AMIPOX Piping System

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Installation Manual

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Table of contents

1
Introductory Information................................................................................................................................4
1.1 Foreword..........................................................................................................................................................4
1.2
Field Technician................................................................................................................................................4
Product Information.......................................................................................................................................5

3
3.1
3.2
3.3
3.4
3.5
3.6

Shipping, Handling and Storage...................................................................................................................6

Inspecting Pipe.................................................................................................................................................6
Repairing Pipe..................................................................................................................................................6
Unloading and Handling Pipe...........................................................................................................................6
Site Pipe Storage..............................................................................................................................................7
Storing Gaskets, Lubricants and Adhesives....................................................................................................7
Transporting Pipe.............................................................................................................................................8

4
4.1
4.2
4.3
4.4
4.5

Joint Types......................................................................................................................................................8
Typer Adhesive bonded Joint...........................................................................................................................8
Seal-Lock Mechanical Joint.............................................................................................................................8
Butt & Wrap - Lamination Joint........................................................................................................................9
Flange Joint......................................................................................................................................................9
Mechanical Coupling........................................................................................................................................9

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5
Adhesive bonded Taper Joint, AT - Jointing procedure...........................................................................10
5.1
Tools for adhesive bonded Joints..................................................................................................................10
5.2 Machining.......................................................................................................................................................10
5.3
Cutting and Shaving of Pipe...........................................................................................................................10
5.4
Preparing for Bonding....................................................................................................................................14
5.5
Applying the Adhesive....................................................................................................................................15
5.6
Curing of the Adhesive...................................................................................................................................16

6
6.1
6.2
6.3
6.4

AMIPOX Seal-Lock Joints ASL - Jointing Procedures.............................................................................18

Tools for Rubber Seal-Lock Joints.................................................................................................................18
Joint Assembly...............................................................................................................................................18
Seal-Lock Jointing..........................................................................................................................................19
Types of Rubber Ring and Locking Strip.......................................................................................................21

7
Flanged Joints..............................................................................................................................................22
7.1
Tools for Flanged Joints.................................................................................................................................22
7.2
Flanged Joint Description...............................................................................................................................22
7.3 Gaskets..........................................................................................................................................................23
7.4 Bolts...............................................................................................................................................................23
7.5
Trouble Shooting............................................................................................................................................23
Butt and Wrap Lamination Joint.................................................................................................................23
Tools for Butt and Wrap Lamination Joint......................................................................................................23
Lamination Procedure....................................................................................................................................24
Butt & Wrap Lamination Jointing....................................................................................................................26

9
9.1

Mechanical Couplers...................................................................................................................................30
Tools for Mechanical Couplers.......................................................................................................................30

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8
8.1
8.2
8.3

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10
Installation of Underground Pipe Systems................................................................................................31
10.1 Procedure.......................................................................................................................................................31
10.2
Trench Construction.......................................................................................................................................31
10.3
Pipe Bedding..................................................................................................................................................31
10.4
Backfill Materials............................................................................................................................................32
10.5
Backfilling Pipe...............................................................................................................................................32
10.6
Burial Depth....................................................................................................................................................33
10.7
Thrust Blocking..............................................................................................................................................34
10.8
Thrust Blocks-Design Construction...............................................................................................................34
10.9 Settlement......................................................................................................................................................35
10.10
Pipe Cast in Concrete....................................................................................................................................35
10.11
Concrete Wall Penetrations and Connections...............................................................................................35
10.12
Multiple Pipes in same Trench.......................................................................................................................36
11
Aboveground Pipe Installation....................................................................................................................37
11.1 General...........................................................................................................................................................37
11.2
Support Types................................................................................................................................................37
11.3
Protective Methods........................................................................................................................................39
11.4
Valve Support.................................................................................................................................................39
11.5
Joining with other Materials...........................................................................................................................39
11.6
UV - Resistance..............................................................................................................................................39
12

Field Hydro Testing......................................................................................................................................40

13

Repair Work..................................................................................................................................................42

13
13.1
13.2
13.3

Safety Precautions.......................................................................................................................................42
Resin, Hardener and Adhesive Kits................................................................................................................42
Cutting, Shaving and Sanding........................................................................................................................42
Hydro Testing.................................................................................................................................................43

1 Introductory Information

1.2 Field Technician

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The supplier can, at the request of the purchaser and

within the terms of the agreement between the
purchaser and the supplier, provide a Field Technician.
The Field Technician can advise the purchaser and/or
the installer to help him achieve a satisfactory pipe
installation. It is recommended that on the job field
service be engaged in the initial stage of installation
and it may continue periodically throughout the project.
The service may range from continuous (essentially full
time) to intermittent depending on the agreement
between purchaser and supplier.

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This manual is designed to assist supervisors and field

engineers in the installation procedures of the AMIPOX
GRE Pipes system. It provides suggestions to avoid/
solve problems during installation and mainly addresses
the usual circumstances that may be encountered in
the field. Unique situations requiring special
considerations are not addressed and should be
resolved in cooperation with the supplier.
Most importantly, this installation guide is not meant to
replace common sense, good engineering practices
and judgment, applicable laws, safety, environmental or
other regulations or local ordinances, nor the
specifications and instructions of the owners
engineers, who are the final authority on each job.
Should any conflicting information in this manual create
doubts how to proceed properly, please consult the
supplier and the owners engineers to obtain
assistance. These instructions are to be used as a
reference only.
The installation procedures outlined in this installation
manual and the suggestions of the field technicians,
when carefully followed, will help in the thorough
execution of a proper, long-lasting installation.

Specifications written for a particular project would

have priority over the general guidelines mentioned
here. Varying circumstances may require deviations
from the procedures described. Please consult the
supplier with any questions or when variations from this
installation manual are being considered.

1.1 Foreword

2 Product Information

AMIPOX pipe systems are produced by the filament

winding method. In this numerically controlled
mechanical process, a continuous glassfiber roving is
impregnated with epoxy resin system.

Glass fibre Roving

The production of GRE starts with the preparation of

the steel mandrel. The steel mandrel is a cylindrical
mould. A loose part (head stack) is attached to the
mandrel end. This mandrel head stack is determining
the shape of the socket (female) and thus the
connection type. There are three connection (jointing)
types: Taper/Taper, Seal- lock and plain ends.

Epoxy Resin Impregnation

Laying carriage moves
in both direction
Rotating mandrel

Curing oven

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During the next process step, the glassfibers are pulled

through a bath filled with epoxy resin.
After impregnation the glassfibers are filament wound
around the polished mandrel under constant tension
applied at a helix angle of 54 +/- 2 degree.
The filament winding process continues until the pipe
has come to the desired wall thickness.
The wall thickness of the pipe depends on the project
requirements and pressure class. In general the higher
the pressure the thicker the wall will be.
The winding is finished with a resin rich topcoat for
weather and UV radiation protection.

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Length adjustment

End machining

Dimension Control
& hydrotest

Figure 2-1 Flow chart AMIPOX winding process

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After the filament winding process is completed, the

mandrel with the pipe will be cured in an oven at about
150C. After curing the mandrel will be removed from
the new formed GRE pipe by means of water pressure.
The new formed GRE pipe will be cut at desired length,
males (male ends) will be machined, dimensionally and
visually checked and hydrostatic tested witness by the
quality department.

Mandrel
Extraction

Ts

Resin

0.5mm

MIN. WT.

0.3mm
(APPROX)

Glass

0.3mm RESIN RICH

100 %

STRUCTURAL WALL

30 %

70 % E- GLASS

0.5mm RESIN RICH LINER

85 %

15 % C- GLASS

Figure 2-2 AMIPOX pipe wall structure

PIPE DIA.

54

WALL THICKNESS COMPOSITION

0%

3 Shipping, Handling and Storage

3.1 Inspecting Pipe

3.3 Unloading and Handling Pipe

All pipes should be inspected upon receipt at the job

site to ensure that no damage has occurred in transit.
Depending on the length of storage, the amount of job
site handling and other factors that may influence the
pipes condition, it is recommended that the pipe be
re-inspected just prior to installation.
Inspect the shipment upon delivery, as follows:

Unloading the pipe is the responsibility of the customer.

Be sure to maintain control of the pipe during
unloading. Guide ropes attached to pipes or packages
will enable easy manual control when lifting and
handling. Spreader bars may be used when multiple
support locations are necessary. Do not drop impact or
bump the pipe, particularly at pipe ends.

Make an overall inspection of the load. If the load is

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3.3.1 Single pipes

When handling single pipes, use pliable straps, slings or
rope to lift. Do not use steel cables or chains to lift or
transport the pipe. Pipe sections can be lifted with only
one support point Figure 3-1, although two support
points placed as in Figure 3-2 is the preferred method
for safety reasons, as it makes the pipe easier to control.
Do not lift the pipe using hooks at the pipe ends or by
passing a rope, chain or cable through the section end
to end.

intact, ordinary inspection while unloading is

normally sufficient to make sure the pipe has arrived
without damage.
If the load has shifted or indicates rough treatment,
carefully inspect each pipe section for damage.
Generally, an exterior inspection will be sufficient to
detect any damage. When pipe size permits, an
interior inspection of the pipe surface at the location
of an exterior scrape may be helpful to determine if
the pipe is damaged.
Check the quantity of each item against the bill of
lading.
Note on the bill of lading any transit damage or loss
and have the carrier representative sign your copy
of the receipt. Claims against the carrier should be
in accordance with their instructions.
If any imperfection or damage is found, segregate

the affected pipes and contact the supplier.
Do not use pipe that appears damaged or defective.

3.2 Repairing Pipe

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Normally, pipes with minor damage can be repaired

quickly and easily at the job site by a qualified
individual. If in doubt about the condition of a pipe,
do not use it.
Figure 3-1 Lifting pipe at one support point

The Field Technician can help you determine whether

repair is required and whether it is possible and
practical. Repair designs can vary greatly due to pipe
thickness, wall composition, application and the type
and extent of the damage. Therefore do not attempt to
repair a damaged pipe without consulting the supplier
first. Repairs must be made by a trained repair
technician. Improperly repaired pipes may not perform
as intended.

