WS TCD 033E R0 Installation Instructions RSLJ

INSTALLATION INSTRUCTIONS
INTEGRAL RUBBER SEAL LOCK JOINT (RSLJ)

WAVISTRONG®
INSTALLATION INSTRUCTIONS - RSLJ
WAVISTRONG®
INSTALLATION INSTRUCTIONS
INTEGRAL RUBBER SEAL LOCK JOINT (RSLJ)
DOC. WS TCD 033E - R0

Issue Date: October 2016
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WAVISTRONG®
TERMS OF USE
All information was correct at the time of publication. However, we reserve the right to alter, amend and update any
of the products, systems and services described in this brochure.
We accept no responsibility for the interpretation of statements made.
© Copyright by Future Pipe Industries
This document contains confidential and proprietary information. Reproduction or disclosure of any part of this
document is only allowed with written authorization by Future Pipe Industries.
Occasionally, Future Pipe Industries will provide updates to this catalogue. In order to assure that the reader is using
the most current version, please visit our website at www.futurepipe.com
All rights are vested at Future Pipe Industries.
For questions and inquiries, please contact the nearest Future Pipe Industries’ sales office or sales agent through
http://www.futurepipe.com/en/contact/
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WAVISTRONG®
TABLE OF CONTENTS
1 SAFETY PRECAUTIONS 3
2 LIST OF ASSEMBLY TOOLS AND CONSUMABLES 3
3 STORAGE GUIDELINES FOR RUBBER O-RINGS, LOCKING STRIPS AND LUBRICANT 4
4 INSTALLATION PROCEDURE 4
5 DIMENSIONS OF RUBBER RING AND LOCKING STRIP 12
6 INSTALLATION TIME 15
7 JOINT DISASSEMBLY 15
7.1. Procedure 15
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WAVISTRONG®
1. SAFETY PRECAUTIONS
Before assembling the Rubber Seal Lock Joint (RSLJ), all safety precautions shall be implemented; refer to the latest
version of Wavistrong installation manual WS TCD 002.
2. LIST OF ASSEMBLY TOOLS AND CONSUMABLES

The following tools are needed:
Item Purpose
Future Pipe Industries’ supplied lubricant . Do not use any other For joint lubrication during insertion
lubricant. Depending on the composition of fluid in the pipeline
and the ambient conditions during pipeline installation, there
are primarily 2 types of lubricants supplied by Future Pipe
Industries: Soap-based and grease-based
Future Pipe Industries’ supplied O-ring 1 Consumable
Future Pipe Industries’ supplied Locking strip(s) 1 Consumable
A rod or a stick with smooth surface and smooth edges, such For placing the O-ring inside its groove
as a cut and smoothened portion of a locking strip
Two pipe clamps or slings For joint engagement
Chain tackles (2 pieces) For joint engagement
For pipe ID up to 500 mm → pulling force capability of 750 kg
For pipe ID > 500 mm → pulling force capability of 1500 kg
Plastic or wooden mallet or a pneumatic hammer To drive the locking strip
Non-fluffy clean-rags For cleaning the joint and for application of
lubricant
Plastic sheets For creating a clean work environment near
the jointing area
Mixing stick (in case of soap-based lubricant) For mixing of soap-based lubricant
Digital level indicator To ensure correct alignment during the
spigot insertion process, and also after the
joint-stretching process
Cleaning fluid For cleaning greasy/contaminated sockets and
spigots, where applicable
1
Warranty does not apply if material utilized in the joint is not procured from Future Pipe Industries.
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WAVISTRONG®
3. STORAGE GUIDELINES FOR RUBBER O-RINGS, LOCKING STRIPS

