Installation Manual13 Print

Installation Manual
Pipe & Fittings Installation Manual

Engineered Composite Solutions
RPS Composites Inc.

740 Main Street
P.O. Box 299
Mahone Bay, Nova Scotia
Canada B0J 2E0
Tel: (902) 624.8383 | (800) 343.9355
Fax: (902) 624.6395
www.rpscomposites.com
Installation Manual
TABLE OF CONTENTS
Purpose and Intended Use.............................................................................................................................................3
Materials.......................................................................................................................................................................4
Safety............................................................................................................................................................................6
Installation.................................................................................................................................................................. 11
Testing........................................................................................................................................................................ 17
Adhesive Bonded Joints Using P1500, E1500 & H1500 Adhesive.................................................................................. 18
Type B Taper Tool Instructions for 1 - 12 (25-200mm) Dia.......................................................................................25
Butt & Wrap Joining 1 - 48 (25-1200mm) Dia. P-150 A-150 & H-150.........................................................................29
PEEL-A-BONDTM
Purpose, Handling, and Removal.......................................................................................................................... 51
Flange Joining............................................................................................................................................................. 52
O-Ring Joining............................................................................................................................................................ 55
Bonder Qualification Procedure (P-150/A-150/H-150).................................................................................................. 57
A Liner Repair Paste Kit.............................................................................................................................................. 59
Saddles
Purpose and Installation...................................................................................................................................... 62
Installation Manual
PURPOSE & INTENDED USE
RPS continually endeavours to improve its products. These changes

may necessitate changes in this manual. The purchaser should ensure
it uses a current version of the Pipe and Fittings Installation Manual.
This manual has been prepared by RPS and is supplied for the
purchasers assistance. It should be read carefully by all those using
RPS products because of the nature of the information contained.
Unless the purchaser has prescribed particular installation procedures, compliance with the procedures outlined herein is essential
for proper performance of RPS products.
The manual covers certain aspects of handling, storage, safety,
inspection, joining, assembly, and installation of RPS pipe, fittings,
and related products.
The information contained in this manual is based on RPS experience
with installation criteria as a manufacturer and supplier of RPS
products. However, it is the purchasers primary responsibility to
ensure proper use of RPS products.
By its written warranty, RPS has warranted that its products are
free from defects in materials and workmanship when installed in
accordance with this manual and when exposed to the purchasers
represented operating conditions. RPS is not responsible for actual
product installation, system design, or system performance. The
owner, engineer, or contractor (or their agents) are responsible
for specifying system design and all procedures for installation,
inspection, and satisfactory system performance; and are responsible for ensuring:
a) this manual and all other procedures, developed for installation,
inspection, and system performance, are supplied to any person
or legal entity using in any way RPS products; and
b) the proper procedures for installation, inspection, and system
performance are followed by any person or legal entity using in
any way RPS products.
RPS liability is limited to the price of the products supplied, as set
out in the warranty. Reference should be made to the RPS Warranty
for particulars.
If the purchaser has any questions about RPS products installation, inquiries should be directed to RPS prior to design, if
possible, and if not, prior to installation. RPS will endeavour to
assist customers with the installation of its product, but in all
situations, it is the purchasers primary responsibility to ensure
proper use of RPS products.
Installation Manual
MATERIALS
2) Cover forklift forks with wood or carpeting to protect pipe

when transporting uncrated FRP products.
Receiving Material
3) Use metal or nylon strapping to tie down load and isolate

strapping with carpet, wood, or masonite if transporting by
truck. NEVER USE CHAIN BINDERS.
1) On arrival inspect load for:

--
shifting of load
--
dislocation of supports
--
damaged cartons or crates
--
damaged goods
4) Supports for pipe and headers to be located at about length

from each end of the pipe if transporting by truck.
Unpacking
1) Check that all items listed on shipping papers are included or are
listed as back ordered.
2) Immediately report any problems to the carrier and to RPS

Unloading and Handling
2) Prior to storing, check that all spool pieces, headers, manifold,

pre-assembled pipe, etc. are marked or identified per customer
drawings for easy future identification.
1) Handle FRP products with care to prevent damage

2) Piping shipped uncrated should only be unloaded by:
--
hand (small light sizes only)
--
slings or ropes attached in 2 places, lifted by hoist or

forklift (all sizes)
--
forklift (for 12 dia. and smaller only - not stacked)
3) Prevent items from receiving any damage such as deep

scratches or impact damage from handling. In particular,
check tapered ends of pipe for large cracks or break-outs.
Ensure that loose protective covers are replaced or adequate
substitutes are found.
--
hand (small crates only)
4) Ensure that mixing instructions, catalysts, etc. are not discarded

or lost. It is a good policy to retain all shipping cartons or crates
of joining material and to store these materials in the same
manner as received for safety, as well as, security measures.
--
slings or ropes using hoists
Storing
--
forklift
1) ENSURE THAT CATALYSTS & PROMOTERS ARE NEVER PLACED

TOGETHER, AS FIRE OR EXPLOSION HAZARD WOULD THEN
BE CREATED.
3) Pipe, fittings, or headers shipped crated should only be

unloaded by:
4) Do not lift pipe by inserting forks into ends of pipe.

5) Do not drop or throw FRP products, chemicals, or taper tools
from the truck to the ground. Do not rest pipe on rocks or
unlevel ground.
2) Avoid careless stacking of pipes or headers.

3) Store pipe on level supports or sand. Do not point load. Be sure
there are no stones, etc. against FRP products. Do not store on
snow if point loading may occur when snow melts.
6) Pipe ends are fragile; HANDLE WITH CARE.

7) DO NOT USE CHAINS OR CABLES.
4) Prevent point loading from supports; if necessary, cover

supports with carpet or masonite, or use saddles. Where saddles
have been used for supporting the pipe during transportation,
these should be used to support the pipe after unloading.
8) NO SMOKING when handling resin, paste, adhesives, or chemicals

9) Do not roll FRP pipe unless over a smooth surface.
Transporting
5) STORE JOINING MATERIALS INSIDE IN COOL, DRY AREAS, 5C. to

25C. (40F. to 75F.). HIGHER TEMPERATURES WILL DECREASE
SHELF LIFE OF CHEMICALS. TAPERING TOOLS SHOULD BE KEPT IN
A DRY AREA.
1) Avoid point loading to prevent damage. If necessary, cover

supports with carpet or wood saddles to disperse loads when
transporting large pipes or headers.
4
Installation Manual
6) RPS pipe, fittings, and headers are coated for ultraviolet
protection and may be stored in the open sun. HOWEVER,
covering must be supplied if the bonding (joining) surfaces are
unprotected and the storage area is exposed to dust, grease, tar,
soot, or other contaminants that could affect the bonding or
joining surfaces.
Field Polyester Resins & Paste

P1500 & H1500 Adhesive
BPO Catalyst (pouch)
Field Epoxy Resins & Paste
E1500 Adhesive
A Liner Repair Paste
7) HEADERS, MANIFOLDS, OR OTHER STRUCTURES OF CRITICAL

CONFIGUR-ATION SHOULD BE FLAT ON MOUNTING SURFACES,
IF APPLICABLE, AND PROTECTED FROM OPEN SUN TO PREVENT
WARPAGE. Note that warpage is usually temporary, but this
cannot be guaranteed.
NOTE: Shelf life of Polyester Resins & Paste vary depending on

the resin formulation. Contact RPS for the specific shelf life for
your project.
8) Heating Blanket Storage

--
Blankets should be stored flat, or wrapped on a paper or

pipe core having a minimum outside diameter of 4.
--
Blanket storage should be such that blankets do not receive

damage from tools or other matter being thrown on top of
them.
9) Do not remove protective coverings until items are ready for

installation, including:
--
plastic end caps from tapered ends of pipe
--
protective cover from flanges
--
plastic covers from joining kits
--
crates or covers from cans or containers of resin or chemicals
See Note Below

6 Months Max.
12 Months Max.
12 Months Max.
12 Months Max.
12 Months Max.
10) CAUTION: NEVER STORE RESINS, ADHESIVES, PASTES,

PROMOTERS, CATALYSTS, OR CLEANING MATERIALS (SOLVENTS,
ACETONE) IN AREAS HAVING OPEN FLAME, SPARKS, HOT
SURFACES, OR OPEN SUN.
Shelf Life
1) All adhesives, paste, and resins are shipped from the factory
with labeled expiry dates. THESE MATERIALS SHALL NOT BE
USED AFTER THE LABELED EXPIRY DATE.
2) Store materials in a cool, dry area at 5C. to 25C. (40F. to 75F.)
or shelf life will be reduced and material may suffer permanent
damage.
3) To assist field contractor scheduling, the following table shows
maximum material shelf life from time of factory packaging to
time of final usage.
5
Installation Manual
SAFETY
5) Positively NO SMOKING, WELDING, OR OPEN FLAME IS TO BE

ALLOWED where adhesives, pastes, resins, acetone, or catalysts
are being used.
Safety Equipment
Application Equipment
Safety Glasses or Chemical
Goggles:
Gloves (rubber, leather, or
leather palm):
3) Dust Masks:
4) Hard Hat and Safety Shoes:
5) Ear Plugs:
6) Water Buckets & Soap:
7) Fire Extinguisher - CO :
2

- dry chemical:
8) Eye Wash Kit:
9) First Aid Kit:
Source
6) Never store resins, adhesives, pastes, promoters, catalysts, or

acetone in areas having open flame, sparks, or hot surfaces.
Hardware Store
7) Explosion proof electric motors or air motors must be used for

mixing in areas of concentrated resin, promoter, catalyst, or
acetone vapors.
Hardware Store
Ind. Supplier
Ind. Supplier
Ind. Supplier
Hardware Store
Ind. Supplier
Ind. Supplier
Ind. Supplier
Ind. Supplier
Material Hazards
The INFORMATION GIVEN BELOW IS A SUMMARY ONLY. For further
information, SEE MATERIAL SAFETY DATA SHEETS.
1) Vinyl Ester and Polyester Resin, Paste, & Adhesive (P1500
/ H1500)
Possible Hazards
Flammable: Fumes may be explosive. Do Not store or expose near
open flame, hot spots, or in contact with strong oxidizing agents. For
fire use water fog, foam, dry chemical, or CO .
All local safety regulations must be followed.

USE YOUR SAFETY EQUIPMENT AT ALL TIMES WHEN MIXING OR
USING RESINS, ACETONE, CATALYSTS, ETC.
Ventilation
Mildly Toxic: Practice good care and caution to avoid skin and eye
contact, and to avoid breathing vapors. For more information, see
Material Safety Data Sheets.
1) Work in well ventilated area when using resins and all associated
catalysts, acetone, etc.
2) MEKP Catalyst
2) Never work in small confined spaces without the buddy

system, and without the guidance of an authorized, qualified
instructor or supervisor. Use air-purifying respirators if ventilation is inadequate.
Flammable Materials
--
40% Methyl Ethyl Ketone Peroxide in Dimethyl Phthalate
--
A strong oxidizing material; an organic peroxide.
--
Use only with Polyester/Vinyl ester Resins per formula
Possible Hazards
1) Fire - Use CO , dry chemical, or foam to fight fire. Use water to

2
cool resins and catalysts if stored near the fire. Use water fog to
fight large fires.
Flammable & Explosive: Do Not store or expose near cobalt naphthenate/octoate, DMA/DEA (dimethylaniline), open flame, sparks, or
hot spots. Do Not store in contact with copper, brass, rubber, or mild
steel. Storage temp. is 18C. to 30C. (65F. to 85F.). For fire use dry
chemical, foam, or CO ; and water spray for large fires.
2) If resins are over catalyzed, they will generate excessive heat

and combustion may occur. REMOVE SMOKING OR BUBBLING
MATERIALS IMMEDIATELY TO AN OUTSIDE, OPEN AREA AND FILL
CONTAINERS WITH WATER.
Toxic: Practice good care and caution to avoid skin and eye contact,
and to avoid breathing vapors. For more information, see Material
Safety Data Sheets.
3) Discard all materials if exposed to water or other fire

fighting chemicals.
IMPORTANT, NEVER MIX DIRECTLY WITH ACCELERATORS SUCH

AS DMA OR COBALT NAPHTHENATE, AS A FIRE OR EXPLOSION
MAY OCCUR. MIX WITH RESIN FIRST.
4) NEVER torch-cut or weld empty cans/drums of resins, acetone,

or other chemicals.
Installation Manual
3) BPO - 40% Benzoyl Peroxide (Catalyst)
Safety Data Sheets.
Possible Hazards
6) Acetone Cleaner - 2 propanone
Flammable & Explosive: Do Not store, expose near, or allow direct

contact with cobalt naphthenate, DMA (dimethylaniline) / DEA
(diethylaniline) or other aniline or amine products, open flame,
sparks, hot spots, or open sun. Storage temp. is 5C. to 25C. (40F.
to 75F.). High temp. will cause to decompose to toxic flammable/
explosive material. Store only in original containers. DO NOT ALLOW
CONTACT WITH OXIDIZING MATERIALS OR ACCELERATORS. For fire use
dry chemical, foam, or CO ; and water spray for large fires.
Possible Hazards
Flammable & Explosive - Very volatile. Vapour forms explosive
mixture with air. Do Not store or expose near open flame or hot
spots. Storage temp. is 5C. to 25C. (40F. to 75F.). Supply good
ventilation. For fire use dry chemical, foam, or CO .
2
Safety Data Sheets.
Safety Data Sheets.
7) Epoxy Resin, Paste, & Adhesive (E1500)

Possible Hazards
IMPORTANT, NEVER MIX DIRECTLY WITH ACCELERATORS SUCH

AS DMA OR COBALT NAPHTHENATE, AS A FIRE OR EXPLOSION
MAY OCCUR. MIX WITH RESIN FIRST.
4)
DMA -
Dimethylaniline (Promoter)
DEA -
Diethylaniline (Promoter)
Flammable: Do Not store or expose near open flame, sparks, or hot

spots. Avoid contact with strong oxidizing agents or mineral acids.
For fire use foam, CO , or dry chemical.
2
Moderately Toxic: Practice good care and caution to avoid skin and
eye contact, and to avoid breathing vapors. For more information,
see Material Safety Data Sheets.
Possible Hazards
Flammable & Explosive: Do Not store or expose near BPO, MEKP,
open flame, sparks, or hot spots. For fire use dry chemical, foam, or
CO . Do Not use sharp stream of water.
8) Epoxy Hardener (Polyamide Resin)
Ground equipment/containers to avoid electrical discharge.
Do Not store near epoxy resins.
Extremely Toxic: Practice good care and caution to avoid skin and eye
contact, and to avoid breathing vapors. For more information, see
Material Safety Data Sheets.
Flammable: Do Not store or expose near open flame, sparks, or hot

spots. For fire use foam, CO , or dry chemical.
Possible Hazards
Moderately Toxic: Practice good care and caution to avoid skin and
eye contact, and to avoid breathing vapors. For more information,
see Material Safety Data Sheets.
IMPORTANT, NEVER MIX DIRECTLY WITH BPO OR MEKP, AS A

FIRE OR EXPLOSION MAY OCCUR. Do Not dispose material in
drains or sewer system.
9) Glass Fiber
5) Air Dry Solution

-
--
10% Paraffin Wax/90% Styrene
from glass mat and woven roving in butt & wrap kits
Possible Hazards
Possible Hazards
Non-Flammable: Use self-contained breathing apparatus in a

sustained fire due to trace amounts of fiber binder & sizing.
Flammable & Explosive: Vapours are explosive. Do Not store or

expose near open flame, sparks, hot spots, or other chemicals. Supply
good ventilation. For fire use dry chemical, foam, or CO . Water is not
2
usually effective.
Health Hazard: May cause temporary mechanical irritation of skin,

eyes, and upper respiratory tract.
Use local exhaust ventilation to keep particulate levels below established limits.
7
Installation Manual
If established limits are exceeded, follow local regulations and use
NIOSH 42 CFR Part 84 respiratory protection (or equivalent in other
national jurisdictions). N95 is usually acceptable unless higher
concentrations or other contaminants warrant.
10) Fiberglass Reinforced Plastic (FRP) Dust
--
from cutting/grinding/sanding of FRP laminates
Possible Hazards
Flammable: Combustible dust; potentially explosive in high concentrations. Avoid sources of ignition.
Use self-contained breathing apparatus in sustained fire. Fight with
water, foam, CO2 , or dry chemicals.
Health Hazard: Dust is composed of cured vinyl ester or polyester
resin, and glass fibers.
This may cause temporary mechanical irritation of skin, eyes, and
upper respiratory tract.
Use local exhaust ventilation to keep particulate levels below
established limits. Use a vacuum unit to capture dust close to source.
Isolate with a protective shelter to keep dust away from fellow
workers or equipment.
If established limits are exceeded, follow local regulations and use
NIOSH 42 CFR Part 84 respiratory protection (or equivalent in other
national jurisdictions). N95 is usually acceptable unless higher
concentrations or other contaminants warrant.
Remove from skin using cold water with as little rubbing as possible
to prevent irritation.
Pressure Testing
See the Testing section of this manual.
Installation Manual
Material Safety Data Sheet
Date: Sep 10, 2012
1) Product Identification
Eye Contact: Flush eyes with running water for at least 15 minutes.
Seek medical attention if irritation persists.
Product: Fibreglass Laminates (RPS Finished Products Pipe, Fittings, etc.)

Manufacturer:

Skin Contact: Wash with mild soap and running water. Use a
washcloth to help remove fibres. To avoid further irritation, DO NOT
rub or scratch irritated areas. Rubbing or scratching may force fibres
into skin. Seek medical attention if irritation persists.
RPS Composites Inc.

