Professional Documents
Culture Documents
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Installation Manual
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Table of contents
1
Introductory Information................................................................................................................................4
1.1 Foreword..........................................................................................................................................................4
1.2
Field Technician................................................................................................................................................4
Product Information.......................................................................................................................................5
3
3.1
3.2
3.3
3.4
3.5
3.6
4
4.1
4.2
4.3
4.4
4.5
Joint Types......................................................................................................................................................8
Typer Adhesive bonded Joint...........................................................................................................................8
Seal-Lock Mechanical Joint.............................................................................................................................8
Butt & Wrap - Lamination Joint........................................................................................................................9
Flange Joint......................................................................................................................................................9
Mechanical Coupling........................................................................................................................................9
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Adhesive bonded Taper Joint, AT - Jointing procedure...........................................................................10
5.1
Tools for adhesive bonded Joints..................................................................................................................10
5.2 Machining.......................................................................................................................................................10
5.3
Cutting and Shaving of Pipe...........................................................................................................................10
5.4
Preparing for Bonding....................................................................................................................................14
5.5
Applying the Adhesive....................................................................................................................................15
5.6
Curing of the Adhesive...................................................................................................................................16
6
6.1
6.2
6.3
6.4
7
Flanged Joints..............................................................................................................................................22
7.1
Tools for Flanged Joints.................................................................................................................................22
7.2
Flanged Joint Description...............................................................................................................................22
7.3 Gaskets..........................................................................................................................................................23
7.4 Bolts...............................................................................................................................................................23
7.5
Trouble Shooting............................................................................................................................................23
Butt and Wrap Lamination Joint.................................................................................................................23
Tools for Butt and Wrap Lamination Joint......................................................................................................23
Lamination Procedure....................................................................................................................................24
Butt & Wrap Lamination Jointing....................................................................................................................26
9
9.1
Mechanical Couplers...................................................................................................................................30
Tools for Mechanical Couplers.......................................................................................................................30
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8.1
8.2
8.3
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Installation of Underground Pipe Systems................................................................................................31
10.1 Procedure.......................................................................................................................................................31
10.2
Trench Construction.......................................................................................................................................31
10.3
Pipe Bedding..................................................................................................................................................31
10.4
Backfill Materials............................................................................................................................................32
10.5
Backfilling Pipe...............................................................................................................................................32
10.6
Burial Depth....................................................................................................................................................33
10.7
Thrust Blocking..............................................................................................................................................34
10.8
Thrust Blocks-Design Construction...............................................................................................................34
10.9 Settlement......................................................................................................................................................35
10.10
Pipe Cast in Concrete....................................................................................................................................35
10.11
Concrete Wall Penetrations and Connections...............................................................................................35
10.12
Multiple Pipes in same Trench.......................................................................................................................36
11
Aboveground Pipe Installation....................................................................................................................37
11.1 General...........................................................................................................................................................37
11.2
Support Types................................................................................................................................................37
11.3
Protective Methods........................................................................................................................................39
11.4
Valve Support.................................................................................................................................................39
11.5
Joining with other Materials...........................................................................................................................39
11.6
UV - Resistance..............................................................................................................................................39
12
13
Repair Work..................................................................................................................................................42
13
13.1
13.2
13.3
Safety Precautions.......................................................................................................................................42
Resin, Hardener and Adhesive Kits................................................................................................................42
Cutting, Shaving and Sanding........................................................................................................................42
Hydro Testing.................................................................................................................................................43
1 Introductory Information
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1.1 Foreword
2 Product Information
Curing oven
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Length adjustment
End machining
Dimension Control
& hydrotest
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Mandrel
Extraction
Ts
Resin
0.5mm
MIN. WT.
0.3mm
(APPROX)
Glass
100 %
STRUCTURAL WALL
30 %
70 % E- GLASS
85 %
15 % C- GLASS
PIPE DIA.
54
0%
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0.2 x L
0.6 x L
0.2 x L
Control Rope
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0.2 x L
0.6 x L
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0.2 x L
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4 Joint Types
AMIPOX offer a comprehensive selection of adhesivebonded and mechanical joining systems for RTR / GRE
piping.
