Adhesive Bonded Joints-TB-TS

Adhesive Bonded Joints-TB/TS
Training Presentation
• Purpose
• Quality
• Inspection
• Requirements for bonding surface
and ambient conditions
Agenda • Dimensions of Taper spigot end

• Preparing for bonding
• Bonding
• Materials , tools and consumables
• Health and Safety
2
Purpose
• To describe the method to assemble Taper-Taper adhesive-bonded joints
Symbol
3
• Purpose
• Quality
• Inspection

• Bonding
4
Quality
 It is advised that the bonder possesses a valid Jointer/Bonder Qualification
Certificate, issued by the pipe manufacturer or a Qualified Certifier.
 After preparation of bell- and spigot end, the actual bonding and finishing of
the adhesive joint shall be performed continuously and without any interruption
or delay.
5
• Purpose
• Quality
• Inspection

• Bonding
6
Inspection
• All pipes, fittings or components used in the pipeline system shall be inspected
for damages, prior to the actual bonding activity.
 Cracks
 Impact Damages
 Scratches
Crack
 Damaged interior / liner Damaged interior
Rejected items shall be separated and quarantined from undamaged materials

to avoid unintentional use.
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Inspection
• Adhesive kits shall be inspected prior
to use. Do not use adhesive kits or
containers showing evidence of
damage or leakage.
• The adhesive shall be used before the

expiry date, which is shown on the
adhesive kit.
• Make sure that storage of adhesive kits

complies with the storage
requirements.
8
• Purpose
• Quality
• Inspection

• Bonding
9
Requirements for bonding surface and ambient conditions
 Cleaning of a plain pipe end or an unprepared bell end
• Both the outer surface of a plain cut (not machined) pipe end and the inner
surface of an unprepared bell must be clean and dry before starting any
operation.
• If these surfaces have been in contact with oil or grease, they must be cleaned
using a clean cloth, which is soaked in clean aceton, M.E.K. or M.I.B.K
• Dry the clean surface with a clean, dry and non-fluffy cloth
10
Unprepared and Prepared Surface
 Unprepared Surface
• An unprepared surface is a surface on the inside of a bell or on the outside of a
pipe end, where the original resin rich coating is still intact as it were after
completion of the manufacturing process. Any manual or mechanical abrasion
process, such as sanding or sand blasting, has never reduced the original
thickness of these resin rich layers.
 Prepared Surface
• A prepared surface is a surface on the inside of a bell or on the outside of a
pipe end that has been abraded manually or mechanically. By the abrasion
process, the reinforcement of the composite may come in direct contact with
the environment and is therefore sensitive for contamination.
11
 Ambient conditions and conditioning of bonding surfaces
• iviv Make it dry by using a clean, dry and non-fluffy
Wet Bonding Surface cloth and is followed by heating of the bonding
areas.
Surface Temperature is less Bonding surface must be heated in order to avoid

than dew point plus 3°C condensate on the bonding surface.
Relative humidity is >95%

Create an environment where the bonding process
Environment is foggy can be performed under conditioned circumstances
( e.g. – Shelter )
Rain / Snow / Hail
12
 Ambient conditions and conditioning of bonding surfaces
Heating of surfaces that are wet or The humidity of a (sheltered) bonding

below dew point plus 3°C is environment can be reduced with a
performed with a heating source hot air blower.
such as a hot air blower or a heating
blanket. If the environment heats up the
bonding surface above 40°C, protect it
from direct radiation by sunlight to
control the surface temperature
Raise the temperature of the
bonding surfaces during the heating The temperature of the bonding
process up to maximum 80°C or set surfaces of spigot and bell during the
the temperature of the heating bonding procedure should be kept
blanket at maximum 80°C. between 15°C and 40°C, but also at
least 3°C above dew point.
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 Cleaning of a machined spigot end or a sanded bell end
In contact with oil or grease
Shall not be used and must be cut.