0.2 x L

0.6 x L

0.2 x L

Control Rope

Figure 3-2 Lifting pipe at two support points

3.3.2 Unitised loads

Unitised loads may be handled using a pair of slings as
shown in Figure 3-3. Do not lift a non-unitised stack of
pipes as a single bundle. Non-unitised pipes must be
unloaded and handled separately (one at a time).

Ensure suitable supports such as clean, nail free

wooden beams. Supports must be spaced at a
maximum interval of 3m and around 1m from each pipe
end.

If at any time during handling or installation of the pipe

any damage such as a gouge, crack or facture occurs,
the pipe should be repaired before the section is
installed.

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0.2 x L

0.6 x L

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0.2 x L

Contact the supplier for inspection of the damage and

for the recommended method of repair or disposal
See Chapter 3.2 .

Figure 3-4 Storing pipe

3.4 Site Pipe Storage

Figure 3-3 Lifting unitised package

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It is generally advantageous to store pipe on flat timber

to facilitate placement and removal of lifting slings
around the pipe.
When storing pipe directly on the ground, be sure that
the area is relatively flat and free of rocks and other
potentially damaging debris. Placing the pipe on
mounds of backfill material has been found to be an
effective way of storing the pipe on site. All pipes
should be chocked to prevent rolling in high winds.
If it is necessary to stack pipes, it is best to stack on
flat timber supports (minimum width of 75 mm) at
quarter point with chocks (see Figure 3-4). If available,
use the original shipping dunnage.

Pipe storage at construction site

3.5 Storing Gaskets, Lubricants and

Adhesives
Rubber ring gaskets, for the seal lock joints, should

Ensure that the stack will be stable in conditions such

as high winds, uneven storage surface or other
horizontal loads. If strong winds are anticipated,
consider using ropes or slings to tie pipes down.
Maximum stack height is approximately 1.5 meters, or
two layers, whichever is higher.

be stored in the shade in their original packing and

should not be exposed to sunlight except during the
pipe joining. Also, the gaskets must be protected
from exposure to greases and oils which are
petroleum derivatives and from solvents and other
harmful substances

4 Joint Types

Gasket lubricant should be carefully stored to

prevent damage. Partially used buckets should be
resealed to prevent contamination of the lubricant.
If temperatures during installation are below 5 C,
gaskets and lubricant should be sheltered until
used.

AMIPOX offer a comprehensive selection of adhesivebonded and mechanical joining systems for RTR / GRE
piping.

Adhesives must be stored indoors at temperatures

Adhesive bonded Taper/Taper joint with matching taper

male and taper female ends, uses adhesive for jointing
and offers superior joint strength by controlled adhesive
thickness. Available in sizes 50 1000 mm (2 40 in),
pressure rated up to 100 bar.

below 38 C. Extended storage at higher

temperatures will degrade the catalyst and the resin
and reduce adhesive strength. Each adhesive Kit is
stamped with an expiry date. They should be
removed from shipping cartons and stacked upright
so that the expiry dates are visible.

4.1 Taper Adhesive bonded Joint

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3.6 Transporting Pipe

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Support all pipe sections on flat timbers, spaced at a

maximum of 4 meters with a maximum overhang of
1 meter. Chock the pipes to maintain stability and
separation. Avoid abrasion.

Maximum stack height is approximately 1.5 meters.

Strap pipe to the vehicle over the support points using
pliable straps or rope. Never use steel cables or chains
without adequate padding to protect the pipe from
abrasion. Bulges, flat areas or other abrupt changes of
curvature are not permitted. Transport of pipes outside
of these limitations may result in damage to the pipes.

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Figure 4-1 Tapered adhesive joint

4.2 Seal-Lock Mechanical Joint

Self-restraint, easy to install, Seal- Lock Mechanical
joint uses nylon key and rubber o-ring for jointing.
Available in sizes 50 1000 mm (2 40 in), pressure
rated up to 70 bar.

Figure 35 Transporting pipe

Figure 4-2 Seal-lock joint

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4.3 Butt & Wrap - Lamination Joint

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Butt-And-Wrap (or Lamination) joint for Plain Ends used

generally for field adjustments and for large diameter
pipes that other types of joints are not available. Butt &
Wrap Joint is available for all sizes.

Type A: with flat gasket

Type B: With O-ring

Figure 4-4 Flanged joint

Mechanical joint offers quick assembly between plain

ends. This joining method, done by means of
mechanical coupling (supply by others) like Viking
Johnson, Dresser, etc., normally used to connecting
different piping material (low pressure application only).

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4.5 Mechanical Coupling

Figure 4-3 Butt & wrap joint

4.4 Flange Joint

Figure 4-5 Mechanical coupling joint
Filament-wound fiberglass flanges are used for jointing
AMIPOX or AMIPOX RTR / GRE piping to existing steel
pipes, valves, pumps and tank nozzles. These are
provided with drilling patterns to mate with metal
flanges conforming to worldwide standards. Flanged
joint uses rubber flat gasket or O ring (depending size
and pressure rating), bolts, nuts & washers for jointing.
Flange Joint is available for all sizes.
9

5 Adhesive bonded Taper Joint, AT - Jointing procedure

Before starting adhesive bonding, all safety precautions

need to be checked. Ensure that all necessary tools and
materials are available.
Adhesive bonded jointing can only be carried out by fully
trained and certified personnel

5.1 Tools for adhesive bonded Joints

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Power drive

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AMIPOX shaving tool(s).

Electrical power drive (available from AMIPOX).
Hacksaw, disc grinder or power jigsaw.
Small electrical or air hand drilling machine
(6 mm drive and 1700-2000 rpm).
Flapper wheel sanders (available from AMIPOX) and
/ or coarse emery cloth; grid 60.
Pairs of winches or come-alongs (available from
AMIPOX).
Pairs of band clamps with puller rings (available
from AMIPOX).
Measuring tape and / or folding rule.
Pi-tape with venire division (available from AMIPOX).
Clean cloth or clean brush.
Pipe fitters wrap around, level and white paint
pencil.
AMIPOX heating blanket and possibly hot air blower.
Insulation blankets.
Pipe vice or stable supports (brackets) with pipe
holding or clamping device of 6 mm.
Elastomeric pads.
Gloves, dust masks and goggles.

For the assembly of adhesive bonded joints the

following is needed:

For adhesive bonding: see instructions provided with

the cement kit.
For machining: see shaver instructions supplied with
shaver.

Figure 5-1 Different type of tools

5.2 Machining
After the pipe has been cut to the exact length, the end
must be machined to the right diameter to ensure a
proper joint. The surface has to be cleaned with clean
cloth. If the surface has been in contact with oil or
grease, it should be cleaned with a clean cloth soaked
in pure acetone, or M.E.K. (methyl ethyl ketone) (free of
water). Do not use thinners, petrol or alcohol for
cleaning. After drying, machining can start.
Wastage of adhesive can be reduced by good planning
and the best use of adhesive kits. Too much adhesive
applied to the female will reduce diameter and result in
restricted flow. Remove excess adhesive with the aid of
a spatula and finish the seam properly and smoothly.
This can be also done inside the pipe, for example, by
pulling a plug threw the pipe. This will prevent problems
using foam pigs later.

5.3 Cutting and Shaving of Pipe

1 Determine the cutting length as shown by subtracting

Come-along installation tool
10

the laying lengths of the fittings from the required

overall length.

OVERLL LENGTH

LAYING

X
LAYING
LENGTH

CUTTING LENGTH

ND

LENGTH

Figure 5-2 Cutting length

(mm)

80-100

Tolerance (X)

(inch)

(mm)

3-4

1.5

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Pipe size range

Figure 5-4 Cutting squareness

150-600

6-24

3.0

700-900

28-36

5.0

1000-1200

40-48

6.0

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2 Mark the pipe using a pipe fitters wrap-around.

When holding the pipe in a vice, use rubber padding

or similar to protect the pipe from damage.

Table A: Maximum tolerance on squareness of cut

male ends

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4 Shaving the pipe

Support and hold the pipe in position firmly

Contaminated pipe surfaces should be

cleaned prior to shaving the pipe ends.
- When holding the pipe in a vice, use rubber
padding or similar to protect the pipe from
damage.

Figure 5-3 Marking the pipe

3 Cut the pipe

Use a hacksaw or an abrasive wheel.

Ensure that cut ends remain within the

tolerances as shown in Table A.

These tolerances can be checked by using,

for example, the arbour of the shaver flush

with the cut end of the pipe.

Figure 5-5 Supporting and holding the pipe firmly

11

Carefully insert the arbour into the pipe.

Fix the arbour to the inside of the pipe by

turning the central tensioning bolt clockwise.

Adjust the shaver to the required male diameter.

-

Be sure to use the correct taper angle.

Take care when shaving the first layer,
because the pipe wall may not be equally
thick on all sides.
- For shaver information and operation
instructions refer to the applicable AMIPOX
Pipe Shaver Operation Instructions.
- Refer to Figure 5-7 and Table B below.

