Polyform User Guide

Polyform User Guide

The following user guide has been designed to provide a step-by-step guide for the application of Polyform.

We have tried to include as much information as possible, however, if you have any questions, queries, or would like to gain some hands-on experience at one of our training sessions, please contact: admin@mwpolymers.co.uk or call: 01332 853001.

Introduction to Polyform

MW Polymers has been supplying Polyform to the gas industry since the 1980s. The product can be used in conjunction with a number of our kits and is available as either a low pressure or medium pressure system. The low pressure kit is unique as it can be used without grit blasting.

Polyform in 1 and 2 litre packs with a Polyprime pre-coat and wrapping

kit

The PE Repair Kit is used in conjunction with Polyform

Introduction to Polyform

When the two parts are mixed, the Polyform will develop a putty-like consistency, which makes it easy to apply as it will not slump when working in awkward or tight spaces. However, you ideally require 12” clearance to ensure you can access the underneath of the pipe. This will enable you to properly inspect the pipe and ensure even coverage around the joint.

PU resins are moisture sensitive. It is therefore important not to get the product or the surface of the pipe excessively wet. If the excavation is filling with water or it is raining, ideally dig a sump hole and pump the water out continuously during the application and for 30-45 minutes after the repair is complete.

Background to Polyform

Polyform is an external repair system designed and manufactured by MW Polymers. It is a polyurethane (PU) based resin designed to permanently repair leaking, corroded or damaged pipes.

It can be applied under live conditions to any size, shape, main or fitting. It can be used on steel, cast iron, ductile iron and plastic pipes.

Once the repair is complete, Polyform is incredibly durable and boasts a 50-year life. It is approved to Gas Industry Standard LC8, UVDB and DIN 30658-1.

The correct application of Polyform will ensure a successful job every time.

Features and benefits• Approval – Polyform is approved to GIS/LC8. This standard is designed for the repair of leaking

ferrous gas mains operating at a maximum pressure of up to 2 bar

• Variety – available for low pressure or medium pressure repairs and works with a number of MW Polymers kits

• Broad application – can be used within the gas, waste water, oil and chemical industries

• Versatile – can be applied to a range of pipes; steel, cast iron, ductile iron and plastic pipes

• Ease of application – the non-slumping consistency means the product is easily applied, particularly as no grit blasting is required for low pressure repairs

• Flexible – the sealant is flexible once applied allowing for pipe movement and lengthening the life of the pipe

• Durable – once cured, the product is waterproof

• Longevity – the product is designed to last for 50 years

• Cost-efficient – using the product reduces the number of man hours typically required, which in turn saves money

• User-friendly – it is non-toxic and odourless

• Polyform is an alternative to encapsulation products that require muffs, fabric or metal components

Step one: Preparation is keyLike most adhesives, the areas you wish to bond should be cleaned and thoroughly dried before attempting the repair. Polyform is gas industry approved for use without grit blasting (on low pressure repairs).

If you have the equipment, shot blasting is best. If this option is not available, use hand tools and wipes to clean the pipe to sound metal. A one metre strip of abrasive tape and a Polyprime pre-coat for cleaning the pipe is included in the kit:

Top tip: the success of the application is 90% preparation! All debris, dirt, scale and moisture must be removed prior to the repair being completed. The application of Polyform only takes around 5-10 minutes, but it is not unusual to spend 1-2 hours prepping the repair area. Taking the time to do this will aid the adhesion process.

Step two: Appropriate PPE

Remove the gloves from both the wrapping and Polyprime pre-coat kits. Put the heavy-duty gloves on ideally taping the cuffs of the glove to your sleeve to prevent the gloves from slipping down.

Put the lightweight gloves over the top of the heavy-duty ones, allowing you to perform the application without the need to change gloves. This process also helps to keep you clean during the repair.

The gloves should be worn in conjunction with other standard PPE such as steel toe cap boots, safety glasses, overalls and anything else required on-site.

Step three: Applying the pre-coat (Polyprime)

To begin with, ensure you have cleaned a large enough area for the application. Once you are happy that the surface of the pipe is clean and dry (including underneath) the next process is to apply the Polyprime pre-coat solution.