AND LUBRICANT
1. Rubber O-rings are delivered in closed bags or 4. Rubber O-rings shall be used on the FIFO
protective boxes from the factory. They must be principle (First IN – First Out) so that those most
stored in their original packing in a sheltered recently received remain in the inventory.
environment, inside a shaded area (protected
from direct sunlight, radiation and artificial light 5. Locking strips shall be stored in a clean condition
containing UV radiation), away from ozone in a sheltered environment, inside a shaded area
generating electrical devices, and in a clean (protected from direct sunlight) until they are
condition until they are ready for use. ready for use.
2. For short term storage, maximum storage 6. Lubricant shall be stored in its original container.
temperature for rubber O-rings shall be 35 °C. Recommended storage temperature is from
For a longer duration (more than 3 months), 0 °C to 65 °C.
maximum storage temperature shall be 25 °C
with a maximum relative humidity of 75%. 7. During storage, keep all consumables away from
chemicals which tend to attack them.
3. Store O-rings without tension (never hang
O-rings).
4. INSTALLATION PROCEDURE
Note: In case of underground piping, before starting the installation, ensure that trenching and bedding is performed
as specified by the design engineer or as per the project-specific method statement.
Note: Sectional view of the joint is shown in Figure 4-1.
Figure 4-1: Sectional view of Rubber Seal Lock Joint (RSLJ).
Single locking strip Two locking strips
1. Start by positioning the holes of locking strip so that

they are easily accessible during the insertion process
of locking strip for the next joint. At this position, place
a mark at the crown of the spigot end indicating “this
side top”. From this point onwards, do not rotate the
pipe during any stage of the assembly process and
always maintain the mark at the top side.
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WAVISTRONG®
2. Remove sand from beneath the socket which needs to

be assembled so as to obtain sufficient clearance from
the soil during the assembly process (Figure 4-2).
Figure 4-2: Excavation beneath the socket and spigot ends to enable assembly.
3. Remove the end protection from the socket and

spigot ends to be assembled.
4. Clean the spigot and socket ends thoroughly with

a non-fluffy clean rag before jointing. In case of
greasy/dirty socket or spigot, use a cleaning fluid.
Do not use material like dusters or paintbrush in
order to avoid fibres from sticking to the surface of
the seal.
5. Visually inspect pipe ends (socket and spigot) and

entire outer surface of pipe for damage. Sand off
any projections or rough edges on the entry profiles
and surfaces which tend to damage the O-ring
during insertion process.
6. Inspect the inner surface of pipe for cleanliness; in

case of deposit of mud, sand, etc., use an acceptable
method to clean the inner surface (such as use of water,
pressurised air, etc.) before installing it into the system.
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WAVISTRONG®
7. To avoid contamination of joint during the insertion Figure 4-3: Placement of plastic sheet underneath the
process, place a plastic sheet underneath the socket joint for creating a clean working area.
and spigot ends (Figure 4-3).
8. To avoid penetration of mud into the joint during

assembly, cover the insertion hole(s) of locking strip
by means of a non-fluffy clean rag or similar.
9. Clean the rubber O-ring with a non-fluffy clean rag or

with water; inspect it for damage, cracks, presence of
any foreign material, any indentation caused by the
removal of contaminant, and permanent deformation.
Figure 4-4: O-ring placement guideline.
10. Ensure that correct O-ring is being used by inspecting
the marking on the O-ring (Figure 5-1). Verify the
type of rubber against project requirements (Table
5-1) and verify the dimensions against Table 5-2.
11. Position the O-ring into the groove of the spigot end
at the farthest side from the face of spigot end (see
Figure 4-4).
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WAVISTRONG®
12. Insert a round tool with smooth edges (such as Figure 4-5: Technique for relieving uneven tension on O-ring.
a cut and smoothened portion of a locking strip)
underneath the O- ring and work it around the pipe
a few times in order to distribute the tension evenly
(see Figure 4-5). Ensure that the O-ring is free of any
twisting. The O-ring should now sit snugly and under
tension inside the groove, and shall be located at the
farthest side from the face of spigot end (see Figure
4-4); if the O-ring does not sit at the prescribed
location, do not roll the O-ring as this will introduce
additional twists – if such a case arises, repeat this
complete step.
13. Apply Future Pipe Industries’ lubricant to the entire Figure 4-6: Application of lubricant on socket end.
inner surface of the socket end first (Figure 4-6),
using a non-fluffy clean rag; do not use a paintbrush
to avoid risk of contamination with bristles/hair
detaching from the paintbrush; do not add water to
the lubricant. Continue with lubricant application on
the O-ring and on the locking strip groove of the
spigot end (Figure 4-7). Avoid any lubricant under
the O-ring in order to prevent it from slipping out of
the groove (see Figure 4-4). Do not try to assemble
the joint without the use of any lubricant. Keep the
lubricated surfaces free of potential contaminants
such as sand and mud.
Figure 4-7: Application of lubricant on spigot end.
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WAVISTRONG®
14. Diameters up to and including 250mm may be Figure 4-8: Technique for fitting of rubber lined caps.
installed without the use of chain tackles. Using
a wooden beam as a lever at the end of the pipe
can apply the force necessary to make the joint. For
larger diameters, fit the rubber lined clamps or slings
on both sides of the joint (Figure 4-8 and Figure 4-9).
15. Ensure that the spigot end is positioned right in front