SPIGOT
DIAMETER
TAPER ANGLE

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NOSE
THICKNESS

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Figure 5-6 Fixing the arbour inside the pipe

INSERT.
DEPTH

Figure 5-7 Taper joint details

inch

100

150

200

Male
diameter

Nose thick

Male
diameter

Nose thick

Male
diameter

degrees

mm

mm

mm

mm

mm

mm

1.2

Series AT 10

Series AT 12

Series AT 14

2.0

84.0

2.0

84.0

2.0

84.0

1.2

2.0

104.0

2.0

104.0

2.0

104.0

1.2

2.0

154.0

2.0

154.0

2.0

154.0

1.2

2.0

204.0

2.0

204.0

2.0

204.0

250

10

1.5

2.0

254.0

2.0

254.0

2.0

254.0

300

12

1.5

2.0

304.0

2.0

304.0

2.0

304.0

350

14

1.5

2.1

354.2

2.1

354.2

2.1

354.2

400

16

1.5

2.1

404.2

2.1

404.2

2.2

404.4

500

20

2.0

2.3

504.6

2.3

504.6

2.3

504.6

600

24

2.0

2.5

605.0

2.5

605.0

2.5

605.0

700

28

1.75

4.0

708.0

4.0

708.0

4.0

708.0

750

30

1.75

4.0

758.0

4.0

758.0

4.0

758.0

800

32

1.75

4.0

808.0

4.0

808.0

5.5

811.0

900

36

1.75

4.0

908.0

4.0

908.0

6.0

912.0

1000

40

1.75

4.5

1009.0

4.5

1009.0

6.5

1013.0

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80

Nose thick

mm

Taper angle

Pipe size

Table B: Shaving Dimensions per Pipe Series

12

Pipe size
mm

inch

Taper angle

Nose thick

Male
diameter

Nose thick

Male
diameter

Nose thick

Male
diameter

degrees

mm

mm

mm

mm

mm

mm

Series AT 16

Series AT 20

Series AT 25

1.2

2.0

84.0

2.0

84.0

2.0

84.0

100

1.2

2.0

104.0

2.0

104.0

2.0

104.0

150

1.2

2.0

154.0

2.0

154.0

2.0

154.0

200

1.2

2.0

204.0

2.0

204.0

2.0

204.0

250

10

1.5

2.0

254.0

2.0

254.0

2.0

254.0

300

12

1.5

2.4

304.8

2.4

304.8

2.4

304.8

350

14

1.5

2.6

355.2

2.6

355.2

400

16

1.5

2.6

405.2

500

20

2.0

2.6

505.2

600

24

2.0

2.6

605.2

700

28

1.75

5.5

711.0

750

30

1.75

6.0

762.0

800

32

1.75

5.5

811.0

900

36

1.75

6.0

912.0

1000

40

1.75

8.0

1016.0

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80

Note: For values specified as (-), consult Amipox Engineering

Table B (continued): Shaving Dimensions per Pipe Series

Maximum shaving depth /feed is 2mm.

Repeat the shaving action until the required male
diameter/male nose thickness is achieved
(Table B)
- Due to possible tolerance spreading, it is
recommended that a nominal sized dummy
female end is used. This may avoid too long or
too short assembly lengths. If the insertion depth
in the dummy is too small, the male end to be
shaved has to be adjusted.

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Shave the taper male.

Sand all bonding surfaces.

Thoroughly sand within 2 hours of assembly.

Use flapper wheel sanders with a small drilling
machine (1700-2000 rpm) or emery cloth with a
grid of 60.
- Bonding surfaces must be dry and clean before
sanding.
- Sanded surfaces must have a dull, fresh finish,
not a polished look.

Figure 5-9 Sanding the male (left) and female (right)

ends

Figure 5-8 Shaving the male end

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 Dry fit and mark the joint.

POSITION AFTER
FINAL ASSEMBLY
WITH ADHESIVE
USING WINCHES

Check the assembly length and mark pipe and

fitting for alignment of elbows, flanges, etc.
- Measure back from the edge of the male the
required insertion depth plus 50 mm and scribe
a line.
- After assembly by pulling the joint together, the
scribe on the pipe should be 50 mm from the
end of the female.

55mm
50mm

SCRIBE
A MARK
HERE

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POSITION IN DRY CONDITION

Figure 5-10 Position after assembly

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5.4 Preparing for Bonding

1 Install the band clamps on both components

keeping sufficient space for the winches when

pulling the joint together. Normally 2 winches will
suffice. If needed, more winches can be used.

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Figure 5-9 Dry fit and length marking

Figure 5-11 Fixing band clamps

2 Dry the bonding surfaces.

During final assembly the male may slip

approximately 5 mm further into the female,
therefore the dry fitted assembly should be
approximately 5 mm longer per joint.

If the relative humidity is higher than 75%, or if the

bonding surfaces are wet, they should be dried.

AMIPOX heating blanket can be used in drying

the surfaces.

3 Pre-heat or cool down the bonding surfaces.

14

It is recommended to keep the bonding surfaces

between 15 C and 40 C.
For warming up, AMIPOX heating blankets can

be used.
If the sun will heat the bonding surfaces to

above 40 C keep them in the shade if possible.

4 Re-sand.

12

14

16

20

25

bar

bar

bar

bar

bar

bar

80

0.1

0.1

0.1

0.1

0.1

0.2

100

0.2

0.2

0.2

0.2

0.2

0.3

150

0.2

0.2

0.2

0.2

0.3

0.4

200

0.3

0.5

0.5

0.5

1.0

1.0

Use a clean dry cloth or brush to remove

10

250

1.0

1.0

1.0

1.0

1.0

2.0

sanding dust etc.

Do not touch the sanded surfaces after sanding
and cleaning.

12

300

1.0

1.0

2.0

2.0

2.0

2.0

14

350

1.0

1.0

2.0

2.0

2.0

2.0

16

400

2.0

2.0

2.0

2.0

3.0

3.0

18

450

2.0

2.0

2.0

2.0

3.0

3.0

20

500

2.0

2.0

2.0

2.0

3.0

4.0

24

600

2.0

3.0

3.0

3.0

5.0

5.0

28

700

3.0

3.0

4.0

4.0

5.0

6.0

30

750

3.0

4.0

5.0

5.0

6.0

7.0

5 Clean the sanded surfaces.

5.5 Applying the Adhesive

1 Select the proper size adhesive kit.
Table C, below shows the quantity of adhesive

needed for one joint.

More joints may be assembled at the same time.
Make sure the adhesive is not out of date.
Refer to the date stamp on the package.
Never split a package, always prepare complete
kits.
Do not use damaged or leaking adhesive kits.

32
36

800

4.0

4.0

5.0

6.0

7.0

8.0

900

4.0

6.0

6.0

7.0

8.0

1000

5.0

6.0

7.0

7.0

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If the sanded surfaces have been contaminated, or if

initial sanding took place more than 2 hours before
assembling, the surfaces should be re-sanded.

40

10

mm

PD

Size
inch

Note: For values specified as (-), consult Amipox Engineering

Table C: Adhesive kits per joint (250 gram kit)

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2 Prepare the adhesive.

Figure 5-12 Adhesive kit

Add the curing agent to the resin.

Stir thoroughly until the mixture has an even
colour (after 2 to 3 minutes)
The recommended storing and mixing
temperatures of the adhesive are shown below.
Storage and usage of adhesive:
- Storing temperature: Below 30 C
- Recommended mixing temperature: 20-35 C
- Below 15 C, the adhesive will not mix well
and the adhesive mix cannot be easily
spread.
- The mixture will cure too fast above 40 C.
- Minimum curing temperature of the adhesive: 80 C.
Make sure that before mixing the adhesive, all
preparations have been done and all parts to be
bonded are ready for assembly, as mixed
adhesive has a limited pot life subject to the
ambient temperature (Table E)
Apply the adhesive immediately after mixing.

Temp. oC

20

25

30

35

40

Setting Time

30min

25min

20min

15min

10min

Table E: Pot life of mixed adhesive in minutes

15

Never use adhesive that has started to gel. This is

the case when the mixture gets clotted and toughens.

 Apply a thin layer of adhesive.

Use a spatula or an adhesive scraper for

applying the adhesive.

It may be necessary to set a bridge (pieces of

wood between winch cables and pipe outside) to

simplify placing of the heating blanket.
Do not remove the winches until the adhesive
has fully cured.
Remove excess adhesive A spatula may be used
to remove excessive adhesive, when possible
also from the inside, as in the flanges.

PD

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All surfaces to be bonded (sanded areas) must

Figure 5-15 Removal of excess adhesive by spatula

be completely covered with adhesive,

approximately 0.5 mm in the female side and
1 mm on the male side.
A too thick layer of adhesive may result in flow
restrictions.
Also make sure that sufficient adhesive is
applied on the cylindrical end of the male that
will be covered by the female.

Figure 5-13 Applying thin layer of adhesive in female

side

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NOT ENOUGH ADHESIVE USED

Figure 5-16 Correct application and assembly

TOO MUCH ADHESIVE USED

5.6 Curing of the Adhesive

Figure 5-14 Incorrect application

Insert the male in the female.

When inserting the male, pay attention to the

1 Apply the heating blanket.

marks and position and keep the joint together.

Letting the male slip back or turning the male
after complete insertion may result in a bad joint.
Hook the 2 winches in the band clamps and
start pulling the joint further together in a smooth
movement until the joint is firmly fixed together
and there is 50 mm between the female and the
mark.

16

Wrap the required sized AMIPOX heating blanket

around the joint keeping the power supply cable

free from the blanket.
Make sure the voltage is correct.
The blanket should be applied as indicated in the
appropriate AMIPOX Heating Blanket Data sheet.
The blanket should be tied down using heat
resistant wire.

Pipe Size
mm

has a cooling effect, it is recommended to cover

the heating blanket with insulation material and it
should not cover the thermostat.

AT10 AT12 AT14 AT16 AT20 AT25

80

1.0

1.0

1.0

1.0

1.0

1.0

100

1.0

1.0

1.0

1.0

1.0

1.0

150

1.0

1.0

1.0

1.0

1.0

1.0

200

1.0

1.0

1.0

1.0

1.0

1.0

250

10

1.0

1.0

1.0

1.0

1.5

1.5

300

12

1.0

1.0

1.5

1.5

1.5

1.5

350

14

1.0

1.0

1.5

1.5

1.5

1.5

400

16

1.0

1.5

1.5

1.5

2.0

2.0

450

18

1.5

1.5

2.0

2.0

2.0

2.0

500

20

1.5

1.5

2.0

2.0

3.0

3.0

600

24

1.5

2.0

3.0

3.0

4.0

4.0

700

28

2.0

750

30

800

32

900

36

40

1000

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Figure 5-17 Apply heating blanket

inch

for proper curing of the adhesive.

When the temperature is below 10C or the wind

Series

3.0

4.0

4.0

4.0

4.0

2.0

3.0

4.0

4.0

4.0

4.0

2.0

4.0

4.0

4.0

4.0

4.0

3.0

4.0

4.0

4.0

4.0

4.0

4.0

4.0

4.0

4.0

4.0

4.0

PD

Firm blanket to pipe surface contact is essential

Table G: Curing time for fitting joints in hours

2 Determine the curing time.

3 Activate the heating blanket.

Write starting time

Curing time is mainly dependent to the distance

(= wall thickness) between blanket and adhesive.

