BONDSTRAND Assembly Instructions for Quick-Lock adhesive bonded joints

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1 BONDSTRAND Assembly Instructions for Quick-Lock adhesive bonded joints 1997 Ameron - FP 170 A 11/97 (formerly BA-20). Printed in Holland.

2 To make the bell and spigot assembly of Bondstrand pipe and fittings using Ameron s thermosetting adhesives, you need only follow these step-by-step instructions. They show you how to cut the pipe, prepare the ends, use the adhesive, stab the joint and cure the adhesive to produce a strong and reliable Quick-Lock joint. 1To cut the pipe to length, measure the desired length and scribe the pipe using a pipefitter s wrap-around (photo 1). Place the pipe in a vise, using 6 mm (1/4 inch) thick rubber pad to protect pipe from damage. Cut pipe with hacksaw, sabre saw, or abrasive wheel (photo 2). Check the squareness of cut by inserting a pipe shaver arbor flush in to the cut pipe. Pipe up to 100 mm (4 inches) should be square to within 1.6 mm (1/16 inch). Larger pipe should be square to within 3.2 mm (1/8 inch). Use a disc grinder or file to correct squareness. Danger: Avoid inhaling dust produced by cutting and grinding operations. Provide adequate ventilation; wear-approved dust respirators. photo 1 photo 3 photo 2 photo 4 photo 5 2Shave the cut end of the pipe using the Bondstrand pipe shaver (photo 4). Shaving can be done manually, but a portable power drive is advisable for larger sizes and if shaving several sections. Measure the shaved pipe using a Pi Taper (photo 5). See table 1 for shaving dimensions. Note 1: Instructions for adjusting and operating the pipe shaver to prepare the correct spigot diameter and length are provided with the shaver or may be obtained from your local Ameron representative. For 25 and 40 mm (1-1 1 /2 ) diameters a compact pipe shaver is available from Ameron. Note 2: Diameters 350 and 400 mm (14 and 16 ) of series 2000M and 7000M have a deviating internal diameter that need different sized arbors. Table 1. Shaved dimensions Pipe Dia Max. Dia. Min.Dia. Spigot Length* (mm) (in) (mm) (in) (mm) (in) (mm) (in) * When correct spigot lengths are taken adjusted on the shaver, the length of the shaved pipe end will be automatically within the min. and max. size as described above.

3 3All fittings, sockets, pipe ends (spigots) and pipe sockets must be clean, dry and sanded within two hours of assembly. Sanding should be accomplished using a mm (1/2 inch) drill motor, rpm (photos 6-8) and flapper type sander with a grit aluminium oxide abrasive, available from Ameron. After sanding, surfaces to be bonded should show a dull fresh finish, not a polished look. Do not forget to lightly sand the edges of the spigot. Clean and dry sanded surfaces are necessary for proper bonding. Sockets with a 25 and 40 mm diameter must be sanded with sandpaper with a grit, since they are too small for the flapper sander. Danger: Avoid inhaling dust produced by sanding operations. Provide adequate ventilation; wear an approved dust respirator. photo 10 Table 2: Mark location for checking spigot insertion Nom. Dia Mark location for checking spigot insertion in mm/in Use table 2 to measure back from the spigot end of 4aeach pipe to be joined (photo 10) and scribe a line using a white grease pencil or soapstone. When the spigot is bottomed in the socket, the scribed line will be 25 mm (1 inch) from the end of the socket. photo 6 photo 7 photo 11 photo 12 bmatch mark the two mating pieces for proper alignment. Taking care to avoid contaminating mating surfaces, fit together loosely the two pieces to be joined (photo 11). Using a white grease pencil or soapstone, mark each piece in a common longitudinal line for subsequent realignment (photo 12). photo 8 photo 9 Thoroughly wipe the sanded socket and spigot with a clean, dry cloth, or use a duster brush to remove dust particles (photo 9). If surfaces are wet, warm with Bondstrand heating blanket until dry, then resand. Protect the bonding surfaces from moisture during bad weather with tenting over the working area. Do not touch the prepared surfaces with bare hands or any articles that would leave an oily film. 5Ameron offers several chemically resistant thermosetting adhesives recommended for use in pipelines transporting most fluids (for exceptions see Bondstrand Chemical Resistance Chart available from Ameron). Because the acceptability for pipelines transporting food or potable water depends on local laws and regulations, contact your Bondstrand supplier for advice or assistance before using adhesives in these services.

