AMIPOX Piping System

Installation Manual

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Table of contents

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1 Introductory Information................................................................................................................................4
1.1 Foreword..........................................................................................................................................................4
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1.2 Field Technician................................................................................................................................................4

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2 Product Information.......................................................................................................................................5
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3 Shipping, Handling and Storage...................................................................................................................6

3.1 Inspecting Pipe.................................................................................................................................................6
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3.2 Repairing Pipe..................................................................................................................................................6

3.3 Unloading and Handling Pipe...........................................................................................................................6
3.4 Site Pipe Storage..............................................................................................................................................7
3.5 Storing Gaskets, Lubricants and Adhesives....................................................................................................7
3.6 Transporting Pipe.............................................................................................................................................8

4 Joint Types......................................................................................................................................................8
4.1 Typer Adhesive bonded Joint...........................................................................................................................8
4.2 Seal-Lock Mechanical Joint.............................................................................................................................8
4.3 Butt & Wrap - Lamination Joint........................................................................................................................9
4.4 Flange Joint......................................................................................................................................................9
4.5 Mechanical Coupling........................................................................................................................................9

5 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

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6 AMIPOX Seal-Lock Joints ASL - Jointing Procedures.............................................................................18
6.1 Tools for Rubber Seal-Lock Joints.................................................................................................................18
6.2 Joint Assembly...............................................................................................................................................18
6.3 Seal-Lock Jointing..........................................................................................................................................19
6.4 Types of Rubber Ring and Locking Strip.......................................................................................................21

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

8 Butt and Wrap Lamination Joint.................................................................................................................23

8.1 Tools for Butt and Wrap Lamination Joint......................................................................................................23

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8.2 Lamination Procedure....................................................................................................................................24

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8.3 Butt & Wrap Lamination Jointing....................................................................................................................26

9 Mechanical Couplers...................................................................................................................................30
9.1 Tools for Mechanical Couplers.......................................................................................................................30
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10 Installation of Underground Pipe Systems................................................................................................31
10.1 Procedure.......................................................................................................................................................31
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10.2 Trench Construction.......................................................................................................................................31

10.3 Pipe Bedding..................................................................................................................................................31
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10.4 Backfill Materials............................................................................................................................................32

10.5 Backfilling Pipe...............................................................................................................................................32
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10.6 Burial Depth....................................................................................................................................................33

10.7 Thrust Blocking..............................................................................................................................................34
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10.8 Thrust Blocks-Design Construction...............................................................................................................34

10.9 Settlement......................................................................................................................................................35
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10.10 Pipe Cast in Concrete....................................................................................................................................35

10.11 Concrete Wall Penetrations and Connections...............................................................................................35
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10.12 Multiple Pipes in same Trench.......................................................................................................................36

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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 Field Hydro Testing......................................................................................................................................40

13 Repair Work..................................................................................................................................................42

13 Safety Precautions.......................................................................................................................................42
13.1 Resin, Hardener and Adhesive Kits................................................................................................................42
13.2 Cutting, Shaving and Sanding........................................................................................................................42
13.3 Hydro Testing.................................................................................................................................................43

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1 Introductory Information

1.1 Foreword Specifications written for a particular project would

This manual is designed to assist supervisors and field
engineers in the installation procedures of the AMIPOX
GRE Pipes system. It provides suggestions to avoid/
solve problems during installation and mainly addresses
the usual circumstances that may be encountered in
the field. Unique situations requiring special
considerations are not addressed and should be
resolved in cooperation with the supplier.
Most importantly, this installation guide is not meant to
replace common sense, good engineering practices
and judgment, applicable laws, safety, environmental or
other regulations or local ordinances, nor the
specifications and instructions of the owners
have priority over the general guidelines mentioned
here. Varying circumstances may require deviations
from the procedures described. Please consult the
supplier with any questions or when variations from this
installation manual are being considered.
1.2 Field Technician
The supplier can, at the request of the purchaser and
within the terms of the agreement between the
purchaser and the supplier, provide a Field Technician.
The Field Technician can advise the purchaser and/or

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engineers, who are the final authority on each job. the installer to help him achieve a satisfactory pipe

Should any conflicting information in this manual create
doubts how to proceed properly, please consult the
supplier and the owners engineers to obtain
assistance. These instructions are to be used as a
reference only.
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The installation procedures outlined in this installation
manual and the suggestions of the field technicians,
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installation. It is recommended that on the job field
service be engaged in the initial stage of installation
and it may continue periodically throughout the project.
The service may range from continuous (essentially full
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time) to intermittent depending on the agreement
between purchaser and supplier.

when carefully followed, will help in the thorough

execution of a proper, long-lasting installation.
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2 Product Information

AMIPOX pipe systems are produced by the filament

winding method. In this numerically controlled Glass fibre Roving
mechanical process, a continuous glassfiber roving is
impregnated with epoxy resin system.

The production of GRE starts with the preparation of

Epoxy Resin Impregnation
the steel mandrel. The steel mandrel is a cylindrical
mould. A loose part (head stack) is attached to the Laying carriage moves
in both direction
mandrel end. This mandrel head stack is determining
the shape of the socket (female) and thus the Rotating mandrel
connection type. There are three connection (jointing)
types: Taper/Taper, Seal- lock and plain ends.
Curing oven
During the next process step, the glassfibers are pulled
through a bath filled with epoxy resin.

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After impregnation the glassfibers are filament wound

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around the polished mandrel under constant tension
Mandrel
applied at a helix angle of 54 +/- 2 degree. Extraction
The filament winding process continues until the pipe
has come to the desired wall thickness.
The wall thickness of the pipe depends on the project N
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requirements and pressure class. In general the higher Length adjustment

the pressure the thicker the wall will be.

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The winding is finished with a resin rich topcoat for

weather and UV radiation protection.
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End machining

After the filament winding process is completed, the

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Dimension Control
mandrel with the pipe will be cured in an oven at about & hydrotest
150C. After curing the mandrel will be removed from
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the new formed GRE pipe by means of water pressure.

The new formed GRE pipe will be cut at desired length, Figure 2-1 Flow chart AMIPOX winding process
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males (male ends) will be machined, dimensionally and

visually checked and hydrostatic tested witness by the
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quality department.
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0.3mm
(APPROX) Resin Glass
0.3mm RESIN RICH 100 % 0%

STRUCTURAL WALL 30 % 70 % E- GLASS

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MIN. WT.

0.5mm RESIN RICH LINER 85 % 15 % C- GLASS

0.5mm

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WALL THICKNESS COMPOSITION

PIPE DIA.

Figure 2-2 AMIPOX pipe wall structure

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3 Shipping, Handling and Storage

3.1 Inspecting Pipe 3.3 Unloading and Handling Pipe

All pipes should be inspected upon receipt at the job
site to ensure that no damage has occurred in transit.
Depending on the length of storage, the amount of job
site handling and other factors that may influence the
pipes condition, it is recommended that the pipe be
re-inspected just prior to installation.
Inspect the shipment upon delivery, as follows:
Unloading the pipe is the responsibility of the customer.
Be sure to maintain control of the pipe during
unloading. Guide ropes attached to pipes or packages
will enable easy manual control when lifting and
handling. Spreader bars may be used when multiple
support locations are necessary. Do not drop impact or
bump the pipe, particularly at pipe ends.

Make an overall inspection of the load. If the load is

intact, ordinary inspection while unloading is 3.3.1 Single pipes
normally sufficient to make sure the pipe has arrived
without damage. When handling single pipes, use pliable straps, slings or
If the load has shifted or indicates rough treatment, rope to lift. Do not use steel cables or chains to lift or

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carefully inspect each pipe section for damage. transport the pipe. Pipe sections can be lifted with only

Generally, an exterior inspection will be sufficient to
detect any damage. When pipe size permits, an
interior inspection of the pipe surface at the location
of an exterior scrape may be helpful to determine if
the pipe is damaged.
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Check the quantity of each item against the bill of
lading.
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one support point Figure 3-1, although two support
points placed as in Figure 3-2 is the preferred method
for safety reasons, as it makes the pipe easier to control.
Do not lift the pipe using hooks at the pipe ends or by
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passing a rope, chain or cable through the section end
to end.

Note on the bill of lading any transit damage or loss

and have the carrier representative sign your copy
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of the receipt. Claims against the carrier should be

in accordance with their instructions.
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If any imperfection or damage is found, segregate

the affected pipes and contact the supplier.
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Do not use pipe that appears damaged or defective.

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3.2 Repairing Pipe

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Normally, pipes with minor damage can be repaired

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quickly and easily at the job site by a qualified

individual. If in doubt about the condition of a pipe,
do not use it.
Figure 3-1 Lifting pipe at one support point
The Field Technician can help you determine whether
repair is required and whether it is possible and
practical. Repair designs can vary greatly due to pipe
thickness, wall composition, application and the type 0.2 x L 0.6 x L 0.2 x L
and extent of the damage. Therefore do not attempt to
repair a damaged pipe without consulting the supplier
first. Repairs must be made by a trained repair
technician. Improperly repaired pipes may not perform
as intended.

Control Rope

Figure 3-2 Lifting pipe at two support points

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3.3.2 Unitised loads
Unitised loads may be handled using a pair of slings as
shown in Figure 3-3. Do not lift a non-unitised stack of
pipes as a single bundle. Non-unitised pipes must be
unloaded and handled separately (one at a time).
Ensure suitable supports such as clean, nail free
wooden beams. Supports must be spaced at a
maximum interval of 3m and around 1m from each pipe
end.

If at any time during handling or installation of the pipe

any damage such as a gouge, crack or facture occurs,
the pipe should be repaired before the section is
installed.

