinwarmweather.Usewithadequateventilation.
31
!
RT, G
T, SS FA
BR
ICATIO
N
-
ADHESIVE MIXING
Whentheweatheriscoolortheadhesivehasbeenstoredinacoolenvironment(below70F),prewarmtheadhesivekits.(Donotheatabove100F!)1. Forepoxyemptyallofthecontentsofthehardenerbottle
intothecanofbaseadhesive.2. Mixallofthebaseepoxyadhesivewithallofthehardener.
NEVERATTEMPTTOSPLITAKIT.Cutthroughtheadhe-sivewiththeedgeofthemixingsticktoassistinmixingthetwocomponents.
3. Mixuntiltheadhesivehasauniformcolorandaconsistentflowoffthemixingstick.Wipedownthesides,bottom,andundertherimofthecanwiththemixingsticktoassurecom-pletemixture.
Completeinformationandsafetyprecautionsarepackagedwitheachadhesivekit.Reviewallsafetyprecautionsthor-oughlybeforemixingtheadhesive.
32
ADHESIVE DISPOSAL: Once the adhesive and hardener havebeen mixed and reacted, nothing can be extracted, and it is classified as non-hazardous material. Dispose of in a nor-mal manner as other solid waste. Excess adhesive andhardener can be mixed, allowed to react, and disposed of asabove. If extra jars of adhesive or hardener have accumulatedwithouttheothercomponenttomixandreact,contactyourFGS regionalmanager.Hardener jars,whenemptyarenotsubject toEPAregulationandcanbedisposedofinanormalmanner.Theseguidelinesarebasedonfederalregulations.Stateandlocalregula-tionsandordinancesshouldbereviewed.
RT,
GT,
SS
FAB
RIC
ATIO
N
-
33
TAB
LE 8
. T
ake-
off D
imen
sion
s fo
r RT,
GT
Fitti
ngs
(Con
tact
FG
S fo
r SS
Dim
ensi
ons)
Dim
ensio
ns
are
used
tocal-
culatep
ipe
leng
th
requ
iremen
ts
to
mee
tpipe
linecen-
terline
tocenter
linedimen
sion
s.
A
AA
A A
Size
45
Elbo
wA
90
Elbo
wA
Tee A
Late
ral
Cro
ss AM
/FW
*B
M/F
W*
C*F
lang
esM-M
olde
dFW
-Filamen
tWou
nd
AB
123/8
23/4
23/4
37/8
21/2
23/4
13/4
3 /4
11/2
27/8
33/8
33/8
51/4
31/4
33/8
13/4
3 /4
225/8
33/8
33/8
65/8
23/4
33/8
21/4
/ 21/8
3 /4
333/4
45/8
45/8
73/4
41/4
45/8
25/8
13/8
437/8
51/8
51/8
943/8
51/8
25/8
/ 31/2
13/8
643/8
61/8
61/8
121 /2
53/4
61/8
3 / 3
3 /4
11/2
881/8
115 /
811
5 /8
161 /
473/8
115 /
84
13/4
1085/8
131 /
813
1 /8
195 /
883/4
131 /
843/4
2
1291/2
1414
243 /
411
3 /4
145
21/4
1412
1 /2
1919
321 /2
153 /
416
31/8
21/2
1613
1 /4
201 /
420
1 /4
353 /
417
3 /4
171 /
431/8
21/2
RT, G
T, SS FA
BR
ICATIO
NB
C
-
34
Table8.1Dryinsertion
dep
thsfors
tand
ardREDTHREADIIand
GREENTHREADpipean
dfittings.
Size
90&45Deg
ree
Elbow
s&Tee
sCrosses
Laterals
Molde
dFlan
ges
FWFlan
ges
TheXvalue
sare
the
nominaldry
spigotinsertion
sused
tosetupta-
perin
gtools.T
he
tolerancesfo
rdry
insertion
are"
for1"-6"an
d
"for
8"-16"pipe
sizes.Th
efinal
insertion
referred
toasthe
wet
locked
up
po
si-
tionwillbelarger
than
theXdimen
-sion
.Dono
tuse
these
dry
inser-
tion
depthsfor
close
tolerance
piping
calcula-
tions.
In.
X-RT
X-G
TX-RT
X-G
TX-RT
X-G
TX-RT
X-G
TX-RT
X-G
T
1-
1-
1-
1NA
1-
1
1
-1
-1
-1
-1
-1
21
11
11
11
1
11
31
11
1
11
1
21
2
41
11
1
11
1
21
2
62
22
22
22
22
2
83
33
23
22
23
3
103
33
33
23
33
312
33
33
33
33
33
146
63
33
3-
-2
2
166
63
3
3
3
-
-1
2
RT,
GT,
SS
FAB
RIC
ATIO
N
-
35
INSERTION DEPTHS FOR SILVER STREAK
SizeCoupled/Mitered
FittingsFilament Wound
Fittings
2 1 2
3 2 2
4 2 3
6 2 2
8 3 5
10 4 5
12 4 6
14 5 4
16 6 5
Table8.2Takeoffandnominaldryinsertiondimensionsforlowpressure,150/225 psig, SILVERSTREAK products. Refer to BulletinA2000orwww.smithfibercast.comformoreinformation.
RT, G
T, SS FA
BR
ICATIO
N
-
36
TAB
LE 9
. T
ake-
off D
imen
sion
s fo
r RT/
GT
Perf
orm
ance
Plu
s Fi
tting
s
Size
(In)
45Elbow
(Lon
gRad
ius)(In)
90Elbow
(Lon
gRad
ius)(In)
Tee(In
)Flan
ges(In
)
Ax-RT
x-GT
Ax-RT
x-GT
Ax-RT
x-GT
A-Van
Stone
812
6
519
6
5
13
65
6
1014
6
6
23
6
6
15
6
6
712
16
77
277
717
7
77
14
17
55
305
5
19
5
5
816
205
5
345
5
21
5
5
918
24
4026
10
20
29
47
31
12
2435
57
3515
Xdimensionsarenominaldry insertionlengths.Pipemustbedriventogetherandfullylockeduptoassurefulljointstrength.Actualinsertionsshouldbe+"for8"andlargerjoints.Insertion depths are for tool set up only. Do not use insertion depths (x) for close tolerance piping. Refer to joint assembly instructions forcompleteinformationonjointlockup.