Nature of the contamination
is not sure
In contact with other than oil

Shall be Sanded and used.
or grease
Clean the surface using a clean, dry and non-

No traces of contamination
fluffy cloth
• Do not touch the cleaned surface, nor allow it to be contaminated.
14
 Sanding of spigot and bell end
• The sanding operation of the bonding surfaces of both, spigot- and bell end,
shall be performed within 2 hours from the actual bonding.
• Sanding of factory prepared bell ends is performed mechanically using an

emery cup, a flapper wheel with a grid of grade P40 to P60.
15
• Apply an even pressure on the sanding equipment to realize a smooth bonding
surface
• Sanded surfaces must have a dull, fresh finish, not a polished look.
16
• A correctly sanded surface does not change in color when continuing sanding
• If there is a label at the location of sanding surface, it shall be removed
completely.
17
• Break sharp edges of the tip of the machined spigot end.
18
• Do not touch the cleaned surface nor allow it to be contaminated
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• Purpose
• Quality
• Inspection

• Bonding
20
Dimensions of Taper spigot end
 Cutting of pipe
• Fix the pipe on support.
Rubber pad Direct contact
• Ensure that the pipe is adequately supported or clamped on a pipe vice.

• Use rubber padding having a minimum thickness of 2 mm or similar to protect
the pipe from damage.
21
Cutting of pipe
• Scribe the pipe at the required length using a pipe fitter’s wrap around
22
Cutting of pipe
• Cut the pipe square using a diamond or carbide coated hacksaw or an
abrasive wheel.
23
Cutting of pipe
• Ensure that the squareness of the cut end remains within required tolerance
24
Dimensions of Taper spigot end Bell
• Determine the required length
• Take notice of the minimum cut length.
25
Shaving of the pipe end
• Select the correct shaver as per required diameter range.
• Check assembly instructions for shaver settings.

• Refer to operating instructions if necessary.
26
• The pipe end must be adequately supported.
• Ensure pipe end to be shaved shall be clean.
27
• Fix the shaver with the arbor into the pipe
Be aware of:
 High forces of power drive
 Rotational movement of shaver
 Possibility to move in two directions
• Use Power drive for easy shaving
28
• Start the shaving procedure.
- Use maximum feed of 2mm until the required spigot dimensions have been
achieved.
- For the best performance don’t use the maximum feed
29
• Measure the nose thickness at 3-6 spots along the spigot circumference by
using Vernier Caliper
• Measured nose thickness is an indication of having achieved the required

spigot diameter.
30
Important Notes:-
• Taking S1 as the controlling dimension, shave the spigot length SA at the required taper
angle
• The shaving length (SA) is the minimum required cementing length. Actual shaved length
is always longer therefore; application of cement should be maintained throughout the
extent of the shaved length.
• Once the required S1 dimension is achieved, a joint geometry should be observed that
allows a gap of 25 mm for 1.75° taper angle and 15 mm for 2.5° taper angle between the
nose tip and bell stopper. These gaps depicted should be maintained as much as
possible. However, the installer shall rely on his judgment to determine the right position at
which to stop pulling during joint assembly.
31
 Shaving of the pipe end
• Check the correctness of the shaved spigot by measuring insert depth using a
(dummy) bell.
• The actual insert depth Should be:
- Equal to or smaller than the maximum insert depth, but also
- Equal to or greater than the minimum insert depth.
32
• Purpose
• Quality
• Inspection

• Bonding
33
Preparing for bonding
 Make an insertion mark on the pipe
• Mark a reference point on the spigot side at a length of BA + 100 – C mm,

where C = 25 mm for 1.75° taper angle and C = 15 mm for 2.5° taper angle. BA
is the bell length up to stopper. The BA dimension is as varies for every pipe
class.
• Make an alignment mark in case a pipe is bonded to a fitting
34
 Dry fit the joint
• Arrange and set the proper supporting devices.

• Install the pulling equipment.
• Dry fit gap shall be 20 to 25 mm for diameter above 150.
• Dry fit gap shall be 30 to 35 mm for diameter 150 and below
35
• Determine the number of adhesive kits.
• Check the surface conditions and temperature
• Check the temperature of the adhesive components
• Start bonding within 2 hours after finishing sanding
36
• Purpose
• Quality
• Inspection

• Bonding
37
Bonding
 Preparation of adhesive
• Check correct adhesive type (conductive / non-conductive).