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Power drive
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5.2 Machining
After the pipe has been cut to the exact length, the end
must be machined to the right diameter to ensure a
proper joint. The surface has to be cleaned with clean
cloth. If the surface has been in contact with oil or
grease, it should be cleaned with a clean cloth soaked
in pure acetone, or M.E.K. (methyl ethyl ketone) (free of
water). Do not use thinners, petrol or alcohol for
cleaning. After drying, machining can start.
Wastage of adhesive can be reduced by good planning
and the best use of adhesive kits. Too much adhesive
applied to the female will reduce diameter and result in
restricted flow. Remove excess adhesive with the aid of
a spatula and finish the seam properly and smoothly.
This can be also done inside the pipe, for example, by
pulling a plug threw the pipe. This will prevent problems
using foam pigs later.
Come-along installation tool
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OVERLL LENGTH
LAYING
X
LAYING
LENGTH
CUTTING LENGTH
ND
LENGTH
(mm)
80-100
Tolerance (X)
(inch)
(mm)
3-4
1.5
PD
150-600
6-24
3.0
700-900
28-36
5.0
1000-1200
40-48
6.0
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SPIGOT
DIAMETER
TAPER ANGLE
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NOSE
THICKNESS
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INSERT.
DEPTH
inch
100
150
200
Male
diameter
Nose thick
Male
diameter
Nose thick
Male
diameter
degrees
mm
mm
mm
mm
mm
mm
1.2
Series AT 10
Series AT 12
Series AT 14
2.0
84.0
2.0
84.0
2.0
84.0
1.2
2.0
104.0
2.0
104.0
2.0
104.0
1.2
2.0
154.0
2.0
154.0
2.0
154.0
1.2
2.0
204.0
2.0
204.0
2.0
204.0
250
10
1.5
2.0
254.0
2.0
254.0
2.0
254.0
300
12
1.5
2.0
304.0
2.0
304.0
2.0
304.0
350
14
1.5
2.1
354.2
2.1
354.2
2.1
354.2
400
16
1.5
2.1
404.2
2.1
404.2
2.2
404.4
500
20
2.0
2.3
504.6
2.3
504.6
2.3
504.6
600
24
2.0
2.5
605.0
2.5
605.0
2.5
605.0
700
28
1.75
4.0
708.0
4.0
708.0
4.0
708.0
750
30
1.75
4.0
758.0
4.0
758.0
4.0
758.0
800
32
1.75
4.0
808.0
4.0
808.0
5.5
811.0
900
36
1.75
4.0
908.0
4.0
908.0
6.0
912.0
1000
40
1.75
4.5
1009.0
4.5
1009.0
6.5
1013.0
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80
Nose thick
mm
Taper angle
Pipe size
12
Pipe size
mm
inch
Taper angle
Nose thick
Male
diameter
Nose thick
Male
diameter
Nose thick
Male
diameter
degrees
mm
mm
mm
mm
mm
mm
Series AT 16
Series AT 20
Series AT 25
1.2
2.0
84.0
2.0
84.0
2.0
84.0
100
1.2
2.0
104.0
2.0
104.0
2.0
104.0
150
1.2
2.0
154.0
2.0
154.0
2.0
154.0
200
1.2
2.0
204.0
2.0
204.0
2.0
204.0
250
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1.5
2.0
254.0
2.0
254.0
2.0
254.0
300
12
1.5
2.4
304.8
2.4
304.8
2.4
304.8
350
14
1.5
2.6
355.2
2.6
355.2
400
16
1.5
2.6
405.2
500
20
2.0
2.6
505.2
600
24
2.0
2.6
605.2
700
28
1.75
5.5
711.0
750
30
1.75
6.0
762.0
800
32
1.75
5.5
811.0
900
36
1.75
6.0
912.0
1000
40
1.75
8.0
1016.0
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POSITION AFTER
FINAL ASSEMBLY
WITH ADHESIVE
USING WINCHES
55mm
50mm
SCRIBE
A MARK
HERE
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the surfaces.
14
between 15 C and 40 C.
For warming up, AMIPOX heating blankets can
be used.