Dimensionsareusedtocal-culatepipelengthrequirementstomeetpipelinecenterlinetocenterlinedimensions.
RT,
GT,
SS
FAB
RIC
ATIO
N
-
B. 1 - 6 Bell & Spigot Joint THESPIGOTMUSTBEALIGNEDANDLOCKEDINTHEBELL.Acockedormisalignedjointwillresultinfalselockupandprematurejointfailureeitherduringtestingoratalaterdate.
1. Whenambienttemperatureisbelow70F,prewarmthebondingsurfaces.Useahotairgun,propanetorchorothercleanburningheatsourcethathasaspreader
typetip,andapplyheatuniformlytobellandspigotuntilwarmtothetouch.Checktemperaturebytouchingbondingsurfaceswiththebackofyourhand.Donottouchwiththefrontofyourhandasthismaycontaminatethejoint.Ifhottothetouch,letcoolbeforeapplyingadhesive.Whenusingatorchtopreheat,warmthebellfirst.Itisthickerandwillholdheatlonger.Ifan
electricheatingcollarisusedtoprewarm,placethejointtogetherdry,thenheattheO.D.ofthebelltoavoidcontaminatingthespigot.CAuTION: Donotusechemicalheatpacksforprewarming.
2. Brushadhesiveonboththebellandspigotbondingsurfaces,applyingathinuniformcoatingtoeach.To
minimizecontamination,applyadhesivetothebellfirst.Adhesiveshouldalwaysbeworkedintothemachinedsurfacebyapplyingpressureduringapplication.Thiswillwetoutthemachinedsurfaceandmaintaintherequiredthinbondline.Besurethatadhesiveisdeepdownintothebellpasttheinsertiondepthandthatallmachinedtapersurfacesonthespigot
andthecutendofthepipeareuniformlycovered.Excessadhesivewillmakethejointmoredifficulttolock.
3. Alignandlockthejoint.For2"orsmallerpipe,insertthespigotintothebelluntilsurfacestouch,thenpush
andturnatthesametimeuntilalockisachieved.Onlyaquartertoahalfturnisusuallyneeded.On3-6diameterpipeoronfittings,pushingandturningtolockthejointisimpracticalanddrivingforcemustbeused.Ahammermaybeusedtoassistinjointlock-up.Placea2x4board
flatacrossthebell.Thefirstfewrapsshouldbelighttopreventanytendencyofthejointtobackout.
37
RT, G
T, SS FA
BR
ICATIO
N
-
Iftheadhesiveorthepipesurfacesarecool,pushandholdforafewsecondstoallowtimefortheadhesivetostartflow-ingoutofthetaperedjoint.
4. Checklockupbymovingfreeendofthepipeinanupanddownorsidetosidemotion.Themovementmustbesufficienttomovethejointbeingchecked.Nomovementshouldbevisibleinthejoint.Ifanymove-mentexists,thejointisnotproperlylockedup.Avoidexcessmovementasthiscoulddamagethespigot.
C. 8 - 24 Bell & Spigot Joint1. Longruns(ditchpiping)mustbesupportedatthejoint
sectionatalltimesuntilfullycured.Liftingnearthecenterofthepipewithabackhoeorsideboomtractorwithoutpropersupportunderthejointcancausedam-agetojointsthatarenotcured.Liftingnearthecenterofthepipeforalignmentisacceptableaslongasthejointdoesnotsupporttheweightofthepipingsection.Blocksorskidsshouldbeusedtosupporttheentirejointsectionuntilthejointisfullycured.Installpipeinstraightalignment;neverinstallpipeinabind.
2. 8"-24" hydraulic come-alongisrecommendedforpipe-to-pipeconnections.Formoredifficultbondingsitu-ationsinapiperackorintightquarters,amanualcome-alongkitwithstrapclampsisavailablefromFGSandisrecommendedforsizesthrough16".Alljoints18"andlargermustuseahydrauliccome-alongtoachievefulljointlockup.Alljointspulledtogetherwiththistypeofdevicemustbevibratedduringinstallationtohelpalignthespigotinthebellandpreventafalselockuporcock-ingofthejoint.RefertoBulletinsNo.F6618orF6619fordetailedinstructionsonhydrauliccome-alongs.
a. Whenusingahydrauliccome-alongon8-24pipe,makesurepipeisrestingonblocksbeforecome-alongcollarsareremoved.Donotremovecollarswhilepipeisstillattachedtocableortractor.Ifcollarsarerestingonblocksafterbonding,leave
38
RT,
GT,
SS
FAB
RIC
ATIO
N
-
pressureoncome-alongandliftgentlywiththechains,justenoughtoremovecollars.Donotplaceexcessivebendingstressacrossthejoint.
3. Strap clamp kitsareavailablefromFGSforpipetofittingconnections.Whenusedinconjunctionwiththehydrauliccome-along,aheavydutyband(strap)clampandtworingbeltstrapsareusedtopullthejointtogeth-er.RefertoBulletinNo.F6641fordetailedinstructionsonStrapClampKits.
4. Ratchet-type come-alongscanbeusedasanalterna-tivetothehydrauliccome-alongs.Usetwo,oneoneachsideofthejoint.Useaheavy-dutystrapclampkittoat-tachthecome-alongstothepipe.Slings,or5/8orlargermanilaropes,arealsoac-ceptable.Aseriesofhalf-hitcheswillgripthepipewhenusingrope.Allowroomtooperatethecome-alongsbyplacingthestrapclamps,slingsorropes18-24oneachsideofthejoint.Takeupcome-alongstogethersothatthejointstaysinalignment.Forcethejointtogetheruntilitissolid.Rapthejointtogetherwitha5lb.deadblowhammer(s)whilekeepingpressureonthecome-alongstoensurethejointisfullyengaged.
