Professional Documents
Culture Documents
AMIPOX - Installation Manual PDF
AMIPOX - Installation Manual PDF
Installation Manual
Table of contents
1 Introductory Information................................................................................................................................4
1.1 Foreword..........................................................................................................................................................4
1.2 Field Technician................................................................................................................................................4
2 Product Information.......................................................................................................................................5
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
2
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
9 Mechanical Couplers...................................................................................................................................30
9.1 Tools for Mechanical Couplers.......................................................................................................................30
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
3
1 Introductory Information
4
2 Product Information
0.3mm
(APPROX) Resin Glass
0.3mm RESIN RICH 100 % 0%
54
±2
°
5
3 Shipping, Handling and Storage
Control Rope
6
3.3.2 Unitised loads Ensure suitable supports such as clean, nail free
wooden beams. Supports must be spaced at a
Unitised loads may be handled using a pair of slings as maximum interval of 3m and around 1m from each pipe
shown in Figure 3-3. Do not lift a non-unitised stack of end.
pipes as a single bundle. Non-unitised pipes must be
unloaded and handled separately (one at a time).
If it is necessary to stack pipes, it is best to stack on 3.5 Storing Gaskets, Lubricants and
flat timber supports (minimum width of 75 mm) at
quarter point with chocks (see Figure 3-4). If available,
Adhesives
use the original shipping dunnage.
• Rubber ring gaskets, for the seal lock joints, should
Ensure that the stack will be stable in conditions such be stored in the shade in their original packing and
as high winds, uneven storage surface or other should not be exposed to sunlight except during the
horizontal loads. If strong winds are anticipated, pipe joining. Also, the gaskets must be protected
consider using ropes or slings to tie pipes down. from exposure to greases and oils which are
Maximum stack height is approximately 1.5 meters, or petroleum derivatives and from solvents and other
two layers, whichever is higher. harmful substances
7
4 Joint Types
• Gasket lubricant should be carefully stored to AMIPOX offer a comprehensive selection of adhesive-
prevent damage. Partially used buckets should be bonded and mechanical joining systems for RTR / GRE
resealed to prevent contamination of the lubricant. piping.
If temperatures during installation are below 5° C,
gaskets and lubricant should be sheltered until
used. 4.1 Taper Adhesive bonded Joint
• Adhesives must be stored indoors at temperatures Adhesive bonded Taper/Taper joint with matching taper
below 38° C. Extended storage at higher male and taper female ends, uses adhesive for jointing
temperatures will degrade the catalyst and the resin and offers superior joint strength by controlled adhesive
and reduce adhesive strength. Each adhesive Kit is thickness. Available in sizes 50 – 1000 mm (2 – 40 in),
stamped with an expiry date. They should be pressure rated up to 100 bar.
removed from shipping cartons and stacked upright
so that the expiry dates are visible.
8
Figure 4-2 Seal-lock joint
9
5 Adhesive bonded Taper Joint, AT - Jointing procedure
10
OVERLL LENGTH
X
LAYING CUTTING LENGTH LAYING
LENGTH LENGTH
ND
Figure 5-4 Cutting squareness
11
• Carefully insert the arbour into the pipe. • Adjust the shaver to the required male diameter.
• Fix the arbour to the inside of the pipe by
turning the central tensioning bolt clockwise. - 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
INSERT.
DEPTH
mm inch degrees mm mm mm mm mm mm
12
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
- Maximum shaving depth /feed is 2mm. - Thoroughly sand within 2 hours of assembly.
- 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
(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.
13
• 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
HERE
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.
Figure 5-9 Dry fit and length marking Figure 5-11 Fixing band clamps
- During final assembly the male may slip 2 Dry the bonding surfaces.
approximately 5 mm further into the female,
therefore the dry fitted assembly should be • If the relative humidity is higher than 75%, or if the
approximately 5 mm longer per joint. bonding surfaces are wet, they should be dried.
• AMIPOX heating blanket can be used in drying
the surfaces.
14
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
24 600 2.0 3.0 3.0 3.0 5.0 5.0
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. 32 800 4.0 4.0 5.0 6.0 7.0 8.0
• More joints may be assembled at the same time.
36 900 4.0 6.0 6.0 7.0 8.0 -
• 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 - -
• Never split a package, always prepare complete Note: For values specified as (-), consult Amipox Engineering
kits.