Table F and G show the recommended curing
time (hours) for each pipe and Fitting joints
respectively.

mm

inch

Series

LO

Pipe Size

AT10 AT12 AT14 AT16 AT20 AT25

80

1.0

1.0

1.0

1.0

1.0

1.0

100

1.0

1.0

1.0

1.0

1.0

1.0

150

1.0

1.0

1.0

1.0

1.0

1.0

200

1.0

1.0

1.0

1.0

1.0

1.0

250

10

1.0

1.0

1.0

1.0

1.0

1.0

300

12

1.0

1.0

1.0

1.0

1.0

1.0

350

14

1.0

1.0

1.0

1.0

1.0

1.0

400

16

1.0

1.0

1.0

1.0

1.0

1.0

450

18

1.0

1.0

1.0

1.0

1.5

1.5

500

20

1.0

1.0

1.5

1.5

1.5

1.5

600

24

1.0

1.5

1.5

1.5

2.0

2.0

700

28

1.0

1.5

2.0

2.0

3.0

3.0

750

30

1.5

1.5

2.0

2.0

3.0

3.0

800

32

1.5

2.0

2.0

2.0

3.0

3.0

900

36

1.5

2.0

3.0

3.0

4.0

4.0

1000

40

2.0

3.0

4.0

4.0

4.0

4.0

Apply electrical power to the heating blanket and

check that it heats up.

Write down on the pipe next to the heating

blanket the starting time.

During the time of curing, the heating blanket

function should be checked regularly; if a cold

heating blanket is found, correct the problem
and start the complete curing cycle again.
During curing the joint should not be moved,
vibrated or otherwise disturbed

Health and safety

Table F: Curing time for taper pipe joints in hours

17

For health and safety data refer to appropriate

AMIPOX Adhesive Product Data sheet.

Wear at all time suitable protective clothing,

gloves and eye protection. Dust masks should

be used during machining and sanding.
Use gloves when working with adhesive, the wet
adhesive may cause irritation by skin contact.

6 AMIPOX Seal-Lock Joints ASL - Jointing Procedures

For assembly of rubber seal-Lock joints the following is

needed:
Lubricant for O-ring and locking strip
A rod or stick
Two (2) pipe clamps
Come along (2) with pulling force 750 kg for
Diameter 500 mm and 1500 kg for larger diameters
Plastic or wooden mallet to drive the locking strip
into the rubber seal lock joint
Non fluffy cleaning-rags

Lubricate the entire surface of the O-ring and

slip it into the first groove on the male end.

Distribute the O-ring evenly in the groove by

slipping a screwdriver under it and sliding the

screwdriver around the joint.
As an alternative for distributing the O-ring in
pipe sizes to 400mm, use a screwdriver to lift
the lubricated O-ring at top centre a distance of
about 20 per cent of the pipe diameter and let it
snap back into the groove.
Do not gouge or abrade the O-ring. A sound
O-ring is the key to a water tight joint.

3 Pipe male insertion

Figure 6-1 Seal-lock joint assembly tools

LO

Come along set of 2 pcs.

Lubricant
Pipe clamps set of 2 pcs.
D Rings set of 4 pcs.
Rubber O ring.
Water bucket
Screwdriver
Mallet
Nylon key

6.2 Joint Assembly

1 Preparation of seal lock joining surfaces

2 O-ring placement

1:
2:
3:
4:
5:
6:
7:
8:
9:

O-ring groove of the male end and all inside

surfaces of the female end or coupling.
Apply lubricant only when you are ready to
complete the joint. Keep lubricated surfaces
clean and free of sand and dirt, as contamination
is likely to interfere with joining and sealing.
Proper lubrication of the O-ring and joint
surfaces is important to avoid cutting the O-ring
or rolling it out of place during assembly.

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Now brush or rub a layer of lubricant into the

6.1 Tools for Rubber Seal-Lock Joints

PD

safety precautions need to be checked.

Ensure that all necessary tools and materials are
available.

Before assembling the rubber Seal-Lock Joints, all

When ready to join the pipe, remove the end

protection from the male pipe end. Loosen and

remove dirt and debris from the grooves using
compressed air, a clean, dry rag or a paint brush .
Clean the grooves and sealing surface of the
female end or coupling. Sand off any projections
or rough edges on the entry ramps which
compress the O-ring during insertion.
18

Place the band clamps on either side of the joint.

Rotate the new pipe so its keyholes are in the

proper position for driving the key(s) for the next

joint.
Align the male end against the female end or
coupling already in place for straight concentric
entry. Proper alignment is essential for joining.
Deflect the joint to conform to the actual
horizontal and vertical alignment of the trench
only after the joint is fully assembled in the
straight position. An AMIPOX joint puller is
recommended for joint assembly.
Connect the ratchet winches to pulling rings
attached to the band clamps on either side of
the pipe. It is often convenient to place one band
clamp just behind the female end or coupling
and the other about 1.5m from the male end.
Tighten the winches evenly on both sides so that
the O-ring enters smoothly and without being
pushed or rolled out of its groove.
Insert the male end until the scribed line is about
6mm from the leading edge of the female end or
coupling. To reduce slippage you may elect to
use rubber pads under the band clamps.
Straightness of entry adds significantly to the
ease of assembly. Sight along the pipe and
carefully observe concentricity and uniformity of
entry.

6.3 Seal-Lock Jointing

5 Positioning and aligning the joined pipe:

STEP 1

After driving the keys, deflect the joint to fit the

STEP 2

hanger supports or trench bottom. With the pipe

fully supported in its final position, release the
lifting straps: for buried pipe in sag curves, it
may be necessary to leave the lead lifting strap
in position to align the next joint during
assembly.
To avoid excessive movement and bending at
turns and branches during the hydrostatic test,
pull straight sections of joined pipe forward as
assembly progresses, using a ratchet winch or
other means to remove play in the joints.

LO

The Seal-Lock jointing is demonstrated step by step in

the subsequent pictures.
End protection (supplied by AMIPOX)
should be removed just prior to assembly to
keep joining surfaces and grooves clean.

holes, and slowly close the joint until the keys

slip into the keyways.
Check the straightness of the entry again by
sighting along the pipe and by aligning the
scribe mark on the male end with the edge of
the female end or coupling.
Use a hammer or mallet to drive the locking keys
through the insertion holes and into the keyways
until the leading end can be seen in the insertion
hole and approximately 75 to 100 mm remain
projecting.
! Note! Drive the key only until you can see its
leading end through the insertion hole. If the key
is driven too far, heat may elongate it and cause
it to stick, making later removal impossible.
Protect the projecting keys of piping exposed to
sunlight or other ultraviolet radiation from
embitterment. Within several days of installation,
spray all exposed key surfaces with a black
acrylic coating, or wrap them with duct tape.
Also, fill keyholes with caulking compound to
prevent intrusion of sand and dirt which may
make later key removal difficult.

PD

Place lubricated locking keys into the insertion

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4 Driving the keys:

19

Lubricate inside the female end and locking

key groove with ample amounts of lubricant
(available on order from AMIPOX). Note that
the pipe already in place has been properly
rotated so that the key-hole of the next joint is
conveniently positioned.

STEP 3

Align the pipe for straight concentric entry.

Proper alignment is essential to ease joining.

STEP 7

Tighten the come-a-longs (provided by user)

on both sides so that the O-ring enters

smoothly without being pushed out of its
groove.

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After coating the O-ring (supplied by AMIPOX)

with lubricant, mount it in the end most groove
in the male pipe end. Insert a screwdriver under

the mounted O-ring and run it around the pipe

to distribute the O-ring in the groove.

STEP 4

PD

STEP 6

The male end of the pipe going in should also

be generously lubricated. Again, make sure
that the keyway is well lubricated.

STEP 5

STEP 8

Mount the band clamps (available on

order from AMIPOX) a convenient distance on
each side of the joint, making certain that the
pipe going in is properly positioned to allow
access to the keyhole of the following joint.

20

Insert the male end until the scribe line is

about inch (6mm) from the leading
edge of the female end or coupling.

STEP 9

Lubricate the locking key (supplied by

AMIPOX) before insertion.

Nominal Pipe Size

Maximum joint deflection

inch

mm

Male x Female

Coupling

2-16

50-400

1/2

18-48

450-1200

1/4

1/2

Table 6-1: Permissible angular deflection at seal lock

joints

6.4 Types of Rubber Ring and Locking

Strip

Place the lubricated locking key into the

keyhole and slowly close the joint until the
key slips easily into the keyway.
Check the pipe alignment. Drive the locking
key only until you can see its leading end
through the keyhole. If the key is driven in too
far, it may bind, making later removal difficult
or impossible.

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STEP 10

PD

The commonly used rubber ring is made of NBR

(Nitrile Butadiene Rubber).Other types of rubber can
be supplied depending on the medium and/or the
temperature.
Locking Keys are normally plastic nylon material but
metallic can also be used depending project
requirement.

Joint completely assembled.

21

7 Flanged Joints

AMIPOX flanges are normally used for joining RTRP to

existing steel pipes, valves or pumps; rubber gaskets
are used for hydrostatic sealing. AMIPOX flanges meet
the dimensional requirements. Drilling patterns of all
common standards such as ANSI, API, and ISO etc.
Before assembling flanged joints, all safety precautions
need to be checked. Ensure that all necessary tools
and materials are available.

! Note! Excess torque can prevent sealing and

can damage flanges.

17

9
21

22

13

9
4

9
3

12

15
6

16

19

14

11

19

PD

7
14 2 23 11

17

18

26

16

10

23 15

20 17

18

19
10

3
15
27

10

11

17

10
1

22

11

25

16

Tools necessary for assembly of flanges:

Ring spanner with required bolt head size.
Torque wrench with required socket size.

1 13

18

24

21

12

20

28
13

14

12

7.1 Tools for Flanged Joints

20

24

16

12

7.2 Flanged Joint Description

13

14

11

AMIPOX flanges are usually flat faced. These

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flanges
must always be accurately aligned and not subject
to any stress.
The bolts and nuts must have washers to avoid
exceeding the permitted surface pressure. As an
alternative, a stub-end type flange with steel
backing ring centre can be installed.
Pipe must not be pulled together by tightening the
bolts. If an R.T.R.P. pipeline is connected to a metal
pipe, this metal pipe must be anchored to prevent
any movement or loads being transmitted to the
R.T.R.P. line.