39
RT, G
T, SS FA
BR
ICATIO
N
TABLE 10. Hydraulic Come-Along Pressures
PipeGrade PipeSize HydraulicPressure
(In.) (psig)
RT,GT,SS 8-1012-16
1500-17501750-2000
RTPP,GTPP 8-1012-1618-24
1500-20002000-2500
3000
-
D. T.A.B. Joint: T.A.B.Jointinstallationproce-duresfollowthenormalbellandspigotoperationsofcleaning,ad-hesivemixing,etc.asdescribedabove.TwoT.A.B.wrenchesarerequiredwhenjoiningT.A.B.pipe.SeparatewrenchesareavailablefromFGSforeachsizepipe.Thewrencheslockaroundthepipeandforcethepipeintoaveryslightovalshape.Therefore,thewrenchesmustbe6"to12"awayfromthejointtoassuregoodjointmakeup. 1. Coverallmachinedareasonthespigotandatleastone-halfinchbeyondthelastthreadinthebellwiththeproperadhesive.
2. ScrewthepipetogetheruntilfirmusingT.A.B.jointwrenches.DONOTOVERTIGHTEN.
Connectionsintofittingsaremadeusingthenormalbellandspigotmethods.Athreadedspigotcanbebondedintoasmoothbell(fitting),orasmoothspigotcanbebondedintoathreadedbell.
E.SaddlesandReductionsNote:ZC-275or3033Adhesiveisrecommendedfor saddles.
Positionthesaddleonthepipeandmarkaroundthesaddlebase.Useafile,asander,orroughsandpaper(16to40grit)toremoveallsurfaceglossfromthepipeO.D.wherethesaddleistobebonded.(Forlargediameterpipe,adiscsanderisusuallymorepractical.)Usecircularorrandompat-ternmotionduringsandingtoeliminategroovesonthepipesurface.Aftersanding,positionthesaddleonthepipeandmarktheholetobecutinthepipe.Cutaholethesamesizeasthesaddleoutletusingapilotdrillandcircularholesaworsabresaw.Donotforcethecutteroritwillfraytheedgesoftheholeexcessively.Cleanallbondingsurfacesasrequired.Note:Besurecleaner(ifused)hasevaporatedbeforeap-plyingadhesivetothebondingsurfaces.ApplyaheavycoatofadhesivetotheO.D.ofthepipe,I.D.ofthesaddle,andtheedgesofthepipewallexposedbythehole.Placethesaddleovertheholeandclampwithtwohoseclampsorabandingtool.(Note:Bandingtoolmustbeatypethatdoesnotleaveslackinthebandswhenthetoolisremoved.Use
40
RT,
GT,
SS
FAB
RIC
ATIO
N
T.A.B.Wrenches
-
41
metalbanding.)Usingalargescrewdriver,handtightenthehoseclampsalternatelyuntilsecureandadhesivesqueezesoutallthewayaroundthesaddle.ThiswillensurethatthepipeO.D.conformstothesaddleI.D.Youcanremovetheclampsorleavetheminplaceaftertheadhesiveiscured.Allow adhesive to cure before bonding in the side run. Usetwobandingtoolstopullthesidesofthesaddledownalternately.Iftwotoolsarenotavailable,tightenthefirstbandsnug,thesecondbandtight,andaddathirdband,pulledtight,onthefirstside.Three-quarterinchbandingisrecommended.Ifthesaddlesareusedonnon-standardpipe(pipenotlistedinFGSlitera-ture),contactyourFGSrepresen-tativeforspecialinstructions.
F.Reducer BushingsInstallreducerbushingsusingablockofwoodandahammerandthesameproceduresasforbellandspigotpipe.Thewoodblockshouldbesizedtoallowthereducerbushingtobecounter-sunkinthebell.Somereducerbushingswillbecoun-ter-sunkbeforetheyareactuallylockedup.Formaximumchemicalresistancewith8"andlargerGreenThreadreducerbushings,coatallmachinedsurfaceswithadhesivejustbeforeassembly.
RT, G
T, SS FA
BR
ICATIO
N
-
42
JOINT CuRE
A. Ambient CureCuretimeisthetimerequiredfortheadhesiveinthe
assembledjointtoharden.Curetimedependsonthetypeofadhesiveandtheambienttemperature,asshowninTable11.
Youcanshortencuretimebyapplyingheat.Althoughalloftheadhesiveswillcureatambienttemperaturesabove70F,itisrecommendedtheybeheat-curedattemperaturesofatleast275Ftomaximizephysicalpropertiesandcorro-sionresistance.Seepage43forinstructionsforusingFGSheatcollarsforheat-curingjoints.
B. High Temperature Heat CollarRefer to Bulletin No. F6640 for complete operating
instructions.
TABLE 11. Adhesive Ambient Cure TimeAdhesive Type Temperature (F) Cure Time (hrs.)
2000
110 1
90 380 470 9
60 16
50 24
8000
110 1
90 2
80 470 6
60 12
55 18
NOTE:Curetimeisthetimebeforethelinecanbetested.Timesmayvarydependingupontemperature,humidity,etc.
RT,
GT,
SS
FAB
RIC
ATIO
N
-
NOTE: Donotbendorfoldheatingcollarasthismaybreaktheheatingelementsandcausethecollartoworkimproperlyornotatall.
For Pipe and Fittings:1. Usethesamesizeheatingcollarasthepipesizeyou
areinstalling,withtheexceptionofflanges.Donotuseaheatingcollarthatisdesignedforalargersizepipe.
2. Withtheun-insulatedflaponthebottom(nexttothefitting),carefullywraptheheatingcollararoundthejoint.Feedthestrapthroughthesquarering.CAUTION:Theun-insulatedflapisextremelyhotwhenthecollarison.DONOTTOUCHwithbarehands.