P.O. Box 299,
Mahone Bay, Nova Scotia, Canada B0J 2E0
(902) 624-8383
Ingestion: Ingestion of this material is unlikely. If it does occur,

observe individual for several days to insure that intestinal blockage
does not occur. Treat symptomatically.
Emergency Contact: CANUTEC (24 hours)

(613) 996-6666
5) Fire Fighting Measures
2) Hazardous Ingredients
Hazardous Ingredients:
CAS No.
Fibreglass Fibres:
25-70
65997-17-3
Cured Vinyl ester Resin:
75-30
None
Flash Point and Method: None

Flammability Limits (%):
Will ignite if exposed to ignition source
Auto Ignition Temperature: Greater than 350C.

Extinguishing Media:
See Section 8) of MSDS for exposure limit data for these ingredients.
Water, foam, CO2,or dry chemical
Unusual Fire and Explosion Hazards: Cutting, abrading, drilling, or

otherwise mechanically altering this product can generate combustible dust which can present a fire or a potential explosion hazard.
Extremely high airborne dust concentrations in combination with
high energy dust are required to produce an explosion.
3) Hazards Identification
Appearance: Solid fibreglass reinforced plastic (various colours)
Odour: Has a mild aromatic odour
Emergency Overview: No unusual emergency conditions are
expected from this product.
Fire Fighting Instruction: Use self contained breathing apparatus

(SCBA) in a sustained fire.
Primary Route(s) of Exposure: Inhalation,

skin, eye
Hazardous Combustion Products: Primary combustion products are

carbon monoxide, carbon dioxide, and organic acids. Other undetermined compounds could be released in small quantities.
Potential Health Effect: Inhalation of excessive concentrations of

polyester resin dust may result in unpleasant deposits of dust in the
nasal passages and in the eyes. See Section 8) for exposure controls.
6) Accidental Release Measures

Land Spill: Scoop up or vacuum material and put into suitable
container for disposal as a non-hazardous waste.
Medical Conditions Aggravated by Exposure: Persons with respiratory

or skin conditions generally aggravated by mechanical irritants may
be at increased risk for worsening their condition from exposure to
this product.
Water Spill: This material will sink and disperse along the bottom of
waterways and ponds.
4) First Aid Measures
Air Release: This material will settle out in the air. It can then be
scooped up or vacuumed for disposal as a non-hazardous waste.
Inhalation: Move person to fresh air. Seek medical attention if

irritation persists.
Installation Manual
Material Safety Data Sheet
Date: Sep 10, 2012
7) Handling and Storage
Storage Temperature:
Not applicable
Storage Pressure:
Not applicable
mechanical alteration of the product should be maintained below

the OSHA PELs. All equipment should be bonded and grounded.
Respiratory: Use an N95 or better respirator under the
following conditions:
General: Cutting, abrading, drilling, or otherwise mechanically

altering this product can generate combustible dust which
can present a fire or a potential explosion hazard. It is prudent
to implement standard safety precautions for handling and
controlling finely divided organic particulate. This includes eliminating ignition sources and build-up of static discharge. Maintain
good housekeeping. Provide adequate ventilation. Properly
maintain and operate dust control devices. All equipment should
be bonded and grounded.
OSHA PEL
(8 hr TWA)
2) fabrication involving power tools.

3) any assemble or fabrication operation, which creates a
dusty environment.
Use respiratory protection in accordance with your companys respiratory protection program, local regulations, or OSHA regulations
under 42 CFR Part 84.
Skin Protection: Loose fitting, long sleeved shirt; long pants;
and gloves.
8) Exposure Control and Personal Protection

Ingredients:

1) in any poorly ventilated space.
ACGIH TLV
(8 hr TWA)
Eye Protection: Safety glasses, goggles, or face shield.

Avoid Irritation: Be careful not to rub or scratch irritated areas, as
they may force fibres into skin and intensify the irritation. The fibres
should be washed off. Use of barrier creams can, in some instances,
be helpful.
Fibreglass Fibres:
5 mg/m3
10 mg/m3
(respirable)

15 mg/m3 (total)
Cured Vinyl ester Resin: non specific, non-hazardous dust

15 mg/m3
Engineering Controls: General dilution ventilation and/or local
exhaust ventilation should be provided as necessary to maintain
exposures below regulatory limits. Dust collection systems should be
used in operations involving cutting, abrading, or drilling and may
be required in operations using power tools. Exposures to dust from
10
Work/Hygienic Practices: Handle in accordance with good industrial

hygiene and safety practices. These practices include avoiding
unnecessary exposures to dusts and fibres by using good local
exhaust ventilation, removal of all material from the skin and eyes
after exposure, removal of material from clothing. (Use vacuum
equipment to remove fibres and dusts from clothing. Compressed
air should never be used. Always wash contaminated work clothes
separately from other laundry and wipe out washer/sink to prevent
loose glass fibres from getting on other articles), keep the work area
clean of dusts and fibres generated during fabrication (Use vacuum
equipment to clean up dusts and fibres. Avoid sweeping or using
compressed air as techniques re-suspend dusts and fibres into the
air), and have access to safety showers and eye wash stations.
Installation Manual
INSTALLATION
4) Usually, about 50% of joints can be factory joined (1 piece

pipe and 1 fitting), leaving the remaining as field joints.
Pipe for field joints would be precut with a trim allowance.
General
This section provides general instructions for properly installing both
aboveground piping and buried piping.
For aboveground piping, suitable methods of determining cut
lengths for both adhesive jointed pipe and butt jointed pipe are
included. Recommendations regarding proper support of the piping
are also included. Details of the various jointing procedures can be
found in the Tapered Adhesive Joining section of this manual.
5) FJ denotes Field Joints. Other joints are assumed to

be prefabricated.
Installation
1) Determine dimension d1, cut & taper PC #1 to this
dimension. Bolt PC #1 to pump flange, bolt PC #6 to
wall flange.
For buried piping, selection and placement of pipe support and

backfill materials are discussed. Jointing of pipe using O-ring joints is
addressed in the O-Ring Joining section of this manual.
2) Determine dimension d5 and d4, cut & taper PC #4 & #5

to these dimensions. Install PC #4 & #5 using an ADHESIVE
JOINT between #5 & #6 and #4 & #5.
Determining Cut Dimensions
3) Using the same procedure, install PC #2 & #3.
1) Pipe Installation using Tapered Adhesive Joints

Assumptions
NOTE: Where space restricts movements, or where the pipe has

been misaligned, it may be necessary to make the last two (2)
joints using butt joints.
4) ENSURE FITS ARE SUCH THAT FLANGES ARE BOLTED

(TORQUED) IN PLACE WITHOUT STRESS FROM
MISALIGNMENT.
1) D dimensions are determined from drawings and then by

actual measurement.
2) Y dimensions are taken from RPS Dimensions Catalogue.
3) d dimensions are D minus Y.
11
Installation Manual
2) Pipe Installation using Butt Joints
5) Determine (measure) dimension D2, then cut PC #2 to suit

this dimension.
Assumptions
1) D dimensions are determined from site drawings and
then by actual measurement. Usually there will be a
factory supplied trim allowance in each change in direction
or between each pair of fixed flanges, etc.
2) FJ denotes Field Joints. Other joints are assumed to
be prefabricated.
Installation
this dimension.
2) Install PC #1 & #5
this dimension.
4) Install PC #4 using a Butt Joint between #4 & #5.
12
6) Install PC #2 using a Butt Joint between #1 & #2.

these dimensions.
8) Install PC #3 using two (2) butt joints.
9) ENSURE FITS ARE SUCH THAT FLANGES ARE BOLTED
(TORQUED) IN PLACE WITHOUT STRESS FROM
MISALIGNMENT.
Installation Manual
Hanging and Supporting RPS Pipe
Hanging and supporting of FRP piping systems differs from hanging
and supporting of steel piping systems. The differences are related to
the differences in mechanical and physical properties between FRP
and steel. The most important differences, and the consequences of
those differences, are summarized below:
FRP - DIFFERENCES FROM STEEL
a) Greater Flexibility (about 1/20 of the rigidity of steel)
Consequences:
Requires closer support spacing
Large oscillations occur more easily
Earlier column failure
Recommendations regarding proper hanging and supporting of RPS

piping systems follows:
1) Hanger Spacings
Ensure that the following maximum hanger spacings are not
exceeded unless approved by the consulting engineer or RPS.
Recommended Maximum Hanger Spacing
NOTE: Table I applies to both A & P series pipe. Spacings
apply to uninsulated pipe containing liquids up to 66C. (150F.),
operating at rated pressure, free to expand, fluid specific
gravity (S.G. 1.0 & 1.3), & maximum 13mm (0.5) deflection.
Reduce spacing if conditions are more severe (insulated pipe,
ends restrained, wind, ice, etc.). Conversely, spacings may be
increased if conditions are less severe (cold non-corrosive liquid,
lower pressures) and approved by the consulting engineer or
RPS.
b) Lower Longitudinal Strength

Consequences:
Requires closer support spacing
Requires support of heavy valves
RECOMMENDED HANGER SPAC ING

Support Spacing (ft.) @ 150 deg. F.*
For RPS P150 & A150 piping
Single Span
Continuous Span
Dia.
1
1
2
3
4
6
8
10
12
14
16
18
20
24
30
36

- Requires prevention of severe water
hammer

- Longitudinal loads are relatively more
important
c) FRP Does Not Yield (no plastic deformation). Fails After Ultimate
Load Reached
Consequences:
Stress concentrations must be avoided
- Avoid line contact and point loads
d) Greater Coefficient of Thermal Expansion (about 2.5 times steel)

Consequences: - Requires greater allowance for
movement
e) Strength and Rigidity Drop Rapidly Above 90C. (200F.)
Consequences: - Careful design needed at high
temperature

Hot spots must be avoided
f) FRP is Flammable, although it can be made self-extinguishing

Consequences: - Choose self-extinguishing resins
where required
SG = 1.0
7.0
7.3
8.0
8.4
8.7
10.9
10.9
13.0
13.7
13.7
15.2
16.7
17.4
19.1
20.5
22.1
SG = 1.3
7.0
7.1
7.5
7.7
8.0
10.0
10.0
11.6
13.0
13.0
14.0
15.0
15.5
17.0
18.3
19.7
SG = 1.0
9.0
9.3
9.8
10.3
10.7
13.3
13.1
15.6
16.4
16.4
18.2
20.0
20.9
22.9
24.6
26.5
SG = 1.3
9.0
8.7
9.2
9.5
9.8
12.2
12.0
13.9
15.6
15.6
16.8
18.0
18.6
20.4
22.0
23.6
Table 1
Criteria: Strength Ratio (SR) in structure > 1.6 Deflection < 0.50
* For 180 deg. F. service, derate span by 0.90
13
Installation Manual
2) Longitudinal Oscillations
e) Heavy equipment such as valves (and valve actuators)

should be supported independently.
a) Prevent irregularities, surging or pulsing of flow rate, as

this may cause undesirable longitudinal oscillations.
f) Pipe supports should be designed and installed to

accurately fit the O.D. of the pipe.
b) Especially on long lines, prevent hi-velocity start-ups or

abrupt shut offs (check valves, etc.) to prevent hydraulic
shock or water hammer.
c) If anchors have been installed, they should be located in
each straight leg once, but not more than once. Often a
single anchor, located at an elbow or tee, will hold two (2)
adjacent legs.
3) Sideways Oscillations
Ensure that long straight runs, hung from single rod hangers, do not
sway sideways. A guide (in lieu of a hanger) in every fourth place
would prevent this condition.
g) Pipe supports must be designed to be rigid enough not to

deform excessively and become ineffective under load.
5) Summary
All of the foregoing subjects involve engineering consideration
and must, therefore, be determined by the consulting engineer.
The following conditions require careful consideration. Please
contact RPS with specific questions about these or any other
installation concerns:

expansion joints and expansion joint tie bolts, O-ring joints, or

bellow joints
4) Pipe Supports
high longitudinal loads
A complete line of standard supports suitable for RPS piping is

included in the RPS Pipe Support Catalogue. The supports shown are
standard supports only. Custom-designed supports are also available
to suit particular project requirements.
restraints using anchors, thrust blocks, thrust collars
cast in concrete walls
retaining sleeves
Supports for RPS pipe must be designed to achieve the intended

function without causing damage to the pipe. Adhering to basic
principles will minimize the chances of damaging the pipe. These
principles include:
column failure
thin wall pipe buckling
support of heavy valves or equipment
a) Supports must be of sufficient width. Widths of saddles

should typically be at least 1/3 of the pipe diameter.
water hammer
vacuum
b) Elastrometric gaskets (typically 1/16 thick for 4 and below,

1/8 thick 6 and above) should be inserted between the
supports and the pipe due to the irregular outside surface
of the pipe. The exterior surface of the pipe should never be
in direct contact with steel or other building material.
insulation, pipe rating, and related hanger spacing
hot spots
transition from buried condition to concrete
c) Pipe should never rest on narrow supports (such as steel

angles). For small diameter piping, slide shields can be
used. For larger diameter piping, saddles should be used.
d) When riser clamps are used, ensure they are not too
flexible. If the clamps are too flexible, they could deform
and damage the pipe.
14
Installation Manual
Buried Pipe & Fittings
3) Excavation
1) Flexibility
a) Excavation will be conducted in such a manner as to

minimize any disturbance to adjacent in-situ soils.
RPS pipe is flexible and, as such, it forms a structural system with

the surrounding soil. The support provided by the pipe bedding
and pipe cover materials is the single most important parameter
in the performance of this type of pipe. Reference: AWWA M45,
ASTM D3839.
2) Materials
Bedding and Initial Backfill
a) In native soils with good drainage, the pipe zone material
(bedding and initial backfill) shall be free of silt and clay
particles, and conform to the following gradation:
Max. Sieve Size
1
3/8
No. 4
No. 10
No. 20
No. 36
Percent Passing by Weight

100
70 - 100
40 - 100
15 - 65
0 - 75
0 - 10
b) In native soils with poor drainage or water infiltration,

the pipe zone material (bedding and initial backfill)
shall be free of silt and clay particles and conform to the
following gradation:
Max. Sieve Size
1
No. 4
b) Remove any unsuitable material from trench bottom and

replace with approved granular material compacted to
95% Standard Proctor Density.
c) Ensure that trench is excavated 6 to 12 below
pipe position. Minimum trench width is 1.25 times
diameter plus 12 (300mm). For 14 and larger,
recommended minimum trench is 1.25 times pipe
diameter plus 24 (600mm).
4) Installation
a) Place pipe bedding material to required thickness (min.
4), and shape bed true to line and grade, free from
depressions and high points. Provide uniform bedding for
the pipe and any protrusions such as joints.
Percent Passing by Weight

100
0 - 10
b) Compact full width of bed to 95% Standard Proctor Density.
Final Backfill
c) Shape bedding to a cylindrical surface conforming to the

pipe radius.
a) Native site material excavated and approved by the

Engineer. Material will be free of frozen lumps, roots
and organic matter, and rocks and boulders of size
greater than 4 (100mm) in any dimension. Excavated
rock material of size greater than 4 (100mm) in any
dimension is unacceptable.
d) Ensure that the pipe is lifted into place using rope or web
slings. Do not use chains or cables.
b) Imported material from a source approved by the Engineer.
15
Installation Manual
e) Lay pipes on prepared bed, true to specified line and grade.
f) Leave adequate clearance at each joint position to:
5) Final Backfilling
a) Internal pipe supports (spiders) should be
installed in large diameter pipe to maintain pipe
shape during backfilling.
b) Place approved backfill in 12 (300mm) lifts to
--
prevent possibility of sand and gravel contaminating

joining surface (especially O-ring joint surface).
specified final heights. Compact backfill to 95%

Standard Proctor Density.
--
provide access to the joint to apply butt & strap materials.
--
provide access to the joint to install bolts, etc.
g) Place embedment materials by methods which will not

disturb or damage the pipe. Work in and compact the
haunching material in the area between the bedding and
the underside of the pipe before placing and compacting
the remainder of the pipe-zone embedment. Place
embedment materials simultaneously on both sides of
the pipe to the spring line. Do not permit compaction
equipment to contact and damage the pipe. Hand tools
are recommended to tamp the embedment materials
adjacent to the pipe, especially in the haunch zone.
h) Place pipe-zone embedment material in uniform lifts
not in excess of 6 (150mm). Compact material to 95%
Standard Proctor Density. Minimum cover over top of the
pipe is 6 (150mm).
16
6) Heavy Over-Loads
Do not pass equipment over the pipe until the backfill has reached a
height of 4 (1.5m) over the top of the pipe (unless pipe is encased in
a culvert or concrete).
7) Transitions Through Concrete
Check that fill supported pipe does not pass through concrete walls
unless supplied with:
a) an expansion joint adjacent to the wall.
b) protection by a long oversized sleeve of corrugated
steel culvert.
Installation Manual
TESTING
for at least 10 minutes or as required for the project. Quick

closing valves and booster pumps without suitable controls
should not be used.
Requirements
Whenever possible, RPS ABCO piping systems should be hydrostatically tested, prior to being put into service, to assure soundness of all
joints and connections.
Liability
The following procedure is offered only as a guide to testing fiberglass pipe. RPS can assume no responsibility or liability for the
consequences of any testing practices.
Procedure
1) Test by Section - When assembling the piping system, it is
recommended that small sections be joined at a time and tested
for leaks before proceeding too far with the next section. This
is particularly important at the beginning of the job when the
techniques are new and the likelihood of leaks is greater.
2) Pipe Support - Ensure that pipe sections being tested are
properly supported and restrained, otherwise a failure could
damage the whole system.
3) Joint Curing - Before testing, the joint should be given the
opportunity to fully cure. Without the application of extra heat,
this will take at least 24 hours for butt joints at 70F. or higher
temperature. Taper joints, which must have been cured by the
application of heat through heating blankets, can be tested after
only a couple of hours. If butt joints have to be tested quickly,
then application of extra heat, using heating blankets for about
1/2 hour, will make it possible to test the joint immediately after
cooling down.
4) A 1 diameter or smaller threaded adapter can be bonded to the
lowest point in the system to permit testing.
NOTE: It is recommended that the pressure be increased in

several steps to minimize any problems should a leak occur.
Safety
1) The test operation should be well planned and carried out with
all due precautions. There is no safe pressure; any pressure is
potentially dangerous.
2) Pressurizing equipment should be operated by qualified and
experienced personnel.
3) Care should be taken during testing to avoid sudden pressure
surges or water hammer, which can be a serious hazard.
4) Testing with air or gas is very dangerous. Only use hydrostatic
test methods.
5) Pressurizing equipment should be suited to the size of the line
and the pressure required.
6) Do not make any adjustment on pressurized fittings; relieve
pressure first.
7) When testing long lines or large diameter pipe at elevated
pressures, realize that a large amount of energy is stored in
the pipe. This energy is many times greater than that stored
in similar steel pipe because of the greater elasticity of FRP
materials. If a joint separates at a high pressure, the sudden
release of energy can cause violent movements of the pipe and
may result in secondary damage away from the original break.
This risk is reduced by testing well supported, restrained, short
sections at one (1) time.
5) Water is introduced into this lowest point.