4 astore adhesives at temperatures below 38 C (100 F) and use before the expiration date stamped on the top flap of the package. Do not use kit if either container shows evidence of leakage. bselect the size of adhesive kit in accordance with table 3. Table 3: Determining adhesive quantities Pipe Dia Kit Size Joints per Kit (mm) (cc) / /2 cobserve the following: (1) Use soap and water to wash skin area with which adhesive components have come in contact. Do not use solvents on the skin. (2) Use water-removable protective creams to avoid allergic reactions. Solvent-removable creams are not recommended. Disposable polyethylene gloves can also be used to avoid contact of Bondstrand adhesive with the hands. dafter the joint has been properly prepared (see steps 1 through 4) and it is ready to be bonded, add the contents of the small container (hardener) to the large container (resin) and stir thoroughly for at least one minute and until no streaks are visible in the mixture (photos 13/14). Immediately after mixing, apply the adhesive to the surfaces to be bonded as described below. If your epoxy adhesive mixture has started to heat in the container, discard and start a new one. Heating indicates that the mixture has started to cure. Be aware of the working time available to you after the adhesive is mixed. Working times at various temperatures are stated on the adhesive package. If the adhesive is not within the 21 C (70 F) and 38 C (100 F) range, you will need to warm or cool it before mixing. The adhesive will not mix and spread well below 21 C and will set up too fast above 38 C. Caution: These adhesive resins and hardeners, separately or combined, will cause skin and eye irritation. Avoid contact with skin and eyes. Do not take internally. In case of contact, wash skin with soap and water. For eyes, flush with plenty of water for at least 15 minutes and get medical attention. For industrial use only. Keep away from children. photo 13 photo 14 6With the spatula supplied in the adhesive kit, or a reusable steel spatula, apply a layer of adhesive approximately 0.8 mm (1/32 inch) thick to the surface of the socket (photo 15).

5 photo 15 photo 16 Too much adhesive on the socket will result in a flow restriction inside the joint. Apply adhesive liberally to the entire spigot surface and a thin layer to the cut end of the pipe. Excess adhesive on the spigot surface will be forced out when the socket and spigot are joined. Correct photo 17 photo 18 calign flanges, tees and other fittings to the matchmarks as you assemble the spigot and socket. Avoid having to rotate the part while assembling. Then, for flanges, check rotational alignment of bolt holes and squareness of flange faces. Flanges with bolt holes more than 1.6 mm (1/16 inch) out of rotational alignment, flanges more than 1.6 mm out of square across the flange face, or any angular errors of more than 1/2 degree in the axial or rotational alignment of spigot and socket joints are likely to introduce subsequent assembly problems. If misaligned, pull joint apart, remove adhesive from the pipe stop area, reapply adhesive as in step 6 and rejoin before adhesive starts to set up. Incorrect! Without delay, insert the pipe slowly and without 7arotation into the socket until the spigot end rests firmly rests against the pipe stop (photo 17). For 150 mm (6 ) pipe and larger, use a light strap winch to seat and clamp the joint. Support the winch on a wooden bridge across the joint so the winch can be left snug while the heating blanket cures the adhesive. Smaller pipe (25, 40, 50, 80 and 100 mm (1, 1 1 /2, 2, 3 and 4 ) is joined by tapping on a 50x100 mm (2 x 4 ) wooden block placed over the pipe end to seat the spigot in to the socket. bfittings may be joined to pipe spigots by using one of the two methods of Step 7a or a 1 kg rubber hammer (Shore A Durometer 70-80) 60 to 75 mm (2 1 /2-3 ) in diameter may be used to tap directly on Bondstrand fittings for proper seating. It may be helpful or even necessary to back up the outside radius of an elbow, tee, lateral, etc. with a sandbag or similar shock absorber while tapping pipe spigots into fittings. photo 19 dcheck for proper seating.the scribed mark on the spigot (see step 4a) should now be 25 mm (1 inch) from the end of the socket (photo 19). eclean up and remove excess adhesive from outside of joint and from front, back and inside of flange. Flange face must be clean and free of adhesive.