3. Tightenthestrapsuntiltheheatingcollarissnugagainstthejoint.
For Flanges:1. For1",11/2"and2"flanges,anindustrialheatgunmaybe
usedtocurethejoint.Besurethattheendofthegunisatleastsixinchesfromtheopeningoftheflange.
2. For3"through16"flangejoints,useaheatingcollarthatisonepipesizesmaller.Removethestrapsfromtheheatingcollar.
3. CarefullyturnthecollarinsideoutwiththeheatedareafacingtheI.D.ofthepipe.PlacetheheatingcollarintheI.D.oftheflange.Asplitringofpipemaybeusedtoholdthecollarinplacewhilethejointiscuring.
For Saddles:1. Placetheheatingcollaroverthesaddleoutlet.During
coolweather,awindshieldisrecommendedtokeepheatonthejoint.Saddlesmustbeheatcuredfortwohours.
Allowthejointtoreturntoambienttemperaturebeforeapply-ingstresstothejoint. NOTE: FGSHighTemperatureelectricheatingcollarsarede-signedtofitaroundfittings,andwilloverlaponpipejointsandcouplings. Exceeding the recommended cure time on pipejointswheretheheatingcollaroverlapsmayshortenthelifeoftheheatingcollarand/ordamagethepipe.
Theuseofinsulationmaybenecessarybelow40Ftopreventheatloss.
43
RT, G
T, SS FA
BR
ICATIO
N
-
NOTE: Thesecuretimesareforenvironmentswarmerthan70F.Ifcooler,see"ColdWeatherInstallationTips"onpage14orconsultFGS.Adhesiveswillcurein24hoursatambienttemperaturesof70-100F.(1) Includessleevecouplings.
250F.(3) 18"-36"collarsareun-insulated.(4) Below50F,theheatingcollarsshouldbewrappedininsulationtoreduce heatloss.(5) 36"heatcollarsrequirespecial20ampconnectors.
C. FGS Heat Packs FGSheatpacksthatcurejointsinapproximatelyonehourarealsoavailable.RefertoBulletinNo.D4500forcompleteinstructionsthatareincludedwitheachkit.Observeallsafetyprecautionslistedontheinstructionsheetsthataccompanytheheatpacks.
44
TAB
LE 1
2. A
dhes
ive
Cur
e Ti
mes
for
Elec
tric
Hea
ting
Col
lars
Pipe
Sys
tem
&
Adh
esiv
e G
rade
Pipe
Siz
e (I
n.)
Cur
e Ti
me
(Min
utes
)Pi
pe (1
)Fi
tting
Flan
ge (2
)Pe
rf. P
lus
Red
Threa
dII
Green
Threa
dSilverStre
ak20
00or80
00SeriesAdh
esive
1-6
1220
15N/A
820
2020
3010
2727
2735
1230
3030
4014
3434
3445
1638
3838
6018
-24
(3,4)
9090
9012
030
-36
(3)(5)
120
120
90NA
GT17
5/25
030
33Adh
esive
1-6
8-12
30 6030 60
30 60NA
NA
GT17
5/25
080
00Adh
esive
14-16
6060
60NA
18-24
9090
90NA
-
Caution:Theadhesivebeadwillcurefasterthantheadhesiveinthejoint.Itisimportantthatthejointnotbepressurizeduntilithasbeensubjectedtothe
propertime-temperaturecycle.Atemperatureversustimetopressurecurveisindicatedintheinstructionspackagedwitheachadhesivekit.
REPAIRS for RED THREAD, GREEN THREAD & SILVER STREAK Piping Systems
Fiberglasspipingsystemsarerelativelysimpletorepair.Normally,repairmeanscuttingoutafittingoradamagedsec-tionofpipeandreplacingitwithnewmaterial.
Caution:Alwaysdetermineexactlywhatfluidhasbeeninthepipingsystem.Contactmaybeharmfultohumans.Takenecessaryprecautions.
Alwaysusethesamepipegrade,fittings,andadhesiveonnewpartsasisintheexistingsystem.Donotmixpipegrades.
Inspecting for Potential Causes of Joint Failure
Joint BackoutIfthebeadisnolongernexttotheedgeofthebell,thejointbackedoutbeforetheadhesivecured.
Cocked JointIfajointiscockedormisaligned,therewillusuallybealargegapbetweenthebellandspigotononeside.
Improperly Cured JointIftheadhesivebeadissoftorflexible,theadhesiveisnotsufficientlycured.
Weathered JointIfthemachinedareaappearsyellow,thejointmayhavebeenexposedtoUVdegradation.
Alldamagedorimproperlyassembledjointsmustberepairedorreplacedasindicatedbelow.
REPAIRING WEATHER DAMAGEIfmachinedsurfacesofpipeorfittingsareexposedto
directsunlightpriortoinstallation,alossofjointbondingstrengthmayoccur.Ifultravioletexposureisgreaterthantwohours,thefollowingstepsmustbetaken: 1. Forexposedspigotends,use60to80gritsandpaperor
EmeryclothandlightlysandtoremoveUVdegradation.Avoidoversandingasthismayalterthetaperangleofthespigotandmayresultinvoidsinthebondline.IfUVdeg-radationistoosevere,cut1fromtheendofthepipeandretaper.
45
RT, G
T, SS FA
BR
ICATIO
N
!
!
-
2. Forexposedbellends(pipeorfittings),sandthoroughlyuntiltheentiresurfaceappearsfresh.Handsandingwith40gritsandpaperisrecommended.Usealightsandingoperationtopreventchangingthetaperangle.
NOTE:COUPLINGSORINTEGRALBELLSWITHT.A.B.THREADSTHATHAVEBEENOVEREXPOSEDMUSTBEREPLACED.
REPAIRING MINOR DAMAGEFordamagedareaslessthanoneinchindiameterinlightchemicalorwaterservice.