6) Bleed off the air through a partially open valve or loose flange
at the highest point of the system. Be cautious of points where
air could be entrapped.
7) After all the air is removed from the system, slowly close valve
and carefully apply hydrostatic pressure. Test pressures should
not exceed 1.5 times the piping system design pressure, and
should not exceed the maximum allowable test pressure of the
lowest-rated component in the system. Maintain test pressure
17
SP-2720-010 Rev. A Pg. 1
Installation Manual
Bonding Procedure Specification for
RPS 150psi Tapered Adhesive Joint
Double Adhesive Kit

PIPE DIA.
(Qualified by PQR SP-2720-011* rev A)
KIT
This Bonding Procedure

Specification (BPS) is
to provide fabrication
details for making a
tapered adhesive joint in
RPS P-150/A-150/H-150
Reinforced Thermosetting
Plastic (RTR) pipe complying with B31.1 Power Piping Code or B31.3
Process Piping Code. All joints shall be made by bonders who have
training in RTR piping and have satisfactorily passed the qualification
tests of the appropriate code.
Joint Kits
1) RPS adhesive kits come in two sizes; single and double. Each
kit includes adhesive, catalyst (ie: curing agent), towels, mixing
sticks, and instruction sheets. The double kits provide two
containers each of adhesive and catalyst (or hardener). The
following is an estimated number of joints per kit, per size, that
can be achieved if an adequate number of joints are prepared
ahead of time.
2) The number of joints per kit is dependent on the Working Time
of the mixed adhesive. This Working Time varies with the
temperature. At 18C. (65F.), you have less than 40 minutes; at
24C. (75F.), you have less than 20 minutes before the adhesive
sets-up in the can. See chart below for approximate Working
Times.prepared ahead of time.
Single Adhesive Kit
PIPE DIA.
BONDS PER
KIT
25mm
40mm
1.5
50mm
80mm
100mm
150mm
200mm
300mm
10
400mm
12
BONDS PER
*Does not apply to E-1500 Adhesive Joint
18
25mm
12
40mm
1.5
12
50mm
12
80mm
10
100mm
150mm
200mm
300mm
10
400mm
12
2) The number of joints per kit is dependent on the Working

Time of the mixed adhesive. This Working Time varies
with the temperature. At 18C. (65F.), you have less than
40 minutes; at 24C. (75F.), you have less than 20 minutes
before the adhesive sets-up in the can. See chart below for
approximate Working Times.
SP-2720-010 Rev. A Pg. 2
Installation Manual
Equipment
1) Type B Tapering Tool for
tapered adhesive joints:
2) Heating collar (110 volt):
3) Pipe clamps, riser clamps,
or friction clamps:
4) Vacuum unit for B Tool
(industrial canister type):
5) Hacksaw or circular saw
with diamond coated or
abrasive blade:
6) Pipe strap wrench:
7) Grease pencil:
8) Measuring tape:
9) Slotted head screwdriver:
10) Wrap-around or stiff paper:
11) 60 grit sandpaper:
12) Coarse file:
13) Wrenches to tighten clamps:
14) Level:
15) Knife or utility knife:
16) Soft wire or masking tape:
Source
RPS
RPS
RPS, Crane Can.,
Grinnell, etc.
Black & Decker
#54840 or equiv.
Ind. Tool Supplier
RPS, Ind. Tool Supp.

Hardware Store
Hardware Store
Hardware Store
Hardware Store
Hardware Store
Hardware Store
Hardware Store
Hardware Store
Hardware Store
Hardware Store
Safety Equipment
Source
1) Leather/leather palm gloves:
Hardware Store
2) Rubber gloves:
Hardware Store
3) Safety glasses:
Hardware Store
4) Ear plugs:
Hardware Store
5) Bucket (filled with water):
Hardware Store
6) Tyvek Suit
Hardware Store

Safety Instructions
Safety Instructions
1) DO NOT SMOKE, have SPARKS, or OPEN FLAME near work area.
2) Work in a well ventilated area or wear PPE as required by local
regulations.
3) Wear leather gloves and safety glasses
when handling and tapering pipe.
4) RPS P1500, H1500, E1500 adhesive and catalyst, (separately

or combined) will cause skin irritation to some people. Avoid
contact with skin and eyes. Wear rubber gloves and safety
glasses. In case of contact, wash skin with soap and water. For
eyes, flush with plenty of water for at least 15 minutes and get
medical attention.
5) Leftover adhesive in can will become
very hot (150C. or 300F. approx.)
after going hard. It is advisable to put
this hot can in a bucket of water to
prevent injury. Do not allow catalyzed
resin to get wet. This may stop the
cure. Uncured resin is hazardous
waste, cured resin is not.
6) Refer to the Safety section of the RPS Installation Manual, and
the supplied MSDSs for more details.
Storage, Handling and Environment
1) Always store adhesive kits in a cool dry location; 40F. to 75F.
(4C. to 24C.).
2) Do not use adhesive after expiration date on label.
3) Do not use adhesive that has started to turn rubbery or hard.
4) Ideal working conditions are between 10oC and 30oC. Exceeding
these may affect cure.
5) Protect bonding surfaces and
adhesive from contamination.
Ambient temperature should exceed
the dew point temperature by 3C
(5F). Water or condensate will
contaminate a joint.
6) Bonding surfaces can be dried with the RPS Heating Collar.
When outdoors, a portable shelter over the joint can protect
from moisture or strong sunlight.
7) In cold weather, warm the adhesive and catalyst, or adhesive
and hardener, to 68F. - 77F. (20C. - 25C.) before mixing.
8) Do not try to split a kit. Always put the contents of one catalyst
pouch in one can of adhesive, or contents of one hardener
container in one can of adhesive.
19
SP-2720-010 Rev. A Pg. 3
Installation Manual
9) Properly dispose unused adhesive by first curing any uncured
resin and curing agents, and then burying in an approved
sanitary landfill area.
10) Clean up all spills with sand, sawdust, or vermiculite and arrange
disposal with an approved waste disposal agency.
Refer to the Type B Taper Tool Instructions, at end of BPS, for correct
use and adjustment of the tapering tool.
4) Check the Fit
Dry fit the joint to check for correct insertion depth.
The joint should fit with no play in
the joint. If the pipe is under-inserted by more than 1/16, retaper
to the correct insertion depth as per
Tapered Adhesive Insertion Lengths
(inches) below.
11) Follow your safety rules.
Joint Preparation
1) Inspection
Carefully inspect pipe and fittings for damage. Pay particular
attention to pipe ends. Damaged areas will generally appear as
bruises on the exterior and/or cracks or crazing on the interior. Do
not use damaged fittings. Damaged pipe sections must be cut out
and discarded.
NOTE: In fitting to fitting joints, the fitting ends must not touch.
If ends touch, the fit must be corrected to the correct gap as per
fitting dimension sheets (see RPS Dimensions Catalogue for
dimensions).

Spigot Edge Thickness
1 to 12
+0.030/-0.015
2) Measuring and Cutting
Insertion Depth
1 to 12
+0.120/-0.060
Item
Diameter
Tolerance
TAPERED ADHESIVE
INSERTION LENGTHS (inches)
Measure the length of pipe

required, allowing for insertion
depth in fitting, and mark a line
around the pipe using a pipefitters
wrap-around.
PIPE DIA.
25mm
40mm
50mm
80mm
100mm
150mm
200mm
250mm
300mm
Cut the pipe on the line using a

hacksaw, port-a-band, or a circular
saw with an abrasive blade.
Pipe end must be square to within
tolerance (face to center-line
dimension +/-1/8 up to and
including 12 dia.).
LENGTH
1
1.5
2
3
4
6
8
10
12
42mm
38mm
38mm
40mm
42mm
47mm
91mm
105mm
124mm
1 3/8
1 3/8
1 3/8
1 3/8
1 3/8
1
3 9/16
4 1/8
4 7/8
3) End Preparation
5) Secure the Joint
Well abraded, clean, dry bonding surfaces are critical to making

good joints.
Steps must be taken to ensure joints are not disturbed during

the curing process. This can
be accomplished by securely
blocking the components using
friction clamps and turnbuckles,
or come-alongs. Clamps and
other securing devices must be
placed so as not to interfere with
application of the heating collar
over the joint.
Fittings are supplied with factory prepared bell or socket ends. Pipe
is supplied with straight cut, plain ends.
Taper the pipe end using RPS Type
B taper tool. This tool is designed
to cut a precise male taper at the
correct angle to match the fitting
bell taper angle for each size.
20
SP-2720-010 Rev. A Pg. 4
Installation Manual
6) Install Clean-out Pig
When assembling adhesive bonded joints, some adhesive will
squeeze out on the inside of the joint. Up to 1/16 bead is normal,
and generally does not present a
problem if the proper amount of
adhesive has been used. If excess
adhesive has been applied, a larger,
undesirable bead will occur inside
the pipe.
To correct this occurrence, prepare
a ball of clean rags or paper Pig
large enough to fit snugly inside
the pipe, and attach to a length
of twine.
Insert the Pig into the pipe on one
side of the joint, and thread the rope
through the pipe on the other side.
Do not pull the Pig through the pipe
until the joint has been secured.
7) Cleaning
Thoroughly clean the ground bonding surfaces by hand sanding
with clean 60-100 grit sandpaper and wiping with a clean, dry brush;
cloth; or paper towel.
Adhesive Application
For E1500, all of the hardener in one

container must be added to all the
adhesive in one can to develop full
joint strength.
DO NOT TRY TO SPLIT THE KITS FOR
ONLY A FEW JOINTS.
NOTE:
The P1500 and H1500
catalyst pillow pouch contains ingredients that tend to separate
after a short time. To ensure all of the ingredients are added
to the adhesive, mix the contents by hand prior to opening the
pouch. Gently mix by squeezing with your fingers until the two
(2) catalysts are well mixed. Be careful not to apply excessive
pressure, as this may result in damage to the pouch.
For P1500 and H1500 mix the catalyst with the adhesive thoroughly.
For E150, mix the white hardener into the black adhesive thoroughly
until the mixture is a uniform grey
colour without any streaks.
Scrape the sides and bottom of the
can. Stir well, then scrape the sides
and bottom again to make certain
there is a thorough mixing of catalyst
and adhesive or hardener and
adhesive. The colder the material, the
more mixing you must do.
2) Apply the Adhesive
Fully wet both bonding surfaces with adhesive using the tongue
depressor provided. Apply sufficient adhesive to pipe end to ensure
joint area is completely filled. Apply an additional 1/16 to 1/8 bead
1) Mix Adhesive
RPS P1500 and H1500Adhesives are two part systems; adhesive
and catalyst.
of adhesive to entrance of bell and to leading edge of pipe.

3) Joint Assembly
1) Align the ends of the
pipe and fitting so that
the adhesive will not
be scraped off during
RPS E1500 Adhesive is also a two part system; Adhesive and hardener.
For P1500 and H1500 all of the catalyst in one pillow pouch must be
added to all the adhesive in one can to develop full joint strength.
21
SP-2720-010 Rev. A Pg. 5
Installation Manual
insertion. Fully insert the pipe end into the fitting until it
bottoms out.

P1500
HEATING COLLAR APPLICATION TIME
(FOR 50F./10C. AND ABOVE)
PIPE SIZE
Check for squeeze out of

adhesive around entire joint
circumference. If squeeze
out is not complete, joint
must be remade.
50
70
APPLICATION TIME (minutes)
1 - 6
25-150mm
80
8 - 12
200-400mm
100
E1500
PIPE SIZE
1 - 4
105
110
120
10
125
12
130
NOTE: If temperature is below 50F./10C., Refer to 3) - Cold

Weather Curing, below.
Heating
Tapered adhesive bonded

joints MUST be cured with
a heating collar to develop
full joint strength and
corrosion resistance.
25-150mm
200-400mm
PIPE SIZE
Curing
1 - 6
8 - 12
H1500
2) Secure the joint. YOU

MUST BE CERTAIN THE
JOINT IS NOT MOVED UNTIL
IT IS COMPLETELY CURED.
DO NOT ALLOW THE PIPE
TO BACK OUT OF THE
JOINT. Remove the clean
out pig.
1) Applying
Collar
Apply a heating collar immediately. Wrap the heating collar

around the joint making sure
it is snug around the pipe,
and the thermostat is on the
outside of the wrap. Secure
the heating collar in place with a piece of soft wire or tape.
When flanges are attached to pipe, the heating collar is rolled
up on the inside of the joint, for joints 100mm (4) and larger.
A special interior heating collar is used for flange joints 3 and
smaller. Make sure that contact is made between the heating
collar and pipe wall. Heat for the recommended time.
22
CHECK THE HEATING COLLAR DURING THE CURE. A properly

operating heating collar will be too hot to hold your hand on.
Periodically, check the heating collar for power draw with an
ammeter or watt meter. If the draw is less than 2/3 of the rating
on the collar, the collar should be discarded.
2) Check the Cure

Remove the collar (not the clamps) and allow the pipe to cool.
Scratch the fillet radius of adhesive with a knife or nail. It should
be as hard as pipe or fitting surface. If slightly rubbery or soft,
reheat the joint until it tests flint hard. If the inside of the joint
can be reached, it also should be checked for hardness. IF
ADHESIVE REMAINS SOFT, JOINT MUST BE REDONE.
3) Cold Weather Curing

If the ambient temperature is below 50F./10C.:
Warm both joining surfaces to a minimum of 50F./10C. The

heating collars can be used for this, but the surfaces should not
be hot to the touch (ie. should not be greater than 95F./35C.),
or working time of the adhesive will be too short.
Warm adhesive and catalyst to 68F.- 77F. (20C.- 25C.)

before mixing.
SP-2720-010 Rev. A Pg. 6
Installation Manual

Control ambient air temperature to at least 50F./10C. by

enclosing joint in local shelter or wrapping with insulation.
General Guidance criteria:

a) Contamination
Eliminate cold air movement through the pipe.
4) RPS Heating Collar

RPS supplies two (2) basic types of heating collars; overlap type
and interior type. The overlap type heating collar can be used for
all outside of joint curing, and only for 4 through 12 inside of joint
curing. For 1 through 3 inside of joint curing, use interior type
heating collar.
b) Mixing

HEATING COLLAR SIZE

(Length x Width)
TEMP.

MAXIMUM NUMBER OF
HEATING COLLARS PER
25mm
3 x 4
80x100mm
260F. 20F.
127C10C
1.5
40mm
4.5 x 4
115x100mm
260F. 20F.
127C10C
50mm
6 x 4
150x100mm
260F. 20F.
127C10C
80mm
9 x 4
230x100mm
260F. 20F.
127C10C
Check that adhesive materials are applied exactly per

instructions.
d) Movement
EXTENSION CORD*
Check that materials (paste and resin) are mixed exactly

per instructions. Mix thoroughly.
c) Application
INTERIOR HEATING COLLAR

PIPE SIZE
Ensure there is no contamination of bonding surfaces (no

grease, tar, soot, oil, water, or other dirt).
Ensure there is no pipe movement before joint is cured.
e) Void Spots

Ensure there are no void or adhesive starved spots around

the fillet.
f) Squeeze Out
OVERLAP HEATING COLLAR
PIPE SIZE
HEATING COLLAR SIZE

(Length x Width)
TEMP.
Inspect if possible to ensure minimal intrusion of adhesive

squeeze-out into the interior bore of the pipe. This bead
should not exceed 1/4 the wall thickness.
MAXIMUM NUMBER
OF HEATING COLLARS
PER
EXTENSION
CORD*
1 to 2
25 to
50mm
20 x 4
510 x 100mm
260F. 20F.
127C10C .
h) Curing
3 to 6
80 to
150mm
46 x 4
1130 x 100mm
260F. 20F.
127C10C
8 to 12
200 to
300mm
88 x 5
2235 x 100mm
280F. 20F.
138C10C
The adhesive resin must be cured. A minimum barcol

hardness of 30 is required.
Barcol hardness can be measured with a barcol tester.