Contact the supplier for inspection of the damage and

for the recommended method of repair or disposal
See Chapter 3.2 .

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0.2 x L 0.6 x L 0.2 x L

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Figure 3-4 Storing pipe

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Figure 3-3 Lifting unitised package

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3.4 Site Pipe Storage

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It is generally advantageous to store pipe on flat timber

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to facilitate placement and removal of lifting slings

around the pipe.

When storing pipe directly on the ground, be sure that

the area is relatively flat and free of rocks and other
potentially damaging debris. Placing the pipe on
mounds of backfill material has been found to be an
effective way of storing the pipe on site. All pipes Pipe storage at construction site
should be chocked to prevent rolling in high winds.

If it is necessary to stack pipes, it is best to stack on
flat timber supports (minimum width of 75 mm) at
quarter point with chocks (see Figure 3-4). If available,
use the original shipping dunnage.
Ensure that the stack will be stable in conditions such
as high winds, uneven storage surface or other
horizontal loads. If strong winds are anticipated,
consider using ropes or slings to tie pipes down.
Maximum stack height is approximately 1.5 meters, or
two layers, whichever is higher.
3.5 Storing Gaskets, Lubricants and
Adhesives
Rubber ring gaskets, for the seal lock joints, should
be stored in the shade in their original packing and
should not be exposed to sunlight except during the
pipe joining. Also, the gaskets must be protected
from exposure to greases and oils which are
petroleum derivatives and from solvents and other
harmful substances

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 4 Joint Types

Gasket lubricant should be carefully stored to
prevent damage. Partially used buckets should be
resealed to prevent contamination of the lubricant.
If temperatures during installation are below 5 C,
gaskets and lubricant should be sheltered until
used.
Adhesives must be stored indoors at temperatures
below 38 C. Extended storage at higher
temperatures will degrade the catalyst and the resin
and reduce adhesive strength. Each adhesive Kit is
stamped with an expiry date. They should be
removed from shipping cartons and stacked upright
so that the expiry dates are visible.
AMIPOX offer a comprehensive selection of adhesive-
bonded and mechanical joining systems for RTR / GRE
piping.
4.1 Taper Adhesive bonded Joint
Adhesive bonded Taper/Taper joint with matching taper
male and taper female ends, uses adhesive for jointing
and offers superior joint strength by controlled adhesive
thickness. Available in sizes 50 1000 mm (2 40 in),
pressure rated up to 100 bar.

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3.6 Transporting Pipe

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Support all pipe sections on flat timbers, spaced at a
maximum of 4 meters with a maximum overhang of
1 meter. Chock the pipes to maintain stability and N
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separation. Avoid abrasion.
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Maximum stack height is approximately 1.5 meters.

Strap pipe to the vehicle over the support points using
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pliable straps or rope. Never use steel cables or chains

without adequate padding to protect the pipe from
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abrasion. Bulges, flat areas or other abrupt changes of

curvature are not permitted. Transport of pipes outside
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of these limitations may result in damage to the pipes.

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Figure 4-1 Tapered adhesive joint

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4.2 Seal-Lock Mechanical Joint

Self-restraint, easy to install, Seal- Lock Mechanical
joint uses nylon key and rubber o-ring for jointing.
Available in sizes 50 1000 mm (2 40 in), pressure
rated up to 70 bar.

Figure 35 Transporting pipe

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Figure 4-2 Seal-lock joint

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4.3 Butt & Wrap - Lamination Joint

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Butt-And-Wrap (or Lamination) joint for Plain Ends used
generally for field adjustments and for large diameter
pipes that other types of joints are not available. Butt & N
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Wrap Joint is available for all sizes. Type A: with flat gasket Type B: With O-ring
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Figure 4-4 Flanged joint

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4.5 Mechanical Coupling

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Mechanical joint offers quick assembly between plain

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ends. This joining method, done by means of

mechanical coupling (supply by others) like Viking
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Johnson, Dresser, etc., normally used to connecting

different piping material (low pressure application only).
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Figure 4-3 Butt & wrap joint

4.4 Flange Joint

Figure 4-5 Mechanical coupling joint
Filament-wound fiberglass flanges are used for jointing
AMIPOX or AMIPOX RTR / GRE piping to existing steel
pipes, valves, pumps and tank nozzles. These are
provided with drilling patterns to mate with metal
flanges conforming to worldwide standards. Flanged
joint uses rubber flat gasket or O ring (depending size
and pressure rating), bolts, nuts & washers for jointing.
Flange Joint is available for all sizes.

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5 Adhesive bonded Taper Joint, AT - Jointing procedure

Before starting adhesive bonding, all safety precautions

need to be checked. Ensure that all necessary tools and
materials are available.

Adhesive bonded jointing can only be carried out by fully

trained and certified personnel

5.1 Tools for adhesive bonded Joints

For the assembly of adhesive bonded joints the
following is needed:

AMIPOX shaving tool(s).

Electrical power drive (available from AMIPOX). Power drive

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Hacksaw, disc grinder or power jigsaw.

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Small electrical or air hand drilling machine
(6 mm drive and 1700-2000 rpm).
Flapper wheel sanders (available from AMIPOX) and
/ or coarse emery cloth; grid 60.
Pairs of winches or come-alongs (available from N
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AMIPOX).
Pairs of band clamps with puller rings (available
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from AMIPOX).
Measuring tape and / or folding rule.
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Pi-tape with venire division (available from AMIPOX).

Clean cloth or clean brush.
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Pipe fitters wrap around, level and white paint Figure 5-1 Different type of tools
pencil.
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AMIPOX heating blanket and possibly hot air blower.

Insulation blankets.
5.2 Machining
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Pipe vice or stable supports (brackets) with pipe

holding or clamping device of 6 mm.
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Elastomeric pads. After the pipe has been cut to the exact length, the end
Gloves, dust masks and goggles. must be machined to the right diameter to ensure a
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proper joint. The surface has to be cleaned with clean

For adhesive bonding: see instructions provided with
the cement kit.
For machining: see shaver instructions supplied with
shaver.
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.

5.3 Cutting and Shaving of Pipe

1 Determine the cutting length as shown by subtracting
the laying lengths of the fittings from the required
overall length.
Come-along installation tool

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 OVERLL LENGTH
X
LAYING CUTTING LENGTH LAYING
LENGTH LENGTH

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Figure 5-4 Cutting squareness

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Pipe size range Tolerance (X)

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Figure 5-2 Cutting length (mm) (inch) (mm)

80-100 3-4 1.5

2 Mark the pipe using a pipe fitters wrap-around.
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150-600 6-24 3.0
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When holding the pipe in a vice, use rubber padding
700-900 28-36 5.0
or similar to protect the pipe from damage.
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1000-1200 40-48 6.0

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Table A: Maximum tolerance on squareness of cut

male ends
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4 Shaving the pipe

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Support and hold the pipe in position firmly

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- Contaminated pipe surfaces should be

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cleaned prior to shaving the pipe ends.

- When holding the pipe in a vice, use rubber
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padding or similar to protect the pipe from

damage.

Figure 5-3 Marking the pipe

3 Cut the pipe

Use a hacksaw or an abrasive wheel.

Ensure that cut ends remain within the
tolerances as shown in Table A.
These tolerances can be checked by using,
for example, the arbour of the shaver flush
with the cut end of the pipe.

Figure 5-5 Supporting and holding the pipe firmly

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 Carefully insert the arbour into the pipe.
Fix the arbour to the inside of the pipe by
turning the central tensioning bolt clockwise.
Adjust the shaver to the required male diameter.
- Be sure to use the correct taper angle.
- Take care when shaving the first layer,
because the pipe wall may not be equally
thick on all sides.
- For shaver information and operation
instructions refer to the applicable AMIPOX
Pipe Shaver Operation Instructions.
- Refer to Figure 5-7 and Table B below.

SPIGOT
DIAMETER
TAPER ANGLE
NOSE
THICKNESS

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Figure 5-6 Fixing the arbour inside the pipe

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INSERT.
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DEPTH

Figure 5-7 Taper joint details

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Male Male Male

Pipe size Taper angle Nose thick Nose thick Nose thick
diameter diameter diameter

mm inch degrees mm mm mm mm mm mm
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Series AT 10 Series AT 12 Series AT 14

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80 3 1.2 2.0 84.0 2.0 84.0 2.0 84.0

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100 4 1.2 2.0 104.0 2.0 104.0 2.0 104.0

150 6 1.2 2.0 154.0 2.0 154.0 2.0 154.0

200 8 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

Table B: Shaving Dimensions per Pipe Series

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 Male Male Male
Pipe size Taper angle Nose thick Nose thick Nose thick
diameter diameter diameter

mm inch degrees mm mm mm mm mm mm

Series AT 16 Series AT 20 Series AT 25

80 3 1.2 2.0 84.0 2.0 84.0 2.0 84.0

100 4 1.2 2.0 104.0 2.0 104.0 2.0 104.0

150 6 1.2 2.0 154.0 2.0 154.0 2.0 154.0

200 8 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 2.4 304.8 2.4 304.8 2.4 304.8

350 14 1.5 2.6 355.2 2.6 355.2 - -

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400 16 1.5 2.6 405.2 - - - -

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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 - N - - -

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800 32 1.75 5.5 811.0 - - - -
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900 36 1.75 6.0 912.0 - - - -

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1000 40 1.75 8.0 1016.0 - - - -

Note: For values specified as (-), consult Amipox Engineering
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Table B (continued): Shaving Dimensions per Pipe Series

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Shave the taper male. Sand all bonding surfaces.

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- Maximum shaving depth /feed is 2mm. - Thoroughly sand within 2 hours of assembly.
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- Repeat the shaving action until the required male - Use flapper wheel sanders with a small drilling
diameter/male nose thickness is achieved machine (1700-2000 rpm) or emery cloth with a
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(Table B) grid of 60.

