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Complete Pipe System Solutions

WAVISTRONG

ASSEMBLY INSTRUCTIONS

CONICAL-CYLINDRICAL (CB-CS) ADHESIVE BONDED JOINT



WAVISTRONGAssemblyInstructions

WAVISTRONG

ASSEMBLY INSTRUCTIONS

CONICAL-CYLINDRICAL (CB-CS) ADHESIVE BONDED JOINT

Date issued : February 1, 2012

Replaces : REP 419/ Rev 00-0101




Wavistrong Assembly Instructions Conical-Cylindrical (CB-CS) Adhesive Bonded Joint

Terms o use

All inormation was correct at the time o going to press. However, we reserve the right to alter, amend and update anyproducts, systems and services described in this brochure.

We accept no responsibility or the interpretation o statements made.

© Copyright by Future Pipe Industries.

This document contains condential and proprietary inormation. Reproduction or disclosure o any part o this document is

only allowed with written authorisation by Future Pipe Industries.

All rights are vested at Future Pipe Industries.




Wavistrong Assembly Instructions Conical-Cylindrical (CB-CS) Adhesive Bonded Joint

Table o contents

Section Page

1 General ................................................................................................................................................... 4

2 Reerences ............................................................................................................................................... 4

3 Quality .................................................................................................................................................... 4

4 Inspection ................................................................................................................................................ 4

5 Requirements or bonding surace and ambient conditions ............................................................................. 5

5.1 Cleaning o a plain pipe end or an unprepared bell end ......................................................................... 55.2 Unprepared and prepared surace ........................................................................................................ 5

5.3 Ambient conditions and conditioning o bonding suraces ........................................................................ 5

5.4 Cleaning o a machined spigot end or a sanded bell end ........................................................................ 6

5.5 Sanding o spigot- and bell end ............................................................................................................ 6

6 Dimensioning o cylindrical spigot end ......................................................................................................... 7

6.1 Cutting o pipe ................................................................................................................................... 7

6.2 Shaving o pipe end ............................................................................................................................ 8

7 Preparing or bonding ............................................................................................................................... 9

7.1 Sanding and conditioning o both bonding suraces ................................................................................ 9

7.2 Dry t and marking ............................................................................................................................. 97.3 Installation o pulling equipment ............................................................................................................ 9

8 Bonding ................................................................................................................................................. 10

8.1 Preparation o adhesive ..................................................................................................................... 10

8.2 Application o adhesive ..................................................................................................................... 10

8.3 Assembly o the spigot in the bell ........................................................................................................ 11

8.4 Curing o the adhesive ...................................................................................................................... 12

9 Materials, tools and consumables .............................................................................................................. 13

9.1 Materials ......................................................................................................................................... 13

9.2 Tools ............................................................................................................................................... 139.3 Consumables .................................................................................................................................... 13

10 Health and saety .................................................................................................................................... 14

Annex A Schemes assembly process Conical-Cylindrical bonded joint ..................................................................... 15

Annex A1 Scheme o spigot dimensioning process ..................................................................................... 15

Annex A2 Scheme o adhesive bonding process ........................................................................................ 16

Annex B Minimum cut length ............................................................................................................................. 17

Annex C Dimensions Cylindrical Spigot ............................................................................................................... 18




Wavistrong Assembly Instructions Conical-Cylindrical (CB-CS) Adhesive Bonded Joint 4

1 General

This document describes the method to assemble Conical-Cylindrical adhesive bonded joints.To ensure that the perormance o the installed joint complies with the requirements used or the design, it is essential that

all personnel involved in the bonding procedure is amiliar with and ully understands the techniques described in this

document.

The instructions in this document are as complete as possible. However, it is not possible to describe all circumstances that

might be encountered in the eld. Thereore, our experienced supervisors may deviate rom the described method in order

to achieve an optimum solution using the latest bonding techniques and processing methods.

Besides, our supervisors may be consulted or clarication o statements made in this document and or advice about

specic problems encountered in the eld.

Annex A shows schemes o the complete assembly process; Annex A1 shows the spigot dimensioning process and Annex

A2 shows the adhesive bonding process.

Denition o words used in these instructions:

- The word “shall” indicates a requirement

- The word “should” indicates a recommendation.

2 Reerences

These instructions are completed with the ollowing reerenced documents:

•WavistrongEasy-FitAdhesiveInstructions

•WavistrongCylindricalSpigotShaverInstructions

3 Quality

It is advised that the bonder possesses a valid Jointer/Bonder Qualication Certicate, issued by the pipe manuacturer or

a Qualied Certier.