Ensure that the tester has been properly calibrated. If a
barcol tester is not available, use a knife point to ensure
that the cured resin is as hard as the pipe. If not, call RPS
for assistance.
* Ensure extension cords are 14 AWG minimum
Abuse can damage the heating collar thermostat. A protective metal

shield over the thermostat is provided, however, handle with care. A
damaged thermostat can result in a poorly cured or burnt joint.
5) Inspection Check List
Visually inspect the joint for alignment, fill, intrusion of the adhesive
into the interior, and cure. Refer to ASME B31.1 or B31.3 for minimum
inspection frequencies.
Tips and Warnings

1) Female ends cannot be made on site.
Sleeve couplings are available.
2) When making multiple joints at one
time, prepare all bonding surfaces
immediately prior to joining to prevent accidental use of a
contaminated surface.
23
SP-2720-010 Rev. A Pg. 7
Installation Manual
3) Do not (under any circumstances) move the assembled

joint before the adhesive is
cured. Always use clamps.
4) If the adhesive does not cure
or is rubbery in spots, it may
indicate that the adhesive was not mixed thoroughly. Redo
the joint.
24
SP-2720-010 Rev. A Pg. 8
Installation Manual
RPS TYPE B TAPERING TOOL
OPERATING INSTRUCTIONS (FOR 1 12 (25 TO 300MM) DIAMETER)
General
The RPS pipe tapering machine was designed as a tool for cutting
outside tapers on RPS ABCO pipe. Each machine is fitted with a
dust extractor hood over the sanding drum. Any high-velocity,
heavy-duty vacuum cleaner fitted with a 2 I.D. intake hose (such as
the Black & Decker #54840) can be used with this grinder. (Vacuum
cleaner and stand not supplied with tool.)
The machine is designed to cut a 7 taper on 1 - 6 (25-150mm) pipe,
and a 4 taper on 8 - 12 (200-300mm) pipe. It can be conveniently
mounted on a pipefitters power drive stand, e.g. Rigid Tristand No.
1206, as shown in the illustration above.
Drive
Dewalt Saw Motor Model #DW384 (Type 3),
5800 RPM, 120 volt, AC/DC, 15 amp.
Safety
See the Safety section, Page 6, and MSDS, Page 9.
Mounting Tapering Tool
Attach the taper tool to the Mounting Plate (Item 18) using the bolts
(Item 19) and Motor Base Shim (Item 34) provided. For 1 to 6, (25
to 150mm) the shim angle is 70, and for 8 to 12 (200 to 300mm)
it is 40. Mount the Taper Tool and Mounting Plate on a solid table
or stand. Ensure the Base Plate (Item 25) or Adapter Plate (Item 35)
is vertical.
Holding Long Lengths of Pipe

For tapering long lengths of pipe, set up V roller stands for handling
and rotating the pipe. Ensure the pipe is level and perpendicular to
tapering tool base plate.
Tapering 8 - 12 (200-300mm) Diameter Pipe

To taper 8, 10, or 12 (200, 250, or 300mm) diameter pipe, the
guides (Item 23) must be in position in the appropriate holes in the
base plate (Item 25). The top
set of holes is for 8 (200mm)
pipe, the center set is for 10
(250mm), and the bottom set
is for 12 (300mm) pipe. Select
the pipe size to be tapered and
put the guides in their appropriate holes.
Position the pipe on V roller
stands and apply a strap wrench
over the pipe. Insert the pipe
over the machine guide (Item
23) and roller (Item 20). Rotate
the pipe on the guide to check
the fit and ensure the pipe is level. Do not make contact with the
grinding stone.
To compensate for variations in pipe inside diameter, the guides have
eccentric mounting studs. Adjustment of a guide can be made by
slackening the guide nut (Item 29), inserting a 1/4 diameter pin
(Item 31) in the hole, and rotating the guide with the pin until a
light contact is made with the pipe inside. Usually only one (1) guide
needs adjustment.
Start the vacuum unit. Start the tapering tool.
CAUTION: CHECK ROTATION OF GRINDER SO THE STRAP WRENCH IS
SECURED THE RIGHT WAY; AGAINST THE DIRECTION OF THE CUTTER,
WHEN THE PIPE IS GROUND.
25
SP-2720-010 Rev. A Pg. 9
Installation Manual
Slowly push the pipe forward until about 1 of pipe is tapered.
Now slowly rotate the pipe one (1) revolution (rotate pipe against
rotation of grinding stone). Continuing to repeat this operation in
1 maximum steps, slowly push the pipe until the pipe is pressing
against the base plate (Item 25). Make one (1) more revolution with
pipe against the base plate. Now move the pipe back from the cutter
and turn the tapering tool and vacuum off.
the mandrel to check the fit and ensure the pipe is level. Do not
make contact with the grinding stone. Refer to Tapering 8 12
Diameter Pipe, Pages 25.
Start the vacuum unit. Start the tapering tool.
CAUTION: CHECK ROTATION OF GRINDER SO THE STRAP WRENCH IS
SECURED THE RIGHT WAY, AGAINST THE DIRECTION OF THE CUTTER,
WHEN THE PIPE IS GROUND.
THE END OF THE TAPERED PIPE SHOULD FEATHER OUT TO 1/32

THICK FOR TAPERED ADHESIVE JOINTS, If not, adjustment of the gap
between the roller (Item 20) and the grinding stone (Item 14) can
be made by slackening the four (4) 3/8 diameter bolts (Item 24),
readjusting for correct gap, and tightening the bolts.
WARNING: Excessive force on the grinding stone may cause the
motor to run too hot and, thus, BURN OUT. Allow a hot motor to
COOL DOWN. For best performance and longest motor life, allow the
tapering tool to operate at high RPM.
Tapering 1 - 6 (25-150mm) Diameter Pipe
To taper 1 - 6 (25-150mm) diameter pipe, the roller assembly (Item
20 & 21) and guide pins (Item 23) must be removed. To remove roller,
insert a 3/8 diameter pin (Item 15) in hole at the end of roller shaft
and unscrew the roller from the base plate (Item 25). To remove
guide (Item 23), loosen and remove nuts and washers (Item 29 & 30).
Install guide mandrel (Item 37 - 42) on adapter plate (Item 35) using
bolt and washer (Item 43). There are six (6) holes in adapter plate
for mandrel location, one (1) for each size of pipe. The closest to the
grinder is for 1 (25mm) pipe, and the farthest is for 6 (150mm) pipe.
Secure adapter plate to base plate (Item 25) using 1/4 diameter
bolts (Item 36).
Position the pipe on V roller
stands and apply a strap wrench
over the pipe. Insert the pipe
over the guide mandrel (Items
37 - 42). Rotate the pipe on
26
Slowly push the pipe forward until about 1 of pipe is tapered. Now,
slowly rotate the pipe one (1) revolution (rotate pipe against rotation
of grinding stone). Then slowly push the pipe into the base plate
(Item 25) and slowly rotate the pipe one (1) revolution. Make one (1)
more revolution with the pipe against the base plate. Now move the
pipe back from the cutter and turn the tapering tool and vacuum off.
Refer to Tapering 8 12 Diameter Pipe, Pages 25.
THE END OF THE TAPERED PIPE SHOULD FEATHER OUT TO 1/32 THICK
FOR TAPERED ADHESIVE, AND TO 1/8 THICK FOR TAPERED BUTT
JOINTS. If not, adjustment of the gap between the mandrel and the
grinding stone (Item 14) can be made by slackening the three (3) 1/4
diameter bolts (Item 36), readjusting for correct gap, and tightening
the bolts.
WARNING: Excessive force on the grinding stone may cause the
motor to run too hot and, thus, BURN OUT. Allow a hot motor to
COOL DOWN. For best performance and longest motor life, allow the
tapering tool to operate at high RPM.
Replacing Grinding Stones
Disconnect power and insert the 3/8 diameter pin (Item 15) through
the bearing housing (Item 6) and then into the hole in the shaft (Item
9). The shaft is now locked. Remove the nut (Item 17) and washer
(Item 16). Slide the grinding stone (Item 14) off the shaft. Install the
replacement grinding stone in reverse order. Do not over tighten the
nut. Remove the pin.
SP-2720-010 Rev. A Pg. 10
Installation Manual
CAUTION - TO PREVENT MOTOR DAMAGE:

Taper at high RPM only - slowing motor will cause burn out.
Protect line with 15 AMP time delay fuse, eg. Fusetron Type TC
115 to 125 volts only
Maximum extension cord lengths and conductor sizes:

25ft.-No.14
35ft.-No.12
55ft.-No.10
90ft.-No. 8
27
SP-2720-010 Rev. A Pg. 11
Installation Manual
RPS TYPE B TAPER TOOL ASSEMBLY
RPS POWER TYPE B TAPERING TOOL PARTS LIST

ITEM QTY DESCRIPTION

1
1
Motor Base

2
1
Motor (Dewalt Saw Motor Model DW384{Type 3}, 5800 RPM, 120V, AC/DC,

15 amp.)

3
1
Motor Mounting Bracket

4
3
Machine Screw (M4 x 0.7 x 25mm CSK HD SS)

5
1
Lovejoy Coupling (#L-075 0.500)

6
1
Bearing Housing

7
2
Bearing (SKF 6205 2RS)

8
2
Retaining Ring (Truarc #5000-200)
9 1 Shaft
10
1
Coupling Guard
11
5
Machine Screw (1/4-20 UNC x 1/2 HX HD SS)
12
1
Dust Extractor and Guard
13 1 Spacer
14
1
Grinding Stone (Dwg. #FB-6265)
15
1
3/8x6 LG Removal Pin
16
1
Washer (3/4 dia. SS)
17
1
Hex Nut (3/4-10 UNC SS)
18
1
Mounting Plate
19
4
Bolt (3/8-16 UNC x 2 1/2 CSK c/w Lwasher & Nut SS)
20 1 Roller
21
1
Roller Shaft
22
1
Retaining Ring (Truarc #5000-100)
23 2
Guide (Eccentric)
28
24
4
25 1
ITEM QTY
26 1
27 1
28 2
29 2
30
4
31
1
32
2
33
2
34 1
35
1
36 3
37
1
38 1
39
1
40 1
41
1
42
1
43
1
44 1
45
2
46 1
47
1
48 1
49
1
50 4
Bolt (3/8-16 UNC x 1 3/4 HX HD c/w HX Nut &Lwasher SS)

Base Plate
DESCRIPTION
Bushing
Key
Machine Screw (10-24 UNCx3/4 CSK HD SS)
Nut (5/8-11 UNC HX Nut SS)
Washer (11/16 I.D.x1 1/2 O.D.x1/16 THK SS)
1/4x6 LG Removal Pin
Bolt (3/8-16 UNCx1 HX HD SS)
Bolt (3/8-16 UNCx1 1/4 HX HD c/w Nut & Lwasher SS)
Motor Base Shim
Adapter Plate
Machine Screw (round HD 1/4-20 UNC x 1 1/4 c/w Lwasher SS)
1 1/2 dia. Mandrel
2 dia. Mandrel
3 dia. Mandrel
4 dia. Mandrel
5 dia. Mandrel
6 dia. Mandrel
Bolt (3/8-16 UNC x 1 long HX HD c/w Lwasher SS)
Extender Arm Unit
Bolt (3/8-16 UNC x 2 1/4 long HX HD c/w Nut & Lwasher SS)
l dia. Mandrel
Modified Guard
32mm Mandrel
65mm Mandrel
Bolt (3/8-16 UNC x 2 1/4 long HX HD c/w Nut & 2 Lwashers SS)
SP-2720-012 Rev. A Pg. 1
Installation Manual
Bonding Procedure Specification for RPS
150psi BUTT & WRAP JOINTS(Qualified by PQR
SP-2720-013 Rev A)
This Bonding Procedure Specification (BPS) is to provide fabrication
details for making a straight Reinforced Thermosetting Plastic (RTR)
butt & wrap joint complying with B31.1 Power Piping Code or B31.3
Process Piping Code. All joints shall be made by bonders who have
training in RTR piping and have satisfactorily passed the qualification
tests of the appropriate code.
Kit Material
The RPS Butt Joint Kit contains all the necessary materials to join RPS
P150, A150 & H150 ABCO pipe to produce a strong, reliable butt joint.
The kit reinforcement is precut E or ECR glass, stacked in sequence of
lamination, and wrapped in polyethylene to protect it from moisture.
An instruction sheet giving step by step joint laminating sequence is
enclosed with each kit. Glass kits can be cut from the attached table
from appropriate material if required. The kits vinyl ester resin,
paste, catalyst, etc. are packed in quantities to suit the customers
needs, [See section 5 for resin/catalyst details] ie:

an exact amount for single joints, or
a bulk amount for many joints
A graduated one pound (1 lb.) container and a graduated syringe are

also included with each set of kits to aid accurate mixing of small
quantities of materials.
Equipment
1) Graduated 1 lb. container:
2) Syringes:
3) 3 Laminating Roller:
4) Tapering Tool Type B:
5) Vacuum unit for B Tool -
Industrial canister type:
6) Hacksaw cutting disc or
circular saw with diamond
coated or abrasive blade:
7) Power disc grinder with 24
or 36 grit sanding pads:
8) Pipe strap wrench:
9) Grease pencil:
10) Measuring tape:
11) Slotted head screwdriver:

12) Wrap-around or stiff paper:
13) 120 grit sandpaper:
14) Coarse file:
15) Paint Brushes (2 - 4):
16) 6 Paint Roller:
17) Level:
18) Knife or utility knife:
19) 1 Gallon & 5 gallon pails:
20) Scissors:
21) Clean rags:
22) Mixing sticks:
23) Weighing scale (10
20 lbs. max.):
24) Cardboard or heavy paper
(3 - 4 wide):
25) Solvent (Acetone):
26) Heat lamp (Cold Weather):
Safety Equipment
1) Leather/leather palm gloves:
2) Rubber gloves:
3) Safety glasses:
4) Half mask with organic
vapour canister

5) Dust mask:
6) Ear plugs:
Hardware Store
Hardware Store
Hardware Store
Hardware Store
Hardware Store
Hardware Store
Hardware Store
Hardware Store
Hardware Store
Hardware Store
Hardware Store
Hardware Store
Industrial Supplier
Hardware Store
RPS, Ind. Supplier
Industrial Supplier
Source
Hardware Store
Hardware Store
Hardware Store
Safety supply shop
Hardware Store
Hardware Store
Source
RPS
RPS
RPS
RPS
Black & Decker
#54840 or equiv.
Ind. Tool Supplier
Ind. Tool Supplier

RPS, Ind. Tool Supp.
Hardware Store
Hardware Store
Safety Instructions
1) All resin, paste, air dry, DMA, and catalyst, separately or
combined, will cause skin irritation to some people. Avoid
contact with skin and eyes. Wear rubber gloves and safety
glasses. In case of contact, wash with flowing water and soap.
For eyes, flush with plenty of water for at least 15 minutes
29
SP-2720-012 Rev. A Pg. 2
Installation Manual
and get medical attention. See the Safety section of the RPS
Installation Manual, and the supplied MSDSs for more details.
2) Wear leather gloves, safety glasses and appropriate PPE when
handling and grinding pipe.
3) Left over catalyzed resin in pot will become very hot (150C. or
300F. approx.) after gelation. It is advisable to put this hot pot
in a bucket of water to reduce fire hazard and unpleasant odor.
i) Properly dispose of used and unused surplus resin by first

curing any uncured resin, and then bury in an approved sanitary
landfill area.
j) Clean up all spills with sand, sawdust, or vermiculite while
wearing appropriate PPE (see MSDS). Arrange disposal with an
approved waste disposal agency.
Joint Preparation
1) Factory Prepared Ends
4) Do not smoke or have an open flame near work area.

5) Work in a well ventilated area and wear PPE as required by
local regulations.
6) Contain nuisance dust when cutting & grinding.
7) DO NOT MIX PROMOTERS (DMA or COBALT NAPHTHANATE) AND
CATALYST (MEKP OR BPO) TOGETHER. RAPID OXIDATION WILL
TAKE PLACE AND A FIRE MAY RESULT.
a) Pipe and pre-spooled pieces are available from the factory

with or without prepared ends. For straight butt joints,
pipe and fittings are usually supplied with butt edges
coated with resin. The ends are then sanded in the field in
preparation for making the joint.
8) Follow your safety rules.

Storage, Handling and Environment
a)
Always store resin, paste, and catalyst in a cool, dry place
(10C. to 25C. or 50F. to 80F.).
b) Store catalysts separately from promoters and resins.
c)
All resins are shipped from RPS with expiry dates on the
label. Do not use resin or paste, which has started to turn stringy,
rubbery or hard, because of age or improper storage.
b) PEEL-A-BOND

The pipe and fittings can be supplied with completely

prepared ends. In this case, all sanding is done at the
factory, and the surfaces are covered with a peel-ply. [RPS
PEEL-A-BOND]. In this case, no sanding, grinding, or
cleaning is required in the field.
When PEEL-A-BOND is supplied, the only joint preparation

required, before applying reinforcement to bonding
surfaces, is the removal of the protective layer; RPS
ABCO PEEL-A-BOND. Grab the overlap tab and pull
firmly, removing the PEEL-A-BOND strip from the whole
d) Reinforcing material must be stored in dry conditions. Do not use

material showing signs of moisture or condensation.
e)
Ideal working conditions are between 10oC and 30oC.
Exceeding these may affect cure.
f) Keep the joint area free of moisture, including condensation.
Ambient temperature should exceed the dew temperature by
3C (5F). When outdoors, build a portable shelter over the joint.
g) The working time or pot life of resin varies with temperature.
The warmer it is, the shorter the working time. At 24C. (75F.),
you have 15 to 30 minutes, and at 18C. (65F.), you have 30 to
60 minutes. Do not use the resin once it has started to gel.
h) Clean your tools regularly while working; shake and dry out
tools completely before using them to laminate again. Solvent
or cleaning fluids in the resin will ruin the cure.
30
SP-2720-012 Rev. A Pg. 3
Installation Manual
circumference of the joint. This should be the last action
before lamination is applied, and the surface should not
be otherwise touched or cleaned after removal of the
protective strip. If the PEEL-A-BOND has been removed
prematurely, either in transit or on the jobsite, clean
the surface to remove any grease, oil, or other contaminate by lightly sanding the contaminated surface. See
PEEL-A-BOND section, Page 51.
SANDING REQUIREMENT
2) Field Prepared Ends

a) Measuring and Cutting
Measure the length of
pipe required and, using
a wrap-around, scribe
a line around the pipe.
Cut on the line using a
hacksaw or a circular saw
with a diamond coated
wheel or abrasive blade.