If the sun will heat the bonding surfaces to
4 Re-sand.
12
14
16
20
25
bar
bar
bar
bar
bar
bar
80
0.1
0.1
0.1
0.1
0.1
0.2
100
0.2
0.2
0.2
0.2
0.2
0.3
150
0.2
0.2
0.2
0.2
0.3
0.4
200
0.3
0.5
0.5
0.5
1.0
1.0
10
250
1.0
1.0
1.0
1.0
1.0
2.0
12
300
1.0
1.0
2.0
2.0
2.0
2.0
14
350
1.0
1.0
2.0
2.0
2.0
2.0
16
400
2.0
2.0
2.0
2.0
3.0
3.0
18
450
2.0
2.0
2.0
2.0
3.0
3.0
20
500
2.0
2.0
2.0
2.0
3.0
4.0
24
600
2.0
3.0
3.0
3.0
5.0
5.0
28
700
3.0
3.0
4.0
4.0
5.0
6.0
30
750
3.0
4.0
5.0
5.0
6.0
7.0
32
36
800
4.0
4.0
5.0
6.0
7.0
8.0
900
4.0
6.0
6.0
7.0
8.0
1000
5.0
6.0
7.0
7.0
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40
10
mm
PD
Size
inch
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Temp. oC
20
25
30
35
40
Setting Time
30min
25min
20min
15min
10min
15
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Pipe Size
mm
80
1.0
1.0
1.0
1.0
1.0
1.0
100
1.0
1.0
1.0
1.0
1.0
1.0
150
1.0
1.0
1.0
1.0
1.0
1.0
200
1.0
1.0
1.0
1.0
1.0
1.0
250
10
1.0
1.0
1.0
1.0
1.5
1.5
300
12
1.0
1.0
1.5
1.5
1.5
1.5
350
14
1.0
1.0
1.5
1.5
1.5
1.5
400
16
1.0
1.5
1.5
1.5
2.0
2.0
450
18
1.5
1.5
2.0
2.0
2.0
2.0
500
20
1.5
1.5
2.0
2.0
3.0
3.0
600
24
1.5
2.0
3.0
3.0
4.0
4.0
700
28
2.0
750
30
800
32
900
36
40
1000
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inch
Series
3.0
4.0
4.0
4.0
4.0
2.0
3.0
4.0
4.0
4.0
4.0
2.0
4.0
4.0
4.0
4.0
4.0
3.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
PD
mm
inch
Series
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Pipe Size
80
1.0
1.0
1.0
1.0
1.0
1.0
100
1.0
1.0
1.0
1.0
1.0
1.0
150
1.0
1.0
1.0
1.0
1.0
1.0
200
1.0
1.0
1.0
1.0
1.0
1.0
250
10
1.0
1.0
1.0
1.0
1.0
1.0
300
12
1.0
1.0
1.0
1.0
1.0
1.0
350
14
1.0
1.0
1.0
1.0
1.0
1.0
400
16
1.0
1.0
1.0
1.0
1.0
1.0
450
18
1.0
1.0
1.0
1.0
1.5
1.5
500
20
1.0
1.0
1.5
1.5
1.5
1.5
600
24
1.0
1.5
1.5
1.5
2.0
2.0
700
28
1.0
1.5
2.0
2.0
3.0
3.0
750
30
1.5
1.5
2.0
2.0
3.0
3.0
800
32
1.5
2.0
2.0
2.0
3.0
3.0
900
36
1.5
2.0
3.0
3.0
4.0
4.0
1000
40
2.0
3.0
4.0
4.0
4.0
4.0
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2 O-ring placement
1:
2:
3:
4:
5:
6:
7:
8:
9:
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STEP 1
STEP 2
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STEP 3
STEP 7
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STEP 4
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STEP 6
STEP 5
STEP 8
20
STEP 9
inch
mm
Male x Female
Coupling
2-16
50-400
1/2
18-48
450-1200
1/4
1/2
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STEP 10
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7 Flanged Joints
17
9
21
22
13
9
4
9
3
12
15
6
16
19
14
11
19
PD
7
14 2 23 11
17
18
26
16
10
23 15
20 17
18
19
10
3
15
27
10
11
17
10
1
22
11
25
16
1 13
18
24
21
12
20
28
13
14
12
20
24
16
12
13
14
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flanges
must always be accurately aligned and not subject
to any stress.
The bolts and nuts must have washers to avoid
exceeding the permitted surface pressure. As an
alternative, a stub-end type flange with steel
backing ring centre can be installed.
Pipe must not be pulled together by tightening the
bolts. If an R.T.R.P. pipeline is connected to a metal
pipe, this metal pipe must be anchored to prevent
any movement or loads being transmitted to the
R.T.R.P. line.