- Due to possible tolerance spreading, it is - Bonding surfaces must be dry and clean before
recommended that a nominal sized dummy sanding.
female end is used. This may avoid too long or - Sanded surfaces must have a dull, fresh finish,
too short assembly lengths. If the insertion depth not a polished look.
in the dummy is too small, the male end to be
shaved has to be adjusted.

Figure 5-9 Sanding the male (left) and female (right)

ends

Figure 5-8 Shaving the male end

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 Dry fit and mark the joint.
POSITION AFTER 55mm
- Check the assembly length and mark pipe and FINAL ASSEMBLY
50mm
WITH ADHESIVE SCRIBE
fitting for alignment of elbows, flanges, etc.
- Measure back from the edge of the male the USING WINCHES A MARK

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required insertion depth plus 50 mm and scribe
a line.
- After assembly by pulling the joint together, the
scribe on the pipe should be 50 mm from the
end of the female.

POSITION IN DRY CONDITION

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Figure 5-10 Position after assembly

5.4 Preparing for Bonding

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1 Install the band clamps on both components
keeping sufficient space for the winches when
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pulling the joint together. Normally 2 winches will

suffice. If needed, more winches can be used.
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Figure 5-9 Dry fit and length marking Figure 5-11 Fixing band clamps

- During final assembly the male may slip
approximately 5 mm further into the female,
therefore the dry fitted assembly should be
approximately 5 mm longer per joint.
2 Dry the bonding surfaces.
If the relative humidity is higher than 75%, or if the
bonding surfaces are wet, they should be dried.
AMIPOX heating blanket can be used in drying
the surfaces.

3 Pre-heat or cool down the bonding surfaces.

It is recommended to keep the bonding surfaces

between 15 C and 40 C.
For warming up, AMIPOX heating blankets can
be used.
If the sun will heat the bonding surfaces to
above 40 C keep them in the shade if possible.

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4 Re-sand. Size 10 12 14 16 20 25
inch mm bar bar bar bar bar bar
If the sanded surfaces have been contaminated, or if 3 80 0.1 0.1 0.1 0.1 0.1 0.2
initial sanding took place more than 2 hours before
assembling, the surfaces should be re-sanded. 4 100 0.2 0.2 0.2 0.2 0.2 0.3
6 150 0.2 0.2 0.2 0.2 0.3 0.4
5 Clean the sanded surfaces.
8 200 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
Use a clean dry cloth or brush to remove
sanding dust etc. 12 300 1.0 1.0 2.0 2.0 2.0 2.0
Do not touch the sanded surfaces after sanding 14 350 1.0 1.0 2.0 2.0 2.0 2.0
and cleaning.
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
5.5 Applying the Adhesive 20 500 2.0 2.0 2.0 2.0 3.0 4.0

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24 600 2.0 3.0 3.0 3.0 5.0 5.0

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1 Select the proper size adhesive kit.
28 700 3.0 3.0 4.0 4.0 5.0 6.0

Table C, below shows the quantity of adhesive 30 750 3.0 4.0 5.0 5.0 6.0 7.0
needed for one joint.
More joints may be assembled at the same time.
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36 N 800
900
4.0
4.0
4.0
6.0
5.0
6.0
6.0
7.0
7.0
8.0
8.0
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Make sure the adhesive is not out of date.
Refer to the date stamp on the package. 40 1000 5.0 6.0 7.0 7.0 - -
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Never split a package, always prepare complete Note: For values specified as (-), consult Amipox Engineering
kits.
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Table C: Adhesive kits per joint (250 gram kit)

Do not use damaged or leaking adhesive kits.
2 Prepare the adhesive.
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Add the curing agent to the resin.

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Stir thoroughly until the mixture has an even

colour (after 2 to 3 minutes)
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The recommended storing and mixing

temperatures of the adhesive are shown below.
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Storage and usage of adhesive:

- Storing temperature: Below 30 C
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- Recommended mixing temperature: 20-35 C

- Below 15 C, the adhesive will not mix well
and the adhesive mix cannot be easily
spread.
- The mixture will cure too fast above 40 C.
- Minimum curing temperature of the adhesive: 80 C.
Make sure that before mixing the adhesive, all
Figure 5-12 Adhesive kit
preparations have been done and all parts to be
bonded are ready for assembly, as mixed
adhesive has a limited pot life subject to the
ambient temperature (Table E)
Apply the adhesive immediately after mixing.

Temp. oC 20 25 30 35 40

Setting Time 30min 25min 20min 15min 10min

Table E: Pot life of mixed adhesive in minutes

Never use adhesive that has started to gel. This is

the case when the mixture gets clotted and toughens.

15
 Apply a thin layer of adhesive.
Use a spatula or an adhesive scraper for
applying the adhesive.
It may be necessary to set a bridge (pieces of
wood between winch cables and pipe outside) to
simplify placing of the heating blanket.
Do not remove the winches until the adhesive
has fully cured.
Remove excess adhesive A spatula may be used
to remove excessive adhesive, when possible
also from the inside, as in the flanges.

F
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Figure 5-13 Applying thin layer of adhesive in female
side
N
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All surfaces to be bonded (sanded areas) must
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be completely covered with adhesive, Figure 5-15 Removal of excess adhesive by spatula
approximately 0.5 mm in the female side and
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1 mm on the male side.

A too thick layer of adhesive may result in flow
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restrictions.
Also make sure that sufficient adhesive is
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applied on the cylindrical end of the male that

will be covered by the female.
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NOT ENOUGH ADHESIVE USED

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Figure 5-16 Correct application and assembly

TOO MUCH ADHESIVE USED

Figure 5-14 Incorrect application 5.6 Curing of the Adhesive

Insert the male in the female.
When inserting the male, pay attention to the
marks and position and keep the joint together.
Letting the male slip back or turning the male
after complete insertion may result in a bad joint.
Hook the 2 winches in the band clamps and
start pulling the joint further together in a smooth
movement until the joint is firmly fixed together
and there is 50 mm between the female and the
mark.
1 Apply the heating blanket.
Wrap the required sized AMIPOX heating blanket
around the joint keeping the power supply cable
free from the blanket.
Make sure the voltage is correct.
The blanket should be applied as indicated in the
appropriate AMIPOX Heating Blanket Data sheet.
The blanket should be tied down using heat
resistant wire.

16
 Firm blanket to pipe surface contact is essential Pipe Size Series
for proper curing of the adhesive. mm inch AT10 AT12 AT14 AT16 AT20 AT25
When the temperature is below 10C or the wind 80 3 1.0 1.0 1.0 1.0 1.0 1.0
has a cooling effect, it is recommended to cover
100 4 1.0 1.0 1.0 1.0 1.0 1.0
the heating blanket with insulation material and it
150 6 1.0 1.0 1.0 1.0 1.0 1.0
should not cover the thermostat.
200 8 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

F
700 28 2.0 3.0 4.0 4.0 4.0 4.0

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750 30 2.0 3.0 4.0 4.0 4.0 4.0
800 32 2.0 4.0 4.0 4.0 4.0 4.0
900 36 3.0 4.0 4.0 4.0 4.0 4.0

Figure 5-17 Apply heating blanket

1000
N40 4.0 4.0 4.0 4.0 4.0 4.0
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Table G: Curing time for fitting joints in hours
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2 Determine the curing time.

3 Activate the heating blanket.
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Write starting time

Curing time is mainly dependent to the distance Apply electrical power to the heating blanket and
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(= wall thickness) between blanket and adhesive. check that it heats up.
Table F and G show the recommended curing Write down on the pipe next to the heating
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time (hours) for each pipe and Fitting joints blanket the starting time.
respectively. During the time of curing, the heating blanket
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function should be checked regularly; if a cold

heating blanket is found, correct the problem
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and start the complete curing cycle again.

Pipe Size Series
During curing the joint should not be moved,
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mm inch AT10 AT12 AT14 AT16 AT20 AT25

vibrated or otherwise disturbed
80 3 1.0 1.0 1.0 1.0 1.0 1.0
100 4 1.0 1.0 1.0 1.0 1.0 1.0 Health and safety
150 6 1.0 1.0 1.0 1.0 1.0 1.0
For health and safety data refer to appropriate
200 8 1.0 1.0 1.0 1.0 1.0 1.0
AMIPOX Adhesive Product Data sheet.
250 10 1.0 1.0 1.0 1.0 1.0 1.0
Wear at all time suitable protective clothing,
300 12 1.0 1.0 1.0 1.0 1.0 1.0 gloves and eye protection. Dust masks should
350 14 1.0 1.0 1.0 1.0 1.0 1.0 be used during machining and sanding.
400 16 1.0 1.0 1.0 1.0 1.0 1.0 Use gloves when working with adhesive, the wet

450 18 1.0 1.0 1.0 1.0 1.5 1.5 adhesive may cause irritation by skin contact.
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

Table F: Curing time for taper pipe joints in hours

17
6 AMIPOX Seal-Lock Joints ASL - Jointing Procedures

Before assembling the rubber Seal-Lock Joints, all
safety precautions need to be checked.
Ensure that all necessary tools and materials are
available.
6.1 Tools for Rubber Seal-Lock Joints
For assembly of rubber seal-Lock joints the following is
needed:
Lubricant for O-ring and locking strip
A rod or stick
Two (2) pipe clamps
Come along (2) with pulling force 750 kg for
Diameter 500 mm and 1500 kg for larger diameters
Now brush or rub a layer of lubricant into the
O-ring groove of the male end and all inside
surfaces of the female end or coupling.
Apply lubricant only when you are ready to
complete the joint. Keep lubricated surfaces
clean and free of sand and dirt, as contamination
is likely to interfere with joining and sealing.
Proper lubrication of the O-ring and joint
surfaces is important to avoid cutting the O-ring
or rolling it out of place during assembly.
2 O-ring placement
Lubricate the entire surface of the O-ring and
slip it into the first groove on the male end.

