AMLANTIT BONDSTRAND©, LTD.

Assembly Instructions

Assembly Instructions
For Bondstrand® Butt-and-Wrap
Lamination Joint (16 Bars)

Scope These assembly instructions cover the bull-and-wrap jointing system of

Bondstrand® RTR pipes and fittings with plain ends (tapered-joint butt-and-
wrapping for 16-bar pressure-rated joints).

The procedure applies to pipe sizes 1” (25 mm.) to 40’ (1000 mm.) ND.

Description The bull-and-wrap joint typically consists of two plain pipe ends which have
been prepared for joining by sanding and tapering the outside surface in the joint
area (tapered ends as in Figure 2). These spigots are abutted end to end and
aligned on the same centerline, and the joint overwrapped with overlapping
layers of resin-impregnated fiberglass fabrics (boat tape and woven roving).
Each layer becomes increasingly thicker to provide a laminate or build-up that
can accommodate both internal pressure and longitudinal forces.

Materials of The butt-and-wrap laminate consists of fiberglass reinforcement materials and

Construction an epoxy resin system to impregnate and bind the reinforcement materials.
For estimated material requirements per size of joint, please refer to Table I for
16-bar pressure rating.

Fiberglass Reinforcement.
. Glass Woven Roving Owens-Corning, PPG, 500 gm./ m.2
Carl Freudenberg, etc.
• Boat Tape Owens-Corning, PPG, 150 gm.lm.2
Carl Freudenberg, etc.
Resin System.
. Epoxy Resin Shell Epikote 827 or DOW 100 Parts by Weight
DER 330
. Hardener (Curing IPD (Isophoronediamine) 24 Parts by Weight
Agent)
. Adhesive Ameron RP34 Adhesive For Initial Jointing
or RP48 Adhesive

1
Materials Important: Store all fiberglass components in a dry but not too cool area in
(Cont...) order to avoid surface condensation when used in warmer conditions outside.
Perform moisture-content checks by weighing samples prior to and after one
hour of heating at 115°C. A moisture content higher than 0.2% makes the
fiberglass fabric unacceptable for lamination use.

Since the curing agent IPD is hygroscopic, keep it stored in closed containers
when not in use. Prepare IPD batches shortly before mixing with the resin
component.

Equipment Check El Hacksaw

List El Abrasive Cutting Disc (Diamond Grit or Carborundum)
ci Pipe Supports
ci White Marker
El Wrap-Around
ci Flapper-Wheel Sanders (Grit-60)
ci Drilling Machine
ci Balance (Weighing Scale)
ci Air-Relieve Rollers (1.5” through 0.375” Diameter)
ci Infra-Red Burners or Hot-Air Guns
ci Heating Blankets
ci Resin Mixer
ci Paint Brush, 4”-Wide
ci Rubber Scraper Plate

Pipe End Preparation Pipe Culling.

Note: This initial step shall be applicable only if a factory-prepared pipe end
needs to be cut and replaced, or a pipe length requires field adjustment. Mark
the pipe section to be cut using a wrap-around and a white marker.

Cut the pipe using a hacksaw or a cutting disc.; make sure that a proper square
cut has been made see Figure I Step I.
-

Preparation of Lamination Area.

Refer to Table 2 for the required lamination length to be prepared for sanding and
tapering.

• For Pipes 1O”ND and Larger.

The area to be prepared for lamination should be equal to one-half of the
nominal size see Lamination Length or L in Table I or Table 2.

• For 8”ND Pipes or Smaller.

The lamination length shall always be 120 mm. Mark the required
lamination lengths and proceed to the end-preparation step.

For tapered-joint butt-and-wrap, grind the lamination section into a gradual

slope. See P1gw-c I, Step 2. Sand or grind the cross section of the pipes (the cut
ends) as well.

Adhesive Fit Layer.

Position the pipe sections for joining. Prepare the adhesive mixture according to
given instructions. Coat the cut ends with adhesive in order to protect them
against penetration of the medium. Coat the external surfaces of the pipe ends
approximately 100 mm. in width, and join them together (Figure 1 Step 3).
-

Wet out the boat tape with adhesive and apply a minimum of 3 layers
circumferentially onto the jointed pipe ends — see Figure 1 Step 3. Use a
heating blanket to cure the initial laminate for one hour. Sand the surface after
curing before proceeding to the following step.