Pipe end must be square

to within tolerance
(face to center-line
dimension +/-1/8 up to
and including 12 dia., or
+/-3/16 for 14 dia. and
larger).
PIPE
DIA.
C (in.)
2.5
2.5
4.5
10
4.5
12
5.5
14
16
18
7.5
20
8.5
24
10
30
12
36
14.5
42
16 .5
48
19
Table No. 1
e) Perhaps the single most important aspect of making a

successful joint is ensuring the bonding surfaces are clean.
Sanded areas can very quickly become contaminated by
airborne dirt and moisture. It is, therefore, recommended
that the time between sanding and lay-up not exceed 4
hours. In fact, lay-up should begin as soon as possible
after sanding. If lay-up cannot begin within 4 hours, the
surfaces should be lightly re-sanded prior to lay-up. It is
very important to have the bonding surfaces perfectly
clean to achieve a strong joint.
b) Field preparation is
usually done using a
high-speed 4 or 7 grinder, 24-36 grit (all sizes).
c) For area shown as C in Figure 2 for straight butt joints,
the surface should be thoroughly sanded to remove all
brushcoat, wax, grease, dirt, or any other contaminant.
f) It is recommended that an inside lay-up be done whenever

the joint is accessible. If the inside of the joint is not accessible, the pipe I.D. is not to be sanded.
g) Coat butt edges of pipe or fittings with lay-up resin to
ensure the edges are
properly sealed.
31
SP-2720-012 Rev. A Pg. 4
Installation Manual
h) Alignment

Align the pipe assembly

and support the pipe
firmly together to
prevent any movement
during the lamination of
the joint.
Item
Diameter
Tolerance
Axial gap

1 to 12
14 to 24 larger
larger
+0.125
+0.188
+0.25
Radial offset

1 to 12
14 to 24
larger
+0.125/-0.125
+0.188/0.188
+0.25/-0.25
All sizes
+/-0.5 degrees
Angularity
more than 1/8 by trimming the edge. At 21C. (70F.), the

liner paste will cure in 10 to 20 minutes. In cold weather, a
heat lamp should be used to achieve a proper cure.
i) Hot Patch

When working with large diameter pipe, it may be

necessary to tack weld the two pipes together to hold
them in place. To do this, use a RPS ABCO Hot Patch Kit and
apply its reinforcement in four (4) evenly spaced locations
on the joint while holding both parts securely. After
curing, the first step of the joint can be laminated between
patches without fear of movement or misalignment. The
hot patches should then be removed and pasting and
laminating in those areas completed.
j) It is advisable to mark the pipe with a pencil at a known

distance just beyond the sanded area. This mark will serve
as a reference in locating the centerline of the joint. This
will aid in ensuring all layers are centered over the joint.
3) Joint Lamination
a) Look up the appropriate Joint Lamination Sequence in
the table found at the end of this section. Refer to this
sheet for the required amounts of paste, resin, catalyst,
etc. Written instruction for the joint are included in all RPS
reinforcement kits.
b) Apply Liner Paste

Catalyze liner paste and apply to joint crevice only. DO NOT

FORCE THE PASTE THROUGH THE CREVICE AND INTO THE
PIPE INTERIOR. THIS WILL IMPEDE FLOW. Avoid a gap of
32
Cured paste should be as hard as pipe surface. If slightly

rubbery or soft, it needs more time. If it will not cure, the
joint process will have to be repeated
CAUTION: The heat lamp will cause bubbling, blistering, or

smoke if held too close or too long to the paste. Remember,
the materials are flammable.
c) Apply Reinforcement

Open the kit material

and lay the strips of
reinforcement near
the work area in
sequence of application.
Measure
out the amount of
resin required. Lay a
cardboard or heavy
paper sheet next to
the work area.
Using a paintbrush,
coat a strip down
the center of the
cardboard sheet with a generous amount of catalyzed
resin. Take the first piece (narrowest) of reinforcement
and lay it binder (finished or smoothest) side up on the wet
strip. Impregnate the reinforcement until all the fibers are
SP-2720-012 Rev. A Pg. 5
Installation Manual
d) Interior Lay-up
soaked. Now carefully lift the reinforcement and wrap it

around the joint area. Do not stretch the glass. Using a
paintbrush, force air bubbles out of the laminate. Do this
with a jabbing motion with the ends of the bristles. Do
not use a painting motion. ALL AIR MUST BE FORCED FROM
BETWEEN THE LAYERS. A laminating roller or paint roller
will also help to force out the air.

The first two (2) layers

must be applied
singularly, however,
the
remaining
reinforcement, may be
applied singularly or
in groups of 2, 3, or
4 layers. Make sure
all overlapped ends are staggered around the joint.
NEVER ALLOW THE GLASS TO SAG.
e) Brushcoat

a) Contamination

Eliminate cold air movement through the pipe.
Check that materials (paste and resin) are mixed exactly

per instructions. Mix thoroughly.
c) Application

Warm both joining surfaces to a minimum of

50F./10C. Heating collars can be used for this, but
the surfaces should not be hot to the touch (ie. should
not be greater than 95F./35C.), or working time of
the resins will be too short.
Control ambient air temperature to at least50F./10C.

by enclosing joint in local shelter or wrapping with
insulation.
Ensure there is no contamination of bonding surfaces (no

grease, tar, soot, oil, water, or other dirt).
b) Mixing
If the ambient temperature is below 50F./10C.:
Visually inspect to criteria

and tolerances in RPS WI-IT-008 on next page (essentially
ASTM D2563 Level 3). Refer to ASME B31.1 or B31.3 for
minimum inspection frequencies.
General Guidance criteria:
NOTE: For large joints, do not mix more resin than can be
used within a 15 to 20 minute period. Use maximum 10 lb.
(4.5 kg) lots.
Warm the resins to 68F.-77F. (20C.-25C.) before

mixing.
Mix brushcoat per attached laminating sequence sheet and

apply over joint exterior
laminate. When there is an
interior laminate, brushcoating is also required.
4) Inspection Check List
After each step of reinforcement (5 layers) is applied, the

lay-up must be allowed to cure for 30 minutes to 2 hours
depending on the temperature and the amount of catalyst
added. During cure, the lay-up generates a considerable
amount of heat. Do not commence the next step until the
lay-up has cooled (you should be able to hold your hand
comfortably on the laminate).
All joints greater than 20 diameter, where accessible,

shall receive an inside joint overlay as specified in the butt
joint instructions.
Check that materials (paste, resin, glass, and brushcoat)

are applied exactly per instructions.
d) Movement

Ensure there is no pipe movement while laminating or

before joint is cured.
e) Sags or Drooping Glass

There should be no sags, drooping, or slipping of wet

reinforcement at the bottom of a joint (caused by resin
rich laminate, by applying too many layers at a time, or by
improper rolling). Check repeatedly until cured
f) Dry Spots

33
Ensure there are no dry or resin starved spots.
SP-2720-012 Rev. A Pg. 6
Installation Manual
5) Materials:
g) Delamination

Resin Material:
There should be no delamination or blisters.
i) Brushcoat
Crevice Paste: Vinyl ester resin with thixotrope
Structural Resin: Vinyl ester resin
Catalyst: MEKP methylethyl ketone peroxide suitable for

vinyl ester per manufacturers instructions
AirDry: a mix of paraffin & styrene
All adhesives, paste, and resins are shipped from the

factory with labeled expiry dates. THESE MATERIALS
SHALL NOT BE USED AFTER THE LABELED EXPIRY DATE.
Check that brushcoat has been applied. If in doubt, use the

acetone test. Apply a small amount of acetone on the resin
surface and rub lightly with the finger until the acetone
evaporates. If the surface softens or becomes tacky,
brushcoat has not been applied or is too thin.
j) Curing

The resin must be cured. A minimum barcol hardness of 30

is required for most resins. Barcol hardness is measured
with a barcol tester. Ensure that the tester has been
properly calibrated. If a barcol tester is not available, use a
knife point to ensure that the cured resin is as hard as the
pipe. If not, call RPS for assistance.
Reinforcements:

Veil: Nexus or C glass
E or ECR glass in chopped strand mat and woven

roving formats.
PIPE SIZE
3
34
1
1
4 5
SP-2720-012 Rev. A Pg. 7
Installation Manual
ACCEPTANCE CRITERIA FOR APPEARANCE OF LAMINATES
This Specification defines the acceptance criteria for appearance of laminates. It shall be used for all projects (including standard products) unless
a project-specific specification is issued. These criteria are generally in accordance with ASTM D-2563 Level II for liners, and level III for structural
layers. Refer to ASTM D-2563 for definition of terms.
ALLOWABLE DEFECTS
STRUCTURAL
DEFECT DESCRIPTION
LINER
LAYERS
1. Air bubble (void)

Air entrapped within and between

the plys of reinforcement
Max. dia., 1.5 mm.

Max. dia., 3.0 mm.
(1/16); Max 2 per in2 (1/8); Max. 4 per in2
2. Pit (pithole)
Small crater in surface of laminate

Max. dia., 1.5 mm. Max. dia. 3.2 mm.

(1/16); Max. depth 0.8mm (1/32) (1/8); Max. depth 1.5mm (1/16)
3. Blister
Rounded elevation on surface of laminate

Max. dia., 3.0 mm.(1/8);

Max. dia., 6.5 mm.
height from surface (1/4); height from
not to be outside drawing
surface not to be outside drawing tolerance
4. Burn
Showing evidence of thermal decomposition
None None
5. Chip

Small piece broken

off edge or surface
Max. dimension of Max. dimension of

break, 3.0 mm. (1/8) break, 6.5 mm. (1/4)
6. Crack
Crack in laminate
None None
7. Crazing

Fine cracks at or
None
under surface of laminate
Max. dimension of
crazing, 25 mm. (1)
8. Delamination, edge

Separation of the layers of material

layers of material in the laminate
Max. dimension,
3.0 mm. (1/8)
Max. dimension,
6.5 mm. (1/4)
9. Delamination, internal

Separation of the layers of material

in the laminate
None None
10. Dry spot
Area of incomplete resin wet-out on surface
None
11. Foreign Inclusion

Particles included in laminate which are

foreing to its composition
Max. dimension 0.8mm (1/32); Max. dimension, 1.5 mm. (1/16);

Max. 1 per ft2 Max. 1per ft2
12. Fracture

Rupture of laminate surface without

complete penetration
None Max. dimension, 29mm. (1 1/8)
13. Exposed Glass

Filaments of glass protruding from surface

and not encased in resin
None
14. Exposed Cut Edges

Edges of laminate where reinforcement

None None
has not been wetted with resin
Max. dia., 14 mm. (9/16)
None
15. Porosity of 50 pits

Accumulation of numerous small pits
(pinhole)
Max. of 25 pits Max. of 50 pits

pinholes per 10 in2
(pinholes) per 10 in2
16. Resin-rich edge

Insufficient reinforcing material at edge

material at edge of molded laminate
Max., 0.4 mm. Max., 0.8 mm.

(1/64) from the edge
(1/32) from the edge
17. Scratch

Shallow mark, groove, furrow, or channel

caused by improper handling or storage

Max. length, Max. length,

25 mm. (1); max. depth 0.125 mm 25 mm. (1); max. depth 0.255 mm.
(0.005) (0.010)
18. Wrinkles

Appears as a wave molded into one or more

plies of reinforcement
3.2 mm. (1/8) but

must not decrease laminate thickness
35
Not applicable
SP-2720-012 Rev. A Pg. 8
Installation Manual
P150 - Lamination Sequence (see Butt & Wrap Joints section 2 above for preparatory steps, including coating edges with catalyzed resin)
PIPE
Paste + Catalyst MEKP
Apply Paste
Cure
1
1 1/2
2
3
4
5
4 oz. + 2.5 cc
4 oz. + 2.5 cc
4 oz. + 2.5 cc
4 oz. + 2.5 cc
4 oz. + 2.5 cc
4 oz. + 2.5 cc
Apply Paste
Apply Paste
Apply Paste
Apply Paste
Apply Paste
Apply Paste
Cure Cure Cure Cure Cure Cure
Resin + Catalyst MEKP

0.25 lb. + 2 cc
0.25 lb. + 2 cc
0.25 lb. + 2 cc
0.38 lb. + 3 cc
0.50 lb. + 4 cc
Apply Reinforcement
2 x 7 NV
2 x 9 NV
2 x 10 NV

2 x 13NV
2 x 17 NV
2 x 19 NV

2 x 7 M
2 x 9 M
2 x 10 M
3 x 13 M
2 x 17 M
Mat = M
3 x 7 M
3 x 9 M
3 x 10 M
3 x 13 M
3 x 17 M
Woven Roving = WR
3 x 7 M
3 x 9 M
3 x 10 M
4 x 13 M
3 x 17 M
Nexus Veil = NV
3 x 7 M
3 x 9 M
3 x 10 M
4 x 13 M
3 x 17 WR

4 x 17 M
Cure
Cure Cure Cure Cure Cure
0.25 lb. + 2 cc

Apply Reinforcement

Cure
0.75 lb. + 6 cc
3 x 21 M
3 x 21 WR
4 x 21 M
4 x 21 WR
5 x 21 M
Cure
Resin + Air Dry

+ Catalyst MEKP
Apply Brushcoat
Cure
2 x 19 M
3 x 19 M
Cure
0.25 lb. + 11 cc
0.25 lb. + 11 cc
0.25 lb. + 11 cc
0.25 lb. + 11 cc
0.25 lb. + 11 cc
0.25 lb. + 11 cc
+ 2.5 cc
+ 2.5 cc
+ 2.5 cc
+ 2.5 cc
+ 2.5 cc
+ 2.5 cc
Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Kit Material:
Liner Paste
4 oz.
4 oz.
4 oz.
4 oz.
4 oz.
Resin
0.5 lb.
0.5 lb.
0.5 lb.
0.63 lb.
0.75 lb.
Air Dry Solution
11 cc
11 cc
11 cc
11 cc
11 cc
Catalyst MEKP
0.25 oz.
0.25 oz.
0.25 oz.
0.28 oz.
0.32 oz.
Nexus Veil
0.01 lb.
0.01 lb.
0.01 lbs.
0.01 lbs.
0.01 lbs.
1 oz. Mat
0.05 lb.
0.07 lb.
0.07 lb.
0.12 lb.
0.13 lb.
Woven Roving
0.06 lb.
36
4 oz.
1.25 lbs.
11 cc
0.46 oz.
0.01 lbs.
0.23 lb.
0.17 lb.
SP-2720-012 Rev. A Pg. 9
Installation Manual
PIPE SIZE
10

12 14 16

4 oz. + 2.5 cc
4 oz. + 2.5 cc
4 oz. + 2.5 cc
4 oz + 2.55 cc
6 oz. + 3.5 cc
0.75 lb. + 7 cc
Apply Paste
Apply Paste
Apply Paste
Apply Paste

Apply Paste
Apply Paste
Apply Paste
Cure
Cure Cure Cure

Cure Cure Cure
0.25 lb. + 2 cc
1.38 lbs. + 10.5 cc 1.75 lbs. + 13.5 cc
0.75 lbs. + 6cc
2.25 lb.s + 17 cc
1.50 lbs + 11.5 cc
Apply Reinforcement
2 x 23 NV
3 x 30 NV
2 of 3 x 19 NV
2 of 3 x 22 M
2 of 4 x 25 M
2 of 4 x 29 M

2 x 23 M
4 x 30 M
2 of 4 x 19 M
2 of 4 x 25 M
2 of 4 x 25 M
2 of 4 x 29 M
Mat = M
3 x 23 M
4 x 30 M
2 of 4 x 19 M
Cure
2 of 5 x 25 M
2 of 5 x 29 M
Woven Roving = WR
5 x 30 M
2 of 5 x 19 M
2.25 lbs. + 17 cc
2 of 5 x 25 WR
Cure
Nexus Veil = NV
5 x 30 WR
2 of 5 x 19 WR
2 of 5 x 22 M
2 of 6 x 25 M
3.38 lbs. + 25.5 cc

6 x 30 M
2 of 6 x 19 M
2 OF 5 X 22 WR
Cure
2 of 6 x 29 M
Cure
Cure Cure Cure

2 of 6 x 22 M
3.25 lbs. + 24.5 cc 2 of 6 x 29 WR
0.88 lb. + 6.5 cc
1.5 lbs. + 11.5 cc 2.25 lbs. + 17 cc
2 of 6 x 22 WR
2 of 6 x 26 M
2 of 7 x 29 M
Apply Reinforcement
3 x 24 M
6 x 31 M
2 of 6 x 20 M
2 of 7 x 22 M
2 of 6 x 26 WR
2 of 7 x 29 WR