6 Cure adhesive joints as follows: Place the thermo- end of your Bondstrand heating blanket 8astat against the assembled joint with the thermostat side facing out from the joint. Wrap the remainder of the blanket around the joint so that any overlap will cover the thermostat. Tie the blanket in place with any nonconducting tie. Pipe Blanket Thermostat Standard Wrap for Pipe and Fitting Joints bit is always a good idea to insulate around the heating blanket and to close the pipe ends. This is essential when it is windy or when the air temperature is below 15 C (59 F). Fiberglass insulation backed with aluminium foil generally works well. Insulation should overlap the blanket sides about 100 mm (4 inch) each way and be tied down near the edges to trap the heat. cflange mounting requires a special wrap. Lay the blanket flat with the thermostat down and, starting at the thermostat end, roll up the blanket. Insert the rolled blanket into the pipe end the depth of the fresh joint, leaving the cord and part of the blanket exposed as shown in the sketch at the left. Fill the space inside the rolled blanket with fiberglass insulation or some other heat resistant material to ensure that the blanket remains snugly against the inside joint surface. dapply alternating current (ac) at the voltage marked on the heating blanket and mark the starting time on the pipe. Make sure the blanket is operating and, in fact, heats up. 9 Curing. All adhesives are cured with and Ameron-approved heating blanket. However, the proper cure time depends on the choice of adhesive and the conditions of service. For a pipe-to-pipe and a pipe-to-flange connection, minimal curing time is 60 minutes. For a pipe-to-fitting joint curing time is min. 90 minutes because wall thickness of fittings is mostly thicker than pipe diameter. Also when using pipe-to-pipe fittings with extra thick wall (such as with series 2000M and 7000M) a curing time of min. 90 minutes is recommended. Tip: Preparations for other assemblies can be handled during this curing process. Heating Blanket Pipe Special Wrap for Flange Mounting Caution: Joint must not be moved, vibrated, or otherwise disturbed during cure of adhesive.

7 Check working of heating blanket regularly to ens- the blanket is operating. When heating blanket 10ure fails to operate correctly, e.g. by a temporary power loss, the entire curing procedure should be repeated. Recommended equipment for installing Bondstrand Pipe (a) Pipe shaver and arbors (Ameron) (b) Hacksaw, saber saw, or abrasive wheel (c) Winch and straps, for 150 mm (6 ) and larger, Dayton No. 2Z096 (d) Pi Tape measuring tape (e) White grease pencil or soapstone (f) Rubber mallet, 2 lb. (Shore A Durometer 70-80) 60 to 75 mm (2 1 /2-3 ) diameter (g) Pipefitter s wrap-around (h) Disc grinder or file (optional) (I) Heat blanker (Ameron) (j) Electric 6 mm (1/4 inch) drive drill motor, rpm. (k) Level (l) Flapper wheel sander or sandpaper (Ameron) (m) Folding rule, 3 m (10 inch) (n) Tape, 15 m (50 inch) (o) Duster brush or clean rags (p) Portable power drive, Ridgid No. 700 or Amaz-O-Thred 181 D. (q) Pipe vise (Pilot No. 20) and is 6 mm (1/4 inch) thick elastomer pad. IMPORTANT This literature and the information and recommendations it contains are based on data reasonably believed to be reliable. However, such factors as variations in environment, application or installation, changes in operating procedures, or extrapolation of data may cause different results. Ameron makes no representation or warranty, express or implied, including warranties of merchantability or fitness for purpose, as to the accuracy, adequacy, or completeness of the recommendations or information contained herein. Ameron assumes no liability whatsoever in connection with this literature or the information or recommendations it contains. Written comments regarding this document are invited. Please write to the Engineering Manager, Ameron Fiberglass Pipe Group, P.O. Box CA Geldermalsen, the Netherlands.

8 Fiberglass Pipe Group Headquarters P.O. Box Houston, TX U.S.A. Phone: (+1) Fax: (+1) Internet: Fiberglass Pipe Division The Americas P.O. Box 878 Burkburnett, TX U.S.A. Phone: (+1) Fax: (+1) Fiberglass Pipe Division Europe Ameron B.V. P.O. Box CA Geldermalsen The Netherlands Phone: (+31) Fax: (+31) Fiberglass Pipe Division Asia Ameron (Pte) Ltd No. 7A, Tuas Avenue 3 Jurong Singapore Phone: (+65) Fax: (+65) / ISO 9001 Certified Firm