This should always be applied sparingly. After a short wait (approximately a few minutes) the Polyprime pre-coat should be tacky to touch, indicating you are ready to apply the Polyform.

Top tip: if there is a delay of more than 20 minutes between applying the Polyprime pre-coat and applying the Polyform, repeat the pre-coat procedure.

Mixing Polyform

In hot weather, the time available to work with Polyform is reduced. In this instance, it is advisable to scoop out the Polyform from the bucket and onto the pipe as quickly as possible. This will allow for a longer working time as the heat created from the curing process is transferred to the pipe and cools the Polyform down.

Top tip: Polyform produces a heat reaction – the resin gets warm as the curing process begins. The weather will affect the cure, for instance, you may find Polyform is slow to cure when it is cold and fast when it is hot. As a rule, mix the bucket until it forms the correct consistency.

Step four: Mixing Polyform

Begin by stirring the base in the bucket to agitate the ingredients as they may have settled in storage.

Top tip: when opening the base and activator, ensure the components to not become contaminated with water or dust.

Note the putty-like consistency after mixing the Polyform activator and

base

Pour in the activator and vigorously mix for 30-45 seconds, ensuring you thoroughly mix the sides and bottom as well.

Step five: Applying Polyform

Using the spatula provided in the kit, manipulate the Polyform around the pipe joint ensuring adequate coverage of the underside. Do not attempt to layer the product gradually as this will weaken the repair and interfere with the curing process.

Top tip: once the Polyform is mixed, you should ideally aim to use it within 90 seconds to get the best results from the product.

Don’t worry about making the repair look pretty, just ensure you have sufficient coverage around the entire circumference of the pipe.

Step six: Wrapping the repair

The next process should be carried out as quickly as possible. Simply remove the lightweight gloves and begin the wrapping process: loosely wrap over the repair ensuring good coverage beyond the area where the Polyform is applied.

Top tip: loosely covering the kit with the wrapping film will contain the resin around the joint while also keeping you clean – Polyform does not wash off clothing!

Step seven: Finishing the wrapping

Once you are happy the Polyform has been encased, gradually pull the film tighter until it changes from opaque to white – this indicates the correct tension has been achieved.

‘Stringing’ film on the ends of the repair prevents the resin from being squeezed out of the middle. Continue to wrap until you are satisfied that there is sufficient coverage to contain the Polyform and maintain external pressure.

Top tip: make a figure of eight with the film when wrapping it around the pipe.

Step eight: Secure the wrapping

Secure the end of the film with adhesive tape to complete the repair.

Final steps:

Ensure the repair does not sit in water immediately after being completed. Also take care not to damage or pierce the film as this will release the internal pressure that is being applied to the Polyform via the wrapping film.

After approximately 45 minutes, the Polyform will have cured to such an extent that it will contain the leak, therefore making the external film redundant.

Note the correct application:

In this image, not enough Polyform has been applied and the wrapping film has been pulled too tight too

soon. This has caused the film to cut into the Polyform and displaced it

instead of being concentrated on the repair area.

On this repair, enough Polyform has been applied with the spatula

provided and the wrapping film has been applied correctly.

Practical advice

• Storage: Keep Polyform out of direct sunlight and frost. Ideally it should be stored between 3˚c - 20˚c

• Normal storage conditions have proven the shelf life to be in excess of 12 months without causing any deterioration to the product

• Expiry dates: The last four digits of the batch code are the expiry code

Practical advice

Recommended volumes (please note: this is just a guideline, please contact us for specific advice):

Size of main Polyprime Pre-coats required

Litres of LP Polyform

Litres of MP Polyform

Vent kits (for MP)

4” 1 2 4 1

6” 1 3 4 1

8” 1 4 8 1

10” 2 6 16 1

12” 3 8 20 2

14” 4 12 28 2

16” 5 14 30 2

18” 7 16 34 3

Disposal

On completion of the repair, any empty containers, soiled gloves or other tools can be disposed of as general waste. Any surplus activator should be mixed with water to cure the residue in a bottle and disposed of as general waste.

Please contact MW Polymers directly on: +44 (0) 1332 835 001 or email: admin@mwpolymers.co.uk if you

have any questions or queries regarding Polyform.