F
Plastic or wooden mallet to drive the locking strip Distribute the O-ring evenly in the groove by

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into the rubber seal lock joint slipping a screwdriver under it and sliding the
Non fluffy cleaning-rags screwdriver around the joint.
As an alternative for distributing the O-ring in
pipe sizes to 400mm, use a screwdriver to lift
6
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the lubricated O-ring at top centre a distance of
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about 20 per cent of the pipe diameter and let it
3 snap back into the groove.
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2
Do not gouge or abrade the O-ring. A sound
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4 O-ring is the key to a water tight joint.

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3 Pipe male insertion

1
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9
Place the band clamps on either side of the joint.
5 8 Rotate the new pipe so its keyholes are in the
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proper position for driving the key(s) for the next

Figure 6-1 Seal-lock joint assembly tools joint.
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Align the male end against the female end or

1: Come along set of 2 pcs. coupling already in place for straight concentric
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2: Lubricant entry. Proper alignment is essential for joining.

3: Pipe clamps set of 2 pcs. Deflect the joint to conform to the actual
4: D Rings set of 4 pcs. horizontal and vertical alignment of the trench
5: Rubber O ring. only after the joint is fully assembled in the
6: Water bucket straight position. An AMIPOX joint puller is
7: Screwdriver recommended for joint assembly.
8: Mallet Connect the ratchet winches to pulling rings
9: Nylon key attached to the band clamps on either side of
the pipe. It is often convenient to place one band
clamp just behind the female end or coupling
6.2 Joint Assembly and the other about 1.5m from the male end.
Tighten the winches evenly on both sides so that
1 Preparation of seal lock joining surfaces the O-ring enters smoothly and without being
pushed or rolled out of its groove.
When ready to join the pipe, remove the end Insert the male end until the scribed line is about
protection from the male pipe end. Loosen and 6mm from the leading edge of the female end or
remove dirt and debris from the grooves using coupling. To reduce slippage you may elect to
compressed air, a clean, dry rag or a paint brush . use rubber pads under the band clamps.
Clean the grooves and sealing surface of the Straightness of entry adds significantly to the
female end or coupling. Sand off any projections ease of assembly. Sight along the pipe and
or rough edges on the entry ramps which carefully observe concentricity and uniformity of
compress the O-ring during insertion. entry.

18
4 Driving the keys: 6.3 Seal-Lock Jointing
Place lubricated locking keys into the insertion The Seal-Lock jointing is demonstrated step by step in
holes, and slowly close the joint until the keys the subsequent pictures.
slip into the keyways.
Check the straightness of the entry again by STEP 1 End protection (supplied by AMIPOX)
sighting along the pipe and by aligning the should be removed just prior to assembly to
scribe mark on the male end with the edge of keep joining surfaces and grooves clean.
the female end or coupling.
Use a hammer or mallet to drive the locking keys
through the insertion holes and into the keyways
until the leading end can be seen in the insertion
hole and approximately 75 to 100 mm remain
projecting.
! Note! Drive the key only until you can see its

F
leading end through the insertion hole. If the key

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is driven too far, heat may elongate it and cause
it to stick, making later removal impossible.
Protect the projecting keys of piping exposed to
sunlight or other ultraviolet radiation from
embitterment. Within several days of installation, N
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spray all exposed key surfaces with a black
acrylic coating, or wrap them with duct tape.
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Also, fill keyholes with caulking compound to

prevent intrusion of sand and dirt which may STEP 2 Lubricate inside the female end and locking
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make later key removal difficult. key groove with ample amounts of lubricant
(available on order from AMIPOX). Note that
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5 Positioning and aligning the joined pipe: the pipe already in place has been properly
rotated so that the key-hole of the next joint is
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After driving the keys, deflect the joint to fit the conveniently positioned.
hanger supports or trench bottom. With the pipe
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fully supported in its final position, release the

lifting straps: for buried pipe in sag curves, it
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may be necessary to leave the lead lifting strap

in position to align the next joint during
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assembly.
To avoid excessive movement and bending at
turns and branches during the hydrostatic test,
pull straight sections of joined pipe forward as
assembly progresses, using a ratchet winch or
other means to remove play in the joints.

19
STEP 3 The male end of the pipe going in should also STEP 6 Align the pipe for straight concentric entry.
be generously lubricated. Again, make sure Proper alignment is essential to ease joining.
that the keyway is well lubricated.

F
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STEP 4
After coating the O-ring (supplied by AMIPOX) STEP 7
Tighten the come-a-longs (provided by user)
with lubricant, mount it in the end most groove on both sides so that the O-ring enters
in the male pipe end. Insert a screwdriver under N
smoothly without being pushed out of its
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the mounted O-ring and run it around the pipe groove.
to distribute the O-ring in the groove.
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O
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STEP 5 Mount the band clamps (available on
order from AMIPOX) a convenient distance on
each side of the joint, making certain that the
pipe going in is properly positioned to allow
access to the keyhole of the following joint.
STEP 8 Insert the male end until the scribe line is
about inch (6mm) from the leading
edge of the female end or coupling.

20
STEP 9 Lubricate the locking key (supplied by
Nominal Pipe Size Maximum joint deflection
AMIPOX) before insertion.

inch mm Male x Female Coupling

2-16 50-400 1/2 1

18-48 450-1200 1/4 1/2

Table 6-1: Permissible angular deflection at seal lock

joints

6.4 Types of Rubber Ring and Locking

Strip

F
The commonly used rubber ring is made of NBR

STEP 10 Place the lubricated locking key into the
keyhole and slowly close the joint until the
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key slips easily into the keyway.
Check the pipe alignment. Drive the locking
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(Nitrile Butadiene Rubber).Other types of rubber can
be supplied depending on the medium and/or the
temperature.
Locking Keys are normally plastic nylon material but
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metallic can also be used depending project
requirement.

key only until you can see its leading end

through the keyhole. If the key is driven in too
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far, it may bind, making later removal difficult

or impossible.
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Joint completely assembled.

21
7 Flanged Joints

AMIPOX flanges are normally used for joining RTRP to ! Note! Excess torque can prevent sealing and
existing steel pipes, valves or pumps; rubber gaskets can damage flanges.
are used for hydrostatic sealing. AMIPOX flanges meet
the dimensional requirements. Drilling patterns of all 16
24 1
9 20
12
24 1 13
25
8 17 8 5
common standards such as ANSI, API, and ISO etc. 3 1 20 5 28 17
12 13 16 9
Before assembling flanged joints, all safety precautions 4 21 4 21

need to be checked. Ensure that all necessary tools 2 4

22 3 22 3
14 11 10 15
and materials are available. 6 19 18 27
18 7 6 7
26 19
6 1
10 2 23 15 14 2 23 11

3 4

7.1 Tools for Flanged Joints 8 7

8
20 17 1
13
5
5 2 16 17
4 9

Tools necessary for assembly of flanges: 10 3

11 1
Ring spanner with required bolt head size. 7 5 18
6 7
15

3 9 14
Torque wrench with required socket size. 10 4
2 11
19

F
6 8 16 1
2 12 8 9

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12 5

7.2 Flanged Joint Description 4

14
13

3
6 11
10 7
AMIPOX flanges are usually flat faced. These 2 15

flanges N
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must always be accurately aligned and not subject Figure 7-2 Bolts tightening sequence
to any stress.
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The bolts and nuts must have washers to avoid

exceeding the permitted surface pressure. As an Torque
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Nominal Pipe Size Final Torque

alternative, a stub-end type flange with steel Increments
backing ring centre can be installed. mm inch (N-m) (N-m)
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Pipe must not be pulled together by tightening the

80 3 15 56
bolts. If an R.T.R.P. pipeline is connected to a metal
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pipe, this metal pipe must be anchored to prevent 100 4 15 56

any movement or loads being transmitted to the 125 5 20 82
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R.T.R.P. line.
150 6 20 82
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200 8 20 82

250 10 30 150
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300 12 30 150

350 14 30 150

400 16 50 250

450 18 80 400

500 20 80 400
Figure 7-1 Flange assembly
600 24 100 500

700-750 28-30 100 500

First, finger tighten all nuts. Bolt threads must be
800 32 100 500
clean and lubricated to attain proper torque. Use
lubricated washers under both nuts and bolt heads 900 36 100 500
to protect flange back faces. 1000-1200 40-48 100 500
Tighten all nuts following the sequences shown in
800 32 100 500
Figure 7-2 below
Do not exceed the torque increments given in 900 36 100 500
Table 7-1 below 1000-1200 40-48 100 500
After all bolts have been tightened to the
recommended torque, recheck the torque on each Table 7-1: Recommended bolt torques
bolt in the same sequence, as previously tightened
bolts may have relaxed.