2
Prepare all equipment and construction materials required for the joint Lamination
lamination — see Table 1 for estimated material requirements per joint size. Do Procedure
not use humid or damp fiberglass materials; use hot-air guns or oven-dry the
fiberglass fabrics before use.
Start the lamination of the filled sections within two hours after sanding or
tapering; re-sanding of the lamination area shall be required if the waiting period
exceeds two hours. Remove any possible dew by slightly heating the pipe ends
from the inside by a heating blanket.

Prepare the resin mix using the correct mixing ratio Resin 100 Parts by
Weight; Hardener 24 Parts by Weight. Take note of the pot life after mixing. The
amount of the mixture depends on the diameter. Several batches could be used
depending on the weather, temperature and gelling time.
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.

• For Pipes 3”ND or Smaller.

For the hand lay-up of the laminate structure, use boat tape as in Table 2
with 50% overlap. Be sure to obtain the minimum required lamination
thickness as indicated in Table 2.

• For Pipes Bigger than 3”ND.

For the hand lay-up of the laminate structure, use boat tape and woven
roving in the sequence as shown in Table 2 and with 50% overlap until the
minimum required laminate thickness is achieved.
Make sure that each applied layer of boat tape or woven roving is thoroughly
impregnated with the resin mixture.
Apply the layers in a circumferential direction onto the pipe-joint ends — see
Figure 1 Steps 4 and 5.

During the wrapping process, tension must be applied so that the resin under
the layer being laid could be pressed out.
Avoid air getting into the laminate by using the air-relieve rollers continuously.
To give the finishing touch, apply one final layer of boat tape spirally wrapped
onto the whole surface of the laminate. Use air-relieve rollers to avoid air
enclosures.
After the final boat tape layer, smooth out the resin from the exterior of the
laminate, using a rubber scraper, to leave a resin-rich surface.
Before curing, use a heat source (hot-air blower, flood light etc.) to allow the
laminate to gel.

Use heating blankets, to cure the buff-and-wrap joint laminate. Curing and Finishing

Check if the heating blanket is working properly. Temperatures in excess of

120 C should be easily achieved if the heating blanket works properly. The
surface contact between the heating blanket and the laminate should be as large
as possible; fit the blanket as snugly as possible to the joint.
Cure the laminate for 4 hours’ minimum. Wherever possible, apply a heating
blanket on the inside as well and close the pipe ends to avoid drafts.
In cold weather, insulate the heating blanket to trap the heat, but do not cover
the blanket’s thermostat housing.
After curing, use sandpaper to remove the rough edges of the laminate and to
generally smooth out the extemal surface.

3
Lamination Figure 1. Tapered Ends Jointing (16-Bar Pressure Rating)
Procedure
(Figure 1...)

STEP 1: PIPE CUTTING

STEP 2: SANDING/GRINDING

STEP 3: FIT LAYER

S
STEP 4: LAMINATION
L
I L
NDd

2L

STEP 5 LAMINATION
 Table I. Estimated Material Requirement
per Butt-&-Wrap Lamination Joint: 16-Bar Pressure Rating

Figure 2.

ND

L L

2L

Note: L = 120 mm. for Pipe Sizes 1”-8”ND

L = ¼ ND for Pipe Sizes 10”ND and Above

Adhesive Laminate Material Requirement

. Ameron RP-34 “Wit’ - 1PD
Nominal or Boat Woven Epoxy Curing
Diameter Ameron RP-48 Tape Roving Resin Agent

(In.) (mm.) 3-oz. Kit 6-oz. Kit (Kg.) (Kg.) (Kg.) (Kg.)

1 25 1 - 0.15 - 0.12 0.03

1% 40 1 - 0.21 - 0.17 0.04
2 50 1 - 0.24 - 0.19 0.04
3 80 1 - 0.35 - 0.27 0.07
4 100 1 - 0.10 0.37 0.38 0.09
6 150 1 - 0.15 0.81 0.77 0.19
8 200 - 1 0.19 1.34 1.24 0.30
10 250 - 1 0.33 2.11 1.96 0.47
12 300 - 1 0.47 3.63 3.30 0.80
14 350 - 2 0.60 5.17 4.65 1.11
16 400 - 2 0.98 7.46 6.80 1.64
18 450 - 2 1.21 10.23 9.24 2.21
20 500 - 3 1.50 14.00 12.50 3.00
24 600 - 3 2.59 23.87 21.34 5.12
28 700 - 4 3.65 40.84 35.89 8.61
30 750 - 4 4.88 49.83 44.13 10.59
32 800 - 4 5.56 60.30 53.11 12.75
36 900 - 5 7.01 85.98 74.99 17.99
40 1000 - 6 9.92 118.20 103.32 24.79