3 x 24 WR
6 x 31 WR
2 of 6 x 20 WR
Cure
2 of 8 x 26 M
2 of 8 x 29 M
Mat = M
4 x 24 M
7 x 31 M
2 of 7 x 20 M
3.25 lbs. + 25 cc
2 of 8 x 26 WR
Cure
Woven Roving = WR
4 x 24 WR
8 x 31 M
2 of 7 x 20 WR
2 of 8 x 23 M
2 of 9 x 26 M
4.88 lbs. + 36.5 cc

5 x 24 M
2 of 8 x 20 M
2 of 8 x 23 WR
Cure
2 of 9 x 30 M
Cure
Cure Cure Cure

2 of 9 x 23 M
3.63 lbs. + 27 cc
2 of 9 x 30 WR

2 of 9 x 23 WR
2 of 9 x 27 M
2 of 10 x 30 M
Apply Reinforcement

2 of 10 x 23 M
2 of 9 x 27 WR
2 of 10 x 30 WR

Cure
2 of 10 x 27 M
2 of 11 x 30 M

2 of 11 x 27 M
Cure
Mat = M

Cure
3.88 lbs. + 29 cc
Woven Roving = WR

2 of 12 x 30 M
Cure

2 of 12 x 30 WR

2 of 13 x 30 M

Cure
Resin + Air Dry
0.25 lb. + 11 cc
0.25 lb. + 11 cc
0.25 lb. + 11 cc
0.38 lb. + 17 cc
0.5 lb. + 23 cc
0.63 lb. + 28 cc
+ Catalyst MEKP
+ 2.5 cc
+ 2.5 cc
+ 2.5 cc
+ 3.5 cc
+ 4.5 cc
+ 5.0 cc
Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Cure
Kit Material:
Liner Paste
4 oz.
4 oz.
4 oz.
4 oz.
6 oz.
0.75 lb.
Resin
1.38 lbs.
3.13 lbs.
4.25 lbs.
6.63 lbs.
9.13 lbs.
14.26 lbs.
Air Dry Solution
11 cc
11 cc
11 cc
17 cc
23 cc
27 ccSIZE

Catalyst MEKP
0.48 oz.
0.95 oz.
1.25 oz.
1.90 oz.
2.70 oz.
4.04 oz.
Nexus Veil
0.01 lb.
0.01 lb.
0.01 lbs.
0.01 lbs.
0.01 lbs.
0.01 lbs.
1 oz. Mat
0.26 lb.
0.79 lb.
1.02 lbs.
1.58 lbs.
2.45 lbs.
3.46 lbs.
Woven Roving
0.19 lb.
0.39 lb.
0.82 lb.
1.49 lbs.
1.69 lbs.
3.05 lbs.
37
SP-2720-012 Rev. A Pg. 10
Installation Manual
PIPE SIZE 18 20 24 30 36
0.88 lb. + 7.5 cc
1.13 lb. + 10 cc
1.5 lb. + 13.0 cc
2.13 lb. + 18.5 cc
3 lb. + 26.5 cc
Apply Paste
Apply Paste
Apply Paste
Apply Paste
Apply Paste
Apply Paste
Cure
Cure Cure
Cure Cure Cure
1.13 lbs. + 8.5 cc
1.25 lbs. + 9.5 cc
2.13 lbs. + 16.0 cc
1.63 lbs. + 12.0 cc
2.13 lbs. + 16.0 cc
Apply Reinforcement
2 of 3 x 32 NV
3 of 3 x 24 NV
3 of 3 x 28 NV
3 of 3 x 34 NV
4 of 3 x 31 NV

2 of 4 x 32 M
3 of 4 x 24 M
3 of 4 x 28 M
3 of 4 x 34 M
4 of 4 x 31 M
Mat = M
2 of 4 x 32 M
3 of 4 x 24 M
3 of 4 x 28 M
3 of 4 x 34 M
4 of 4 x 31 M
Cure
Cure
Cure
3 of 5 x 28 M
Cure
4 of 5 x 31 M

3.38 lbs. + 25.5 cc
3.50 lbs. + 26.5 cc
Cure
4.75 lbs. + 40.5 cc
Cure
Woven Roving = WR
2 of 5 x 33 M
3 of 5 x 24 M
4.88 lbs. + 36.5 cc
3 of 5 x 35 M
7.38 lbs. + 55.5 cc
Nexus Veil = NV
2 of 5 x 33 WR
3 of 5 x 24 WR
3 of 6 x 28 M
3 of 5 x 35 WR
4 of 6 x 31 M
2 of 6 x 33 M
3 of 6 x 24 M
3 of 6 x 28 WR
3 of 7 x 35 M
4 of 6 x 31 WR

2 of 6 x 33 WR
3 of 6 x 24 WR
3 of 7 x 28 M
3 of 7 x 35 WR
4 of 8 x 31 M

2 of 8 x 33 M
3 of 8 x 24 M
3 of 7 x 28 WR
3 of 8 x 35 M
4 of 8 x 31 WR
Cure
Cure
Cure
3 of 9 x 28 M
Cure
4 of 9 x 31 M
5.0 lbs. + 37.5 cc
5.63 lbs. + 42.0 cc
Cure
8.38 lbs. + 63 cc
Cure
Apply Reinforcement
2 of 8 x 33 M
3 of 8 x 25 M
7.25 lbs. + 54.5 cc
3 of 9 x 35 M
10.88 lbs. + 81.5 cc
Cure
2 of 8 x 33 WR
3 of 8 x 25 WR
3 of 9 x 29 M
3 of 9 x 35 WR
4 of 10 x 31 M
2 of 9 x 33 M
3 of 10 x25 M
3 of 9 x 29 WR
3 of 10 x 35 M
4 of 10 x 31 WR
Mat = M
2 of 9 x 33 WR
3 of 10 x 25 WR
3 of 11 x 29 M
3 of 10 x 35 WR
4 of 11 x 31 M
Woven Roving = WR
2 of 10 x 33 M
3 of 11 x 25 M
3 of 11 x 29 WR
3 of 12 x 35 M
4 of 11 x 31 WR
Cure
Cure
Cure
3 of 12 x 29 M
Cure
4 of 13 x 31 M
7.0 lbs. + 52.5 cc
7.38 lbs. + 55.5 cc
Cure
11.75 lbs. + 88.5 cc
Cure
Apply Reinforcement
2 of 11 x 34 M
3 of 11 x 25 M
9.75 lbs. + 73.5 cc
3 of 13 x 35 M
15.25 lbs. + 114.5 cc
Cure
2 of 11 x 34 WR
3 of 11 x 25 WR
3 of 13 x 29 M
3 of 13 x 35 WR
4 of 14 x 32 M
2 of 13 x 34 M
3 of 13 x 25 M
3 of 13 x 29 WR
3 of 14 x 35 M
4 of 14 x 32 WR
Mat = M
2 of 13 x 34 WR
3 of 13 x 25 WR
3 of 14 x 29 M
3 of 14 x 35 WR
4 of 15 x 32 M
Woven Roving = WR
2 of 14 x 34 M
3 of 14 x 25 M
3 of 14 x 29 WR
3 of 16 x 35 M
4 of 15 x 32 WR
Cure
Cure
Cure
3 of 16 x 29 M
Cure
4 of 17 x 32 M
5.88 lbs. + 44.0 cc
Cure
14.88 lbs. + 112.0 cc
Cure
Apply Reinforcement
3 of 15 x 26 M
12.5 lbs. + 94.0 cc
3 of 16 x 36 M
18.63 lbs. + 140.0 cc
Cure
3 of 15 x 26 WR
3 of 16 x 30 M
3 of 16 x 36 WR
4 of 17 x 32 M

3 of 16 x 26 M
3 of 16 x 30 WR
3 of 18 x 36 M
4 of 17 x 32 WR

3 of 18 x 30 M
3 of 18 x 36 WR
4 of 19 x 32 M

3 of 18 x 30 WR
3 of 19 x 36 M
4 of 19 x 32 WR
Cure
Cure
3 of 19 x 30 M
Cure
4 of 20 x 32 M
Cure
18.38 lbs. + 138.0 cc
Cure

3 of 20 x 36 M
22.75 lbs. + 171.0 cc
Apply Reinforcement
3 of 20 x 36 WR
4 of 21 x 32 M

3 of 22 x 36 M
4 of 21 x 32 WR

3 of 22 x 36 WR
4 of 23 x 32 M

3 of 23 x 36 M
4 of 23 x 32 WR
Cure
Cure
4 of 24 x 32 M
Cure
38
SP-2720-012 Rev. A Pg. 11
Installation Manual
P150
- Lamination Sequence (see Butt & Wrap Joints section 2 above for preparatory
steps, including coating edges with catalyzed resin)
PIPE SIZE 18 20
24 30 36
PIPE SIZE 18 20 24 30 36
18.38 lbs. + 138.0 cc
22.75 lbs. + 171.0 cc

3 of 20 x 36 M
4 of 21 x 32 M
Apply Reinforcement
3 of 20 x 36 WR
4 of 21 x 32 WR

3 of 22 x 36 M
4 of 23 x 32 M

3 of 22 x 36 WR
4 of 23 x 32 WR

3 of 23 x 36 M
4 of 24 x 32 M
Cure Cure
Cure
27.25 lbs. + 205.0 cc

4 of 25 x 33 M
Apply Reinforcement
4 of 25 x 33 WR

4 of 26 x 33 M

4 of 26 x 33 WR

4 of 28 x 33 M
Cure Cure
1.63 lbs. + 12 cc
1.88 lbs. + 14 cc
2.25 lbs. + 17 cc
(Inside lay-up when
4 of 4 x 20 M
4 of 4 x 24 M
5 of 4 x 23 M
accessible)
4 of 5 x 20 M
4 of 5 x 24 M
5 of 5 x 23 M

4 of 6 x 20 NV
4 of 6 x 24 NV
5 of 6 x 23 NV
Cure
Cure Cure Cure
Resin + Air Dry
0.75 lb. + 34 cc
0.88 lb. + 40 cc
1.25 lb. + 57 cc
1.88 lbs. + 85.0 cc
2.63 lbs. + 120 cc
+ Catalyst MEKP
+ 7.0 cc
+ 8.0 cc
+ 11 cc
+ 16.5 cc
+ 23 cc
Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Cure
Kit Material:
Liner Paste
0.88 lb.
1.13 lb.
1.5 lb.
2.13 lb.
3 lb.
Resin
17.26 lbs.
24.52 lbs.
39.39 lbs.
63.53 lbs.
109.2 lbs.
Air Dry Solution
34 cc
40 cc
57 cc
85 cc
120 cc
Catalyst MEKP
4.88 oz.
6.90 oz.
11.0 oz.
1.2 lbs.
1.8 lbs.
Nexus Veil
0.01 lbs.
0.01 lbs.
0.04 lbs.
0.05 lbs.
0.06 lbs.
1 oz. Mat
4.04 lbs.
6.11 lbs.
9.78 lbs.
15.82 lbs.
27.36 lbs.
Woven Roving
4.03 lbs.
5.92 lbs.
9.58 lbs.
16.55 lbs.
28.96 lbs.
39
SP-2720-012 Rev. A Pg. 12
Installation Manual
PIPE SIZE
42
42 (Contd)

4.13 lb. +36 cc
Apply Paste
Apply Paste
Cure Cure
5.13 lbs. + 38.5 cc
37.25 lbs. + 280 cc
Apply Reinforcement
5 of 3 x 29 NV
5 of 29 x 31 M

5 of 4 x 29 M
5 of 29 x 31 WR

5 of 4 x 29 M
5 of 31 x 31 M
Mat = M
5 of 5 x 29 M
5 of 31 x 31 WR
Cure
5 of 6 x 29 M
5 of 32 x 31 M

Cure Cure
9.63 lbs. + 72 cc
Apply Reinforcement
5 of 7 x 30 M
Mat = M
5 of 7 x 30 WR
Woven Roving = WR
5 of 8 x 30 M

5 of 35 x 36 M

5 of 8 x 30 WR
Cure
5 of 10 x 30 M

Cure
13.63 lbs. + 103 cc
Apply Reinforcement
5 of 10 x 30 M
Mat = M
5 of 10 x 30 WR
Woven Roving = WR
5 of 12 x 30 M

5 of 12 x 30 WR
Cure
5 of 13 x 30 M
Cure
18.38 lbs + 138 cc
Apply Reinforcement
5 of 14 x 30 M
Mat = M
5 of 14 x 30 WR
Woven Roving = WR
5 of 16 x 30 M

5 of 16 x 30 WR
Cure
5 of 17 x 30 M
Cure
22.63 lbs.+ 170 cc
Apply Reinforcement
5 of 18 x 30 M
Mat = M
5 of 18 x 30 WR
Woven Roving = WR
5 of 19 x 30 M

5 of 19 x 30 WR
Cure
5 of 21 x 30 M
Cure
28.25 lbs. + 213 cc
Apply Reinforcement
5 of 22 x 31 M
Mat = M
5 of 22 x 31 WR
Woven Roving = WR
5 of 23 x 31 M

5 of 23 x 31 WR
Cure
5 of 25 x 31 M
Cure
40
48
48 (Contd)
5.38 lb. + 48 cc
Apply Paste
Cure
6.13 lbs. + 46 cc
43.5 lbs. + 327 cc
5 of 3 x 33 NV
5 of 30 x 35 M
5 of 4 x 33 M
5 of 30 x 35 WR
5 of 5 x 33 M
5 of 32 x 35 M
5 of 5 x 33 M
5 of 32 x 35 WR
5 of 6 x 33 M
5 of 33 x 35 M
Cure Cure
10.88 lbs. + 81.5 cc
49.88 lbs. + 375 cc
5 of 7 x 34 M
5 of 34 x 36 M
5 of 7 x 34 WR
5 of 34 x 36 WR
5 of 8 x 34 M
5 of 10 x 34 WR
5 of 35 x 36 WR
5 of 10 x 34 M
5 of 37 x 36 M
Cure Cure
16.25 lbs. + 122 cc
5 of 11 x 34 M
5 of 11 x 34 WR
5 of 12 x 34 M
5 of 12 x 34 WR
5 of 14 x 34 M
Cure
21.625 lbs. + 163 cc
5 of 15 x 34 M
5 of 15 x 34 WR
5 of 16 x 34 M
5 of 16 x 34 WR
5 of 18 x 34 M
Cure
26.38 lbs. + 198 cc
5 of 18 x 34 M
5 of 18 x 34 WR
5 of 20 x 34 M
5 of 20 x 34 WR
5 of 22 x 34 M
Cure
32.38 lbs. + 243 cc
5 of 22 x 35 M
5 of 22 x 35 WR
5 of 24 x 35 M
5 of 24 x 35 WR
5 of 25 x 35 M
Cure
SP-2720-012 Rev. A Pg. 13
Installation Manual
PIPE SIZE
42
42 (Contd)
48

32.38 lbs. + 243 cc
38 lbs. + 285.5 cc
Apply Reinforcement
5 of 25 x 31 M
5 of 26 x 35 M
Mat = M
5 of 25 x 31 WR
5 of 26 x 35 WR
Woven Roving = WR
5 of 27 x 31 M
5 of 28 x 35 M

5 of 27 x 31 WR
5 of 28 x 35 WR
Cure
5 of 28 x 31 M
5 of 29 x 35 M

Cure
Cure
2.75 lbs. + 21 cc
(Inside lay-up when
6 of 4 x 23 M
accessible)
6 of 5 x 23 M
Cure
6 of 6 x 23 NV
Cure
Resin + Air Dry
3.63 lb. + 165 cc
+ Catalyst MEKP
+ 32 cc
Apply Brushcoat
Apply Brushcoat
Cure Cure
Kit Material:
Liner Paste
4.25 lb.
5.38 lb.
Resin
173.66 lbs.
252.29 lbs.
Air Dry Solution
165 cc
216 cc
Catalyst MEKP
3lb
4lb 5 oz.
Nexus Veil
0.07 lbs.
0.08 lbs.
1 oz. Mat
43.14 lbs.
62.81 lbs.
Woven Roving
46.22 lbs.
68.24 lbs.
41
48 (Contd)
3.13 lbs. + 23.5 cc

7 of 4 x 23 M
7 of 5 x 23 M
7 of 6 x 23 NV
Cure
4.75 lb. + 216 cc
+ 42 cc
Apply Brushcoat
Cure
SP-2720-012 Rev. A Pg. 14
Installation Manual
A150 - Lamination Sequence (see Butt & Wrap Joints section 2 above for preparatory steps, including coating edges with catalyzed resin)
PIPE SIZE

4 oz. + 2.5 cc
4 oz. + 2.5 cc
4 oz. + 2.5 cc
4 oz. + 2.5 cc
4 oz. + 2.5 cc
Apply Paste
Apply Paste
Apply Paste
Apply Paste
Apply Paste
Apply Paste
Cure
0.25 lb. + 2 cc
0.25 lb. + 2 cc
0.25 lb. + 2 cc
0.38 lb. + 3 cc
0.50 lb. + 4 cc
Apply Reinforcement

2 x 7 M
2 x 9 M
2 x 10 M
3 x 13 M
2 x 17 M
Mat = M
3 x 7 M
3 x 9 M
3 x 10 M
3 x 13 M
3 x 17 M
Woven Roving = WR
3 x 7 M
3 x 9 M
3 x 10 M
4 x 13 M
3 x 17 M
Nexus Veil = NV
3 x 7 M
3 x 9 M
3 x 10 M
4 x 13 M
3 x 17 WR