10

Figure 7-1 Flange assembly

First, finger tighten all nuts. Bolt threads must be

clean and lubricated to attain proper torque. Use

lubricated washers under both nuts and bolt heads
to protect flange back faces.
Tighten all nuts following the sequences shown in
Figure 7-2 below
Do not exceed the torque increments given in
Table 7-1 below
After all bolts have been tightened to the
recommended torque, recheck the torque on each
bolt in the same sequence, as previously tightened
bolts may have relaxed.

15

Figure 7-2 Bolts tightening sequence

Nominal Pipe Size

Torque
Increments

Final Torque

mm

inch

(N-m)

(N-m)

80

15

56

100

15

56

125

20

82

150

20

82

200

20

82

250

10

30

150

300

12

30

150

350

14

30

150

400

16

50

250

450

18

80

400

500

20

80

400

600

24

100

500

700-750

28-30

100

500

800

32

100

500

900

36

100

500

1000-1200

40-48

100

500

800

32

100

500

900

36

100

500

1000-1200

40-48

100

500

Table 7-1: Recommended bolt torques

22

8 Butt and Wrap

Lamination Joint
7.3 Gaskets
For AMIPOX fiberglass flanges assembly, use full-face
gaskets of an elastomeric suitable for the service
pressure and temperature and fluids in the system.
Gaskets should be 1/8 inch (3mm) thick with shore
durometer hardness between 60 and 75. Refer to
ASTM D1330 specification for sheet rubber gaskets,
grade 1 or 2, to establish minimum physical property
requirements for use with water, Rubber gasket with
steel inlay or compressed fiber is used for high
pressure AMIPOX flanges and Rubber O Ring sealing
is also used for higher pressure and diameters.

This lamination method is used to join plain-end pipe

sections through overlapping layers of fiberglass
reinforcement (woven roving and boat tape) thoroughly
impregnated with a resin system, it is generally
intended for field adjustments works where adhesive
bonded joints cannot be accommodated. This jointing
method needs to be performed only by experienced
and trained pipe technicians under AMIPOX field
engineer supervision. Before starting a butt and wrap
(lamination) joint, all safety precautions need to be
checked. Ensure that all necessary tools and materials
are available.

8.1 Tools for Butt and Wrap

Lamination Joint

7.5 Trouble Shooting

If the assembled joint leaks:

Loosen it and remove all bolts, nuts, washers and

gaskets.
Check for alignment of assembly. Rebuild to correct
alignment as required.
Check the gasket for damage. If damaged, discard
and replace it with new, undamaged, gasket.
Check flanges for seal ring damage. In particular,
check the condition of the inner seal rings. Flanges
with damaged inner seal rings must be removed
and new, undamaged, flanges installed
If leaks occur as a result of deficiencies in non fibreglass components of the piping system, consult
the manufacturer of the defective components for
recommended corrective procedures.
Clean and re-lubricate old threads and washers
before re-joining.
Repeat the joining procedure outlined above.
After corrective action has been taken, retest the
joint to make sure proper sealing is achieved.

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For butt and wrap lamination joint the following tools/

equipment are needed:
Measuring tape + pipe fitters wrap-a-round
+ marker pen and a pair of scissors
Cleaning-rags
Abrasive cutting disc (diamond grid or
carborundum)
Flapper wheel sander or grinding disc
Air Relive Rollers, Paint Brush and Rubber Scraper
Plate
Gloves, dust masks sets, and safety glasses.
Shelter (depending on the weather circumstances)
Infra-Red Burners or Hot Air Guns and Heating
blankets
Electric Power Source
Materials: Glass Reinforcement (Woven Roving and
Boat Tape), Resin & Hardener and Adhesive Kits.

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AMIPOX flanges are thicker than metal flanges and

require washers. This should be taken into account
when calculating the bolt length. For flange thickness
see the appropriate AMIPOX product datasheet for
dimension data.

PD

7.4 Bolts

! Note! Quantity and specification refer to the

instructions supplied with butt & wrap kits).

Figure 8-1 Tools and accessories for butt & wrap

lamination joints

23

installation and material knowledge.

Information about safety regulation and measures.
Account of special working conditions; jobsite,
weather, influence, etc.
Installation equipment and materials.
Check the pipes and fittings for visible damage.
If necessary, clean the parts to be connected.

Material Description

Specifications

Epoxy Resin

AMIANTIT approved
commercial grade such
as: Araldite GY6010, DER
330 and Epikote 827

Hardener

IPD

Boat Tape

Adhesive

Mixing Ratio Resin

to Hardener is
100:24 ppw

150 grams per Sq.

2 and 4 wide
meter
500 grams per Sq.
4 and 6 wide
meter
250 grams kits
Two components

within two hours after sanding or grinding;

re-sanding of lamination area shall be required
if the waiting period exceeds two hours.

C Adhesive fit layer

Check whether the sections to be joined

together are dry, clean and at the right

temperature.
Position the pipe sections for joining.
Prepare the adhesive mixture according to

given instructions. The two components

must be stirred (e.g. 1 minute) until there is

a uniform color.
When fixing by bonding the front edges

together; first, a thin coat of adhesive is


applied thoroughly onto the front edges.

Subsequently, a second thicker coat is

applied external surfaces of the pipe ends

approximately 100 mm in width, then the

sections are connected and their alignment

is checked.
Wet out boat tape with adhesive and apply

a minimum of three layers circumferentially

onto the joined pipe ends.
Use a heating blanket to force cure the

initial laminate for one hour.

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Woven Roving

Remarks

block/fix them firmly, so they cannot slip.

Start the lamination of the fitted sections

Centre the parts to be laminated and

1 Preparation
Qualification of the installation staff by means of

PD

8.2 Lamination Procedure

Note! Store all fiberglass components in a dry, clean, cool and

covered area. IPD is hygroscopic, keep it stored in close
containers when not in use. Prepare IPD batches shortly before
mixing with resin component.

Table 8-1: Raw materials used in butt & wrap

lamination joints

FIT LAYER
BOATTAPE WITH ADHESIVE
CIRCUMFERENTIAL, 3 LAYERS

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2 Process
A Cutting the pipe
Determine the length of the pipe sections,

taking into account the dimensions of the

fittings see Figure 8-2 below.
Mark the pipe sections with the aid of a

marking template.
Clamp the pipe in a vice; plies of rubber or

similar material should be used to protect

the pipe.
Cut the pipe with a hack saw, grinding

wheel, etc. Make sure the cut is straight

and right-angled.
Cut right through, do not break off. Support

the free end of the pipe. Use a fine-tooth

saw. The liner must not to be damaged.

B Prepare pipe ands and fittings

Prepare pipe and fitting ends by means of

grinding and leveling. Which angle about

which length.
Secure and prepare the pipe end.
The prescribed lamination length must be

maintained and checked.
The resin coat on the surface must be

completely removed by sand blasting or


grinding till the glass fibers are exposed.
Remove dirt and chips with a clean rags

and dry brush.
24

MAX. 5mm (FILL GAP WITH ADHESIVE)

< 250mm OD USE 50mm width boat tape

250mm OD USE 100mm width boat tape

LAMINATION SEQUENCE

L
Figure 8-2 Fit layer schematic
sketch

BOATTAPE 50% OVERLAP, 2 LAYERS

D Lamination sequence
WOVEN ROVING 50% OVERLAP, 5 LAYERS
Start the lamination of the fitted section

2 (see point C above) within two hours

after sanding; re-sanding
of lamination area
BOATTAPE 50% OVERLAP, 1 LAYER

shall be required if the waiting period

3 exceeds two hours.
Remove dirt using clean rags and dry
* REPEAT THIS SEQUENCE UNTIL THE MINIMUM

brush
and also remove any possible
REQUIRED LAMINATE THICKNESS IS ACHIEVED
NOTE:. SIZEmoisture
by
heating the surfaces by
150 ND AND BELOW
USEslightly
ONLY BOATTAPE

means of heating blankets.
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.

FIT LAYER
L.T.

LAMINATE OVERLAY

W.T.

Be sure that the curing agent is carefully

mixed with the resin. The temperature of

the resin and curing agent mixture should
not exceed 25C.
L

For pipes 150 ND or smaller:

For the hand lay-up of the laminate structure, use
boat tape with 50% overlap.
Be sure to obtain the minimum required lamination
thickness, see Figure 8-4.

L
2L

NOTE:
L = 120mm FOR PIPE SIZES 50mm ND TO 200mm ND
L = ND FOR PIPE SIZES 250mm ND AND ABOVE
LT = LAMINATION THICKNESS = 2 x PIPE WALLTHICKNESS

Figure 8-4 Minimum lamination length and

thickness

PD

E Curing and finishing

The lamination will harden at ambient

temperatures. This can be speeded up by

applying heat, for example using an

infrared device or hot air gun.
The hardening process needs to be carried

out gradually.
After the lamination is no longer sticky,

curing can be continued with the aid of


heating blankets, hot air guns or ovens.
Heating up to the curing temperature

should also be performed gradually.
Heating blankets are the most appropriate

to use for field butt &wrap joining.
Check if the heating blanket is working

properly, temperature in excess of

120C 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.
The curing time only starts when the

laminate has reached the correct curing

temperature.
Cure the laminate for 4 hours minimum.

Whenever possible apply a heating blanket

on the inside as well and close the pipe

ends to avoid air drafts.
After curing, use sandpaper to remove the

rough edges of the laminate and to

generally smooth out the external surface
The joint is ready and can be tested when

the laminate is fully cured and has cooled

down.

