138
Rubber Lining of Pipes
√ √
√ √
Figure 15.6  Sheet-laying procedure.
air. The overlap joints should be finally rerolled. The
sheets should be marked by segments with a chalk
stick, each segment being marked after rolling to dif-
ferentiate rolled as well as unrolled surfaces.
Procedure of Tank Inspection
Before Lining
After fabrication of the tank, the metal surface should
be inspected for any pitting or projections, which should
be leveled out by grinding. This visual inspection should
be done before the tank is hydraulically tested since rust
formed immediately after the hydraulic test will camou-
flage the defects on the surface. Any leaks at the metal
joints found during hydraulic testing should be repaired
before the start of rubber lining and not during the oper-
ation. Before the start of rubber lining the tank should
be properly earthed. The lining operator should check
the earthing beforehand.
Anticorrosive Rubber Lining
In the case of pipes, the sandblasted inner sur-
faces are coated by pouring with adhesive solutions.
For this purpose the pipes are laid obliquely on two
“A” frame stands of different height, say 3 ft and/or
2½ ft. While pouring the adhesive through the pipe,
the pipe is rotated slowly and the excess is collected
in a container at the opposite end. This operation
is repeated twice in each case, the coating of the
adhesive solution being allowed to dry. Next, a pre-
viously formed tube of rubber having length of at
least 50 cm longer than that of the pipe is closed at
both ends. At one end a small opening is made by
pinching and the tube is inflated with air. The tube
is then drawn into the coated pipe with the aid of
a rope made of nylon or cotton duck. The air pres-
sure is then increased by additional pumping of air
through the pinched hole to allow the tube to be
pressed well on the wall of the pipe. The two closed
ends of the tube are then cut open and one of the
protruding ends is folded and pressed into contact
with the whole area of the flange of the mild steel
pipe (Fig. 15.7).
The other end of the pipe remains free when the
mild steel pipe is firmly clamped. A bell-shaped rub-
ber bung of low hardness (45 degrees A) is slowly
drawn into the pipe from the end where the rubber is
folded and fixed onto the flange by means of a cable
attached to an electric winch motor. The diameter
of this rubber bung is about 10% greater than the
inside diameter of the pipe to be lined and is coated
with lubricants such as talc and soft soap to reduce
the friction when it is drawn through. When the
bung moves, it presses the rubber tube against the
wall of the mild steel pipe and expels the air trapped
between the tube and the pipe. Finally, the free end
of the tube is then pressed onto the other flange with
a roller and stitched. The lined pipe is now ready
for autoclave vulcanization. Recommended maxi-
mum lengths of straight pipe for satisfactory lin-
ing are given in Table 15.3. There is no standard
for the maximum length of straight pipes of vari-
ous diameters for lining. Since lengthy pipes with
smaller diameters cannot be accessed for inspection
and testing, the maximum lengths of straight pipes
are recommended based on normal and convenient
industrial practice.
The conventional method of lining pipes involves
the use of rubber bungs. In this method, the green
15: Manufacturing Rubber Sheets and Application Procedures 139

Figure 15.7  Rubber lining of long pipe using a rubber bung tool.

Figure 15.8  Rubber lining of short pipe using a vacuum. (1) Hose made from ebonite closed at one end. (2) Iron
pipe. (3) Soft rubber cover with hose connection to the pump. (4) Iron bell with hose connection to the pump. (5)
Vacuum pump.

Table 15.3  Recommended Maximum Lengths of Straight Pipes for Lining

Nominal Bore (mm) Maximum Length Between Flanges (mm)
25 1000
40 2000
50 3000
65 4000
80 5000
100 and above 6000

