Each weld kit is supplied with a premeasured quantity of glass strips for making the butt and strap

joint for a particular pipe size with a desired pressure rating. Therefore, it is extremely important that all materials be properly applied to the joint to insure that the finished product will have the required wall thickness and pressure rating of the pieces that are joined.
Tools Power disc sander, with 12-24 or 24-36 grit grinding discs Saber saw, with 24 tooth metal-cutting blade or tungsten carbide blade 10scissors or retractable razor knife Serrated aluminum or teflon rollers, 1diameter x 3wide Wrap-a-round or straight-edged gasket material Supplies Dust brushes or clean rags to remove dust from sanded surfaces 3wide stiff bristle brushes or paint roller, for wetting out glass strips Cellophane, mylar film or unwaxed paper, for pre-wetting glass strips Mixing sticks (wooden tongue depressors) Paper or plastic mixing cups Milliliter graduates for measuring resin and catalyst Safety goggles or glasses Protective gloves, neoprene or polyethylene Dust masks

Instructions for Butt and Strap Joints

Precut Strips

Application

Fig.1

Fig.2

Fig.3

All butt welds are to be made in accordance with NBS Specification PS 15-69. The actual procedure will be performed as follows: 1. Measure off length of pipe (or duct) required and using a marker and straight edge, draw a line completely around surface to be cut (Fig.1). 2. Cut pipe (or duct) with a saber saw using a fine toothed blade or a circular saw with an abrasive blade. Cut ends will be coated with resin so as to cover any exposed fibers (Fig. 2). 3. Pipe ends to be joined will be sanded back four inches beyond the required weld dimension. (Fig. 3)
Continued on back...

Cross section after entrapped air is rolled out

Instructions for Butt and Strap Joints

Butt and Wrap Layers vs. Pipe size Use the following table to determine the types, widths and sequence of reinforcement strips to be used in making a weld on Bondstrand pipe. To find the type and size of reinforcement strip for each weld layer, simply perform the following steps. (1) On the table below, find the diameter of the pipe to be welded. (Diameter are shown across the top of the table. (2) Read straight down the column under your pipes diameter. Numbers in each box give, in order of application, the width and type of reinforcement for that particular weld strip. 150 psi Pressure Pipe Diameter Inches
12 4 2 3 4 4 5 5 6 6 7 C M M M R M R M R M 14 4 2 3 4 4 5 5 6 6 7 C M M M R M R M R M 16 4 2 3 4 4 5 5 6 6 7 C M M M R M R M R M 18 4 2 3 4 4 5 5 6 6 7 C M M M R M R M R M 20 4 2 3 4 4 5 5 6 6 7 C M M M R M R M R M 24 4 2 3 3 4 4 5 5 6 6 C M M R M R M R M R 30 4 2 3 3 4 4 5 5 6 7 C M M R M R M R M R 36 4 2 3 4 4 5 5 6 6 7 C M M M R M R M R M Up to 9 Layers Maximum

Fig.4

Fig.5

Fig.6

4.

Stage

Pipe will be placed in the position in which they are to be welded. A catalyzed thixotrophic polyester paste will be applied to the joint seam. This will eliminate resin flow through the crack as the actual weld is applied. (Fig. 4) Make certain work area and surfaces are clean and dry.

5. The precut fiberglass kit is then saturated with catalyzed resin along side of joint area (Fig. 5). 6. The saturated weld is then picked up like a bandage and wrapped around the joint (Fig. 6).

1st Stage

7R 8M 8R 9M 10 M

7R 8M 8R 9M 10 M 10 R 12 M 12 M

7R 8M 8R 9M 10 M 10 R 11 M 12 M

7R 8M 8R 9M 10 M 10 R 11 M 11 R

7R 8M 8R 9M 10 M 10 R 11 M 11 R 12 12 13 13 14 15 M R M R M M

7M 7R 8M 8R 9R 10 M 10 R 11 M 11 12 12 13 13 14 R M R M R M R M R M

8M 8R 9M 9R 10 R 1M 11 R 2M 12 R 3M 13 R 4M 14 R 5M 15 R 6M 16 R 8M 18 19 19 20 R M R M

7R 8M 8R 9M 10 M 10 R 11 M 11 R 12M 12 R 13 M 13 R 14 M 14 R 15 15 16 16 18 18 20 20 22 22 24 24 26 M R M R M R M R M R M R M

Up to 9 Layers Maximum 2nd Stage

12 M 12 M 12R 13R 14 M 14 M

6 Layers Maximum 3rd Stage

15 M 14 15 15 16

4 Layers Maximum 4th Stage

Fig.7

Fig.8

7. A serrated roller is then used to smooth the weld and remove any air bubbles that may have been trapped beneath the weld when applied (Fig.7). 8. The joint should be made in steps not to exceed 9 layers in thickness. The outer surface of each strip should be lightly sanded prior to the next being applied. 9. An inside weld, consisting of 2 layers of chopped strand mat plus C-veil may be used in larger diameter pipe. 10. A final gel coat is applied after the weld has taken its initial cure (Fig. 8). CAUTION: Welding Resin is combustible. Keep away from heat and open flame. Use with adequate ventilation. Avoid prolonged breathing of vapor. Avoid prolonged and repeated contact with skin. In tanks and other confined areas, observe the following precautions to prevent hazards of fire or explosion or damage to health: (1) circulate adequate fresh air continuously during application and curing; (2) use fresh air masks and explosion-proof equipment; (3) prohibit all flames, sparks, welding and smoking. See application instructions included with shipment for equipment and methods recommended for safe application procedure.

Legend
Example C = C-veil M = Mat R = Woven Roving 4C = 4 C-veil 4M = 4 Mat 4R = 4 Wove Roving

Note: (Reference item 9) For all pipe 20 diameter and over, there are several important variations from the normal sequence of weld construction, these are: 1. The Base C-veil strip and strips No. 1 and No. 2 are to be applied INSIDE THE PIPE. 2. The Base strip is to be applied over the other two inside strips instead of the against the pipe as usual. 3. Once the inside portion of the weld is constructed, the remaining strips (from Strip #3) are applied in the ordinary manner on the outside of the pipe.

Ameron International Fiberglass - Composite Pipe Group 9720 Cypresswood Dr., Suite 325 Houston, TX 77070 Phone: 832-912-8282 Fax: 832-912-9393 www.ameronfpd.com

FP-0101