22

7.3 Gaskets
For AMIPOX fiberglass flanges assembly, use full-face
gaskets of an elastomeric suitable for the service
pressure and temperature and fluids in the system.
Gaskets should be 1/8 inch (3mm) thick with shore
durometer hardness between 60 and 75. Refer to
ASTM D1330 specification for sheet rubber gaskets,
grade 1 or 2, to establish minimum physical property
requirements for use with water, Rubber gasket with
steel inlay or compressed fiber is used for high
pressure AMIPOX flanges and Rubber O Ring sealing
is also used for higher pressure and diameters.
7.4 Bolts
AMIPOX flanges are thicker than metal flanges and
require washers. This should be taken into account
when calculating the bolt length. For flange thickness
see the appropriate AMIPOX product datasheet for
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dimension data.
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7.5 Trouble Shooting
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If the assembled joint leaks:
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Loosen it and remove all bolts, nuts, washers and
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gaskets.
Check for alignment of assembly. Rebuild to correct
R
alignment as required.
Check the gasket for damage. If damaged, discard
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and replace it with new, undamaged, gasket.
Check flanges for seal ring damage. In particular,
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check the condition of the inner seal rings. Flanges
with damaged inner seal rings must be removed
and new, undamaged, flanges installed
If leaks occur as a result of deficiencies in non-
fibreglass components of the piping system, consult
the manufacturer of the defective components for
recommended corrective procedures.
Clean and re-lubricate old threads and washers
before re-joining.
Repeat the joining procedure outlined above.
After corrective action has been taken, retest the
joint to make sure proper sealing is achieved.
8 Butt and Wrap
Lamination Joint
This lamination method is used to join plain-end pipe
sections through overlapping layers of fiberglass
reinforcement (woven roving and boat tape) thoroughly
impregnated with a resin system, it is generally
intended for field adjustments works where adhesive
bonded joints cannot be accommodated. This jointing
method needs to be performed only by experienced
and trained pipe technicians under AMIPOX field
engineer supervision. Before starting a butt and wrap
(lamination) joint, all safety precautions need to be
checked. Ensure that all necessary tools and materials
are available.
8.1 Tools for Butt and Wrap
F
Lamination Joint
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For butt and wrap lamination joint the following tools/
equipment are needed:
N
Measuring tape + pipe fitters wrap-a-round
+ marker pen and a pair of scissors
Cleaning-rags
Abrasive cutting disc (diamond grid or
carborundum)
Flapper wheel sander or grinding disc
Air Relive Rollers, Paint Brush and Rubber Scraper
Plate
Gloves, dust masks sets, and safety glasses.
Shelter (depending on the weather circumstances)
Infra-Red Burners or Hot Air Guns and Heating
blankets
Electric Power Source
Materials: Glass Reinforcement (Woven Roving and
Boat Tape), Resin & Hardener and Adhesive Kits.
! Note! Quantity and specification refer to the
instructions supplied with butt & wrap kits).
Figure 8-1 Tools and accessories for butt & wrap
lamination joints
23
8.2 Lamination Procedure Centre the parts to be laminated and
block/fix them firmly, so they cannot slip.
1 Preparation Start the lamination of the fitted sections
Qualification of the installation staff by means of within two hours after sanding or grinding;
installation and material knowledge. re-sanding of lamination area shall be required
Information about safety regulation and measures. if the waiting period exceeds two hours.
Account of special working conditions; jobsite,
weather, influence, etc. C Adhesive fit layer
Installation equipment and materials. Check whether the sections to be joined
Check the pipes and fittings for visible damage. together are dry, clean and at the right
If necessary, clean the parts to be connected. temperature.
Position the pipe sections for joining.
Prepare the adhesive mixture according to
Material Description Specifications Remarks
AMIANTIT approved
given instructions. The two components
Epoxy Resin commercial grade such Mixing Ratio Resin must be stirred (e.g. 1 minute) until there is
as: Araldite GY6010, DER

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330 and Epikote 827 to Hardener is a uniform color.
100:24 ppw

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Hardener IPD When fixing by bonding the front edges
150 grams per Sq. together; first, a thin coat of adhesive is
Boat Tape 2 and 4 wide
meter applied thoroughly onto the front edges.
500 grams per Sq.
Woven Roving 4 and 6 wide Subsequently, a second thicker coat is
Adhesive
meter
250 grams kits Two components Napplied external surfaces of the pipe ends
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Note! Store all fiberglass components in a dry, clean, cool and
approximately 100 mm in width, then the
covered area. IPD is hygroscopic, keep it stored in close sections are connected and their alignment
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containers when not in use. Prepare IPD batches shortly before
mixing with resin component. is checked.
Wet out boat tape with adhesive and apply
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Table 8-1: Raw materials used in butt & wrap

a minimum of three layers circumferentially
lamination joints
onto the joined pipe ends.
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Use a heating blanket to force cure the

2 Process initial laminate for one hour.
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A Cutting the pipe

Determine the length of the pipe sections, FIT LAYER
R

taking into account the dimensions of the BOATTAPE WITH ADHESIVE

CIRCUMFERENTIAL, 3 LAYERS
fittings see Figure 8-2 below.
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Mark the pipe sections with the aid of a

marking template. MAX. 5mm (FILL GAP WITH ADHESIVE)
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< 250mm OD USE 50mm width boat tape

Clamp the pipe in a vice; plies of rubber or 250mm OD USE 100mm width boat tape
similar material should be used to protect LAMINATION SEQUENCE
the pipe. Figure 8-2 Fit layer schematic
L sketch
BOATTAPE 50% OVERLAP, 2 LAYERS
Cut the pipe with a hack saw, grinding
wheel, etc. Make sure the cut is straight 1

and right-angled. D Lamination sequence WOVEN ROVING 50% OVERLAP, 5 LAYERS

Cut right through, do not break off. Support Start the lamination of the fitted section
the free end of the pipe. Use a fine-tooth 2 (see point C above) within two hours

saw. The liner must not to be damaged. after sanding; re-sanding of lamination area
BOATTAPE 50% OVERLAP, 1 LAYER

shall be required if the waiting period

B Prepare pipe ands and fittings 3 exceeds two hours.
Prepare pipe and fitting ends by means of Remove dirt using clean rags and dry
* REPEAT THIS SEQUENCE UNTIL THE MINIMUM
grinding and leveling. Which angle about brush and also remove any possible
REQUIRED LAMINATE THICKNESS IS ACHIEVED
which length. NOTE:. SIZEmoisture by
150 ND AND BELOW USEslightly
ONLY BOATTAPE heating the surfaces by
Secure and prepare the pipe end. means of heating blankets.
The prescribed lamination length must be Prepare the resin mix using the correct
maintained and checked. mixing ratio Resin = 100 parts by weight;
The resin coat on the surface must be Hardener = 24 parts by weight. Take note
completely removed by sand blasting or of the pot life after mixing. The amount of
grinding till the glass fibers are exposed. the mixture depends on the diameter.
Remove dirt and chips with a clean rags Several batches could be used depending
and dry brush. on the weather, temperature and gelling time.

24
 FIT LAYER
L.T.
LAMINATE OVERLAY
W.T.
Be sure that the curing agent is carefully
mixed with the resin. The temperature of
the resin and curing agent mixture should
not exceed 25C.
L L
2L
For pipes 150 ND or smaller:
For the hand lay-up of the laminate structure, use NOTE:
L = 120mm FOR PIPE SIZES 50mm ND TO 200mm ND
boat tape with 50% overlap.
L = ND FOR PIPE SIZES 250mm ND AND ABOVE
Be sure to obtain the minimum required lamination
LT = LAMINATION THICKNESS = 2 x PIPE WALLTHICKNESS
thickness, see Figure 8-4.
Figure 8-4 Minimum lamination length and
thickness
For pipes larger than 150 ND:
For the hand lay-up of the laminate structure, use E Curing and finishing

F
boat tape and woven roving in the sequence as The lamination will harden at ambient

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shown in Figure 8-3 and with 50% overlap until the temperatures. This can be speeded up by
minimum required laminated thickness is achieved, applying heat, for example using an
see Figure 8-4. infrared device or hot air gun.
Make sure that each applied layer of boat tape or The hardening process needs to be carried
woven roving is thoroughly impregnated with resin N
out gradually.
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mixture. After the lamination is no longer sticky,
Apply the layers in the circumferential direction onto curing can be continued with the aid of
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the pipe joint ends. heating blankets, hot air guns or ovens.
During the wrapping process, tension must be Heating up to the curing temperature
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applied so that the resin under the layer being laid should also be performed gradually.
could be pressed out. Heating blankets are the most appropriate
O

Avoid air getting into the laminate by using the air- to use for field butt &wrap joining.
relieve rollers continuously. Check if the heating blanket is working
ES

To give the finishing touch, apply one final layer of properly, temperature in excess of
boat tape spirally wrapped onto the whole surface 120C should be easily achieved if the
R

FITof LAYER
the laminate. Use air relieve rollers to avoid air heating blanket works properly. The
enclosures. BOATTAPE WITH ADHESIVE
CIRCUMFERENTIAL, 3 LAYERS
surface contact between the heating
W

After the final boat tape layer, smooth out the resin blanket and the laminate should be as large
from the exterior of the laminate using a rubber as possible. Fit the blanket as snugly as
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scraper to leave a resin MAX.rich surface.

5mm (FILL GAP WITH ADHESIVE)
possible to the joint.
< 250mm OD USE 50mm width boat tape
250mm OD USE 100mm width boat tape The curing time only starts when the
LAMINATION SEQUENCE laminate has reached the correct curing
L
BOATTAPE 50% OVERLAP, 2 LAYERS
temperature.
Cure the laminate for 4 hours minimum.
1 Whenever possible apply a heating blanket
WOVEN ROVING 50% OVERLAP, 5 LAYERS
on the inside as well and close the pipe
ends to avoid air drafts.
2 After curing, use sandpaper to remove the
BOATTAPE 50% OVERLAP, 1 LAYER
rough edges of the laminate and to
generally smooth out the external surface
3 The joint is ready and can be tested when
the laminate is fully cured and has cooled
* REPEAT THIS SEQUENCE UNTIL THE MINIMUM
REQUIRED LAMINATE THICKNESS IS ACHIEVED
down.
NOTE:. SIZE 150 ND AND BELOW USE ONLY BOATTAPE

E Finishing work
Clean up the area.
Figure 8-3 Lamination sequence 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
8.3 Butt & Wrap Lamination Jointing
The butt & wrap lamination jointing is demonstrated
step by step in the subsequent pictures.