• Check required quantities.
• Check expiry date of adhesive kits.
• Storage temperature shall be between 10°C and 30°C.
• Recommended mixing temperature 20°C and 35°C.
• Bad processing at temperatures <15°C.
• Too fast curing at temperatures >40°C.
38
Bonding
 Pot Life of Adhesive
• Pot life of adhesive is the time period after the hardener is mixed with the
resin to the point when the adhesive starts to turn tacky/gelled.
• The pot life of easy fit adhesive is as per the table below.
39
Application of adhesive
• Apply (with some force) a thin layer of adhesive covering the spigot and the
bell.
• Apply a second uniform layer of adhesive of approx. 0.5 mm on the spigot only
• Make sure to apply an adhesive layer on the cut end of the spigot.
• Make sure to apply sufficient adhesive on the cylindrical part of the spigot that
will be covered by the bell
40
Assembly of the spigot in the bell
• Insert the spigot in the bell and apply an equal load using the pulling
equipment
• Stop pulling until the spigot does not enter into the bell anymore
41
Check insertion depth
• Check the insert depth by measuring the distance (Dist) between the head of
the bell and the insertion mark
• Check the position of the alignment mark in case a fitting is bonded
42
Finishing of adhesive bonded joint
• Remove excessive adhesive from the outside and if possible from the inside
• The fillet on the head of the bell should be smoothly rounded; the inside might
be cleaned with a plug or a spatula if accessible
• Keep the tension on the pulling equipment until the adhesive is fully cured.
43
Finishing of adhesive bonded joint
 Cleaning Plug Details
44
Curing of the adhesive
• Wrap a heating blanket around the joint covering the whole bonded area.
• Ensure full contact with pipe surface
• Eventual overlap should be outside of the insulation blanket
• Connect the temperature gauge and the control unit.
45
• Insulate the heating blanket and close at least one open end of the jointed
pipeline
• Switch on the electric power and check the functioning of the heating blanket.
• The curing time starts when the required surface temperature (125ºC) is
reached.
• Write the starting time and required curing time on the pipe
• Check the temperature of the heating blanket at the end of the curing process
46
• Adhesive bonded flanges shall be cured by placing the heating blanket

against the inner surface of the flange.
• For an optimal heat transfer the blanket shall be pressed against the inner
surface of the jointed parts.
• Excess adhesive has to be removed from the inside of the joint surface.
47
• Purpose
• Quality
• Inspection

• Bonding
48
Materials
 Adhesive ( Easy-Fit)
• Easy-Fit adhesive kits contains,

- Large can - Dark grey resin.
- Small can - White hardener.
- Mixing spatula.
- Instruction bulletin.
• The net weight of Wavistrong Easy-Fit adhesive kit is 250 g
• The net weight of conductive Wavistrong Easy-Fit adhesive kit contains 230 g.
49
Tools
 Shavers
The shaver is provided with two diamond coated cutters, each having a specific
taper angle.
ID (mm) Taper angle (˚)

25 - 150 1.75
200 - 600 2.5
50
Tools
 Shaver Parts
Aluminum Block Assembly Shaft Assembly
51
Tools
 Shaver Parts
 Power Drive
• Used to drive various shaver types.
• Suitable for either 120 Volts or 230 Volts.
• Personal safety (Clothing, no alcohol,

no drugs, etc.)
• Use in dry environment, not to be used

in explosive areas.
• Specific safety measure to be taken.

Power Drive (Rotating device, high torque, two
directions of rotation).
52
Tools
 Shaver Parts
• Arbors or Mandrels
• The arbor are centers of the shaver.

• Various types available, depending on shaver type.
• By tightening the tensioning bolt's, the arbor expands to grip the inside of the pipe.
• Check the condition of the O-rings before use.
53
Tools
 PI Tape
• Used for measuring S1value.

• S1 = OD (outer diameter) at the tip of the tapered spigot
54
Tools
 Rubber mandrel, emery cups and emery paper
• For cleaning of bonding surfaces use rubber mandrel with emery cups or
emery paper.
• Use grid 40 – 60.
• Take good care during abrading to avoid over polishing of the tapered bell.
• Replace the emery cups and emery on a regular basis.
55
Tools
 Pipe Racks/Cradles & Ratchets
Used for fixation:

• Use rubber padding between GRE and support.
• Avoid direct contact between ratchets and GRE.
• Avoid ovalisation of pipe by pulling band clamps to tight.
56
Tools
 Pipe Pullers, nylon straps and latch belts
Used for joint insertion:

• Use 2 band clamps for Taper-Taper joints.
• Use wooden wedges between puller lugs and pipe.
• Position of pulling lugs must face each other (180 degrees)
57
Tools
 Pipe Pullers
• Pullers must be operated simultaneously for straight insertion.