4 x 17 M
Cure
Apply Reinforcement

Cure
Resin + Air Dry
0.25 lb. + 11 cc
0.25 lb. + 11 cc
0.25 lb. + 11 cc
0.25 lb. + 11 cc
0.25 lb. + 11 cc
+ Catalyst MEKP
+ 2.5 cc
+ 2.5 cc
+ 2.5 cc
+ 2.5 cc
+ 2.5 cc
Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Cure
Kit Material:
Liner Paste
4 oz.
4 oz.
4 oz.
4 oz.
4 oz.
Resin
0.5 lb.
0.5 lb.
0.5 lb.
0.63 lb.
0.75 lb.
Air Dry Solution
11 cc
11 cc
11 cc
11 cc
11 cc
Catalyst MEKP
0.25 oz.
0.25 oz.
0.25 oz.
0.28 oz.
0.32 oz.
Nexus Veil
0.01 lb.
0.01 lb.
0.01 lbs.
0.01 lbs.
0.01 lbs.
1 oz. Mat
0.05 lb.
0.07 lb.
0.07 lb.
0.12 lb.
0.13 lb.
Woven Roving
0.06 lb.
42
5
4 oz. + 2.5 cc
Apply Paste
Cure
0.25 lb. + 2 cc
2 x 19 M
3 x 19 M
Cure
0.75 lb. + 6 cc
3 x 21 M
3 x 21 WR
4 x 21 M
4 x 21 WR
5 x 21 M
Cure
0.25 lb. + 11 cc
+ 2.5 cc
Apply Brushcoat
Cure
4 oz.
1.25 lbs.
11 cc
0.46 oz.
0.01 lbs.
0.23 lb.
0.17 lb.
SP-2720-012 Rev. A Pg. 15
Installation Manual
PIPE SIZE
10
12
14

4 oz. + 2.5 cc
4 oz. + 2.5 cc
4 oz. + 2.5 cc
4 oz. + 2.5 cc
6 oz. + 3.5 cc
Apply Paste
Apply Paste
Apply Paste
Apply Paste
Apply Paste
Apply Paste
Cure
0.25 lb. + 2 cc
1.38 lbs. + 10.5 cc 1.75 lbs. + 13.5 cc 0.75 lbs. + 6 cc
2.25 lbs. + 17 cc
Apply Reinforcement

2 x 23 M
4 x 30 M
2 of 4 x 19 M
2 of 3 x 22 M
2 of 4 x 25 M
Mat = M
3 x 23 M
4 x 30 M
2 of 4 x 19 M
2 of 4 x 22 M
2 of 4 x 25 M
Woven Roving = WR
5 x 30 M
2 of 5 x 19 M
Cure
2 of 5 x 25 M
Nexus Veil = NV
5 x 30 WR
2 of 5 x 19 WR
2.25 lbs. + 17 cc
2 of 5 x 25 WR

6 x 30 M
2 of 6 x 19 M
2 of 5 x 22 M
2 of 6 x 25 M
Cure
Cure
Cure
Cure
2 of 5 x 22 WR
Cure
0.88 lb. + 6.5 cc
1.5 lbs. + 11.5 cc 2.25 lbs. + 17 cc
2 of 6 x 22 M
3.25 lbs. + 24.5 cc
Apply Reinforcement
3 x 24 M
6 x 31 M
2 of 6 x 20 M
2 of 6 x 22 WR
2 of 6 x 26 M

3 x 24 WR
6 x 31 WR
2 of 6 x 20 WR
2 of 7 x 22 M
2 of 6 x 26 WR
Mat = M
4 x 24 M
7 x 31 M
2 of 7 x 20 M
Cure
2 of 8 x 26 M
Woven Roving = WR
4 x 24 WR
8 x 31 M
2 of 7 x 20 WR
3.25 lbs. + 25 cc
2 of 8 x 26 WR

5 x 24 M
2 of 8 x 20 M
2 of 8 x 23 M
2 of 9 x 26 M
Cure
Cure
Cure
Cure
2 of 8 x 23 WR
Cure
2 of 9 x 23 M
3.63 lbs. + 27 cc
Apply Reinforcement
2 of 9 x 23 WR
2 of 9 x 27 M

2 of 10 x 23 M
2 of 9 x 27 WR

Cure
2 of 10 x 27 M
Mat = M
2 of 11 x 27 M
Woven Roving = WR
Cure
Cure

Resin + Catalyst
0.25 lb. + 2.5 cc
0.25 lb. + 2.5 cc
0.25 lb. + 2.5 cc
0.38 lb. + 3.5 cc
0.5 lb. + 4.5 cc
(MEKP)

Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Cure
Kit Material:
Liner Paste
4 oz.
4 oz.
4 oz.
4 oz.
6 oz.
Resin
1.38 lbs.
3.13 lbs.
4.25 lbs.
6.63 lbs.
9.13 lbs.
Air Dry Solution
11 cc
11 cc
11 cc
17 cc
23 cc
Catalyst MEKP
0.48 oz.
0.95 oz.
1.25 oz.
1.90 oz.
2.70 oz.
Nexus Veil
0.01 lb.
0.01 lb.
0.01 lbs.
0.01 lbs.
0.01 lbs.
1 oz. Mat
0.26 lb.
0.79 lb.
1.02 lbs.
1.58 lbs.
2.45 lbs.
Woven Roving
0.19 lb.
0.39 lb.
0.82 lb.
1.49 lbs.
1.69 lbs.
43
16
0.75 lb. + 7 cc
Apply Paste
Cure
1.50 lbs. + 11.5 cc
2 of 4 x 29 M
2 of 4 x 29 M
2 of 5 x 29 M
Cure
3.38 lbs. + 25.5 cc
2 of 6 x 29 M
2 of 6 x 29 WR
2 of 7 x 29 M
2 of 7 x 29 WR
2 of 8 x 29 M
Cure
4.88 lbs. + 36.5 cc
2 of 9 x 30 M
2 of 9 x 30 WR
2 of 10 x 30 M
2 of 10 x 30 WR
2 of 11 x 30 M
Cure
3.88 lbs. + 29 cc
2 of 12 x 30 M
2 of 12 x 30 WR
2 of 13 x 30 M
Cure
0.63 lb. + 5.0 cc
Apply Brushcoat
Cure
0.75 lb.
14.26 lbs.
27 cc
4.04 oz.
0.01 lbs.
3.46 lbs.
3.05 lbs.
SP-2720-012 Rev. A Pg. 16
Installation Manual
PIPE SIZE
18
20
24
30

0.88 lb. + 7.5 cc
1.13 lb. + 10 cc
1.5 lb. + 13.0 cc
2.13 lb. + 18.5 cc
Apply Paste
Apply Paste
Apply Paste
Apply Paste
Apply Paste
Cure
Cure
Cure
Cure
Cure
1.13 lbs. + 8.5 cc
1.25 lbs. + 9.5 cc
2.13 lbs. + 16.0 cc
1.63 lbs. + 12.0 cc
Apply Reinforcement

2 of 4 x 32 M
3 of 4 x 24 M
3 of 4 x 28 M
3 of 4 x 34 M
Mat = M
2 of 4 x 32 M
3 of 4 x 24 M
3 of 4 x 28 M
3 of 4 x 34 M
Cure
Cure
Cure
3 of 5 x 28 M
Cure
3.38 lbs. + 25.5 cc
3.50 lbs. + 26.5 cc
Cure
4.75 lbs. + 40.5 cc
Woven Roving = WR
2 of 5 x 33 M
3 of 5 x 24 M
4.88 lbs. + 36.5 cc
3 of 5 x 35 M
Nexus Veil = NV
2 of 5 x 33 WR
3 of 5 x 24 WR
3 of 6 x 28 M
3 of 5 x 35 WR
2 of 6 x 33 M
3 of 6 x 24 M
3 of 6 x 28 WR
3 of 7 x 35 M

2 of 6 x 33 WR
3 of 6 x 24 WR
3 of 7 x 28 M
3 of 7 x 35 WR

2 of 8 x 33 M
3 of 8 x 24 M
3 of 7 x 28 WR
3 of 8 x 35 M
Cure
Cure
Cure
3 of 9 x 28 M
Cure
5.0 lbs. + 37.5 cc
5.63 lbs. + 42.0 cc
Cure
8.38 lbs. + 63 cc
Apply Reinforcement
2 of 8 x 33 M
3 of 8 x 25 M
7.25 lbs. + 54.5 cc
3 of 9 x 35 M
Cure
2 of 8 x 33 WR
3 of 8 x 25 WR
3 of 9 x 29 M
3 of 9 x 35 WR
2 of 9 x 33 M
3 of 10 x25 M
3 of 9 x 29 WR
3 of 10 x 35 M
Mat = M
2 of 9 x 33 WR
3 of 10 x 25 WR
3 of 11 x 29 M
3 of 10 x 35 WR
Woven Roving = WR
2 of 11 x 33 M
3 of 11 x 25 M
3 of 11 x 29 WR
3 of 12 x 35 M
Cure
Cure
Cure
3 of 12 x 29 M
Cure
7.0 lbs. + 52.5 cc
7.38 lbs. + 55.5 cc
Cure
11.75 lbs. + 88.5 cc
Apply Reinforcement
2 of 11 x 34 M
3 of 11 x 25 M
9.75 lbs. + 73.5 cc
3 of 13 x 35 M
Cure
2 of 11 x 34 WR
3 of 11 x 25 WR
3 of 13 x 29 M
3 of 13 x 35 WR
2 of 13 x 34 M
3 of 13 x 25 M
3 of 13 x 29 WR
3 of 14 x 35 M
Mat = M
2 of 13 x 34 WR
3 of 13 x 25 WR
3 of 14 x 29 M
3 of 14 x 35 WR
Woven Roving = WR
2 of 14 x 34 M
3 of 14 x 25 M
3 of 14 x 29 WR
3 of 16 x 35 M
Cure
Cure
Cure
3 of 16 x 29 M
Cure
5.88 lbs. + 44.0 cc
Cure
14.88 lbs. + 112.0 cc
Apply Reinforcement
3 of 15 x 26 M
12.5 lbs. + 94.0 cc
3 of 16 x 36 M
Cure
3 of 15 x 26 WR
3 of 16 x 30 M
3 of 16 x 36 WR

3 of 16 x 26 M
3 of 16 x 30 WR
3 of 18 x 36 M

3 of 18 x 30 M
3 of 18 x 36 WR

3 of 18 x 30 WR
3 of 19 x 36 M
Cure
Cure
3 of 19 x 30 M
Cure
Cure
18.38 lbs. + 138.0 cc

3 of 20 x 36 M
Apply Reinforcement
3 of 20 x 36 WR

3 of 22 x 36 M

3 of 22 x 36 WR

3 of 23 x 36 M
Cure
Cure

44
36
3 lb. + 26.5 cc
Apply Paste
Cure
2.13 lbs. + 16.0 cc
4 of 4 x 31 M
4 of 4 x 31 M
4 of 5 x 31 M
Cure
7.38 lbs. + 55.5 cc
4 of 6 x 31 M
4 of 6 x 31 WR
4 of 8 x 31 M
4 of 8 x 31 WR
4 of 9 x 31 M
Cure
10.88 lbs. + 81.5 cc
4 of 10 x 31 M
4 of 10 x 31 WR
4 of 11 x 31 M
4 of 11 x 31 WR
4 of 13 x 31 M
Cure
15.25 lbs. + 114.5 cc
4 of 14 x 32 M
4 of 14 x 32 WR
4 of 15 x 32 M
4 of 15 x 32 WR
4 of 17 x 32 M
Cure
18.63 lbs. + 140.0 cc
4 of 17 x 32 M
4 of 17 x 32 WR
4 of 19 x 32 M
4 of 19 x 32 WR
4 of 20 x 32 M
Cure
22.75 lbs. + 171.0 cc
4 of 21 x 32 M
4 of 21 x 32 WR
4 of 23 x 32 M
4 of 23 x 32 WR
4 of 24 x 32 M
Cure
SP-2720-012 Rev. A Pg. 17
Installation Manual
PIPE SIZE
18
20
24
30

Apply Reinforcement

Cure
1.63 lbs. + 12 cc
1.88 lbs. + 14 cc
(Inside lay-up when
4 of 4 x 20 M
4 of 4 x 24 M
accessible)
4 of 5 x 20 M
4 of 5 x 24 M

4 of 6 x 20 NV
4 of 6 x 24 NV
Cure
Cure Cure
Cure
Resin + Catalyst
0.75 lb. + 7.0 cc
0.88 lb. + 8.0 cc
1.25 lb. + 11 cc
1.88 lbs. + 16.5 cc
(MEKP)

Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Apply Brushcoat
Cure
Cure
Cure
Cure
Cure
Kit Material:
Liner Paste
0.88 lb.
1.13 lb.
1.5 lb.
2.13 lb.
Resin
17.26 lbs.
24.52 lbs.
39.39 lbs.
63.53 lbs.
Air Dry Solution
34 cc
40 cc
57 cc 85 cc
120 cc
Catalyst MEKP
4.88 oz.
6.90 oz.
11.0 oz.
1.2 lbs.
Nexus Veil 0.03 lbs.
0.03 lbs.
0.06 lbs.
1 oz. Mat
4.04 lbs.
6.11 lbs.
9.78 lbs.
15.82 lbs.
Woven Roving
4.03 lbs.
5.92 lbs.
9.58 lbs.
16.55 lbs.
45
36
27.25 lbs. + 205.0 cc
4 of 25 x 33 M
4 of 25 x 33 WR
4 of 26 x 33 M
4 of 26 x 33 WR
4 of 28 x 33 M
Cure
2.25 lbs. + 17 cc
5 of 4 x 23 M
5 of 5 x 23 M
5 of 6 x 23 NV
Cure
2.63 lbs. + 23 cc
Apply Brushcoat
Cure
3 lb.
109.2 lbs.
1.8 lbs..
27.36 lbs.
28.96 lbs.
SP-2720-012 Rev. A Pg. 18
Installation Manual
PIPE SIZE
42
42 (Contd)
48
48 (Contd)

4.13 lb. +36 cc
5.38 lb. + 48 cc
Apply Paste
Apply Paste
Apply Paste
Cure Cure
Cure
5.13 lbs. + 38.5 cc
37.25 lbs. + 280 cc
6.13 lbs. + 46 cc
43.5 lbs. + 327 cc
Apply Reinforcement
5 of 29 x 31 M
5 of 30 x 35 M
Mat = M
5 of 4 x 29 M
5 of 29 x 31 WR
5 of 4 x 33 M
5 of 30 x 35 WR
Woven Roving = WR
5 of 4 x 29 M
5 of 31 x 31 M
5 of 5 x 33 M
5 of 32 x 35 M

5 of 5 x 29 M
5 of 31 x 31 WR
5 of 5 x 33 M
5 of 32 x 35 WR
Cure
5 of 6 x 29 M
5 of 32 x 31 M
5 of 6 x 33 M
5 of 33 x 35 M

Cure Cure Cure Cure
9.63 lbs. + 72 cc
10.88 lbs. + 81.5 cc
49.88 lbs. + 375 cc
Apply Reinforcement
5 of 7 x 30 M
5 of 7 x 34 M
5 of 34 x 36 M
Mat = M
5 of 7 x 30 WR
5 of 7 x 34 WR
5 of 34 x 36 WR
Catalyst MEKP
5 of 8 x 30 M
5 of 8 x 34 M
5 of 35 x 36 M

5 of 8 x 30 WR
5 of 8 x 34 WR
5 of 35 x 36 WR
Cure
5 of 10 x 30 M
5 of 10 x 34 M
5 of 37 x 36 M

Cure
Cure Cure
13.63 lbs. + 103 cc
16.25 lbs. + 122 cc
Apply Reinforcement
5 of 10 x 30 M
5 of 11 x 34 M
Mat = M
5 of 10 x 30 WR
5 OF 11 X 34 WR
Woven Roving = WR
5 of 12 x 30 M
5 of 12 x 34 M

5 of 12 x 30 WR
5 of 12 x 34 WR
Cure
5 of 13 x 30 M
5 of 14 x 34 M
Cure
Cure
18.38 lbs + 138 cc
21.625 lbs. + 163 cc
Apply Reinforcement
5 of 14 x 30 M
5 of 15 x 34 M
Mat = M
5 of 14 x 30 WR
5 of 15 x 34 WR
Woven Roving = WR
5 of 16 x 30 M
5 of 16 x 34 M

5 of 16 x 30 WR
5 of 16 x 34 WR

5 of 17 x 30 M
5 of 18 x 34 M
Cure
Cure
22.63 lbs.+ 170 cc
26.38 lbs. + 198 cc
Apply Reinforcement
5 of 18 x 30 M
5 of 18 x 34 M
Mat = M
5 of 18 x 30 WR
5 of 18 x 34 WR
Woven Roving = WR
5 of 19 x 30 M
5 of 20 x 34 M

5 of 19 x 30 WR
5 of 20 x 34 WR
Cure
5 of 21 x 30 M
5 of 22 x 34 M
Cure
Cure
28.25 lbs. + 213 cc
32.38 lbs. + 243 cc
Apply Reinforcement
5 of 22 x 31 M
5 of 22 x 35 M
Mat = M
5 of 22 x 31 WR
5 of 22 x 35 WR
Woven Roving = WR
5 of 23 x 31 M
5 of 24 x 35 M

5 of 23 x 31 WR
5 of 24 x 35 WR
Cure
5 of 25 x 31 M
5 of 25 x 35 M
Cure
Cure
46
SP-2720-012 Rev. A Pg. 19
Installation Manual
PIPE SIZE
42
42 (Contd)
48

32.38 lbs. + 243 cc
38 lbs. + 285.5 cc
Apply Reinforcement
5 of 25 x 31 M
5 of 26 x 35 M
Mat = M
5 of 25 x 31 WR
5 of 26 x 35 WR
Woven Roving = WR
5 of 27 x 31 M
5 of 28 x 35 M

5 of 27 x 31 WR
5 of 28 x 35 WR
Cure
5 of 28 x 31 M
5 of 29 x 35 M

Cure
Cure
(Contd Next
2.75 lbs. + 21 cc
(Contd Next
(Inside lay-up when
Column)
6 of 4 x 23 M
Column)
accessible)
6 of 5 x 23 M
Cure
6 of 6 x 23 NV
Cure
Resin + Catalyst
3.63 lb. + 32 cc
(MEKP)

Apply Brushcoat
Apply Brushcoat
Cure Cure
Kit Material:
Liner Paste
4.25 lb.
5.38 lb.
Resin
173.66 lbs.
252.29 lbs.
Air Dry Solution
165 cc
216 cc
Catalyst MEKP
3lb
4lb 5 oz.
Nexus Veil
0.05 lbs.
0.05 lbs.
1 oz. Mat
43.14 lbs.
62.81 lbs.
Woven Roving
46.22 lbs.
68.24 lbs.
47
48 (Contd)
3.13 lbs. + 23.5 cc

7 of 4 x 23 M
7 of 5 x 23 M
7 of 6 x 23 NV
Cure
4.75 lb. + 42 cc
Apply Brushcoat
Cure
SP-2720-012 Rev. A Pg. 20
Installation Manual
P150 Lamination sequence, sample instructions
NOTE: See Individual Product Specification for actual dimensions and sequence.
Manufacturing Specification
8 P-150 Field Butt Joint
48
SP-0104-002
September 17, 2009
Revision: F
SP-2720-012 Rev. A Pg. 21
Installation Manual
49
SP-0104-002
September 17, 2009
Revision: F
SP-2720-012 Rev. A Pg. 22
Installation Manual
50
SP-0104-002
September 17, 2009
Revision: F
SP-2720-012 Rev. A Pg. 23
Installation Manual
PEEL-A-BOND
4) Removal of PEEL-A-BOND
a) The only joint preparation required before beginning
lay-up or adhesive application is the removal of the
protective layer of RPS ABCO PEEL-A-BOND (immediately
before lay-up or adhesive application).
1) Purpose
b) Grab the overlap tab and pull firmly, removing the RPS
ABCO PEEL-A-BOND strip from the whole circumference
of the joint.