(unvulcanized) rubber sheet is made in the form of
a tube called a slew and the tube is drawn into the
coated pipe. The tube length is longer than the length
of the pipe. The bung diameter is also larger than that
of the pipe. The rubber bung is drawn from one end
of the tube toward the other end using a winch motor.
The travel of the bung presses the tube against the wall
of the pipe and expels the air trapped between the rub-
ber and the pipe. After this process, the lined pipe is
cured.
The disadvantages of this process are (1) folding
of the slew during the passage of the bung, (2) air
entrapment, and (3) low productivity.
To overcome these disadvantages, a special process
using a vacuum technique can be adopted (Fig. 15.8).
In western countries this process is popular. The tube or
slew is closed at one end and drawn into the coated pipe.
The open end of the tube is stuck to the flange of the pipe
and closed with a soft rubber cover, which is connected
to a vacuum pump by a hose. A metallic cover, which is
140
also connected to the pump, is put over the other end of
the pipe. The air inside the tube is sucked out through
the soft rubber cover at one end and at the same time
the air between the tube and the pipe is removed via
the metallic cover. The vacuum thus created should be
adjusted in such a fashion that the tube is kept balanced,
and at a suitable moment the vacuum inside the tube
is released. On release of the vacuum, air flows into
the tube at controlled parameters and presses the tube
against the wall of the pipe. By this process it can be
ensured that no air remains trapped. This procedure is
suitable for pipes of smaller lengths. For long-distance
piping systems, small pipes need to be flange joined.
Storage of Rubber-Lined Pipes
The following precautions are to be taken while
storing rubber-lined pipes prior to erection and
commissioning:
• The outside surfaces of the rubber-lined pipes
should be protected against atmospheric cor-
rosion, such as rusting, with an anticorrosive
weather-resistant coating based on chlorosulfo-
nated polyethylene or neoprene. A primer coat of
red oxide is given. In many installations, epoxy
coating or chlorinated rubber-based coating is
also applied if cost considerations are not signifi-
cant. It is, however, recommended that a suitable
white paint is applied to the outer surface as this
will reduce the heat transmitted through the rub-
ber lining and the adhesive bonding beneath it.
• The pipes should be stored in stands at least
about 3 ft above ground level for handling with-
out damage.
• It is advisable to avoid direct exposure to sun
and the lined pipes should be protected under
suitable shelters against extreme climatic condi-
tions. However, this is not possible in huge tanks
in port terminals and therefore a weather-resis-
tant coating is given.
• The pipes should be covered with tarpaulin if
stacked outdoors and free air flow should be
ensured to avoid hot air packets to prevent pre-
mature oxidation.
• The ideal measure will be that the rubber-lined
surface is always kept wet with water to arrest
the likely deterioration from ultraviolet rays and
ozone attack during storage.
Anticorrosive Rubber Lining
Surface Preparation for Rubber
Lining
The advent of the sophisticated protective rubber
lining has brought about the necessity to acquire a
wider knowledge of precise end conditions that must
be fulfilled at the metal surface to achieve the utmost
adhesion and bonding of the lining material to the
metal. The performance of any type of lining is very
much dependent on the cleanliness of the surface. The
environment in which the equipment, storage tanks,
or road tankers are located determines to a great
extent the type of lining that should be specified; for
example, a tank that is located in a harbor terminal
will have to be rubber lined adopting a precured rub-
ber sheet with a self-curing adhesive bonding solu-
tion. If maximum life expectancy of a rubber lining
is expected, it should be firmly adhered to the metal.
The key to the lifespan and effectiveness of lined
equipment exposed to a corrosive environment is its
design and construction. The design and construc-
tion include not only the structural design enabling
maneuverability during lining operation, but also the
surface preparation. Proper surface preparation plays
a vital role in the ultimate protection against corro-
sion. For film formation of the adhesive coating of
even thickness all over and for uniform wetting and
drying, removal of surface contaminants is all that is
required.
Methods of Surface Preparation
Several methods for preparing the metal surfaces
before rubber lining are as follows:
• Cleaning with hand tools,
• Cleaning with power tools,
• Cleaning by sandblasting,
• Cleaning by waterblasting,
• Cleaning with steam, high-pressure water, and
chemicals, and
• Pickling with acid.
Cleaning by hand tools is the oldest process. Today
this is employed only when power tools are not avail-
able and where the surface is inaccessible to power
tools and is too small. The generally used hand tools
are wire brush, scraper blades, chipping hammer, and
emery or sand paper. Handheld electric or pneumatic
15: Manufacturing Rubber Sheets and Application Procedures 141

Table 15.4  Swedish Standard SIS 05 5900 1967

Sa1 Light blast cleaning to remove mill scale, rust, and paint
Sa2 Widely known as commercial blast
Sa2.5 Very thorough blast cleaning to achieve near white metal. Inferior to Sa3
Sa3 Blast cleaning to visually clean steel. Surface to be completely free from oil, grease,
mill scale, and rust