10
15
Torque
Increments
Final Torque
mm
inch
(N-m)
(N-m)
80
15
56
100
15
56
125
20
82
150
20
82
200
20
82
250
10
30
150
300
12
30
150
350
14
30
150
400
16
50
250
450
18
80
400
500
20
80
400
600
24
100
500
700-750
28-30
100
500
800
32
100
500
900
36
100
500
1000-1200
40-48
100
500
800
32
100
500
900
36
100
500
1000-1200
40-48
100
500
22
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7.4 Bolts
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Material Description
Specifications
Epoxy Resin
AMIANTIT approved
commercial grade such
as: Araldite GY6010, DER
330 and Epikote 827
Hardener
IPD
Boat Tape
Adhesive
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Woven Roving
Remarks
1 Preparation
Qualification of the installation staff by means of
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FIT LAYER
BOATTAPE WITH ADHESIVE
CIRCUMFERENTIAL, 3 LAYERS
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2 Process
A Cutting the pipe
Determine the length of the pipe sections,
taking into account the dimensions of the
fittings see Figure 8-2 below.
Mark the pipe sections with the aid of a
marking template.
Clamp the pipe in a vice; plies of rubber or
similar material should be used to protect
the pipe.
Cut the pipe with a hack saw, grinding
wheel, etc. Make sure the cut is straight
and right-angled.
Cut right through, do not break off. Support
the free end of the pipe. Use a fine-tooth
saw. The liner must not to be damaged.
LAMINATION SEQUENCE
L
Figure 8-2 Fit layer schematic
sketch
D Lamination sequence
WOVEN ROVING 50% OVERLAP, 5 LAYERS
Start the lamination of the fitted section
2 (see point C above) within two hours
after sanding; re-sanding
of lamination area
BOATTAPE 50% OVERLAP, 1 LAYER
shall be required if the waiting period
3 exceeds two hours.
Remove dirt using clean rags and dry
* REPEAT THIS SEQUENCE UNTIL THE MINIMUM
brush
and also remove any possible
REQUIRED LAMINATE THICKNESS IS ACHIEVED
NOTE:. SIZEmoisture
by
heating the surfaces by
150 ND AND BELOW
USEslightly
ONLY BOATTAPE
means of heating blankets.
Prepare the resin mix using the correct
mixing ratio Resin = 100 parts by weight;
Hardener = 24 parts by weight. Take note
of the pot life after mixing. The amount of
the mixture depends on the diameter.
Several batches could be used depending
on the weather, temperature and gelling time.
FIT LAYER
L.T.
LAMINATE OVERLAY
W.T.
L
2L
NOTE:
L = 120mm FOR PIPE SIZES 50mm ND TO 200mm ND
L = ND FOR PIPE SIZES 250mm ND AND ABOVE
LT = LAMINATION THICKNESS = 2 x PIPE WALLTHICKNESS
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LAMINATION SEQUENCE
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BOATTAPE 50% OVERLAP, 2 LAYERS
1
WOVEN ROVING 50% OVERLAP, 5 LAYERS
2
BOATTAPE 50% OVERLAP, 1 LAYER
3
*
E Finishing work
Clean up the area.
Dispose waste products in an environment
friendly manner.
Subsequently activities must be performed
in accordance with the instructions, e.g.
supports, pressure tests, etc.
25
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STEP 1
26
STEP 4
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STEP 3
27
STEP 6
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PD
STEP 5
28
STEP 8
PD
STEP 7
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9 Mechanical Couplers
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STEP 9
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30
10.1 Procedure
Secondary backfill
zone compacted in
layers of 30 cm
0.7 x D
Primary backfill
zone compacted in
layers of 15 cm
15 cm Bedding
15 cm Foundation
Final backfill
excavated soil
compacted in
layers of 30 cm
30 cm
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Secondary backfill
zone compacted in
layers of 30 cm
15 cm Bedding
15 cm Foundation
Primary backfill
zone compacted in
layers of 15 cm
Final backfill
excavated soil
compacted in
layers of 30 cm
F
N
0.7 x D
PD
30 cm
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particle size.
No frozen material
No organic material
No debris (tires, bottles, metals, etc.)
DN
450
13
500-1200
19
PD
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RTR products.
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Rubber pad
Road surface
Shrinking
sleeve
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prior to backfilling.