STEP 1 Pipe cutting, aligning and initial grinding. STEP 2 Initial fit-up layer with adhesive and boat tape.

F
PD
N
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ES
R
W
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26
STEP 3 Heat cure of the initial fit-up. STEP 4 Marking lamination length and surface grinding.

F
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N
O

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ES
R
W
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27
STEP 5 Cleaning of surface for lamination, preparation STEP 6 Mixing of resin and hardener and start of
of working area and check of materials for lamination. application to the surface for lamination.

F
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N
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R
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28
STEP 7 First layers of boat tape impregnated with the STEP 8 Layers of woven roving to be impregnated with
resin mixture. resin mixture as well and air removal using air relieve
rollers.

F
PD

N
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R
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29
 9 Mechanical Couplers

STEP 9 Final layers of boat tape and woven roving,
allowing the laminate to gel and dry and finally heat cure
for 4 hours.
Generally, mechanical couplers are used for joining
plain ended GRE / RTR pipes to pipes made from other
materials. A step coupler can join pipes with different
outer diameters. This type of joint is unrestrained.
These couplers can also be used for preliminary repairs.
However, restraining couplers should not be used as
these may damage the AMIPOX pipes.
Specific information can be obtained from the supplier
of the coupler.

F
PD

N
O
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Figure 9-1 Mechanical couplers

O
ES

Before starting the assembly of a mechanical coupler,

check that all safety precautions have been taken and
R

that all necessary tools and materials are available

W

9.1 Tools for Mechanical Couplers

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For Straub and Taylor Kerr: Allen key and torque wrench
For Dresser, Viking Johnson and inland couplers: - ring
spanner
AMIPOX pipes have lower torques than steel pipes,
depending on the wall thickness

30
10 Installation of Underground Pipe Systems

To ensure long life and trouble-free service from
underground piping systems, proper application of the
principles of excavation is essential.
Laying and jointing, bedding, backfilling and field
testing is required. If pipe is installed by a contractor it
is equally essential that these principles be reflected in
the phrasing of contract documents and that the
customer enforce them through inspection. The
recommended practices presented in this guide for the
installation of buried AMIPOX pipe are developed from
the two basic concepts outlined below. Both should be
rigorously maintained to obtain best results. Firstly, the
The minimum width (W) at the bottom of the trench
for a single pipe shall be:
W = 1.25* OD + 300 mm.
The space between the pipe and the trench wall
must be 150 mm wider than the used compaction
equipment.
Respecting pipe stiffness, operation conditions, soil
characteristics and wheel load the minimum
recommended burial depth is 0.9 m.
Refer Figure 10-1 and Figure 10-2 below for stable
and unstable standard trench construction details.
W

manufacturers recommendations for assembling pipe

Final backfill
sections and curing the joints should be carefully excavated soil
followed. Secondly, each section of pipe should have compacted in
layers of 30 cm

F
its support well distributed under the pipe rather than

PD
concentrated at points or along a narrow portion of the Secondary backfill
30 cm zone compacted in
pipe bottom. This is accomplished by providing proper layers of 30 cm
bedding. These instructions are intended to be used as D
0.7 x D
a guide only and should be amended for a specific job.
Because any specification should be properly applied Primary backfill
N
zone compacted in
15 cm Bedding
15 cm Foundation
O
and adapted to meet the requirements in force, there is layers of 15 cm
no specific or implied assurance that inclusion of these
TI

paragraphs in a specification will insure a successful Figure 10-1 Standard trench construction stable soils
job. However, they should assist materially in
LU

accomplishing this objective.

W
O

Final backfill
excavated soil
10.1 Procedure compacted in
ES

layers of 30 cm

Secondary backfill
The type of installation procedure appropriate for 30 cm zone compacted in
R

AMIPOX pipe varies with pipe, cover depth, width, D

layers of 30 cm
0.7 x D
native soil characteristics, surcharge loads and backfill
15 cm Bedding
W

materials. Primary backfill

zone compacted in 15 cm Foundation
The native material must adequately confine the pipe layers of 15 cm
LO

zone backfill to achieve proper pipe support. The

following installation procedures are intended to assist Figure 10-2 Standard trench construction unstable soils
the installer in achieving a proper pipe installation.

10.3 Pipe Bedding

10.2 Trench Construction
The bedding should be placed over a firm, stable
The trench construction highly depends on the soil trench bottom so as to provide proper support. The
parameters, such as type, density and moisture finished bed must provide a firm, stable and uniform
content. The construction of the trench should comply support for the pipe barrel and any protruding feature
with following requirements and recommendation: of its joint.
The common practice is to provide 150 mm of bedding
The trench shape is determined by the classification below the barrel and 75 mm below the joint. For soft or
on the soil, which can be unstable or stable. unstable trench bottoms, an additional foundation may
Top sides of the trench must be cleared from rocks be needed to achieve firm support for the bedding.
or any other sharp/heavy materials.
The trench foundation shall consist of a compacted
sand layer without stones or sharp objects.
Loosen a hard and uneven trench foundation in
order to prevent point loading.
Keep the trench dry during installation; if necessary
use of a pumping system and drainage.

31

Figure 10-3 Assembly inside trench
O
TI
LU
O
ES
R
Figure 10-4 Pipe bedding
W
The bedding material may need to be imported to
provide proper gradation and pipe support. The
LO
recommended materials for bedding are SC1 or SC2.
To determine if the native material is acceptable as a
bedding material, it should meet all of the requirements
of the pipe zone backfill. This determination must be
made constantly during the pipe installation process
because native soil conditions may vary and change
suddenly along the length of a pipeline.
The bed must be over-excavated at each joint location
to ensure that the pipe has a continuous support and
does not rest on the couplings. The coupling area must
be properly bedded and backfilled after joint assembly
is completed. See Figure 9-3 for proper and improper
bedding support.
10.4 Backfill Materials
For classification of various backfill materials and types
of embedment, reference is made to AWWA Manual
M45 or ASTM D 3839, the following general restrictions
apply:
32
The limits for the maximum particle size and stone
size given in Table 3-2 must be adhered to.
No soil clumps greater than two times the maximum
particle size.
No frozen material
No organic material
No debris (tires, bottles, metals, etc.)
DN Max. Size (mm)
450 13
500-1200 19
Table 10-1: Maximum particle size
F
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The backfill above the pipe zone may be made with
excavated material with a maximum particle size of up
to 300 mm providing there is at least 300 mm cover
over the pipe. Stones larger than 200 mm should not
N
be dropped on the 300 mm layer covering the pipe
crown from a height greater than 2 meters.
10.5 Backfilling Pipe
Immediate backfilling after joining is recommended as it
will prevent two hazards, i.e. floating of pipe due to
heavy rain and thermal movements due to large
differences between day and night temperatures.
Floating of pipe can damage the pipe and create
unnecessary reinstallation costs. Thermal expansion
and contraction can cause loss of seal due to
movement of several pipe lengths accumulated at one
joint.
If sections of pipe are placed into the trench and
backfilling is delayed, each pipe should have the centre
section backfilled to the crown to help minimize
movements at the joint.
Proper selection, placement and compaction of pipe
zone backfill are important for controlling the vertical
deflection and are critical for pipe performance. Care
must be taken so that the backfill material is not
contaminated with debris or other foreign materials that
could damage the pipe or cause loss of support. The
hunching material in the area between the bedding and
the underside of the pipe should be worked in and
compacted before placing the remainder of the backfill
(see Figure 10-4 and Figure 10-5)
 correct: pipe firmly supported
Figure 10-4 Proper haunch backfill
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Figure 10-5 Improper haunch
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Procedure & requirements
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The procedure and the requirements comprise:
W
Temporary installation devices must be removed
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prior to backfilling.
The maximum particle size for pipe zone
embedment is related to the pipe diameter and is
described in the backfill material specification (see
Table 9-1).
Dumping large quantities of backfill material at one
spot on top of the pipe may cause damage; spread
the applied backfill material.
Backfill material shall be compacted in layers of 150
mm. make sure pipe is not be displaced due to
backfilling.
When reaching a compactions, height of 0.3 * ID
below the crown of the pipe, compaction may be
continued in layers of 300 mm.
Each layer of backfill shall have a compaction grade
of at least 85% Standard Proctor Density (SPD).
Compaction is performed on both sides of the pipe,
never across the pipe. A vibrating plate with an
impact force of 3000 N is used.
Do not use heavy pneumatic hammers or vibrating
equipment until having reached a backfill level of
500 mm over the crown of the pipe.
Avoid any contact between compaction tools and
RTR products.
Use hand camping only method of compacting
within 150 mm envelop around the pipe
circumference there after hand operation vibratory
plate compactors can be used.
10.6 Burial Depth
When live loads are less than the conventional H20-S16
loading, the burial depth measured from the top of pipe
should be at least 3 feet (0.91 m) for all diameters.
At road crossings where the loading exceeds H20-S16,
use one of the following methods:
F
Bury the pipe deeper; AMIPOX will make
PD
recommendation on increased depth of burial upon
request provided complete loading and soil
conditions are submitted for an engineering
analysis.
N
Use casing pipe and collars to protect the pipe;
when casings/sleeves are used, take care that the
pipe is properly bedded at the points of entry and
exit of the casing pipe, pad the pipe to prevent
rubbing against the steel casing and spacers to
support the pipe inside the casing (see Fig. 10-6).
Road surface
Shrinking
Rubber pad
sleeve
Casing pipe 3m Spport
Figure 10-6 Road crossing pipe protection with
casing pipe
Relief plates are used if pipes are installed at
shallow depth in well compacted sandy soils or in
case the soil and traffic load cause an excessive
loading or deformation of the GRE pipe. The plate is
specially designed and dimensioned to minimise the
transfer of wheel load on the pipe.
Top load free space
Polystyrene foam Relief plate
0.5 x OD 45
Spread
OD
Figure 10-7 Relief plate
33
10.7 Thrust Blocking
+
+
AMIPOX adhesive bonded tapered joints and seal-lock
mechanical joints are fully restrained thrust blocks are
not needed. Unless recommended as per below points +
+