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For pipes larger than 150 ND:

For the hand lay-up of the laminate structure, use
boat tape and woven roving in the sequence as
shown in Figure 8-3 and with 50% overlap until the
minimum required laminated thickness is achieved,
see Figure 8-4.
Make sure that each applied layer of boat tape or
woven roving is thoroughly impregnated with resin
mixture.
Apply the layers in the circumferential direction onto
the pipe joint ends.
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
FIT
of LAYER
the laminate. Use air relieve rollers to avoid air
BOATTAPE WITH ADHESIVE
enclosures.
CIRCUMFERENTIAL, 3 LAYERS
After the final boat tape layer, smooth out the resin
from the exterior of the laminate using a rubber
5mm (FILL GAP WITH ADHESIVE)
scraper to leave a resin MAX.rich
surface.
< 250mm OD USE 50mm width boat tape
250mm OD USE 100mm width boat tape

LAMINATION SEQUENCE
L
BOATTAPE 50% OVERLAP, 2 LAYERS

1
WOVEN ROVING 50% OVERLAP, 5 LAYERS

2
BOATTAPE 50% OVERLAP, 1 LAYER

3
*

REPEAT THIS SEQUENCE UNTIL THE MINIMUM

REQUIRED LAMINATE THICKNESS IS ACHIEVED

NOTE:. SIZE 150 ND AND BELOW USE ONLY BOATTAPE

Figure 8-3 Lamination sequence

E Finishing work
Clean up the area.
Dispose waste products in an environment
friendly manner.
Subsequently activities must be performed

in accordance with the instructions, e.g.

supports, pressure tests, etc.
25

8.3 Butt & Wrap Lamination Jointing

The butt & wrap lamination jointing is demonstrated
step by step in the subsequent pictures.
STEP 2

Initial fit-up layer with adhesive and boat tape.

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Pipe cutting, aligning and initial grinding.

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STEP 1

26

STEP 4

Marking lamination length and surface grinding.

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Heat cure of the initial fit-up.

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STEP 3

27

Cleaning of surface for lamination, preparation

of working area and check of materials for lamination.

STEP 6

Mixing of resin and hardener and start of

application to the surface for lamination.

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STEP 5

28

First layers of boat tape impregnated with the

resin mixture.

STEP 8

Layers of woven roving to be impregnated with

resin mixture as well and air removal using air relieve
rollers.

PD

STEP 7

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29

9 Mechanical Couplers

Final layers of boat tape and woven roving,

allowing the laminate to gel and dry and finally heat cure
for 4 hours.

Generally, mechanical couplers are used for joining

plain ended GRE / RTR pipes to pipes made from other
materials. A step coupler can join pipes with different
outer diameters. This type of joint is unrestrained.
These couplers can also be used for preliminary repairs.
However, restraining couplers should not be used as
these may damage the AMIPOX pipes.
Specific information can be obtained from the supplier
of the coupler.

PD

STEP 9

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Figure 9-1 Mechanical couplers

Before starting the assembly of a mechanical coupler,

check that all safety precautions have been taken and
that all necessary tools and materials are available

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9.1 Tools for Mechanical Couplers

For Straub and Taylor Kerr: Allen key and torque wrench
For Dresser, Viking Johnson and inland couplers: - ring
spanner
AMIPOX pipes have lower torques than steel pipes,
depending on the wall thickness

30

10 Installation of Underground Pipe Systems

The minimum width (W) at the bottom of the trench

for a single pipe shall be:

W = 1.25* OD + 300 mm.
The space between the pipe and the trench wall
must be 150 mm wider than the used compaction
equipment.
Respecting pipe stiffness, operation conditions, soil
characteristics and wheel load the minimum
recommended burial depth is 0.9 m.
Refer Figure 10-1 and Figure 10-2 below for stable
and unstable standard trench construction details.
W

10.1 Procedure

The trench construction highly depends on the soil

parameters, such as type, density and moisture
content. The construction of the trench should comply
with following requirements and recommendation:
The trench shape is determined by the classification

on the soil, which can be unstable or stable.

Top sides of the trench must be cleared from rocks

Secondary backfill
zone compacted in
layers of 30 cm

0.7 x D

Primary backfill
zone compacted in
layers of 15 cm

15 cm Bedding
15 cm Foundation

10.3 Pipe Bedding

The bedding should be placed over a firm, stable
trench bottom so as to provide proper support. The
finished bed must provide a firm, stable and uniform
support for the pipe barrel and any protruding feature
of its joint.
The common practice is to provide 150 mm of bedding
below the barrel and 75 mm below the joint. For soft or
unstable trench bottoms, an additional foundation may
be needed to achieve firm support for the bedding.

or any other sharp/heavy materials.

sand layer without stones or sharp objects.
order to prevent point loading.

Keep the trench dry during installation; if necessary

Final backfill
excavated soil
compacted in
layers of 30 cm

Figure 10-2 Standard trench construction unstable soils

Loosen a hard and uneven trench foundation in

30 cm

The trench foundation shall consist of a compacted

Figure 10-1 Standard trench construction stable soils

LO

10.2 Trench Construction

Secondary backfill
zone compacted in
layers of 30 cm

15 cm Bedding
15 cm Foundation

Primary backfill
zone compacted in
layers of 15 cm

The type of installation procedure appropriate for

AMIPOX pipe varies with pipe, cover depth, width,
native soil characteristics, surcharge loads and backfill
materials.
The native material must adequately confine the pipe
zone backfill to achieve proper pipe support. The
following installation procedures are intended to assist
the installer in achieving a proper pipe installation.

Final backfill
excavated soil
compacted in
layers of 30 cm

F
N

0.7 x D

PD

30 cm

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To ensure long life and trouble-free service from

underground piping systems, proper application of the
principles of excavation is essential.
Laying and jointing, bedding, backfilling and field
testing is required. If pipe is installed by a contractor it
is equally essential that these principles be reflected in
the phrasing of contract documents and that the
customer enforce them through inspection. The
recommended practices presented in this guide for the
installation of buried AMIPOX pipe are developed from
the two basic concepts outlined below. Both should be
rigorously maintained to obtain best results. Firstly, the
manufacturers recommendations for assembling pipe
sections and curing the joints should be carefully
followed. Secondly, each section of pipe should have
its support well distributed under the pipe rather than
concentrated at points or along a narrow portion of the
pipe bottom. This is accomplished by providing proper
bedding. These instructions are intended to be used as
a guide only and should be amended for a specific job.
Because any specification should be properly applied
and adapted to meet the requirements in force, there is
no specific or implied assurance that inclusion of these
paragraphs in a specification will insure a successful
job. However, they should assist materially in
accomplishing this objective.

use of a pumping system and drainage.

31

 The limits for the maximum particle size and stone

size given in Table 3-2 must be adhered to.

No soil clumps greater than two times the maximum

particle size.

No frozen material
No organic material
No debris (tires, bottles, metals, etc.)

Figure 10-3 Assembly inside trench

DN

Max. Size (mm)

450

13

500-1200

19

PD

Table 10-1: Maximum particle size

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The backfill above the pipe zone may be made with

excavated material with a maximum particle size of up
to 300 mm providing there is at least 300 mm cover
over the pipe. Stones larger than 200 mm should not
be dropped on the 300 mm layer covering the pipe
crown from a height greater than 2 meters.

Figure 10-4 Pipe bedding

10.5 Backfilling Pipe

LO

The bedding material may need to be imported to

provide proper gradation and pipe support. The
recommended materials for bedding are SC1 or SC2.
To determine if the native material is acceptable as a
bedding material, it should meet all of the requirements
of the pipe zone backfill. This determination must be
made constantly during the pipe installation process
because native soil conditions may vary and change
suddenly along the length of a pipeline.
The bed must be over-excavated at each joint location
to ensure that the pipe has a continuous support and
does not rest on the couplings. The coupling area must
be properly bedded and backfilled after joint assembly
is completed. See Figure 9-3 for proper and improper
bedding support.

10.4 Backfill Materials

For classification of various backfill materials and types
of embedment, reference is made to AWWA Manual
M45 or ASTM D 3839, the following general restrictions
apply:

32

Immediate backfilling after joining is recommended as it

will prevent two hazards, i.e. floating of pipe due to
heavy rain and thermal movements due to large
differences between day and night temperatures.
Floating of pipe can damage the pipe and create
unnecessary reinstallation costs. Thermal expansion
and contraction can cause loss of seal due to
movement of several pipe lengths accumulated at one
joint.
If sections of pipe are placed into the trench and
backfilling is delayed, each pipe should have the centre
section backfilled to the crown to help minimize
movements at the joint.
Proper selection, placement and compaction of pipe
zone backfill are important for controlling the vertical
deflection and are critical for pipe performance. Care
must be taken so that the backfill material is not
contaminated with debris or other foreign materials that
could damage the pipe or cause loss of support. The
hunching material in the area between the bedding and
the underside of the pipe should be worked in and
compacted before placing the remainder of the backfill
(see Figure 10-4 and Figure 10-5)

correct: pipe firmly supported

Avoid any contact between compaction tools and

RTR products.

Use hand camping only method of compacting

within 150 mm envelop around the pipe

circumference there after hand operation vibratory
plate compactors can be used.

10.6 Burial Depth

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Figure 10-4 Proper haunch backfill

When live loads are less than the conventional H20-S16

loading, the burial depth measured from the top of pipe
should be at least 3 feet (0.91 m) for all diameters.
At road crossings where the loading exceeds H20-S16,
use one of the following methods:
Bury the pipe deeper; AMIPOX will make
recommendation on increased depth of burial upon
request provided complete loading and soil
conditions are submitted for an engineering
analysis.
Use casing pipe and collars to protect the pipe;
when casings/sleeves are used, take care that the
pipe is properly bedded at the points of entry and
exit of the casing pipe, pad the pipe to prevent
rubbing against the steel casing and spacers to
support the pipe inside the casing (see Fig. 10-6).

Figure 10-5 Improper haunch

Rubber pad

Procedure & requirements

Road surface

Shrinking
sleeve

The procedure and the requirements comprise:

LO

Temporary installation devices must be removed

prior to backfilling.

embedment is related to the pipe diameter and is

described in the backfill material specification (see
Table 9-1).
Dumping large quantities of backfill material at one
spot on top of the pipe may cause damage; spread
the applied backfill material.
Backfill material shall be compacted in layers of 150
mm. make sure pipe is not be displaced due to
backfilling.
When reaching a compactions, height of 0.3 * ID
below the crown of the pipe, compaction may be
continued in layers of 300 mm.
Each layer of backfill shall have a compaction grade
of at least 85% Standard Proctor Density (SPD).
Compaction is performed on both sides of the pipe,
never across the pipe. A vibrating plate with an
impact force of 3000 N is used.
Do not use heavy pneumatic hammers or vibrating
equipment until having reached a backfill level of
500 mm over the crown of the pipe.