of the socket end and that both sections are fully
aligned. Do not try to join two pipes at an angle, as
the O-ring may slip out of the groove.
16. Attach the chain tackles (if utilised) to the clamps on

both sides of the pipes to be connected.
Figure 4-9: Rubber lined caps when fully engaged.
Note: The above mentioned clamps are available from

Future Pipe Industries or can also be made by the client
according the Future Pipe Industries’ drawings.
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WAVISTRONG®
17. Insert the spigot manually into the socket end until the Figure 4-10: Zoomed-in view of the first compression
O-ring reaches the compression zone as illustrated zone on Rubber Seal Lock Joint (RSLJ).
in Figure 4-10.
18. Ease the spigot slowly and gradually into the socket
until the required depth of entry is achieved while
ensuring alignment throughout the insertion process.
19. During the insertion process, remove the cover placed

on the insertion hole and inspect the penetration of
O-ring as it moves deeper into the joint. Continue
insertion until it is possible to engage the locking
strip(s).
20. In case of doubt where the spigot was difficult to

insert, check with a thin feeler gauge, all throughout
the circumference if possible, to confirm that the
O-ring is correctly located in the right position in
the groove. If it proves difficult to insert the feeler
gauge throughout the circumference due to slight
misalignment of the joint, then the joint shall be
straightened to enable such inspection. If complete
circumferential check with feeler gauge is not
possible, then dismantle the joint and restart the
assembly process.
21. Apply some lubricant on the locking strip, including

at the tip.
Note: At low temperatures, a plastic locking strip may

become less flexible. In this case it is advisable to heat the
locking strip up to around 20 °C.
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WAVISTRONG®
22. Insert the locking strip manually while ensuring that Figure 4-11: Manual insertion process of locking strip.
the bevelled end rests against the inner surface of the
socket (see Figure 4-11 and Figure 4-12).
23. Using a plastic or wooden mallet or a pneumatic

hammer, tap the locking strip home until it is
completely around the joint (see Figure 4-12 and
Figure 4-13). The end of the locking strip sticks out
by approximately 100 mm. This allows disassembly
of the newly assembled joints. Repeat this step for
the second locking strip (applicable where the joint
design contains 2 locking strips).
24. Once the locking strips are completely inserted,

temporary supports, where installed, shall be
removed to avoid the risk of losing the stretching
of the joint which will be executed in the next step.
Figure 4-12: Illustration of location for locking strip’s
Replace any temporary supports with permanent
final engagement.
bedding support.
25. The newly installed pipe shall be pulled outwards

(by applying axial tension) so as to fully engage
the locking strip(s) against the stop collar. While
applying this stretching force, ensure that the joint is
fully straight in terms of axial alignment. Stretching
can be done manually for pipe diameters up to and
including 250mm; for larger diameters, mechanical
pulling may be required. Approximate capacity of
pulling equipment is 750 kg for diameters up to and
including 500mm, and 1500 kg for larger diameters.
If pulling is not executed correctly, the pipeline may Figure 4-13: Insertion process of locking strip using
move during hydrotest due to end-thrust induced by a mallet.
internal pressure.
26. If necessary, and only after assembly of the joint,