Ater preparation o spigot- and bell end, the actual bonding and nishing o the adhesive joint shall be perormed

continuously and without any interruption or delay.

4 Inspection

All pipes, ttings or components used in the pipeline/piping system shall be inspected or damages, prior to the actual

bonding activity. Rejected items shall be separated and quarantined rom undamaged materials to avoid unintentional use.

Adhesive kits shall be inspected prior to use. Do not use adhesive kits or containers showing evidence o damage or

leakage.

The adhesive shall be used beore the expiry date, which is shown on the adhesive kit.

Make sure that storage o adhesive kits complies with the storage requirements.

Ensure all necessary tools and materials are available. Take notice o the saety precautions stated in this document and

those in the reerenced instructions.




5 Wavistrong Assembly Instructions Conical-Cylindrical (CB-CS) Adhesive Bonded Joint

5 Requirements or bonding surace and ambient conditions

This section gives descriptions o specic conditions o the pipe suraces meant or adhesive bonding, as well as methods toobtain the required condition o the bonding suraces.

5.1 Cleaning o a plain pipe end or an unprepared bell end

Both, the outer surace o a plain cut (not machined) pipe end and the inner

surace o an unprepared (see section 5.2) bell must be clean and dry beore

starting any operation.

I these unprepared suraces o product ends have been in contact with oil or

grease, they must be cleaned using a clean cloth, which is soaked in clean

acetone, M.E.K. (Methyl Ethyl Ketone) or M.I.B.K. (Methyl Iso Butyl Ketone).Dry the cleaned surace with a clean, dry and non-fuy cloth.

I there are no traces o oil or grease contamination on these pipe ends, clean

the suraces using a clean, dry and non-fuy cloth (see g. 5.1.a).

5.2 Unprepared and prepared surace

An unprepared surace is a surace on the inside o a bell or on the outside o a pipe end, where the original resin rich

coating is still intact as it was ater completion o the manuacturing process. Not any manual or mechanical abrasion

process, such as sanding or sand blasting, has ever reduced the original thickness o these resin rich layers.

A prepared surace is a surace on the inside o a bell or on the outside o a pipe end that has been abraded manually or

mechanically. By the abrasion process, the reinorcement o the composite may come in direct contact with the environmentand thereore this surace is sensitive or contamination.

5.3 Ambient conditions and conditioning o bonding suraces

I the bonding suraces are visibly wet, these suraces must be dried and heated.

I the temperature o the bonding suraces is less than dew point plus 3 0C, these suraces must be heated in order to avoid

condensate on the bonding surace.

I the relative humidity o the environment is > 95 %, i it is oggy, or i there is any orm o precipitation (e.g. rain, snow,

hail), precautionary measures must be taken to create an environment where the bonding process can be perormed under

conditioned circumstances (e.g. a shelter).Drying o wet suraces is perormed using a clean, dry and non-fuy cloth and is ollowed by heating o the bonding

areas.

Heating o suraces that are wet or below dew point plus 3 0C is perormed with a heating source such as a hot air blower

or a heating blanket.

The humidity o a (sheltered) bonding environment is reduced with e.g. a hot air blower.

Raise the temperature o the bonding suraces during the heating process up to maximum 80 0C, or set the temperature o

the heating blanket at maximum 80 0C.

I the environment heats the bonding surace above 40 0C, protect it rom direct radiation by sunlight.

The temperature o the bonding suraces o spigot- and bell end during the bonding procedure should be kept between

15 0C and 40 0C, but also at least 3 0C above dew point.

Precautionary measures shall be taken to guarantee the compliance with the required humidity and temperature conditions

during the complete bonding procedure.

Fig. 5.1.a





5.4 Cleaning o a machined spigot end or a sanded bell end

A machined, prepared or sanded bonding surace that has been in contact with oil or grease shall not be used and mustbe cut.

Machined, prepared or sanded bonding suraces that are contaminated by other means than oil or grease can be cleaned

by sanding (see section 5.5).

In case o doubt about the nature o the contamination cut the concerned spigot- or bell end.

I there are no traces o contamination on these pipe ends, clean the suraces using a clean, dry and non-fuy cloth.

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

5.5 Sanding o spigot- and bell end

The sanding operation o the bonding suraces o both, spigot- and bell end,shall be perormed within 2 hours rom the actual bonding.