3m

Casing pipe

The maximum particle size for pipe zone

Spport

Figure 10-6 Road crossing pipe protection with

casing pipe
Relief plates are used if pipes are installed at

shallow depth in well compacted sandy soils or in

case the soil and traffic load cause an excessive
loading or deformation of the GRE pipe. The plate is
specially designed and dimensioned to minimise the
transfer of wheel load on the pipe.
Polystyrene foam

0.5 x OD

Top load free space

Relief plate

45
Spread

OD

Figure 10-7 Relief plate

33

10.7 Thrust Blocking

+
+

AMIPOX adhesive bonded tapered joints and seal-lock

mechanical joints are fully restrained thrust blocks are
not needed. Unless recommended as per below points

Evaluation of the need for thrust blocks is the

F
PD

Figure 10-8 Typical AMIPOX pipe system with thrust

blocks

Soil Type Description

Safe Bearing Pressure

(Sp) kg/m2

Rock, hard thick layers

195

Rock, equal to good masonry

24.5

Rock equal to best brick

14.64

Rock equal to poor brick

4.8

responsibility of the engineering agency designing

the system. The decision will depend on the
exposure to temperature change, surges of internal
pressure and the geometry of the pipeline layout.
For each of these factors, singly or in combination,
the effect of movement and thrusts on the pipe
joints and fittings must be evaluated.
Temperature changes produce stress in buried pipe
which is restrained by friction of the surrounding
bedding, by passive soil pressure at fittings, or by
thrust blocks.
Hydrostatic thrusts at fittings depend on the degree
of restraint on the pipe bonded to those fittings. In a
fully restrained pipe (blocked against movement at
both ends) with all joints bonded, the Poisson effect
produces considerable tension in the pipe wall; that
is as internal pressure is applied, the pipe expands
circumferentially and at the same time tries to
shorten longitudinally. This tensile force in the
AMIPOX pipe wall acts to reduce the hydrostatic
thrust on a fitting by about 50%.

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Clay, always dry

3.9

Clay, fairly dry

1.95

Clay soft

0.97

Gravel, coarse sand, firm

7.8

Sand, compact, firm

3.9

Sand, clean, dry

1.95

Table 10-2: Safe bearing pressure of soils

10.8 Thrust Blocks-Design and

Construction

Bearing area required is computed using the formula

LO

Once the applied thrusts are determined, the

designer of thrust blocks must consider soil

strength, soil stability and location of the water
table.
Blocks must have:
- Adequate bearing area to resist the soil thrust.

- Bearing surface against undisturbed soil.

- The resultant thrust vector passing


perpendicularly through the centre of the bearing

surface (except for valves). Should the soil be

unstable or the installation below the water table,

the engineer will have to make special provision

to ensure stability.
! Note! It is important that any connecting metallic


pipe must be anchored at the point of connection

to prevent excessive stresses being transferred

to the pipe.

At =

where:
At = Bearing area of thrust block
R = Reaction
SP = Allowable soil bearing pressure
Thrust blocks for AMIPOX pipe systems should be

34

R
Sp

poured after hydrostatic testing of the pipe. This will

allow for clear visual inspection of all fitting joints
during the test. To retain pipe in proper alignment
while testing, the placement of sand bags and or
partial backfilling may be required. Joints may be
left exposed for observation during test.
Thrust blocks should be shaped with the designed
bearing area against virgin earth of the trench wall.
Smaller blocks using a dry mix may be shaped by
hands but larger blocks will require forms

 The trench should be undercut beneath the pipes at

10.10 Pipe Cast in Concrete

Concrete can be poured around AMIPOX piping

system.

300 mm away from the pipe.

The pipe system must be pressure tested prior to

casting.
Cradles are provided with steel clamps and rubber
lining in order to prevent floating.
Buckling of the pipe during casting can be
prevented by pressurizing the system.
Note that concrete shrinks when setting; this may result
in extra loading of the GRE pipe system. Ensure that
the allowable external pressure is not exceeded by
using pressure relief valves.

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10.9 Settlement

Do not pour concrete directly onto pipe.

The vibrating equipment must be kept at least

PD

least 6 inches to give additional thrust resistance

and to provide for an adequate concrete envelope
around the fittings. At least 6 inches of concrete
should be over the top of the pipe.
The centre of the thrust block should coincide with
the horizontal centreline of the pipe.
Unless otherwise specified by the engineer,
acceptable concrete is 1 part Portland cement, 2
parts washed sand and 3-parts washed gravel with
enough water for a relatively dry mix. The dry mix is
easier to shape and offers higher strength.
It is important that the concrete be worked
thoroughly around the elbows for maximum surface
contact. Take care that entire area between the
fittings and the freshly cut trench wall is filled with
concrete and free of voids.

Flexible rubber seal lock joints have to be installed in

pairs (ASL); one joint is placed at the beginning of the
deviation while the other is located at the end of this
area, in order to create a rocker pipe. The rocker pipe
will act as a hinge.

The longer the rocker pipe, the higher the loads on the
joints. This can be avoided by using more rocker pipes.
Based on the soil parameters, the number of rocker
pipes is determined.

LO

Note that the length of the sections shall be limited in

order to avoid excessive bending which may result in
failure of pipe or joint.
The section length = ID + minimal 0.5 m. Mechanical
O-ring joints shall be installed at both ends to
accommodate further settlements.
Original
position

Figure 10-10 Pipe cast in concrete

Sag

10.11 Concrete Wall Penetrations

and Connections
Several methods are used for AMIPOX pipe
connections through concrete walls.
1 Puddle flange

Flexible
joint

Flexible joint
Settled profile
ofter subsidence
Location of pipe
after subsidence

Figure 10-9 Settlement

Factory made puddle flange consists of a GRE ring

which is directly laminated on a pipe piece (exact
location by client) with standard dimensions of
approximate 50 mm thickness and a diameter of 50 mm
greater than the diameter of the pipe to be installed.
A rubber pad wrap is recommended to protect the
surrounding pipe portions.

35

Puddle Flange

10.12 Multiple Pipes in same Trench

Rubber pad wrap

around pipe

When two or more pipes are installed parallel or cross

over in the same trench, there should be clear spacing
between the pipes, as shown in Figure 9-14.
It is advisable, when laying pipes of different diameters
in the same trench, to lay them with the same invert
level. When this is not possible, use backfill material
type SC1 or SC2 to fill all the space from the trench
bottom to the invert of the higher pipe. Proper
compaction must be achieved (min 90%SPD)

RTR pipe

Concrete wall

100 (typ)

Figure 10-11 Pipe passing through wall with puddle

flange

D (R1+R2) /2 BUT NOT LESS THAN 300MM

R2

R1

PD

2 Support saddles

Two 180 degree support saddles are bounded on the

pipe for tie where it fits in the wall and slightly
protruding outside the wall.

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2 - RTR support
saddle 180^
bonded on pipe
RTR pipe

R1
R2

(R1+R2) 2 BUT NOT LESS THAN 300MM

Concrete wall

Figure 10-14 Spacing between pipes in the same

trench

LO

Figure 10-12 Pipe passing through wall with support

saddle
3 Metal pipe sleeve

This type of wall penetration pipe should be fitted into a

metal pipe sleeve a minimum is 50mm larger in
diameter than the AMIPOX pipe size. The opening
between the metal pipe sleeve and the AMIPOX should
be caulked with a waterproof compound which will dry
to a firm but pliable mass.

Sand bedding

RTR pipe

Packing seal

Figure 10-13 Wall penetration with metal pipe sleeve

36

11 Aboveground Pipe Installation

11.1 General
This section gives guidelines for proper installation of
AMIPOX pipe systems installed above the surface of
the ground.

Type A Wall type support

180 GRE
180^
GREsaddle
SADDLE
permitting
PERMITTING
AFFIXEDtoTO
affixed
pipe
PIPE

PD

Type B Sitting on pipe sleeper

11.2 Support Types

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Those who know how to install steel pipe will find that
most of the same skills and techniques apply but there
are some important differences. AMIPOX pipe requires
protection against potential external abrasion or
crushing at points where supports are located.
In general, the objective of any above ground
installation is to provide supports, guides and anchors
points in such a way that deflection of unsupported
span lengths are maintained within acceptable limits
over the long-term.

Aboveground piping system

Type C Floor type support

Figure 11-1 Typical Simple Supports

B Guide supports:
Support vertical loads and restrain lateral movement.
The main use of guides is to avoid buckling and
maintain alignment when axial compressive loads exist
in a pipe. Typical, for guide support are shown in
Figure 11.2 below

LO

There are three main types of supports

Simple support
Guide support
Anchor support

Following is set of rules to be followed when designing

and positioning supports anchors and guides.
Avoid point loads.
Meet minimum support dimensions.
Protect against abrasion.
Support valves and other heavy equipment
independently of the pipe in both vertical and
horizontal installations.
Avoid excessive bending.
Avoid excessive loading in vertical runs.

Type A Pipe clamp loose fit

Type B U bolt loose fit

Figure 11-2 Typical guide supports

A Simple supports:
To prevent excessive pipe deflection due to the weight
of the pipe and the fluid, horizontal pipe should be
supported at intervals recommended in the support
spacing tables provided by AMIPOX Typical for simple
support are shown in Figure 11-1

U-bolt with 3-mm thick

rubber protection to pipe

Type C Guide support vertical pipe run

37

support can be bolted

C Anchor supports:

directly to the flange

Anchors supports must positively, restrain the

movement of the pipe against all applied forces.
The low modulus and light weight of AMIPOX pipe
cause these pipes to move easily when emptied and
filled rapidly during the cycle of operation and under
water hammer conditions. If the movement causes
excessive bending stresses, it must be controlled by
anchoring at changes in direction.
Pipe anchors divide a pipe system into sections or runs
and must be attached in structural material capable of
withstanding any applied forces. In some case pumps,
tanks and other similar equipment functions as
anchors.

Typical for anchor supports are shown in

PD

Type B Anchor support on flange

Figure 11-3

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support to be welded
or anchor to a base

support can be bolted

directly to the flange
support to be welded
or anchor to a base

Type C Anchor support on valve horizontal line

LO

Valve support arrangement

support can be bolted

directly to the flange

GRE support saddle

04 nos. 180 saddle

support to be welded
or anchor to a base

3-mm thick rubber protection

in between pipe & clamp
support to be welded
or anchor to a base

Type A Straight pipe

Type D Anchor support on valve vertical line

Figure 11-3 Typical anchor supports

38

11.3 Protective Methods

11.5 Joining with other Materials

Some recommended protective methods include:

The most appropriate method to join objects of different

materials is by using a flange. A mechanical coupler
might be an alternative. For details about these joints,
reference is made to manufacturers documentation.