Table C: Adhesive kits per joint (250 gram kit)
• Do not use damaged or leaking adhesive kits.
2 Prepare the adhesive.
Temp. oC 20 25 30 35 40
15
• Apply a thin layer of adhesive. • It may be necessary to set a bridge (pieces of
• Use a spatula or an adhesive scraper for wood between winch cables and pipe outside) to
applying the adhesive. 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.
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 10°C 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
700 28 2.0 3.0 4.0 4.0 4.0 4.0
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
1000 40 4.0 4.0 4.0 4.0 4.0 4.0
Figure 5-17 Apply heating blanket
Table G: Curing time for fitting joints in hours
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
17
6 AMIPOX Seal-Lock Joints ASL - Jointing Procedures
• Before assembling the rubber Seal-Lock Joints, all • Now brush or rub a layer of lubricant into the
safety precautions need to be checked. O-ring groove of the male end and all inside
• Ensure that all necessary tools and materials are surfaces of the female end or coupling.
available. • Apply lubricant only when you are ready to
complete the joint. Keep lubricated surfaces
clean and free of sand and dirt, as contamination
6.1 Tools for Rubber Seal-Lock Joints is likely to interfere with joining and sealing.
Proper lubrication of the O-ring and joint
For assembly of rubber seal-Lock joints the following is surfaces is important to avoid cutting the O-ring
needed: or rolling it out of place during assembly.
• Lubricant for O-ring and locking strip
• A rod or stick 2 O-ring placement
• Two (2) pipe clamps
• Come along (2) with pulling force 750 kg for • Lubricate the entire surface of the O-ring and
Diameter ≤500 mm and 1500 kg for larger diameters slip it into the first groove on the male end.
• Plastic or wooden mallet to drive the locking strip • Distribute the O-ring evenly in the groove by
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
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
leading end through the insertion hole. If the key
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,
spray all exposed key surfaces with a black
acrylic coating, or wrap them with duct tape.
Also, fill keyholes with caulking compound to
prevent intrusion of sand and dirt which may STEP 2 Lubricate inside the female end and locking
make later key removal difficult. key groove with ample amounts of lubricant
(available on order from AMIPOX). Note that
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
• After driving the keys, deflect the joint to fit the conveniently positioned.
hanger supports or trench bottom. With the pipe
fully supported in its final position, release the
lifting straps: for buried pipe in sag curves, it
may be necessary to leave the lead lifting strap
in position to align the next joint during
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.
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 smoothly without being pushed out of its
the mounted O-ring and run it around the pipe groove.
to distribute the O-ring in the groove.
STEP 5 Mount the band clamps (available on STEP 8 Insert the male end until the scribe line is
order from AMIPOX) a convenient distance on about ¼ inch (6mm) from the leading
each side of the joint, making certain that the edge of the female end or coupling.
pipe going in is properly positioned to allow
access to the keyhole of the following joint.
20
STEP 9 Lubricate the locking key (supplied by
Nominal Pipe Size Maximum joint deflection
AMIPOX) before insertion.
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
3 4
3 9 14
• Torque wrench with required socket size. 10 4
2 11
19
6 8 16 1
2 12 8 9
12 5
14
13
3
6 11
10 7
• AMIPOX flanges are usually flat faced. These 2 15
flanges
must always be accurately aligned and not subject Figure 7-2 Bolts tightening sequence
to any stress.
• The bolts and nuts must have washers to avoid
exceeding the permitted surface pressure. As an Torque
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)
• 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
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
R.T.R.P. line.
150 6 20 82
200 8 20 82
250 10 30 150
300 12 30 150
350 14 30 150
400 16 50 250
450 18 80 400
500 20 80 400
Figure 7-1 Flange assembly
600 24 100 500
22
8 Butt and Wrap
Lamination Joint
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
330 and Epikote 827 to Hardener is a uniform color.
100:24 ppw • When fixing by bonding the front edges
Hardener IPD
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
meter
Adhesive 250 grams kits Two components applied external surfaces of the pipe ends
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
containers when not in use. Prepare IPD batches shortly before
mixing with resin component. is checked.