3m
Casing pipe
Spport
0.5 x OD
Relief plate
45
Spread
OD
F
PD
195
24.5
14.64
4.8
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3.9
1.95
Clay soft
0.97
7.8
3.9
1.95
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At =
where:
At = Bearing area of thrust block
R = Reaction
SP = Allowable soil bearing pressure
Thrust blocks for AMIPOX pipe systems should be
34
R
Sp
casting.
Cradles are provided with steel clamps and rubber
lining in order to prevent floating.
Buckling of the pipe during casting can be
prevented by pressurizing the system.
Note that concrete shrinks when setting; this may result
in extra loading of the GRE pipe system. Ensure that
the allowable external pressure is not exceeded by
using pressure relief valves.
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10.9 Settlement
PD
The longer the rocker pipe, the higher the loads on the
joints. This can be avoided by using more rocker pipes.
Based on the soil parameters, the number of rocker
pipes is determined.
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Sag
Flexible
joint
Flexible joint
Settled profile
ofter subsidence
Location of pipe
after subsidence
35
Puddle Flange
RTR pipe
Concrete wall
100 (typ)
R2
R1
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2 Support saddles
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2 - RTR support
saddle 180^
bonded on pipe
RTR pipe
R1
R2
Concrete wall
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Sand bedding
RTR pipe
Packing seal
11.1 General
This section gives guidelines for proper installation of
AMIPOX pipe systems installed above the surface of
the ground.
180 GRE
180^
GREsaddle
SADDLE
permitting
PERMITTING
AFFIXEDtoTO
affixed
pipe
PIPE
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Those who know how to install steel pipe will find that
most of the same skills and techniques apply but there
are some important differences. AMIPOX pipe requires
protection against potential external abrasion or
crushing at points where supports are located.
In general, the objective of any above ground
installation is to provide supports, guides and anchors
points in such a way that deflection of unsupported
span lengths are maintained within acceptable limits
over the long-term.
B Guide supports:
Support vertical loads and restrain lateral movement.
The main use of guides is to avoid buckling and
maintain alignment when axial compressive loads exist
in a pipe. Typical, for guide support are shown in
Figure 11.2 below
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A Simple supports:
To prevent excessive pipe deflection due to the weight
of the pipe and the fluid, horizontal pipe should be
supported at intervals recommended in the support
spacing tables provided by AMIPOX Typical for simple
support are shown in Figure 11-1
C Anchor supports:
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Figure 11-3
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support to be welded
or anchor to a base
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support to be welded
or anchor to a base
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Support saddle
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concrete wall
butterfly valve
support
11.6 UV - Resistance
To manufacture AMIPOX RTR Products, a pigment is
added to the resin system, which improves the
resistance to UV Radiation of the finished products.
The pigmentation delays the effect of the UV but does
not completely eliminate it. Pipes exposed to direct
sunlight for long period of time will definitely undergo
changes in appearance. The rate of appearance change
will depend on the intensity of sunlight and length of
exposure.
Although no failures are known to have resulted from
this change of appearance, it does cause a dull, grey
appearance, which some users wish to avoid. Surface
degradation has little effect on piping system
performance. However, the mechanical properties or
structural integrity of the RTR products are not affected
by this surface change of appearance.
One can prevent or control the effect by painting with
good quality solvent-based paint. However, it is
recommended to delay the application of paint till the
weathering has occurred in order to have good paint
adhesion.
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Testing manifold
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13 Repair Work
1 General
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8 Depressurising
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must be replaced.
In the case of pipes with damage to the
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14 Safety Precautions
Laminated joints
- Grind off the entire laminate including the
bonding laminate and affix a new laminate
See section Laminated Joints.
Seal-Lock joints
- If it is not possible to open the joint, cut it
out and replace it (taking due account of
the systems flexibility) See section
Seal-Lock Joints.
- If you can open the joint, established and
correct the causes of the problem
(e.g. new O-ring, remove dirt, replace pipe)
See section Seal-Lock Joints.
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Flanged joints
- Check whether all the bolts have been
properly torque.
- Check whether the flanges as parallel.
- Check the flanges and seals for damage
and replace if necessary See section
Flanged Joints.
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Distributed by:
AMIPOX
First Industrial City
P.O. Box 589
Dammam, 31421
Saudi Arabia
Tel.: + 966 (3) 847 1500
Fax: + 966 92 000 4070
info@amiantit.com
www.amiantit.com
FT-AMIPOX V1 01-13-ENG
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