power tools for cleaning include sanders, pneumatic
scalers, needle guns, and rotary steel brushes.
Sandblasting is by far the best and most practical
method and for large areas this is the method fol-
lowed. For outdoor blasting operation, coarse river
sand is used. For indoor blasting, steel shots are used.
Sandblasting is the cheapest method and is widely
used. Sandblasting is done using compressed air at
an output pressure of 6 kg/cm2. Low pressure reduces
blasting efficiency considerably.
The high and low points of the blasted surface are
called the “peaks and valleys” and are an important
factor for anchoring of the adhesive coating. The
sandblasting nozzles generally in use will have either
1/4″, 5/16″, or 3/8″ diameter. Where sufficient air is
available at the correct uniform pressure, the larger-
sized nozzles are preferred to smaller ones for more
area coverage.
The sandblasting operation can be continuous or
intermittent. For continuous sandblasting, the flow
of sand should be continuous. For rubber linings of
large storage tanks, sandblasting is done intermit-
tently, simultaneously followed by primer coats. For
productivity, the sandblasting equipment may have
double hopper arrangements.
Blasted surface qualities are often specified by
users of rubber-lined equipment. A white surface fin-
ish after blasting corresponds to Swedish standard
Sa3 [5] or BS standard 7079 [6] and to first quality
[7,8]. This white finish is defined as a surface with
a gray white, uniform metallic color slightly rough-
ened to form a suitable anchor pattern (peaks and
valleys) for primer coat and subsequent lining. The
finished surface should be free of all oil, grease, dirt,
visible mill scale, rust corrosion products, oxides or
remaining adhesive or paint coatings, or any other
foreign matter.
A near white surface finish corresponds to Swedish
standard Sa2½ or BS4232 second quality. This fin-
ish is defined as one that is free from all oil, grease,
dirt, mill scale, rust, corrosion products, oxides, or
remaining coatings, except for very slight shadows
of light streak discoloration. At least 95% of the sur-
face shall have the appearance of a white metal sur-
face finish and the reminder shall be limited to light
discoloration.
A commercially blasted surface finish corresponds
to Swedish standard Sa2 third quality (Table 15.4).
The finish is defined as one from which oil, grease,
dirt, rust, mill scale, and foreign matter have been
completely removed from the surface, except for
slight shadows streaks or discoloration and pitting.
In the case of old tanks, the surface might have been
pitted, allowing slight residues settling at the bottom
of the pits. These should be removed by brushing.
Waterblasting
Waterblasting will remove substances such as
loose and blistered paints, loose rust, grease, and
other accumulated residue. Since waterblasting will
not produce a surface equivalent to that produced by
sandblasting, it is nevertheless an economical method
of cleaning for lining applications.
Cleaning with steam, hot water using chemi-
cal additives is adopted in connection with other
methods. This method is known as “sweating.” For
example, preparatory to relining of a tank handling
caustic soda for its service life, it is good practice
first to thoroughly clean with steam or high-pressure
hot water before sandblasting. A 5% by weight phos-
phoric acid solution in water added to the steam or
high-pressure water will neutralize any alkali resi-
dues. Care, however, should be taken by the operator
to avoid exposure to fumes and spillage, and stan-
dard precautionary methods and measures should be
strictly followed. At times authentic information as
to the use of acidic water handling in cleaning opera-
tions is not provided by the equipment suppliers. In
this case, such cleaning operations should not be
resorted to without seeking expert advice. Pickling is
done to clean the surface of small metal parts using
dilute hydrochloric or sulfuric acids in pickling tanks
142
that are rubber lined. The acid pickling process will
yield a fresh metal surface suitable for bonding with
rubber for manufacturing metal rubber-bonded com-
ponents. This process is followed mainly in the man-
ufacture of rubber-bonded components.
References
[1] 
Compounding and Properties of Bayprene
Garde Neoprene Rubbers, Technical Information
Bulletin, Bayer AG, Leverkusen, Germany,
1976.
[2] 
ASTM D1646, Standard Test Methods for
Rubber–Viscosity, Stress Relaxation and
Pre-vulcanisation Characteristics (Mooney
Viscometer), 2007.
Anticorrosive Rubber Lining
[3] M.G. Fontana, N.D. Greene (Eds.), Corrosion
Engineering, second ed., McGraw-Hill, New
York, NY, USA, 1978, p. 264.
[4] S. Johnson, Across the Bench–Cleaning Moulds:
Part II, Mould Making Technology, 2004. Article
110406 http://mouldmakingtechnology.com/
articles/110406.html.
[5] SIS 05 59 00, Preparation of Steel Substrates
before Application of Paints and Related Products–
Visual Assessment of Surface Cleanliness, 1967.
[6] BS 7079, Preparation of Steel Substrates before
Application of Paints and Related Products, 1990.
[7] A. Blanc, M. Mc Evoy, R. Plank (Eds.),
Architecture and Construction in Steel, Taylor &
Francis, London, UK, 1993, p. 352.
[8] Talleres Reunidos SA, Spain. http://www.taresa.
es/fiche.html.