Bonding suraces must be clean and dry at the start o the sanding operation

(see sections 5.1, 5.3 and 5.4).

Sanding o unprepared bell ends is perormed mechanically, using an emery

cup with a grid o grade P40 to P60 (see g. 5.5.a).

Sanding o actory and/or eld prepared spigot- and bell ends is perormed

mechanically using an emery cup, a fapper wheel or emery cloth with a grid

o grade P40 to P60.

A correctly sanded surace does not change in colour when continuing sanding

(see g. 5.5.b).

Bonding suraces must be sanded equally in circumerential direction.

The bonding surace must stay smooth by applying an even pressure on the

sanding equipment.

Do not orget to sand the pipe stop shoulder in the bell end, nor the head o the

bell end.

Break sharp edges o the tip o the machined spigot end.

The bonding surace is cleaned using a dry and clean dust bristle

(see g. 5.5.c).

Sanded suraces must have a dull, resh nish, not a polished look.

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

Fig. 5.5.a

Fig. 5.5.b

Fig. 5.5.c





6 Dimensioning o cylindrical spigot end

In case a pipe with the correct length and (actory) shaved spigot end is available, then continue with section 7 o theseinstructions.

This section 6 is relevant in case the pipe length has to be adjusted or a spigot end has to be shaved.

Make sure to comply with the relevant requirements stated in section 5 beore starting a next step in the activities to

complete the bonding procedure.

6.1 Cutting o pipe

a Contaminated pipe suraces must be cleaned prior to perorm any operation on the pipe

(see relevant requirements stated in section 5).

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

Use rubber padding having a minimum thickness o 2 mm or similar to protect the pipe rom damage.

c Determine the required length rom the product drawing or

by measurement (see g. 6.1.c).

d Scribe the pipe at the required length, using a pipe tters’ wrap-around

(see g. 6.1.d); take notice o the minimum cut length (see Annex B).

e Cut the pipe square using a diamond coated or carbide hacksaw or an

abrasive wheel.

Ensure that the squareness o the cut end remains within required

tolerance (A) (see g. 6.1. and table 6.1.).

Table 6.1. Tolerance cut end

ID (mm) A (mm)

25 - 400 ± 3

Fig. 6.1.c

Fig. 6.1.d

Fig. 6.1.





7 Preparing or bonding

Beore any actual bonding activity can start, the spigot- and bell end to be jointed shall be prepared as described below.Especially in the small diameter range, more joints may have to be prepared, as more joints can be made with one

adhesive kit; in some cases it may be advantageous to assemble more joints at the same time (see section 2).

7.1 Sanding and conditioning o both bonding suraces

Make sure to comply with the relevant requirements stated in section 5.

Note 1

The maximum number of sanding operations for each of the bonding surfaces, either the spigot- or the bell end, is two.

In case the spigot is re-sanded the relevant spigot dimensions shall be checked by measuring.For dimensional requirements see Annex C, table C.

Determine the spigot diameter S1.

The wall thickness of the spigot (T) is measured at a number (>= 6) of positions at the end of the spigot, equally spaced in

the circumference.

In case the number of sanding operations of the bonding surfaces is more than two, or the spigot dimensions are not in

compliance with the requirements, the product shall not be used or the spigot end shall be cut.

7.2 Dry ft and marking

In order to be able to check the required nal position o the spigot relative to

the bell, the joint o a pipe and a tting is marked with an alignment mark.

Scribe a line, parallel to the axis o the product on the outer surace o the bell,

continuing on the outer surace o the pipe containing the shaved spigot end

(see g. 7.2).

7.3 Installation o pulling equipment

a I possible, the conical-cylindrical adhesive bonded joint is assembled without the use o mechanical pulling

equipment. However, starting rom ID 200 mm it is allowed to mount the spigot in the bell using pulling equipment.

b The pulling equipment is installed at both sides o the joint; normally two winches will suce.

The position o the winches is equally spaced over the circumerence o the parts to be jointed in order to realise

centric entrance o the spigot in the bell.

Make sure that there will be sucient space to apply adhesive on the bonding suraces.

c Respect the required alignment o the parts to be jointed as well as the support during the bonding operation.

Fig. 7.2





8.3 Assembly o the spigot in the bell

a Parts to be jointed shall be aligned as true as possible.Any visual misalignment is unacceptable.

b Insert the spigot in the bell and push it home while rotating slowly one

quarter o a rotation, i possible.