• Wet out boat tape with adhesive and apply
Table 8-1: Raw materials used in butt & wrap
a minimum of three layers circumferentially
lamination joints
onto the joined pipe ends.
• Use a heating blanket to force cure the
2 Process initial laminate for one hour.
A Cutting the pipe
• Determine the length of the pipe sections, FIT LAYER
taking into account the dimensions of the BOATTAPE WITH ADHESIVE
CIRCUMFERENTIAL, 3 LAYERS
fittings see Figure 8-2 below.
• Mark the pipe sections with the aid of a
marking template. MAX. 5mm (FILL GAP WITH ADHESIVE)
• 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
24
FIT LAYER
L.T.
LAMINATE OVERLAY
W.T.
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 25°C.
L L
2L
For pipes 150 ND or smaller:
t 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 = ½ND FOR PIPE SIZES 250mm ND AND ABOVE
t 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:
t For the hand lay-up of the laminate structure, use E Curing and finishing
boat tape and woven roving in the sequence as t The lamination will harden at ambient
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.
t Make sure that each applied layer of boat tape or t The hardening process needs to be carried
woven roving is thoroughly impregnated with resin out gradually.
mixture. t After the lamination is no longer sticky,
t Apply the layers in the circumferential direction onto curing can be continued with the aid of
the pipe – joint ends. heating blankets, hot air guns or ovens.
t During the wrapping process, tension must be t Heating up to the curing temperature
applied so that the resin under the layer being laid should also be performed gradually.
could be pressed out. t Heating blankets are the most appropriate
t Avoid air getting into the laminate by using the air- to use for field butt &wrap joining.
relieve rollers continuously. t Check if the heating blanket is working
t To give the finishing touch, apply one final layer of properly, temperature in excess of
boat tape spirally wrapped onto the whole surface 120°C should be easily achieved if the
of the laminate. Use air relieve rollers to avoid air heating blanket works properly. The
enclosures. surface contact between the heating
t 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
scraper to leave a resin – rich surface. possible to the joint.
t The curing time only starts when the
LAMINATION SEQUENCE laminate has reached the correct curing
L
BOATTAPE 50% OVERLAP, 2 LAYERS
temperature.
t 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 t 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 t 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
t Clean up the area.
Figure 8-3 Lamination sequence t Dispose waste products in an environment-
friendly manner.
t 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.
↑ ↑
↑ ↑
26
STEP 3 Heat cure of the initial fit-up. STEP 4 Marking lamination length and surface grinding.
↑ ↑
↑ ↑
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.
↑ ↑
↑ ↑
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.
↑ ↑
↑ ↑
29
9 Mechanical Couplers
STEP 9 Final layers of boat tape and woven roving, Generally, mechanical couplers are used for joining
allowing the laminate to gel and dry and finally heat cure plain ended GRE / RTR pipes to pipes made from other
for 4 hours. 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.
30
10 Installation of Underground Pipe Systems
To ensure long life and trouble-free service from • The minimum width (W) at the bottom of the trench
underground piping systems, proper application of the for a single pipe shall be:
principles of excavation is essential. W = 1.25* OD + 300 mm.
Laying and jointing, bedding, backfilling and field • The space between the pipe and the trench wall
testing is required. If pipe is installed by a contractor it must be 150 mm wider than the used compaction
is equally essential that these principles be reflected in equipment.
the phrasing of contract documents and that the • Respecting pipe stiffness, operation conditions, soil
customer enforce them through inspection. The characteristics and wheel load the minimum
recommended practices presented in this guide for the recommended burial depth is 0.9 m.
installation of buried AMIPOX pipe are developed from • Refer Figure 10-1 and Figure 10-2 below for stable
the two basic concepts outlined below. Both should be and unstable standard trench construction details.
rigorously maintained to obtain best results. Firstly, the W
Secondary backfill
The type of installation procedure appropriate for 30 cm zone compacted in
AMIPOX pipe varies with pipe, cover depth, width, D
layers of 30 cm
0.7 x D
native soil characteristics, surcharge loads and backfill
Primary backfill 15 cm Bedding
materials. 15 cm Foundation
zone compacted in
The native material must adequately confine the pipe layers of 15 cm
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.
31
• 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.)
≤ 450 13
500-1200 19
Figure 10-3 Assembly inside trench
Table 10-1: Maximum particle size
32
correct: pipe firmly supported
• 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.