AMIPOX saddles, which provide a clean, corrosion-

free surface acting as stiffening saddle for the pipe.

Saddles are bonded to the pipe.
Elastomeric material such as rubber, neoprene or
even cut-up tire casings. This material may be held
in place by pipe clamps or pipe insulation straps.
When using support styles that clamp the pipe, be
sure that clamping forces do not crush the pipe.
Local crushing could result from a poor fit, and all around crushing could result over tightening.

Flanges can be drilled according most of the relevant

standards. When a flanged GRE pipe section is joined
with a metal pipe section, the metal section must be
anchored to avoid transmission of loads and
displacements to the GRE pipe section.
Instrument connections can be made using a saddle
and a bushing.

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Support saddle

Figure 11-5 Reducing saddle with metallic bushing

11.4 Valve Support

Valves and pumps in AMIPOX lines must be supported

independently. Figure 10-3 C and D shows how
supports may be bolted to a flange to support weight,
to resist thrust and torque and to provide electrical
grounding.
water baffle

LO

concrete wall

butterfly valve
support

Figure 11-4 Valve box connections

If a GRE flange is connected to a steel flange, the
support should preferably be at the side of the steel
flange.
One suggestion would be concrete supports, with steel
connections able to carry the full load of the valve.
Also, the bending and torque forces caused by opening
and closing of valves should be absorbed. Hand
operated butterfly valves can be supported or mounted
in a manhole as f shown in Figure 10-4.

11.6 UV - Resistance
To manufacture AMIPOX RTR Products, a pigment is
added to the resin system, which improves the
resistance to UV Radiation of the finished products.
The pigmentation delays the effect of the UV but does
not completely eliminate it. Pipes exposed to direct
sunlight for long period of time will definitely undergo
changes in appearance. The rate of appearance change
will depend on the intensity of sunlight and length of
exposure.
Although no failures are known to have resulted from
this change of appearance, it does cause a dull, grey
appearance, which some users wish to avoid. Surface
degradation has little effect on piping system
performance. However, the mechanical properties or
structural integrity of the RTR products are not affected
by this surface change of appearance.
One can prevent or control the effect by painting with
good quality solvent-based paint. However, it is
recommended to delay the application of paint till the
weathering has occurred in order to have good paint
adhesion.

39

12 Field Hydro Testing

PD

Testing manifold

1 Preparations prior to test

Inspect the completed installation to assure that all

work has been finished properly. Of critical
importance is:
Joints assembled correctly.
System restraints (i.e. thrust blocks and other
anchors) in place and properly cured.
Flange bolting torques per instructions.
Backfilling completed to minimum burial.
Valves and pumps anchored.
Backfill and compaction near structures and at
closure pieces has been properly carried out

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3 Pressurize the line slowly

Considerable energy is stored in a pipeline under

pressure, and this power should be respected.
Apply 0.8 times the pressure and allow 24 hours to
settle.
4 Ensure that the gauge location will show the

Some job specifications require the completed

pipe installation to be hydrostatically tested prior to
acceptance and service. This is good practice as it
can permit early detection and correction of some
installation flaws, damaged products etc. If a field
hydro test is specified, it must be done regularly as
installation proceeds. Good construction practice would
be to not exceed pipe testing with installation by more
than approximately 1000 meters in order to properly
assess the quality of work. The first field hydro test
should ideally include at least one air valve or drainage
chamber to assess the total pipeline system. In
addition to routine care, normal precautions and typical
procedures used in this work, the following suggestions
should be noted:

highest line pressure or adjust accordingly.

Locations lower in the line will have higher pressure
due to additional head.

5 Ensure that the maximum test pressure does not

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exceed 1.5x PN.

Normally, the field test pressure is either a multiple
of the operating pressure or the operating pressure
plus a small incremental amount. However, in no
case should the maximum field test pressure
exceed 1.5 x PN.

6 If, after a brief period for stabilization, the line

does not hold constant pressure, ensure that
thermal effect (a temperature change), system
expansion or entrapped air is not the cause.
If the pipe is determined to be leaking and the
location is not readily apparent, the following
methods may aid in the discovery of the problem
source:

Field hydro testing unit

2 Filling the line with water

Open valves and vents, so that all air is expelled

from the line during filling and avoid pressure
surges. Fill from the lowest point. Long straight
sections may be vented using an inflatable ball or
foam pig to expel the air.

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Check flange and valve areas.

Check line tap locations.
Use sonic detection equipment.
Test the line in smaller segments to isolate the
leak.

13 Repair Work

7 Causes of pressure drop

Below listed are some typical repair methods:

The following causes may affect pressure and can

be used as a check list:

1 General

The system shall be considered to have passed the

hydro test if there is no leaking of water from the
piping at any location and there is no significant
pressure loss that can be accounted for by usual
engineering considerations.

The repair procedure shall be prepared and qualified

by the contractor in accordance with the pipe
manufacturers recommendations. It shall be
demonstrated that the repair method restores the
specified properties.

Leaks in pipe, fittings and joints are repaired by

replacing the defective part. In some cases,
especially for buried systems, insufficient space
and/or difficult accessibility to pipes and fittings
may occur.

Each application of a GRE pipe system and each

type of product or design requires a different repair
and/or replacement procedure.

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Temperature change, by day as well as by night.

Leakage of valves, fittings, hydrants, etc.
Leakage of gaskets.
Dirt at sealing ring.
Wrong installation of O-ring (slip ring).
Pipes or fittings insufficiently blocked in the
trench resulting in displacement.
Air Lock
Leaking test equipment.
Stabilizing time too short.
Leaking joint.
Leakage in fittings.
Leakage of the pipe as result of damage
(cracks).
Settlement of the pipe system.

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2 Minor surface damage

8 Depressurising

Minor damage to the surface of pipes, fittings

and laminates (e.g. scratches, scour marks) is

sealed with resins or adhesive (respective
instruction must be followed).
Reinforced wall not be damaged.

3 Damage to reinforced wall

Depressurising of the system must be carried out

carefully to avoid a negative pressure.

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Fittings showing damage to the reinforced wall

must be replaced.
In the case of pipes with damage to the

reinforced wall it is generally necessary to

replace part of the pipe. For this the damaged
section of the pipe is cut out with sufficient
spacing left from the visible damage and
replaced by a new section. If this is not possible
for operation or other reasons, a necessary
recommendation must be obtained from AMIPOX.
A provisional repair of the leak is possible, for
example, by means of a supplementary laminate
or by bonding a saddle to the pipe (pipe must be
drained) or by means of a mechanical coupling
(non - tensile resistant).

4 Leakages from joints

Assembled pipe inside trench before backfilling

Adhesive bonded joints

- The leaking joint must be cut out and

replaced (see section Adhesive Bonded

Joints).
- If allowed, the leak can be repaired with a

laminate (taking due account of the

operating pressure, specification) See

section Laminated Joints.

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14 Safety Precautions

Laminated joints

- Grind off the entire laminate including the

bonding laminate and affix a new laminate

See section Laminated Joints.

The following safety precautions should be respected

when dealing with AMIPOX products.

14.1 Resin, Hardener and Adhesive Kits

For required rescue and safety measures when

using adhesives, resins, hardener and

Any other chemicals always refer to safety data
sheet supplied with it.
In order to avoid irritation of the respiratory system,
satisfactory ventilation should be provided.
Always clean up the work area. GRE and cured
adhesive are chemically inert and do not have to be
treated as chemical waste.
Waste shall always be disposed in an environment
friendly manner.

Seal-Lock joints

- If it is not possible to open the joint, cut it

out and replace it (taking due account of

the systems flexibility) See section

Seal-Lock Joints.
- If you can open the joint, established and

correct the causes of the problem

(e.g. new O-ring, remove dirt, replace pipe)

See section Seal-Lock Joints.

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Flanged joints

- Check whether all the bolts have been

properly torque.
- Check whether the flanges as parallel.
- Check the flanges and seals for damage

and replace if necessary See section


Flanged Joints.

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14.2 Cutting, Shaving and Sanding

When cutting or grinding GRE materials the following
personnel protection is necessary to protect eyes and
skin:

A dust mask covering nose and mouth.

A pair of safety goggles.
Gloves and overall.
Close overall sleeves with adhesive tape to keep
the dust out.
Wear protective clothing to protect the body.
Machining should be carried in a well-ventilated
room or in open air.

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14.3 Hydro Testing

If system is to be hydro tested, adequate safety
precautions must be taken, as a safe test pressure
does not exist. Any pressure in itself is dangerous.
Experienced personnel must operate the test
equipment. Only persons involved in the test or
inspection are allowed in the immediate area of the
testing system. Only one person should be in charge
and everyone else must follow his/her instructions.
Do not change anything on the pipes system when it is
under pressure. Leaking joints may only be repaired
after the pressure has been fully released.
The test equipment must be installed at a safe distance
from the connection to the pipe system. If welding
needs to take place, the GRE material must be
protected from hot works.

Pipe assembly inside the trench using come-along

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Distributed by:

AMIPOX
First Industrial City
P.O. Box 589
Dammam, 31421
Saudi Arabia
Tel.: + 966 (3) 847 1500
Fax: + 966 92 000 4070
info@amiantit.com
www.amiantit.com

FT-AMIPOX V1 01-13-ENG

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This handbook is intended as a

guide only. All values listed in the
product specifications are nominal.
Unsatisfactory product results may
occur due to environmental
fluctuations, variations in operating
procedures, or interpolation of
data. We highly recommend that
any personnel using this data have
specialised training and experience
in the application of these products
and their normal installation and
operating conditions.
The engineering staff should
always be consulted before any
of these products are installed to
ensure the suitability of the
products for their intended purpose
and applications. We hereby state
that we do not accept any liability,
and will not be held liable, for any
losses or damage which may result
from the installation or use of any
products listed in this handbook
as we have not determined the
degree of care required for product
installation or service. We reserve
the right to revise this data, as
necessary, without notice. We
welcome comments regarding this
handbook.