Pay attention to the alignment mark on the outer surace with regard to

the orientation o the parts to be jointed.

c When using pulling equipment or joints ID > 200 mm, the winches are

hooked, each winch is equally loaded and the sections to be bonded

are pulled together with a smooth movement.

d Make sure that the spigot is inserted centrically into the bell until the

entrance o the spigot is stopped by the shoulder in the bell.

Note 2

Continuation of activities on the pipeline/piping system may never result in

displacement of the position of the spigot relative to the bell in whatever

direction or orientation.

e Remove the excessive adhesive rom the outer surace

(see g. 8.3.d1) and i possible rom the inside o the joint.

The llet on the head o the bell should be smoothly rounded; the inside

might be cleaned with a plug (see g. 8.3.d2).

Fig. 8.3.d1

Fig. 8.3.d2





8.4 Curing o the adhesive

a Until completion o the cure o the adhesive the joint shall not be moved, vibrated or otherwise disturbed.

b Wrap the required size and voltage heating blanket around the joint,

ensuring ull coverage o the bond area and keeping the power supply

cable ree rom the blanket.

Tie the heating blanket down using e.g. a string or steel wire and

assuring an optimal surace contact with the bell (see g. 8.4.b).

c Overlapping ends o oversized blankets risk to be over-heated.

Insulate overlapping ends and position the overlap outside the

insulation.

d Insulate the heating blanket with suitable insulating material

(by preerence a re blanket or equivalent). Close at least one open end

o the jointed pipe line sections in order to avoid cooling down by

draught.

Insulating material should overlap the sides o the blanket with at least

100 mm and should match the pipe (see g. 8.4.d).

e Apply electric power to the heating blanket.

I applicable, adjust the temperature o the blanket such that the surace

temperature o the jointed parts complies with the requirements stated in

the relevant adhesive instructions (see section 2).

Check the unctioning o the heating blanket, at least at the start and atthe end o the curing process, by measuring the surace temperature o the bell using a (digital) thermometer.

The curing time starts when the required surace temperature o the jointed components is reached. Write the

starting time o the curing on the pipe, next to the heating blanket (see g. 8.4.d).

For the required curing process reerence is made to the relevant adhesive instructions (see section 2).

g Adhesive bonded fanges shall be cured by placing the heating blanket

against the inner surace o the fange.

For an optimal heat transer the blanket shall be pressed against the

inner surace o the jointed parts, ater the excess adhesive has been

removed rom the inside o the joint (see g. 8.4.g).

h I the curing process does not comply with the requirements o the curing

cycle, the complete curing cycle shall be repeated.

i The electrical power to the heating blanket shall be switched o ater

completion o the curing time and ater having checked the surace

temperature or the last time.

Indicate the end time o the curing cycle on the pipe.

It is advised to mark the joint, indicating that the adhesive is cured.

Allow the joint to cool down beore loading mechanically or hydrostatically.

Fig. 8.4.b

Fig. 8.4.d

Fig. 8.4.g





9 Materials, tools and consumables

9.1 Materials

•Adhesive*

9.2 Tools

•Shaver*

•Heatingblanket(plustemperaturecontroller,ifapplicable)*

•Measuringtapeand/orfoldingrule

•Verniercalliper •Pi-tape

•Pipetters’wrap-around

•Levelandmarker

•Protractor

•Pipeviceorstablesupports(brackets)withrubbercoatedclampingdevice

•Hacksaw,discgrinderorpowerjigsaw

•Smallelectricalorairdrivengrindingmachine

•Pairsofwinchesorcome-alongs(ifapplicable)

•Pairsofbandclampswithpullerrings(ifapplicable)

•Insulationmaterialor-blankets

•Digitaltemperaturegaugeforsurfacetemperaturemeasurement

•Dewpointmeter •Thermometer

•Relativehumiditymeter

•Infraredthermometer

•Hotairblower

•Tenting(subjecttoweatherconditions)

* To be supplied by the pipe manufacturer.