a permitted deflection angle may be used (see
Table 4-1) for the purpose of aligning it with the
trench layout. Do not use the maximum permitted
angle where soil settlement is anticipated; consult
with system design engineer regarding maximum
permitted deflection angle in such cases.
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WAVISTRONG®
27. After correct alignment is ensured, secure the joint Figure 4-14: Joint secured so it does not move anymore.
as shown in Figure 4-14 by supporting it with
correct backfill material on both sides of the joint.
Pay special attention to place the backfill material
under the pipe haunches2 (Figure 4-15). This is the
initial stage of supporting where the purpose is only
to ensure that the pipe is secured as the installation
continues towards the next joint.
28. After a reasonable stretch of pipeline is installed, it is

possible to fine-tune the pipeline’s alignment further.
If this fine-tuning is done, the secure-backfill process
may need to be repeated Figure 4-15: Haunch support methodology.
Table 4-1: Permitted angular deflection

Angular Deflection
ID (mm)
RSLJ
50 1°30’
80 1°30’
100 1°30’
125 1°30’
150 1°30’
200 1°30’
250 1°30’
300 1°30’
350 1°30’
400 1°30’
450 1°30’
500 1°30’
600 1°30’
700 1°
750 1°
800 1°
900 1°
1000 1°
1200 1°
1400 1°
2
Haunch is the zone below the pipe’s centreline and under the pipe’s arc as illustrated in Figure 4-14
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WAVISTRONG®
5. DIMENSIONS OF RUBBER RING AND LOCKING STRIP

The commonly used rubber rings are made of either NBR (Nitril Butadiene Rubber) or EPDM (Ethane propene diene
monomer). Other types of rubber can be supplied depending on the medium and/or the temperature.
The different types of rubber can be recognized by the following colour codes:
Table 5-1: O-ring types

Type Abbreviation Short code Colour code
Styrene butadiene rubber SBR S Red spot
Nitril butadiene rubber NBR N Yellow spot
Ethane propene diene monomer EPDM E Blue spot
Fluoro-elastomer FKM F -
Hydrogenated nitril butadiene rubber H-NBR H -
The dimensions Dr and Do are shown on the O-ring as well as the year and month of production.
Figure 5-1: O-ring with typical identification marks.
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WAVISTRONG®
Figure 5-2: Illustration of O-ring.
Table 5-2: O-ring dimensions

ID (mm) Dr (mm) Do (mm)
50 7 52.5
80 7 90
100 7 109
125 10 132
150 10 156
200 10 207
250 14 260
300 14 311
350 14 360
400 17 409
450 17 460
500 22 508
600 22 610
700 26 690
750 26 740
800 26 790
900 26 880
1000 26 980
1200 30 1120
1400 32 1370
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WAVISTRONG®
Figure 5-3: Illustration of locking strip.
Table 5-3: Locking strip dimensions

PN (bar)
ID (mm) Quantity H (mm) B (mm) Length (mm)
Min. Max.
50 32 32 1 8 12 420
80 32 32 1 8 12 420
100 25 32 1 8 12 420
125 25 32 1 10 14 550
150 20 32 1 10 14 780
16 20 1
200 10 14 780
25 32 2
12.5 20 1
250 16 20 1330
25 32 2
12.5 20 1
300 16 20 1330
25 32 2
8 16 1
350 16 20 1330
20 25 2
8 16 1
400 16 20 1700
20 25 2
8 16 1
450 16 20 1700
20 25 2
8 12.5 1
500 20 24 2260
16 25 2
8 12.5 1
600 20 24 2260
16 25 2
8 12.5 1
700 23 40 2885
16 20 2
8 12.5 1
750 23 40 2885
16 20 2
8 12.5 1
800 23 40 2885
16 20 2
900 8 12.5 2 23 40 1765
1000 8 12.5 2 23 40 1765
1200 8 12.5 2 23 40 2260
1400 8 8 2 23 40 2385
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WAVISTRONG®
6. INSTALLATION TIME 7. JOINT DISASSEMBLY