5
 2o R,9~5
Recommended Layering Sequence
Table 2.
for the Laminate Structure: 16-Bar Pressure Rating i~.,-.
0/
—
—~

ND:
40
Inch
ND:
1000
mm.
Lamination
Length 500
(mm.)
Lamination
Thickness 35.6
(mm.)
Sequence
Number
ofLa ers
1 BT
2 BT
3 WR
4 WR
5 WR
6 WR
7 WR
8 BT
9 WR
10 WR
11 WR
12 WR
13 WR
14 BT
15 WR
16 WR
17 WR
-r 18 Wi?
19 WR
20 BT
21 WR
22 WR
23 WR
24 WR
25 WR
26 BT
27 Wi?
28 WR
29 WR
30 Wi?
31 Wi?
32 BT
33 Wi?
34 WR
35 WR
36 BT

Note: 1. BT = Boat Tape, 2’ or 4” Wide; WR = Woven Roving.

2. L = Lamination Length; 2L = Total Length of Joint Lamination.
3. Overlapping shall be 50% of each layer. Use the layering sequence as in
the above table until the minimum laminate thickness is achieved.

t~≤
‘.~ 2’~x~ 6
Company Overview Bondstrand Limited is a joint-venture company joining the Saudi Arabian
Amiantit Company (A Saudi Joint Stock Company) of Dammam, Kingdom of Saudi
Arabia, with Ameron BV (Ameron Fiberglass Pipe Group-Europe) of Geldermalsen,
The Netherlands, a wholly-owned subsidiary of Ameron International
Corporation, Pasadena, California, USA. This joint venture brings two firms
together in an endeavor to provide high-technology fiberglass pipe products
(marketed under the trade name Bondstrand®) and professional services to the
rapidly growing Saudi Arabian and Gulf Region industrial market for high-
performance fiberglass RTRP.

Quality Assurance For the design, manufacture and QC testing of Bondstrand RTRP systems,
lSO900l Bondstrand Ltd. has established a quality management system which conforms to
both national and international standards. Bondstrand Ltd.’s quality system was
audited in June 1994 by TUV-CERT. The successful audit furnished proof and
certification that requirements according to DIN !S09001 EN 29001 BS 5750 Part I
have been fulfilled.

Important Notice This product literature and the recommendations for usage it contains are based
on test data reasonably believed to be reliable. It is intended that this literature
be used by personnel having specialized training in accordance with currently
accepted industry practice and normal operating conditions. Variations in
environment, changes in operating procedures, or extrapolation of data may
cause unsatisfactory results. We recommend that your engineers verify the
suitability of this product for your intended application. Since we have no control
over the conditions of service, we expressly disclaim responsibility for the results
obtained, or for any consequential or incidental damages of any kind incurred.

Amiantit Marketing and Sales Offices

Central Province Western Province Eastern Province Export Division
P.O. Box 1029 P.O. Box 2140 P.O. Box 589 P.O. Box 589
Riyadh 11431 Jeddah 21451 Dammam 31421 Dammam 31421

TeL #01-465-8153 TeL #02-651-5676 TeL #03-857 1160 TeL #03-857-1160

Fax #01-463-1389 Fax #02-651-6149 Fax #03-857-1156 Fax #03-857-8824
Tlx. #401008 AwIuA Si TIx. #6OI43JAWJEDSJ Tix. #803401 AwEPMSJ Tix. #8OJO84APSJDAMSi

Bondstrand Ltd.°
A Member of the Amiantit Group of Companies
P.O. Box 589, Dammam 31421, Saudi Arabia

Phone #009663-8571160
Fax #009663-8577540
#802958 CCPDAMSJ

Accredited Firm
Manufacturing Plant: First Industrial City,
Dammam, Kingdom of Saudi A abia.

Bondstrand RTRP is also manufactured by Ameron

Plants in Japan, Singapore, Holland, and USA.

Bondstrand Catalog No. BLAS 05 - April 1997. Revised II Januaiy 1999

Printed in the Kingdom ofSaudi Arabia