9.3 Consumables

•Cuttingdisks

•Emerydisks,emerycups,emerycloth,apperwheels(allgradeP40toP60)

•Spatula(rubberscraperplate,llingknife),markerpen,dust(paint)brush

•Rubbergloves,workinggloves,dustmasks,safetygoggles

•Cleaningplug

•Overalls,safetyshoes,safetyhelmet

•Cleaningrags,cleaninguidsuchasacetone,MethylEthylKetone(MEK)orMethylIsoButylKetone(MIBK)





10 Health and saety

When working with GRE products, ollowing saety precautions shall be taken:

•Wearatalltimesuitableprotectiveclothing

•UsePersonnelProtectiveEquipment(PPE),suchas:

-Longsleeves

- Hard hat (i required by site conditions)

- Saety shoes

- Glasses

- Gloves (or mechanical and chemical protection)

- Dust mask (during machining and sanding)

- Ear protection (during mechanical operations)

For health and saety data reerence is made to the applicable instructions

(see section 2).

Fig. 10





Annex A Schemes assembly process Conical-Cylindrical bonded joint

Annex A1 Scheme o spigot dimensioning process





Annex A2 Scheme o adhesive bonding process





Annex B Minimum cut length

Fig.BMinimumcutlength(Lo)forpipeConicalBell–CylindricalSpigot

TableBMinimumcutlength(Lo)(mm)

ID (mm)PN (bar)

8 12,5 16 20 25 32

25 280

40 280

50 280

65 290

80 540

100 540 550

125 550 565

150 550 560 575

200 550 565 580 600250 560 565 580 600 625

300 560 575 595 620 650

350 570 570 590 610 640

400 580 580 600 625 660





Annex C Dimensions Cylindrical Spigot

Fig. C Spigot dimensions

Table C Dimensions Cylindrical Spigot

PN(bar)

ID(mm)

(T)*(mm)

Tmin*(mm)

Tmax*(mm)

S1*(0,+0,4)

(mm)

SA*(0,+4)(mm)

8350 3,3 2,6 4,1 356,6 74

400 3,7 2,9 4,5 407,4 84

12,5

250 3,0 2,5 3,5 256,0 64

300 3,5 2,9 4,1 307,0 64

350 4,0 3,3 4,7 358,0 75

400 4,5 3,7 5,3 409,0 85

16

200 3,0 2,6 3,4 206,0 54

250 3,7 3,2 4,7 257,4 69

300 4,3 3,7 4,9 308,6 80

350 4,9 4,2 5,6 359,8 95

400 5,6 4,8 6,4 411,2 105

20

150 2,9 2,6 3,2 155,8 54

200 3,8 3,4 4,2 207,6 69

250 4,6 4,1 5,6 259,2 85

300 5,4 4,8 6,0 310,8 100

350 6,2 5,5 6,9 362,4 116

400 7,0 6,2 7,8 414,0 131

*(T) =Nominalwallthicknessofthespigot(forreferenceonly)

TolT = Tolerance on wall thickness o the spigot (T)

= ± (0.002 x ID, ≥ 0.3)

*Tmin

= Minimum wall thickness o spigot

= T – TolT

*Tmax

= Maximum wall thickness o spigot

= T + TolT

*S1 =NominalSpigotDiameter

*SA =NominalSpigotLength





Fig. C Spigot dimensions

Table C Dimensions Cylindrical Spigot

PN(bar)

ID(mm)

(T)*(mm)

Tmin*(mm)

Tmax*(mm)

S1*(0,+0,4)

(mm)

SA*(0,+4)(mm)

25

100 2,9 2,6 3,2 105,8 44

125 3,1 2,8 3,4 131,2 54

150 3,6 3,3 3,9 157,2 64

200 4,6 4,2 5,0 209,2 85

250 5,6 5,1 6,1 261,2 105

300 6,6 6,0 7,2 313,2 126

350 7,6 6,9 8,3 365,2 146

400 8,7 7,9 9,5 417,4 167

32

25 2,3 2,0 2,6 29,6 34

40 2,3 2,0 2,6 44,6 34

50 2,3 2,0 2,6 54,6 34

65 2,9 2,6 3,2 70,8 44

80 2,9 2,6 3,2 85,8 44

100 3,1 2,8 3,4 106,2 54

125 3,7 3,4 4,0 132,4 69

150 4,3 4,0 4,6 158,6 80

200 5,6 5,2 6,0 211,2 105

250 6,9 6,4 7,4 263,8 131

300 8,2 7,6 8,8 316,4 157

*(T) =Nominalwallthicknessofthespigot(forreferenceonly)

TolT = Tolerance on wall thickness o the spigot (T)

= ± (0.002 x ID, ≥ 0.3)

*Tmin

= Minimum wall thickness o spigot

= T – TolT

*Tmax

= Maximum wall thickness o spigot

= T + TolT

*S1 =NominalSpigotDiameter

*SA =NominalSpigotLength



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