Estimated installation times on site are shown in In principle, it is possible to take rubber seal joints
Table 6-1. apart within a short period after installation. In
practice, the joint which needs to be disassembled
These estimated times are typical values based on:
may be located in the middle of a pipeline; due to
1. Uninterrupted work.
the lack of space to pull the spigot out of the socket
2. Sufficient space and an open trench for in this case, the pipe may be cut at an optimum
underground applications, etc. location. If the pipe is cut to enable disassembly, it
can be laminated.
3. An installation crew of 3 persons (two in the
trench, one outside).
7.1. Procedure
4. Competent installation personnel with optimal Note: This procedure does not apply to joints that contain
training. 2 locking strips engaged with a single groove, as in the
case of very large diameters such as ID ≥ 900mm.
5. Favourable weather conditions.
1. Push the pipe back to free up the locking strip.
6. Piping to be installed is as part of a straight run
with no fittings. 2. Grip the locking strip with a pair of pliers or a plate
clamp. Tap the pliers or use a crane to pull the plate
7. Excluding the handling time of pipe (example: clamp to remove the locking strip. If the locking strip
stringing of the pipe inside a trench). jams, slightly rotate and/or align the pipe while
pulling the strip.
Table 6-1: Installation time
ID (mm) Time (min.)3 3. Pull the spigot end out of the socket until the
50 5 rubber ring is positioned at the insertion hole of
the locking strip.
80 5
100 5 4. Pull the rubber ring through this hole, cut the
125 5 rubber ring and remove the ring completely
150 5 through the hole.
200 10
5. Now the joint can be released completely by pulling
250 15
the spigot out of the socket.
300 15
350 15
400 15
450 20
500 20
600 20
700 20
750 25
800 25
900 25
1000 30
1200 30
1400 30
3
For ID > 250mm, installation time includes the time taken for clamping and assembly of the joint. It has also been
taken into account that during assembly, the pipe will be moved using a powered equipment such as a crane.
15

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INSTALLATION INSTRUCTIONS

INTEGRAL RUBBER SEAL LOCK JOINT (RSLJ)

DOC. WS TCD 033E - R0

© Copyright by Future Pipe Industries

All rights are vested at Future Pipe Industries.

2 LIST OF ASSEMBLY TOOLS AND CONSUMABLES 3

3 STORAGE GUIDELINES FOR RUBBER O-RINGS, LOCKING STRIPS AND LUBRICANT 4

5 DIMENSIONS OF RUBBER RING AND LOCKING STRIP 12

2. LIST OF ASSEMBLY TOOLS AND CONSUMABLES

3. STORAGE GUIDELINES FOR RUBBER O-RINGS, LOCKING STRIPS

Figure 4-1: Sectional view of Rubber Seal Lock Joint (RSLJ).

Single locking strip Two locking strips

1. Start by positioning the holes of locking strip so that

2. Remove sand from beneath the socket which needs to

3. Remove the end protection from the socket and

4. Clean the spigot and socket ends thoroughly with

5. Visually inspect pipe ends (socket and spigot) and

6. Inspect the inner surface of pipe for cleanliness; in

8. To avoid penetration of mud into the joint during

9. Clean the rubber O-ring with a non-fluffy clean rag or

Figure 4-7: Application of lubricant on spigot end.

15. Ensure that the spigot end is positioned right in front

16. Attach the chain tackles (if utilised) to the clamps on

Figure 4-9: Rubber lined caps when fully engaged.

Note: The above mentioned clamps are available from

19. During the insertion process, remove the cover placed

20. In case of doubt where the spigot was difficult to

21. Apply some lubricant on the locking strip, including

Note: At low temperatures, a plastic locking strip may

23. Using a plastic or wooden mallet or a pneumatic

24. Once the locking strips are completely inserted,

25. The newly installed pipe shall be pulled outwards

26. If necessary, and only after assembly of the joint,

28. After a reasonable stretch of pipeline is installed, it is

Table 4-1: Permitted angular deflection

5. DIMENSIONS OF RUBBER RING AND LOCKING STRIP

Table 5-1: O-ring types

Figure 5-1: O-ring with typical identification marks.

Figure 5-2: Illustration of O-ring.

Table 5-2: O-ring dimensions

Figure 5-3: Illustration of locking strip.

Table 5-3: Locking strip dimensions

6. INSTALLATION TIME 7. JOINT DISASSEMBLY

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