• Come along jacks may be used for large diameter pipes.
• Store the pullers in a dry area.
58
Tools
 Heating Blankets
• Used for curing adhesive bonded joints from the inside or outside.
• Available for pipe sizes 2” till 28”, check blanket size before use.
• Using 120 Volts alternating current
• The blankets provide thermostatically controlled heat (temperature varies from
~90°C till ~200°C).
• Make sure the blanket is in direct contact with pipe.
59
Tools
 Other Tools • Relative humidity meter
• Dummy of bell end • Infra red thermometer
• Measuring tape and/or folding rule • Hot air blower
• Vernier calliper • Tenting (subject to weather
conditions)
• Pipe fitters’ wrap-around
• Level and marker
• Hacksaw, disc grinder or power
jigsaw
• Small electrical or air driven grinding
machine
• Insulation material or blankets
• Digital temperature gauge for
surface temperature measurement
• Dew point meter
• Thermometer
60
Consumables
 Cutting disks
• Emery disks, emery cups, emery cloth, flapper wheels (all grade P40 to P60)
• Spatula (rubber scraper plate, filling knife), marker pen, dust (paint) brush
• Rubber gloves, working gloves, dust masks, safety goggles
• Cleaning plug
• Overalls, safety shoes, safety helmet
• Cleaning rags, cleaning fluid such as acetone, Methyl Ethyl Ketone (MEK) or
Methyl Iso Butyl Ketone (MIBK)
61
• Purpose
• Quality
• Inspection

• Bonding
62
Health and Safety
 Wear at all time suitable protective clothing.

 Use Personnel Protective Equipment (PPE), such as:
- Long sleeves
- Hard hat (if required by site conditions)
- Safety shoes
- Glasses
- Gloves (for mechanical and chemical protection)
- Dust mask (during machining and sanding)
- Ear protection (during mechanical operations)
63
THANKS
64

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Adhesive Bonded Joints-TB/TS

Agenda • Dimensions of Taper spigot end

Agenda • Dimensions of Taper spigot end

Agenda • Dimensions of Taper spigot end

Rejected items shall be separated and quarantined from undamaged materials

• The adhesive shall be used before the

• Make sure that storage of adhesive kits

Agenda • Dimensions of Taper spigot end

Surface Temperature is less Bonding surface must be heated in order to avoid

Relative humidity is >95%

Heating of surfaces that are wet or The humidity of a (sheltered) bonding

In contact with oil or grease

Shall not be used and must be cut.

In contact with other than oil

Clean the surface using a clean, dry and non-

• Do not touch the cleaned surface, nor allow it to be contaminated.

• Sanding of factory prepared bell ends is performed mechanically using an

• Break sharp edges of the tip of the machined spigot end.

• Do not touch the cleaned surface nor allow it to be contaminated

Agenda • Dimensions of Taper spigot end

Rubber pad Direct contact

• Ensure that the pipe is adequately supported or clamped on a pipe vice.

• Take notice of the minimum cut length.

• Check assembly instructions for shaver settings.

• Ensure pipe end to be shaved shall be clean.

• Use Power drive for easy shaving

• Measured nose thickness is an indication of having achieved the required

Agenda • Dimensions of Taper spigot end

• Mark a reference point on the spigot side at a length of BA + 100 – C mm,

• Arrange and set the proper supporting devices.

Agenda • Dimensions of Taper spigot end

• Check correct adhesive type (conductive / non-conductive).

• Adhesive bonded flanges shall be cured by placing the heating blanket

Agenda • Dimensions of Taper spigot end

• Easy-Fit adhesive kits contains,

ID (mm) Taper angle (˚)

Aluminum Block Assembly Shaft Assembly

• Used to drive various shaver types.

• Suitable for either 120 Volts or 230 Volts.

• Personal safety (Clothing, no alcohol,

• Use in dry environment, not to be used

• Specific safety measure to be taken.

• The arbor are centers of the shaver.

• Used for measuring S1value.

Used for fixation:

Used for joint insertion:

• Pullers must be operated simultaneously for straight insertion.

• Rubber gloves, working gloves, dust masks, safety goggles

• Overalls, safety shoes, safety helmet

Agenda • Dimensions of Taper spigot end

 Wear at all time suitable protective clothing.

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