A. Flanged Systems:Ifpossible,simplyreplacetheentireflangedlength.Otherwise,cutoutthedamagedsection,thenbondnewflangestotheremainingpipeendsaccord-ingtorecommendedprocedures.Next,fabricateanewflange-by-flangespooltothelengthrequired.Boltinthenewpipesection.
Flangedfittingsshouldberemovedfromthesystemwhen
damagedandreplacedwithanewfitting.
B. Tapered Systems: Makeapatchtocoverdamagedarea.1. Cutalengthofgoodpipetoadequatelycoverthe
damagedareaandextend3-4oneithersideofthedamagedarea.
2. Slitthispatchlength-wisetwiceandremoveasectionsothataboutthree-fourthsofthecircumferenceremainsfor1"-4"pipeandone-halfthecircumferencefor6"andlargerpipe.
3. Thoroughlysandtheinnersurfaceofthepatchandsandacorrespondingareaonthepipearoundthedamagedsection.
4. Cleanthebondingsurfaces,thenap-plyathickcoatingofadhesivetobothsurfaces,snapthepatchinplace,andapplypressurewithhoseclamps.Theclampsmaybeleftonorremovedaftercuring.
46
RT,
GT,
SS
FAB
RIC
ATIO
N
-
REPAIRING EXTENSIVE DAMAGEWhenthedamagedareainthepipewallislargerthanoneinchindiameter,orforrepairofpipeinseverechemicalser-vicethatrequiresalinedproduct,followtheseinstructions:
1. Whendamageislocal(lessthanoneinchlong,butmorethantwoinchesaroundthecircumferenceofthepipe),checktoseeifthereisenoughslackinthepipetocutoutthedamagedsec-tion,re-taperthecutends,andbondasleevecouplingbetweenthetaperedends.
2. Whendamageisextensive(toolargeforreplacementbyasinglesleevecoupling),cutoutthedamagedsection,taperthecutends,andinstalltwosleevecouplingsandapipenipple.This procedure requires sufficient slack in the line to make the final joint by lifting the pipe (or moving the pipe to one side) to engage the bell and spigot joint.
3. Ifthelinecannotbemovedsufficientlytoinstallasleevecouplingorasleevecouplingspoolpiece,taperbothendsofthepipeandinstallflanges.
4. Ifitisimpossibletotaperthepipeintheditch,youcaninstallanewsectionofpipebyoverwrappingtheplaincutends.a. Cleananarealargeenoughforinstallerstoworkon
bothsidesandunderthepipe.Cutoutthedamagedsectionofpipeandmeasurethegap.Cutasectionofgoodpipethatisnotmorethanone-halfinchshorterthanthelengthtobereplaced(1/4"maximumgaponeachend).
b. Sandtheendsofthepipetoremoveallresingloss.Alignthereplacementpipesectionwiththepipelineandblockupallsectionstomaintainalignment.Allsectionsmustberigidsotheywillnotmoveduringtheoverwrappingprocedure.Tackweldsshouldbeusedbyplacing1"x2"patchesofglassclothandad-hesive(fourpatchesspacedat90intervalsaroundthepipe).SeeOverwrapping on p. 48.
47
RT, G
T, SS FA
BR
ICATIO
N
-
REPAIRING LEAKING JOINTSOverwrappingIfajointleaksbecauseofimproperinstal-lation,youcanrepairitbyoverwrappingwithglassclothandresin.Thetemperatureintheworkareashouldbe75F-90F.Besuretoprotecttheoverwrapfromthesun.
1. Use7-10oz.glassclothfromFGS.Componentsfortheepoxyoverwrapareavailableinan8088repairkits(seeTable13).
2. Useagrinderorsanderwithcoarsegrittoremoveglossfiveinchesoneithersideofthejoint.
3. Beveltheshoul-dertoblendinwiththepipewallandaddputtytomakeasmoothtransitionfromfittingtopipe.Thelengthofthisputtyshouldbeheldtoaminimum,becausetheputtyhaslimitedpressurecapabilities.
48
TABLE 13. WELDFAST 8088-S Overwrap Repair KitsPipe
Size (In.)Layers
of GlassGlass Width
(In.)Number of kits
Required per Joint1 4 8 0.25
11/2 4 8 0.252 6 8 0.753 6 8 0.754 6 8 1.006 6 8 1.508 8 8 2.5010 10 8 3.5012 12 8 5.0014 14 8 6.5016 16 8 8.00
RT,
GT,
SS
FAB
RIC
ATIO
N
NOTE: An 8088L (Large) repair kit is available from FGS for 8" andlargeroverwraps.A2088overwrapkitisavailableforapplicationswithtemperaturesatorbelow200F.
-
CAuTION: There must not be any pressure on the line or any fluid leaking from the joint when performing this procedure.
4. Re-sandandcleansurfacesincludingbevel.5. Thoroughlymixtheadhesiveandhardenerwiththestir
stickuntilthereisauniformcolorandaconsistentflowoffthestirstick.
6. Usingapaintbrush,applythemixedadhesivetoallsandedareas.
7. Eachpieceofglassclothmustbeslightlylongerthanthepreviouspiece,becausetheO.D.ofthepipebecomeslargerasyouaddglasscloth.Cutthefirstpiecetoallowfortwoinchesofoverlap.Whenthislengthisnolongersufficienttooverlapatleastone-halfinchontheends,determineanewlengthwithtwoinchesofoverlap.
8. Centerapieceofglassclothoverthejoint.Pullontheclothwhilepositioningitandwetitoutbypaintingwithadhesive.Brushtoremoveanytrappedairbubblesinthewrap.Startatoneendoftheclothandworkaroundthecircumference,wettingtheclothwithresin.Worktheclothawayfromthestartingendandfromthecenteroftheclothtothesides.Theclothmustbethoroughlywet-tedwithadhesive,butdonotspendalotoftimeinoneareaastheclothwillwetout(loseitsshiny,whiteappear-ance)withtime.Bythetimetheclothhasbeenworkeddownsmoothlywithnoairbeneathit,mostofitwillbewettedout.