Evaluation of the need for thrust blocks is the

responsibility of the engineering agency designing
the system. The decision will depend on the
exposure to temperature change, surges of internal
pressure and the geometry of the pipeline layout.
For each of these factors, singly or in combination,
the effect of movement and thrusts on the pipe Figure 10-8 Typical AMIPOX pipe system with thrust
joints and fittings must be evaluated. blocks
Temperature changes produce stress in buried pipe

F
which is restrained by friction of the surrounding

PD
bedding, by passive soil pressure at fittings, or by
thrust blocks.
Safe Bearing Pressure
Hydrostatic thrusts at fittings depend on the degree Soil Type Description (Sp) kg/m2
of restraint on the pipe bonded to those fittings. In a Rock, hard thick layers 195
fully restrained pipe (blocked against movement at N Rock, equal to good masonry 24.5
O
both ends) with all joints bonded, the Poisson effect Rock equal to best brick 14.64

produces considerable tension in the pipe wall; that Rock equal to poor brick 4.8
TI

is as internal pressure is applied, the pipe expands Clay, always dry 3.9
Clay, fairly dry 1.95
circumferentially and at the same time tries to
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Clay soft 0.97

shorten longitudinally. This tensile force in the
Gravel, coarse sand, firm 7.8
AMIPOX pipe wall acts to reduce the hydrostatic
O

Sand, compact, firm 3.9

thrust on a fitting by about 50%.
Sand, clean, dry 1.95
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Table 10-2: Safe bearing pressure of soils

10.8 Thrust Blocks-Design and
R

Construction
W

Bearing area required is computed using the formula

Once the applied thrusts are determined, the
LO

designer of thrust blocks must consider soil

strength, soil stability and location of the water R
table. At = Sp

Blocks must have:

- Adequate bearing area to resist the soil thrust.
- Bearing surface against undisturbed soil.
- The resultant thrust vector passing
perpendicularly through the centre of the bearing
surface (except for valves). Should the soil be
unstable or the installation below the water table,
the engineer will have to make special provision
to ensure stability.
! Note! It is important that any connecting metallic
pipe must be anchored at the point of connection
to prevent excessive stresses being transferred
to the pipe.
where:
At = Bearing area of thrust block
R = Reaction
SP = Allowable soil bearing pressure
Thrust blocks for AMIPOX pipe systems should be
poured after hydrostatic testing of the pipe. This will
allow for clear visual inspection of all fitting joints
during the test. To retain pipe in proper alignment
while testing, the placement of sand bags and or
partial backfilling may be required. Joints may be
left exposed for observation during test.
Thrust blocks should be shaped with the designed
bearing area against virgin earth of the trench wall.
Smaller blocks using a dry mix may be shaped by
hands but larger blocks will require forms

34
 The trench should be undercut beneath the pipes at
least 6 inches to give additional thrust resistance
and to provide for an adequate concrete envelope
around the fittings. At least 6 inches of concrete
should be over the top of the pipe.
The centre of the thrust block should coincide with
the horizontal centreline of the pipe.
Unless otherwise specified by the engineer,
acceptable concrete is 1 part Portland cement, 2
parts washed sand and 3-parts washed gravel with
enough water for a relatively dry mix. The dry mix is
easier to shape and offers higher strength.
It is important that the concrete be worked
thoroughly around the elbows for maximum surface
contact. Take care that entire area between the
10.10 Pipe Cast in Concrete
Concrete can be poured around AMIPOX piping
system.
Do not pour concrete directly onto pipe.
The vibrating equipment must be kept at least
300 mm away from the pipe.
The pipe system must be pressure tested prior to
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.

F
fittings and the freshly cut trench wall is filled with Note that concrete shrinks when setting; this may result

PD
concrete and free of voids. in extra loading of the GRE pipe system. Ensure that
the allowable external pressure is not exceeded by
using pressure relief valves.
10.9 Settlement
N
O
Flexible rubber seal lock joints have to be installed in
pairs (ASL); one joint is placed at the beginning of the
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deviation while the other is located at the end of this

area, in order to create a rocker pipe. The rocker pipe
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will act as a hinge.

O

The longer the rocker pipe, the higher the loads on the
joints. This can be avoided by using more rocker pipes.
ES

Based on the soil parameters, the number of rocker

pipes is determined.
R

Note that the length of the sections shall be limited in

W

order to avoid excessive bending which may result in

failure of pipe or joint.
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The section length = ID + minimal 0.5 m. Mechanical

O-ring joints shall be installed at both ends to Figure 10-10 Pipe cast in concrete
accommodate further settlements.

Original
position 10.11 Concrete Wall Penetrations
and Connections
Sag

Several methods are used for AMIPOX pipe

connections through concrete walls.

1 Puddle flange
Flexible Flexible joint
joint
Settled profile
ofter subsidence
Factory made puddle flange consists of a GRE ring
Location of pipe which is directly laminated on a pipe piece (exact
after subsidence
location by client) with standard dimensions of
approximate 50 mm thickness and a diameter of 50 mm
Figure 10-9 Settlement
greater than the diameter of the pipe to be installed.
A rubber pad wrap is recommended to protect the
surrounding pipe portions.

35
 Puddle Flange
Rubber pad wrap 10.12 Multiple Pipes in same Trench
around pipe
RTR pipe When two or more pipes are installed parallel or cross
over in the same trench, there should be clear spacing
between the pipes, as shown in Figure 9-14.
It is advisable, when laying pipes of different diameters
in the same trench, to lay them with the same invert
Concrete wall level. When this is not possible, use backfill material
type SC1 or SC2 to fill all the space from the trench
bottom to the invert of the higher pipe. Proper
100 (typ) compaction must be achieved (min 90%SPD)

Figure 10-11 Pipe passing through wall with puddle D (R1+R2) /2 BUT NOT LESS THAN 300MM
flange
D
R1 R2

F
2 Support saddles

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Two 180 degree support saddles are bounded on the
pipe for tie where it fits in the wall and slightly
protruding outside the wall.
2 - RTR support N
O
saddle 180^
bonded on pipe R1
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RTR pipe
F
R2
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O

F (R1+R2) 2 BUT NOT LESS THAN 300MM

ES

Concrete wall
Figure 10-14 Spacing between pipes in the same
trench
R

Figure 10-12 Pipe passing through wall with support

W

saddle
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3 Metal pipe sleeve

This type of wall penetration pipe should be fitted into a

metal pipe sleeve a minimum is 50mm larger in
diameter than the AMIPOX pipe size. The opening
between the metal pipe sleeve and the AMIPOX should
be caulked with a waterproof compound which will dry
to a firm but pliable mass.

Sand bedding

RTR pipe Packing seal

Figure 10-13 Wall penetration with metal pipe sleeve

36
11 Aboveground Pipe Installation

11.1 General
This section gives guidelines for proper installation of
AMIPOX pipe systems installed above the surface of
the ground.
Type A Wall type support

180 GRE
180^ GREsaddle
SADDLE permitting
PERMITTING
AFFIXEDtoTO
affixed pipe
PIPE

Type B Sitting on pipe sleeper

F
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Aboveground piping system

Those who know how to install steel pipe will find that N
O
most of the same skills and techniques apply but there
are some important differences. AMIPOX pipe requires
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protection against potential external abrasion or Type C Floor type support

crushing at points where supports are located.
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In general, the objective of any above ground Figure 11-1 Typical Simple Supports
installation is to provide supports, guides and anchors
O

points in such a way that deflection of unsupported B Guide supports:

span lengths are maintained within acceptable limits Support vertical loads and restrain lateral movement.
ES

over the long-term. The main use of guides is to avoid buckling and
maintain alignment when axial compressive loads exist
R

in a pipe. Typical, for guide support are shown in

11.2 Support Types Figure 11.2 below
W

There are three main types of supports

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Simple support
Guide support
Anchor support

Following is set of rules to be followed when designing

and positioning supports anchors and guides.
Avoid point loads. Type A Pipe clamp loose fit Type B U bolt loose fit
Meet minimum support dimensions.
Protect against abrasion. Figure 11-2 Typical guide supports
Support valves and other heavy equipment
independently of the pipe in both vertical and
horizontal installations.
Avoid excessive bending.
Avoid excessive loading in vertical runs.