Road surface
Figure 10-5 Improper haunch
Shrinking
sleeve Rubber pad
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 +
+
produces considerable tension in the pipe wall; that Rock equal to poor brick 4.8
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
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
Sand, compact, firm 3.9
thrust on a fitting by about 50%.
Sand, clean, dry 1.95
34
• The trench should be undercut beneath the pipes at 10.10 Pipe Cast in Concrete
least 6 inches to give additional thrust resistance
and to provide for an adequate concrete envelope Concrete can be poured around AMIPOX piping
around the fittings. At least 6 inches of concrete system.
should be over the top of the pipe.
• The centre of the thrust block should coincide with • Do not pour concrete directly onto pipe.
the horizontal centreline of the pipe. • The vibrating equipment must be kept at least
• Unless otherwise specified by the engineer, 300 mm away from the pipe.
acceptable concrete is 1 part Portland cement, 2 • The pipe system must be pressure tested prior to
parts washed sand and 3-parts washed gravel with casting.
enough water for a relatively dry mix. The dry mix is • Cradles are provided with steel clamps and rubber
easier to shape and offers higher strength. lining in order to prevent floating.
• It is important that the concrete be “worked” • Buckling of the pipe during casting can be
thoroughly around the elbows for maximum surface prevented by pressurizing the system.
contact. Take care that entire area between the
fittings and the freshly cut trench wall is filled with Note that concrete shrinks when setting; this may result
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
Flexible rubber seal lock joints have to be installed in
pairs (ASL); one joint is placed at the beginning of the
deviation while the other is located at the end of this
area, in order to create a rocker pipe. The rocker pipe
will act as a hinge.
The longer the rocker pipe, the higher the loads on the
joints. This can be avoided by using more rocker pipes.
Based on the soil parameters, the number of rocker
pipes is determined.
Original
position 10.11 Concrete Wall Penetrations
and Connections
Sag
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
2 Support saddles
Sand bedding
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
180º GRE
180^ GREsaddle
SADDLE permitting
PERMITTING
AFFIXEDtoTO
affixed pipe
PIPE
Those who know how to install steel pipe will find that
most of the same skills and techniques apply but there
are some important differences. AMIPOX pipe requires
protection against potential external abrasion or Type C Floor type support
crushing at points where supports are located.
In general, the objective of any above ground Figure 11-1 Typical Simple Supports
installation is to provide supports, guides and anchors
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.
over the long-term. The main use of guides is to avoid buckling and
maintain alignment when axial compressive loads exist
in a pipe. Typical, for guide support are shown in
11.2 Support Types Figure 11.2 below
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
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
support to be welded
or anchor to a base
support to be welded
or anchor to a base
38
11.3 Protective Methods 11.5 Joining with other Materials
Some recommended protective methods include: The most appropriate method to join objects of different
materials is by using a flange. A mechanical coupler
• AMIPOX saddles, which provide a clean, corrosion- might be an alternative. For details about these joints,
free surface acting as stiffening saddle for the pipe. reference is made to manufacturers’ documentation.
Saddles are bonded to the pipe.
• Elastomeric material such as rubber, neoprene or Flanges can be drilled according most of the relevant
even cut-up tire casings. This material may be held standards. When a flanged GRE pipe section is joined
in place by pipe clamps or pipe insulation straps. with a metal pipe section, the metal section must be
• When using support styles that clamp the pipe, be anchored to avoid transmission of loads and
sure that clamping forces do not crush the pipe. displacements to the GRE pipe section.
Local crushing could result from a poor fit, and all-
around crushing could result over tightening. Instrument connections can be made using a saddle
and a bushing.
Support saddle
39
12 Field Hydro Testing
Testing manifold
1 Preparations prior to test
40
13 Repair Work
7 Causes of pressure drop Below listed are some typical repair methods:
41
14 Safety Precautions
42
43
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
of these products are installed to
ensure the suitability of the
products for their intended purpose
and applications. We hereby state
that we do not accept any liability,
and will not be held liable, for any
losses or damage which may result
from the installation or use of any
products listed in this handbook
as we have not determined the
degree of care required for product
installation or service. We reserve
the right to revise this data, as
necessary, without notice. We
welcome comments regarding this
handbook.
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