9. Topreventthicksectionsorhumpsintheoverwrap,cen-terthenextpieceofglassclothonthejointstartingfromanewpointonthecircumference.RepeatStep8untilalllayersareapplied.
10.Shouldtheoverwrapstarttogiveoffheat,discontinuewrappingandletthejointcureandcoolwithafan.Sandthecuredlayerstoremovetheglossbeforerestartingtheoverwrapprocedure.
11. Payparticularattentiontothebottomoftheoverwrapasthisistheareathatmaysagandismostdifficulttosee.
12. Intemperaturesabove90F,protecttheoverwrapfromdirectsunlight.
49
!
RT, G
T, SS FA
BR
ICATIO
N
-
PART VFABRICATION OF F-CHEM PIPE AND FITTINGS
A. Matched Tapered Bell and Spigot Joint PrepNote:Itisessentialthatpipeandfittingsurfacesbe
sanded,clean,dry,andfreeofoil,grease,andsolventcon-tamination.
1. Preparethebellandspigotendsofthepipebysandingthebondingsurfaceswith36to60gritabrasive.
Thesandedareashouldextendatleast1/2"beyondthelengthofthebell.
2. Neversandmorethantwo(2)hoursbeforemakingthejoint.
3. Wipethesandedareawithaclean,dry,lint-freecloth,andavoidtouchingthesurfaceswithbarehandsordirtygloves.
DO NOT uSE SOLVENTS.
Note:F-CHEMfittingsareavailablewithflangedorplainendsonly.SeeManualNo.F6080, Pipe Installation Hand-book for Socket Joints and Butt & Wrap Joints,forjoiningF-CHEMfittingsandpipewithbutt&wrapjoints.
B. Joint Assembly1. Coupler Instructions Attachthebandsorchains
tothepipe.Havethejacksandallothermaterialready,priortomixingtheresinandcatalyst.
Placebandclampsorchainsapproximately3to4feetfromthejointonboththebellandthespigotpieces.Slipthe"D"ringsintoplaceonthehorizontalcenterline,onbothsidesofthepipe,priortoattachingthecouplerhooks.
Unreelthecouplersandhookthejacksintoplace.Thecablesmaybeleftunattachedtoallowworkingroomfortheapplicationoftheadhesive.
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2. Mixing Weldfast CL-100 Adhesivea. MixthecanofPart"A"resin
tofullydisperseanyliquidwhichmayhaveseparatedduringstorage.Itshouldbealightpurplecolor.
b. AddtherecommendedtubesofPart"B"catalysttothePart"A"resincan.
c. Mixthoroughlyforaminimumof twominutesoruntilthecolorisa consistentlightgreen.
3. Pot Life Potlife(workingtime)mayvarywithchangesintempera-
tureandhumidity.
4. Applying Weldfast CL-100 and Bonding Pipea. Usethebrushtoapply
generousamountsofcatalyzedresintothebellendfirst,thenapplytothespigotend.
b. Alignthejointandguidethespigotendintothebell.
c. Attachcouplerhooksandjackthejointintofirmengagement.Checkaroundthejointlinetobesurethatitiseven,whichindicatesproperalignment.
d. Usebrushtofillinanygapsinadhesive.Leavecouplerinplaceduringinitialcure(approximatelyonehour).
TABLE 14. CL-100 Adhesive Estimated Pot Life
Pipe PotLife PotLifeResin @70F @90FSystem Adhesive (min.) (min.)
VinylEster CL-100 20 10
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C. Joint CureCuretimeisthetimerequiredfortheadhesiveinthe
assembledjointtohardenanddependsontheambienttem-perature.Cure Time for CL-100 Adhesive is 24 hours.Curetimecanbedecreasedandjointstrengthincreasedbyheatingthejointfrom175Fto225F.Heatcureisstronglyrecom-mendedforpipingsystemscarryingfluidsattemperaturesabove120F.
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ADHESIVE DISPOSAL: Once the adhesive and catalyst havebeenmixedandreacted,nothingcanbeextracted,anditisclassi-fiedasnon-hazardousmaterial.Disposeofinanormalmannerasothersolidwaste.Excessadhesiveandcatalystcanbemixed,al-lowedtoreact,anddisposedofasabove.Ifextracansofadhesiveor tubesof catalysthaveaccumulatedwithout theother compo-nenttomixandreact,contactyourFGSregionalmanager.Cata-lysttubes,whenemptyarenotsubjecttoEPAregulationandcanbedisposedof inanormalmanner.Theseguidelinesarebasedonfederalregulations.Stateandlocalregulationsandordinancesshouldbereviewed.
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INSTRuCTIONS FOR uSING FGS SILICON RuBBER HEAT BLANKET
Caution:ReadOperatingInstructionsBeforeUsing. Useonlywith120voltpoweroutlet. Blanketshouldnotbeusedinwetconditions. Tears,cutsorpuncturesintheblanketcancreatea
potentialsafetyhazard. Thethermostatmustbewrappedintheblankettoprevent
overheating.
1. Useonlythepropersizeheatblanketforthepipebeingjoined.
2. Aftertheadhesivefillethashardened,wraptheblanketaroundthejointbyfirstplacingthethermostatendoftheblanketagainstthejointwiththethermostatfacingout.Wraptheremainderoftheblankettightlyaroundthepipe.Holditinplaceduringtheheatingprocess.
NOTE:Checkheatblankettemperaturetobesureitis heatingproperly.
3. Avoidexcessflexingoftheblanket.Abnormalflexingcancausebreakageandshortentheservicelifeoftheblanket.DONOTcreasetheheatblanket.
4. Usealuminumfoiltoprotectheatblanketfromadhesive.5. DONOTusecleaningsolvents.Solventspenetratethe
rubberanddamagetheheatingwires.6. DONOTcarryormovetheblanketbyliftingitwiththe
cordalone.Supporttheweightoftheblanketseparatelyfromthecordtoavoidabusingthecord-to-blanketcon-nection.
Impropersizingoruseoftheheatblanketscancauseexcessheatingwhichcandamageboththepipingandheatblankets.