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 U-bolt with 3-mm thick
spacing tables provided by AMIPOX Typical for simple rubber protection to pipe

support are shown in Figure 11-1

Type C Guide support vertical pipe run

37
C Anchor supports: support can be bolted
Anchors supports must positively, restrain the directly to the flange
movement of the pipe against all applied forces.
The low modulus and light weight of AMIPOX pipe
cause these pipes to move easily when emptied and
filled rapidly during the cycle of operation and under
water hammer conditions. If the movement causes
excessive bending stresses, it must be controlled by
anchoring at changes in direction.
Pipe anchors divide a pipe system into sections or runs
and must be attached in structural material capable of
withstanding any applied forces. In some case pumps,
tanks and other similar equipment functions as support to be welded
anchors. or anchor to a base

F
Typical for anchor supports are shown in
Type B Anchor support on flange

PD
Figure 11-3

N
O
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support can be bolted

directly to the flange
LU

support to be welded
O

or anchor to a base
ES

Type C Anchor support on valve horizontal line

R
W

Valve support arrangement

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support can be bolted

directly to the flange

GRE support saddle

support to be welded
04 nos. 180 saddle
or anchor to a base

3-mm thick rubber protection

in between pipe & clamp

support to be welded
or anchor to a base

Type A Straight pipe Type D Anchor support on valve vertical line

Figure 11-3 Typical anchor supports

38
11.3 Protective Methods
Some recommended protective methods include:
AMIPOX saddles, which provide a clean, corrosion-
free surface acting as stiffening saddle for the pipe.
Saddles are bonded to the pipe.
Elastomeric material such as rubber, neoprene or
even cut-up tire casings. This material may be held
in place by pipe clamps or pipe insulation straps.
When using support styles that clamp the pipe, be
sure that clamping forces do not crush the pipe.
Local crushing could result from a poor fit, and all-
around crushing could result over tightening.
O
Support saddle
TI
LU
11.4 Valve Support
O
Valves and pumps in AMIPOX lines must be supported
independently. Figure 10-3 C and D shows how
ES
supports may be bolted to a flange to support weight,
to resist thrust and torque and to provide electrical
R
grounding.
W
concrete wall water baffle
LO
butterfly valve
support
Figure 11-4 Valve box connections
If a GRE flange is connected to a steel flange, the
support should preferably be at the side of the steel
flange.
One suggestion would be concrete supports, with steel
connections able to carry the full load of the valve.
Also, the bending and torque forces caused by opening
and closing of valves should be absorbed. Hand
operated butterfly valves can be supported or mounted
in a manhole as f shown in Figure 10-4.
11.5 Joining with other Materials
The most appropriate method to join objects of different
materials is by using a flange. A mechanical coupler
might be an alternative. For details about these joints,
reference is made to manufacturers documentation.
Flanges can be drilled according most of the relevant
standards. When a flanged GRE pipe section is joined
with a metal pipe section, the metal section must be
anchored to avoid transmission of loads and
displacements to the GRE pipe section.
Instrument connections can be made using a saddle
and a bushing.
F
PD
N
Figure 11-5 Reducing saddle with metallic bushing
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.
39
12 Field Hydro Testing

Some job specifications require the completed

pipe installation to be hydrostatically tested prior to
acceptance and service. This is good practice as it
can permit early detection and correction of some
installation flaws, damaged products etc. If a field
hydro test is specified, it must be done regularly as
installation proceeds. Good construction practice would
be to not exceed pipe testing with installation by more
than approximately 1000 meters in order to properly
assess the quality of work. The first field hydro test
should ideally include at least one air valve or drainage
chamber to assess the total pipeline system. In
addition to routine care, normal precautions and typical
procedures used in this work, the following suggestions
should be noted:

F
PD
Testing manifold
1 Preparations prior to test

Inspect the completed installation to assure that all

work has been finished properly. Of critical N
3 Pressurize the line slowly
O
importance is:
Joints assembled correctly. Considerable energy is stored in a pipeline under
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System restraints (i.e. thrust blocks and other pressure, and this power should be respected.
anchors) in place and properly cured. Apply 0.8 times the pressure and allow 24 hours to
LU

Flange bolting torques per instructions. settle.

Backfilling completed to minimum burial.
O

Valves and pumps anchored. 4 Ensure that the gauge location will show the
Backfill and compaction near structures and at highest line pressure or adjust accordingly.
ES

closure pieces has been properly carried out Locations lower in the line will have higher pressure
due to additional head.
R

5 Ensure that the maximum test pressure does not

W

exceed 1.5x PN.

Normally, the field test pressure is either a multiple
LO

of the operating pressure or the operating pressure

plus a small incremental amount. However, in no
case should the maximum field test pressure
exceed 1.5 x PN.

6 If, after a brief period for stabilization, the line

Field hydro testing unit
source:
2 Filling the line with water
Open valves and vents, so that all air is expelled
from the line during filling and avoid pressure
surges. Fill from the lowest point. Long straight
sections may be vented using an inflatable ball or
foam pig to expel the air.
does not hold constant pressure, ensure that
thermal effect (a temperature change), system
expansion or entrapped air is not the cause.
If the pipe is determined to be leaking and the
location is not readily apparent, the following
methods may aid in the discovery of the problem
Check flange and valve areas.
Check line tap locations.
Use sonic detection equipment.
Test the line in smaller segments to isolate the
leak.

40
 13 Repair Work

7 Causes of pressure drop Below listed are some typical repair methods:

The following causes may affect pressure and can 1 General

be used as a check list:
The repair procedure shall be prepared and qualified
Temperature change, by day as well as by night. by the contractor in accordance with the pipe
Leakage of valves, fittings, hydrants, etc. manufacturers recommendations. It shall be
Leakage of gaskets. demonstrated that the repair method restores the
Dirt at sealing ring. specified properties.
Wrong installation of O-ring (slip ring).
Pipes or fittings insufficiently blocked in the Leaks in pipe, fittings and joints are repaired by
trench resulting in displacement. replacing the defective part. In some cases,
Air Lock especially for buried systems, insufficient space
Leaking test equipment. and/or difficult accessibility to pipes and fittings
Stabilizing time too short. may occur.

F
Leaking joint.

PD
Leakage in fittings. Each application of a GRE pipe system and each
Leakage of the pipe as result of damage type of product or design requires a different repair
(cracks). and/or replacement procedure.
Settlement of the pipe system.
N
2 Minor surface damage
O
The system shall be considered to have passed the
hydro test if there is no leaking of water from the Minor damage to the surface of pipes, fittings
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piping at any location and there is no significant and laminates (e.g. scratches, scour marks) is
pressure loss that can be accounted for by usual sealed with resins or adhesive (respective
LU

engineering considerations. instruction must be followed).

Reinforced wall not be damaged.
O

8 Depressurising
3 Damage to reinforced wall
ES

Depressurising of the system must be carried out

carefully to avoid a negative pressure. Fittings showing damage to the reinforced wall
R

must be replaced.
In the case of pipes with damage to the
W

reinforced wall it is generally necessary to

replace part of the pipe. For this the damaged
LO

section of the pipe is cut out with sufficient

spacing left from the visible damage and
replaced by a new section. If this is not possible
for operation or other reasons, a necessary
recommendation must be obtained from AMIPOX.
A provisional repair of the leak is possible, for
example, by means of a supplementary laminate
or by bonding a saddle to the pipe (pipe must be
drained) or by means of a mechanical coupling
(non - tensile resistant).

4 Leakages from joints

Adhesive bonded joints

- The leaking joint must be cut out and
replaced (see section Adhesive Bonded
Joints).
- If allowed, the leak can be repaired with a
laminate (taking due account of the
operating pressure, specification) See
Assembled pipe inside trench before backfilling section Laminated Joints.

41

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.
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
O
Flanged Joints.
TI
LU
O
ES
R
W
LO
Pipe assembly inside the trench using come-along
42
14 Safety Precautions
The following safety precautions should be respected
when dealing with AMIPOX products.
14.1 Resin, Hardener and Adhesive Kits
For required rescue and safety measures when
using adhesives, resins, hardener and
Any other chemicals always refer to safety data
sheet supplied with it.
In order to avoid irritation of the respiratory system,
satisfactory ventilation should be provided.
Always clean up the work area. GRE and cured
adhesive are chemically inert and do not have to be
treated as chemical waste.
F
Waste shall always be disposed in an environment
PD
friendly manner.
14.2 Cutting, Shaving and Sanding
N
When cutting or grinding GRE materials the following
personnel protection is necessary to protect eyes and
skin:
A dust mask covering nose and mouth.
A pair of safety goggles.
Gloves and overall.
Close overall sleeves with adhesive tape to keep
the dust out.
Wear protective clothing to protect the body.
Machining should be carried in a well-ventilated
room or in open air.
14.3 Hydro Testing
If system is to be hydro tested, adequate safety
precautions must be taken, as a safe test pressure
does not exist. Any pressure in itself is dangerous.
Experienced personnel must operate the test
equipment. Only persons involved in the test or
inspection are allowed in the immediate area of the
testing system. Only one person should be in charge
and everyone else must follow his/her instructions.
Do not change anything on the pipes system when it is
under pressure. Leaking joints may only be repaired
after the pressure has been fully released.
The test equipment must be installed at a safe distance
from the connection to the pipe system. If welding
needs to take place, the GRE material must be
protected from hot works.
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43
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PD
F
 This handbook is intended as a
guide only. All values listed in the
product specifications are nominal.
Unsatisfactory product results may
occur due to environmental
fluctuations, variations in operating
procedures, or interpolation of
data. We highly recommend that
any personnel using this data have
specialised training and experience
in the application of these products
and their normal installation and
operating conditions.
The engineering staff should
always be consulted before any

F
of these products are installed to

PD
ensure the suitability of the
products for their intended purpose
and applications. We hereby state
that we do not accept any liability,
N and will not be held liable, for any
O
losses or damage which may result
from the installation or use of any
TI

products listed in this handbook

as we have not determined the
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degree of care required for product

installation or service. We reserve
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the right to revise this data, as

necessary, without notice. We
ES

welcome comments regarding this

handbook.
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LO

AMIPOX
First Industrial City
P.O. Box 589
Dammam, 31421
FT-AMIPOX V1 01-13-ENG

Saudi Arabia
Tel.: + 966 (3) 847 1500
Fax: + 966 92 000 4070
info@amiantit.com
Distributed by: www.amiantit.com