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TABLE 15. 110 Volt Silicon Rubber Heat Blanket Models(For use with F-CHEM pipe)
PipeSize 4-8 10-14 16-20
Model C D E
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TABLE 16. Silicon Rubber Heat Blanket Cure Times for Adhesive Joint Fabrication
NOTE:Heatblanketcuretimereferstothattimewhentheheatsourcecanberemovedandthepipeinstalledandtestedatrecommendedpressures.Heatblankethourspertainto70-100Ffabricationenvironment.Curetimeswillbelongerforcoldertemperatures.Fortemperaturesbelow70F,see"ColdWeatherInstallationTips"onpage14orconsultFGSTechnicalServices.Ifnoheatsourceisavailable,adhesiveswillcureatambienttemperaturesof70-100Fin24hours.
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Piping System/Adhesive Grade
Pipe Size(In.)
B&S Joints(hrs.)
F-CHEMCL-1004-14 1
16-20 4
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REPAIR & MODIFICATIONfor F-CHEM PIPING SYSTEMS
Fiberglasspipingsystemsarerelativelysimpletorepair.Normally,repairmeanscuttingoutafittingoradamagedsec-tionofpipeandreplacingitwithnewmaterial.
Caution:Alwaysdetermineexactlywhatfluidhasbeeninthepipingsystem.Contactmaybeharmfultohumans.Takenecessaryprecautions.
Alwaysusethesamepipegrade,fittings,andadhesivewhenrepairingorreplacingdamagedsections,ormodifyingthesystem.
Ifyouhaveanyquestionsaboutthechemicalservice,pipegradeselection,orsystemoperatingconditions,callyourlocalFGSDistributororFiberGlassSystemsdirect.
NOTE: Whenmakingrepairs,besureallsurfacestobebonded
aredry,cleanandthoroughlysanded.Goodadhesiveconnectionscannotbemadeonwetorcontaminatedsurfaces.
REPLACING DAMAGED PIPEPipeleaksthroughthepipewallarealmostalwaystheresultofphysicaldamagetothepipefromimpact,vacuum,excessivebending,orotherabusiveconditions.Thedam-agedsectionshouldalwaysbereplacedusingthefollowingprocedures:
Flanged Systems: Ifpossible,simplyreplacetheentireflangedlength.Other-wise,cutoutthedamagedsection,thenbondnewflangestotheremainingpipeendsaccordingtorecommendedproce-dures.Next,fabricateanewflange-by-flangespooltothelengthrequired.Boltinthenewpipesection.
Flangedfittingsshouldberemovedfromthesystemwhendamagedandreplacedwithanewfitting
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Tapered Bell & Spigot Systems:Cutoutthesectionofpipewhichleaks,makingsurecutsaresquare.Drythepipeends.Cutanewlengthofpipethesamelengthasthepiecethatwascutout.UsetwoFGSbutt&wrapkitstobondthenewpipeintoplace.RefertoManual No. F6080 for Butt & Wrap Jointdetailedinstructions.
REPLACING DAMAGED FITTINGSIfaleakdevelopsinanF-CHEMfitting,itwillusuallybenecessarytocutouttheleakingpartandreplaceit.UseFGSbutt&wrapkitstobondthenewfittingintoplace.Referto Manual No. F6080fordetailedinstructions.TEMPORARY FIXES, OVERWRAP
ButtWrap ButtWrap
ButtWrapJoint
ProblemFitting
Step1-CutoutSection
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Asatemporaryrepair,aleakingfitting,pipeorjointcanbeoverwrappedwitharesinandglasslay-up.Thisrequiresresin,catalyst,fiberglassreinforcement,tools,andaclean,dryworkarea.Manytimesanoverwrapisthepreferredmethod,particularlywhenfittingsareinaclose,complexmanifoldorassembly.Customoverwrapkitsareavailableforeachpipesizeandpressureclassification.ContactFGS.
Application Procedure:Beforemakingtheover-wrap,readtheseinstructionscarefully.1. Sandthesurfaceareathoroughlyforanequaldistance
oneachsideoftheleak.Thesandedsurfaceshouldextendatleast1/2beyondthewidestlayerofglasssup-pliedwiththekit.Removeallsurfaceglazes,paint,oil,grease,scale,moisture,orotherforeignmaterialtoen-sureproperbondingoftheresinmaterialtothesurface.
2. Usetheapplicatorbrushtoremovealldustfromthesandedarea.
3. Ifrepairingabell&spigotpipejoint,usetheWELDFASTadhesiveputtysup-pliedinthekittoformataperedbeadasshowninthissketch.Thebeadwillprovideasmoothtransitionfromfittingtopipe.
4. Layouttheprecutfabmatandsurfacingveilonaflat,clean,drysurface(i.e.,cardboard,plywood,etc.).
5. AddcontentsofPart"B"tube(s)tocontainerofPart"A"(resin).Usingoneofthewoodenstirrers,mixthecontentsthoroughlyforatleastoneminute.
6. Usetheapplicatorbrushtoapplyaliberal,evencoatingoftheresinmixturetotheentiresandedsurface.
7. Usingthe3"roller,thoroughlysaturatethefabmatlaidoutonyourworkingsurface.Applywet-outfabmattothejointtobeoverlaidplacingthematsidedown.Usingthe3"roller,continuetorolloutthematerialuntilallentrappedairhasbeenrolledoutandthefabmatiscontouredsmoothlytothesurface.
8. Forjointsizes4"andlarger,repeatStep#7above.
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TaperedWeldfastBead
Veil &FabmatOverlay
SpigotEnd
BellEnd
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9. Placesurfacingveiloverthefabmatand,againusingthe3"roller,applyaliberalamountofresinandworkoutallairasinStep#7.
Be sure that the pipe surface is thoroughly wet out with catalyzed resin.
Some guidelines on the overwrap are:1. Theoverwrapshouldbeequallyspacedoneachsideof
thepointoftheleak.2. Theoverwrapshouldbearoundtheentirecircumference
ofthepipeorfitting.3. Thepressureratingandpipediameterwilldeterminethe
overwrapthickness.ConsultFGStechnicalservicestodeterminespecificinformationaboutdesignoftheover-wrap.
4. Theresinsystemoftheoverwrapshouldbecompatiblewiththeresinsystemoftheexistingpipeorfittings.
5. Curetheoverwrapcompletelybeforepressuretesting.
RefertoManualNo.F6080Butt & Wrap Joint Sectionfordetailedinstructions.
TAPPING INTO AN F-CHEM LINEThemostcommonmethodfor
addingabranchortappingintoanexistingF-CHEMlineistheuseofaT-Miter.Forcompleteinstruc-tions,seeBulletin Nos. D4235, D4240 or D4242,suppliedwitheachT-Miterkit.
Application of a T-Miter:1. Cuttheendofthenewbranchpipewithacontourto
matchtheexistinglinepipeoutsidediameter.2. Trialfitthebranchpipetothelinepipetoensureminimal
gapsandmarkfortheholeinthelinepipe.3. Cutaholeinthelinepipethesamediameterasthe
branchpipeinsidediameter.4. Sandbothpipeswitha36-60gritabrasivetocomplete
roughenthebondingsurface1/2beyondthewidestlayeroffiberglasstobeapplied.
5. Usetheadhesivesuppliedinthekittosealtheedgesofthepipeandbondthebranchtotheexistingpipe.
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6. Mixtheresinsuppliedinthekitandwetoutthesandedpipesurfacesandsuppliedfiberglass.
7. ApplythefiberglasstothepipejointaccordingtotheinstructionssuppliedintheT-Miterkit.
8. Curethefiberglasslayup.
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PART VIINSTALLATION CONSIDERATIONS
TESTING RECOMMENDATIONS
THESE PROCEDuRES MuST BE FOLLOWED IN OR-DER TO AVOID SERIOuS PERSONAL INJuRY OR PROP-ERTY DAMAGE. FAILuRE TO DO SO WILL RESuLT IN LOSS OF WARRANTY, AND BuYER, INSTALLER, OR ANY EMPLOYEE, AGENT, OR REPRESENTATIVE THEREOF, ASSuMES THE RISK OF ANY DAMAGE OR INJuRY TO PERSON OR PROPERTY.
NOTE:Followallapplicablelocalcodesandprudentengineeringpractices.
HYDROSTATIC TESTINGWhereverpossible,FGSpipingsystemsshouldbehydro-
staticallytestedpriortobeingputintoservice.Careshouldbetakenwhentesting,asinactualinstallation,toavoidwaterhammer.Locatealltestequipmentawayfromtheendofthepipingsystem.
AboveGround:Allanchors,guidesandsupportsmustbeinplacepriortotesting.
BuriedSystems:Beforetesting,makesurethepipingsys-temissecureintheditchwithcompletebeddingunderthepipeandenoughbackfillmaterialinthemiddleofthepipetoholdthepipeinplace.Jointsshouldbeleftopenforvisualinspectionduringtest.
Tohydrostaticallytesttheline,observethefollowing:Watershouldbeintroducedatthelowestpointinthesystemandtheairbledoffthroughapartiallyopenvalveorlooseflangeatallthehighpoints.Slowlyclosethevalve,andbringthesystemgraduallyuptothedesiredpressure.
A. Test Procedures (RT, GT, SS) Thenormalrecommendedprocedureistoconducta
cyclicpressuretest.Thepipingsystemissubjectedto10pressurizationcyclesat11/2timestheanticipatedordesignoperatingpressure.Pressureisthenkeptonthesystemfor1-8hourswhilethelineisinspectedforleaks.Whenhighertestpressuresaredesired,thetestpressureshouldnotexceed11/2timesthemaximumratedcyclicpressureforthelowestratedcomponentinthesystem.Forlowpressureapplications,suchasdrainlines,thecyclictestmaybereplacedbyasteadypressuretest.Linesthatcanbesubjectedtoseveretemperaturecycles,suchas
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steamcondensatelines,hotwaterlines,andcoldwaterlines,shouldbe testedusingthecyclictestprocedureat11/2timesthecyclicpressurerating,evenifthesystemistooperateatrelativelylowpressure.Vacuumorexternalpressuretestingmustnotexceedtheexternalpressurerating.
B. Test Procedures (F-CHEM) Testpressureshouldnotbemorethan1-1/2timesthe
workingpressureofthepipingsystem,andneverexceed1-1/2timestheratedoperatingpressureofthelowestratedcomponentinthesystem.Whentestingiscomplet-ed,openalloftheairbleedsbeforedrainingthepiping.Thiswillpreventvacuumcollapseofthepipe.
WARNINGS:Air Testing:Hydrostatictestshouldbeusedinsteadofairorcompressedgasifpossible.Whenairorcompressedgasisusedfortesting,tremendousamountsofenergycanbestoredinthesystem.Ifafailureoccurs,theenergymaybere-leasedcatastrophically,whichcanresultinpropertydamageandpersonalinjury.Incaseswheresystemcontaminationorfluidweightpreventstheuseofhydrostatictest,airtestmaybeusedwithextremecaution.Toreducetheriskofairtesting,usethetablebelowtodeterminemaximumpressure.Whenpressurizingthesystemwithairorcompressedgas,theareasurroundingthepipingmustbeclearedofpersonneltopreventinjury.Holdairpressureforonehour,thenreducethepressuretoonehalftheoriginal.Personnelcanthenentertheareatoperformsoaptestofalljoints.Again,extremecautionmustbeexercisedduringairtestingtopreventpropertydam-ageorpersonnelinjury.If air or compressed gas testing is used, FGS will not be responsible for any resulting injury to personnel or damage to property, including the piping system.Airorcompressedgastestingisdoneentirelyatthediscretionandriskofmanagementatthejobsite.
Forlargerdiameters,contactFibe