RPS ABCO pipe, fittings, or prespooled pieces may be factory

prepared for field joining and protected with PEEL-A-BOND. This
eliminates the need for sanding or cleaning in the field, greatly
reducing joint preparation time, and minimizing dust and noise.
2) Handling & Storage
a) The ends of pipe and fittings are factory protected against
damage during shipment.
b) The end protection is to be left in place as long as possible
while handling the pipe.
3) Premature Removal of PEEL-A-BOND
If the PEEL-A-BOND has been removed prematurely (either in

transit or on the jobsite), lightly sand contaminated surface to
remove any grease, oil, or other contaminant.
51
NOTE:This should be the last action before lay-up or

adhesive application begins, and the surface should
not be otherwise touched or cleaned after removal of
the protective strip.
Installation Manual
FLANGE JOINING
1) Drilling

Unless otherwise specified, all flanges are drilled in accordance

with the ANSI B16.5, Cl.150 drilling pattern for pipe sizes up to
24 in diameter, and ANSI B16.47 Series A Cl.150 drilling pattern
for pipe larger than 24 in diameter.
2) Gaskets
a) Use a full face gasket with a Shore A hardness of 60 - 70.
Recommended gasket thicknesses are:
Torquing Sequence
RECOMMENDED BOLT TORQUES FOR RPS P150
A150 OR H150 FLANGES*
FULL FACE Flanges
Pipe
Recommended
Max. Torque
Increments
--
1 - 6 =
1/8
Dia.
Torque (ft.lb.)
(ft.lb.)
(ft.lb.)
--
8 - 18 =
3/16
25mm
10
15
40mm
15
23
50mm
25
38
80mm
35
53
100mm
25
38
10
150mm
35
53
10
200mm
40
60
10
10
250mm
40
60
10
12
300mm
50
75
10
14
350mm
65
98
10
16
400mm
60
90
10
18
450mm
70
105
10
20
500mm
70
105
15
22
550mm
85
125
15
24
600mm
100
150
15
28
700mm
100
150
15
30
750mm
105
158
15
32
800mm
145
218
15
4) Torque
36
900mm
145
218
15
42
1100mm
155
233
15
48
1200mm
150
225
15
--
> 20
=1/4
b) Care must be taken when using specialized gaskets such as

fluoropolymer ribbed, partial envelope, or ring gaskets. These
gaskets act as raised faces and should be treated as such; see 5)
Raised-Face Flanges, Page 53.
c) Ensure that gaskets used in ABRASION SYSTEMS have an
inside diameter that is at least larger than the pipes inside
diameter. This will prevent the gasket from protruding into the
flow and causing turbulence that would result in an abnormally
high rate of pipe erosion.
3) Alignment

Be sure mating flanges align well. Misaligned flanges may be

damaged during bolting.
Tighten nuts in the sequence shown using the suggested increments. Do not exceed the bolt torques outlined in the table. Go
through the bolting sequence as often as is required to reach
the recommended torque level. After doing this, check all bolts
to ensure no relaxation has occurred. Bolt torques may decrease
over time due to gasket relaxation, compression set, extrusion,
etc. Retorquing may be necessary to ensure a leak tight joint.
NOTE: Success of bolted joints depends on specific characteristics of the gasket material, the pipe alignment, external loads,
etc. As a result, RPS cannot accept responsibility for sealing
beyond the performance of the flange itself.
52
Installation Manual
a) Check the gasket for material flaws.
LAP Joint Style Flange
Pipe
Dia.
Recommended
Max. Torque
(ft.lb.)
(ft.lb.)
Increments
b) Check the faces of mating flanges for dirt or grit, or any

deep scratches across the flange face.
Torque (ft.lb.)
1
25mm
2.5
40mm
2.5
50mm
10
15
80mm
15
23
100mm
15
23
150mm
20
30
200mm
20
30
10
250mm
20
30
12
300mm
30
45
10
14
350mm
40
60
10
16
400mm
40
60
10
18
450mm
40
60
10
20
500mm
40
60
10
22
550mm
55
80
15
24
600mm
65
98
15
28
700mm
70
105
15
30
750mm
75
112
15
32
800mm
100
150
15
36
900mm
100
150
15
42
1100mm
110
165
15
48
1200mm
110
165
15
c) Check for misalignment.

7) Restraining Rods on Expansion Joints Flange Stress

Expansion joints often have restraining rods. The expansion

joint should not in any way, at any time, be restrained by rods,
which restrain the RPS flanges directly. Use substantial metal
backing rings, etc. to prevent excessive stress in the flanges.
In general, avoid the use of restraining rods.
8) Suggested Bolt Length (RPS P/A/H150 Full

Faced Flanges)*
SIZE
* Recommended bolt torques are based upon a full face

gasket with Shore A hardness of 60 - 70 and sealing rings on
the flange faces.
5) Raised-Face Flanges

The use of raised-face flanges should be avoided when mating

to FRP flanges. Damage to the FRP flange may result during
bolt torquing.
If raised-face flanges must be used, take one of the

following precautions:
RPS P/H150 to
ANSI B16.5 150# STEEL
25mm
2 65mm
40mm
3 80mm
50mm
3 80mm
80mm
3 80mm
100mm
3 90mm
150mm
3 90mm
200mm
4 100mm
250mm
10
4 115mm
300mm
12
4 115mm
* Allowed for 1/8 gasket & 2 washers (American Standard SAE flat
washers)
a) Use a Lap Joint style FRP flange.

b) Fill the space around the raised portion of the flange with a
hard shim (eg. metal, PVC, etc.)
c) Use a steel back-up ring on the back of the FRP flange
6) Leaking

RPS P/H150 to
Bring bolt torque to maximum allowed. If leaks persist, do not

exceed the maximum torque, but determine the true cause:
53
Installation Manual
Suggested FRP Flange Connections
Fig 1 - Full face flange connection. Full bearing surface
Fig 2 - Raised face flange connection
Fig 3 - Water type valve
Fig 4 - Lugged type valve
Fig 5 - Face flange connection (with backing ring) at

expansionjoint with tie rods
54
Installation Manual
O-RING JOINING
b) Joining force can be appliedwith come-a-longs and cables,

attached between lugs, provided for that purpose. Do not
push joint together with excavating machinery.
1) General

O-Ring joints are made using factory machined, grooved spigots

and accurate bells; which provide the required compression of
the O-Ring gasket.
2) Before Insertion
a) Check bell surface and groove bottom to make sure that
there are no deep scratches, resin spills, or delaminations,
which could cause leaks.
b) Protect the inside bottom of bell with carpet or
board, as personnel may walk in and out during
testing and inspection.
c) Check edge of bell is free from sharp ridges, which could
cut in the gasket while assembling.
c) Insert to specified depth or to marks on spigot end. If joints

are spaced more than 60 apart, the required insertion
depth varies with pipe length, pipe temperature at the
time of installation, and operating temperature. In that
case, contact RPS Engineering for instructions.
d) Check O-Ring to ensure it is not damaged and that splice is

solidly bonded.
e) Lubricate O-Ring and bell generously with non-petroleum
base lubricant (margarine or other vegetable fat).
d) Lifting of pipe slightly during insertion can be helpful.

Use rope or web slings, never chains, as it could
damage the pipe.
f) Position splice in O-Ring at bottom during installation.

g) Immobilize previously installed pipe, as substantial forces
may be exerted on it during insertion.
3) During Insertion
a) Direction of insertion should be straight in line with pipe.
Make sure O-Ring gaskets are not displaced.
e) Align the pipes in line with each other within 1.

4) After Insertion
a) Pressure test between O-Rings if a double O-Ring system is
being used.

55
If a single O-Ring system is being used, conduct a hydrostatic test, if possible.
Installation Manual
Follow specified and approved procedures only,
as hazardous conditions can develop if the test is
improperly performed. See Testing section, Page 17,
for additional information.
b) Plug test hole as specified on applicable drawings.
c) Check pipe support, if outside, to ensure that pipe rests
evenly on soil and there are no unsupported lengths or
point loads from rocks or other objects.
56
Installation Manual
FIELD BONDER QUALIFICATION
PROCEDURE (ASME B31.3)
General
This procedure is suitable for qualifying bonders for jointing RPS
P-150, A-150, or H-150 piping in sizes 1 - 24 (25-600mm) dia. in
accordance with ASME B31.3 Process Piping (see note 5). The joint
types covered by this procedure are the Tapered Adhesive Joint and
the Butt & Wrap Joint.
Procedure:
Step 1: Assemble the appropriate Test Assembly shown on
Page 58 in strict accordance with the appropriate
jointing procedures.
Notes:
a) The bonder must demonstrate his/her knowledge
of the safe handling procedures for resins, catalysts,
and reinforcements. He/She must also be aware of
the possible health hazards involved in using the
materials (refer to Material Safety Data Sheets).
NOTE: The bonder must be familiar with the RPS Installation manual,
and in particular, read the sections on Materials, Safety, Adhesive
Bonded Joining, and Butt & Wrap Joining, before beginning the
qualification process.
b) The bonder must demonstrate his/her ability to

correctly catalyze the resin, and must be familiar with
the types of reinforcement used in the laminate.
References:
c) The bonder must be able to recognize the effects

of ambient temperatures on catalyst action and
curing time.
1) RPS P1500 1 - 12 Tapered Adhesive Joint Instructions

2) RPS Pipe & Fittings Installation Manual
3) RPS WI-IT-007 Barcol Hardness Testing.
Note: The qualified technician will complete a written

test to ensure he/she comprehends a), b), & c)
above. The test results will be kept on file with
RPS QA.
4) RPS WI-IT-008 Acceptance Criteria for Appearance of Laminates

Notes:
1) Jointing instructions are detailed in the RPS Pipe & Fittings
Installation Manual. A copy of Reference 1 is included in every
P1500 Kit; specific butt jointing instructions are included in
every butt jointing kit.
2) The Test Assemblies to be used for the qualification procedure
are shown on Page 58. Only one of the two assemblies needs to
be fabricated and tested, the choice of which depends upon the
availability of pipe end closures (ie. swell plugs).
3) This procedure may also be used to qualify bonders for jointing
RPS piping of lesser pressure ratings than 150 psi. For example,
this procedure would also qualify bonders for jointing RPS 100
psi rated pipe.
4) This procedures is to be carried out under the supervision of a
qualified technician, so designated by RPS.
5) To qualify bonders for jointing piping larger than 24 (600mm)
dia., contact RPS for appropriate instructions.
Step 2: The joints must be allowed to cure at least eight (8) hours
at no less than 20C.
Step 3: The Test Assembly shall be examined for workmanship and
dimensional accuracy by the qualified technician. Visual
quality must meet or exceed RPS WI-IT-008 Acceptance
Criteria for Appearance of Laminates. Dimensional
accuracy must be in accordance with the fabrication
tolerances stated in the RPS Dimensions Catalogue. Degree
of cure of the joints must meet or exceed RPS WI-IT-007
Barcol Hardness Testing.
Step 4: Subject the Test Assembly to a hydrostatic test at a pressure
of 450 psig.
Caution: Refer to the Testing section of this Manual for procedures and safety precautions associated with hydrostatic
testing.
57
The pressure shall be held for a period of one (1) hour. There
shall be no evidence of leaking or damage to the joints.
Installation Manual
Notes:
1) Failure to meet all requirements of this Procedure will necessitate a full re-qualification of the bonder.
2) Re-qualification of a bonder is also required when:
a) The bonder has not made RPS P-150, A-150 or H-150 joints
for a period of six (6) months.
b) There is specific evidence to question the bonders ability
to make acceptable joints.
NOTES:
1. Joining procedure shall be in accordance with RPS P-1500
Tapered adhesive joint instructions RPS pipe and fittings
installation manual
2. Joining procedure shall be in accordance with butt & wrap
joining RPS pipe and fittings installation manual.
3. Bolt up blind flanges (for hydrotest) in accordance with
flange joining RPS pipe RPS pipe and fittings installaion
manual
4. Seal end with swell plug
5. Material P-150, A-150 or H-150
58
Installation Manual
RPS A Liner Repair Paste Kit
3) Bucket filled with water
Intended Use
4) Dust mask
Areas of type A pipe or fittings, that have exhibited gradual

localized wear, can be repaired
with a RPS A Liner Repair
Paste Kit. The kit is designed to
repair abrasion resistant liner
areas only, and is not intended
for structural repairs. Where
structural areas have been
eroded, the affected section should be replaced or repaired
before the liner paste is applied.
5) Ear plugs
6) Leather or leather palm gloves
Safety Instructions
a) All paste and hardener; separately or combined; will cause
skin irritation to some people. Hardeners, in particular,
should be handled with care. Avoid contact with skin
and eyes. Wear rubber gloves and safety glasses. In case
of contact, wash with flowing water and soap. For eyes,
flush with plenty of water for at least 15 minutes and
get medical attention. See Safety Section, Page 6, of RPS
Installation Manual for details.
Each RPS A Liner Repair Paste Kit contains paste, hardener,

instruction sheet, mylar, and mixing stick.
b) Leftover paste in can will become very hot (100C. or

210F.) after going hard. It is advisable to put cans of
leftover paste in a bucket of water to reduce fire hazard
and unpleasant odor.
Kit Sizes
c) DO NOT smoke or have an open flame near work area.
The RPS A Liner Repair Paste Kit is available in three (3) sizes:
d) Work in well ventilated area.
SIZE (gm/oz)
e) Wear leather gloves and safety glasses when handling and

grinding pipe (See Safety Section, Page 6, and MSDS, Page
9, of RPS Installation Manual).
COVERAGE for 3mm or 1/8 THICK

(cm x cm/in. x in.)
400/14
28 x 28/11 x 11
800/28
39 x 39/15 x 15
1600/56
55 x 55/22 x 22
f) Sanding with a power tool generates a large amount of

dust, which can be a nuisance. Wear suitable dust mask
and glasses, and use a vacuum unit to collect dust. Build a
protective shelter around work area to keep dust away from
fellow workers and adjacent machinery and equipment.
Application Equipment Required

1) Rotary Die or Disc Grinder with carbide grit (60 grit or coarser)
2) 40 to 60 grit sandpaper
3) Drill Motor for mixing (using mixing blade)
4) Putty Knives for spreading paste
5) Trowel for spreading paste
Safety Equipment Required
Repair Procedures
These procedures cover:
1) Surface Preparation (Sanding)

1) Rubber gloves
2) Safety glasses
59
When a worn liner area is to be repaired, mark a perimeter line

75mm (3) back around the worn area. Thoroughly dry the area
using rags, towels, heat lamp, or heat gun. Ensure the entire
area is dry, since the smallest amount of moisture will hamper
the bonding of the A Liner Repair Paste. Using a power sander
Installation Manual
with 40 to 60 grit, roughen the worn area. All glossy and shiny
surfaces shall be removed.

NOTE: The rougher the surface, the better the adhesion of the
A Liner Repair Paste.
Remove all loose dirt and dust with a rag or a blast of dry,
oil-free air.
Apply mylar over paste and smooth out by hand while removing
trapped air. Use mylar in strip form, since larger sheets will
wrinkle too much.
2) Repair Paste Application

3) Curing
The A Liner Repair Paste is a two (2) part system:
1) A Liner Repair Paste
2) Hardener
When mixing the hardener and paste together, ALL of the

Hardener in one (1) container must be added to ALL the Paste
in the other can to develop full
repair strength. DO NOT try to
split the kit for small repair jobs.
Mix the white Hardener into

the black A Liner Repair Paste
thoroughly till the mixture is
a uniform color without any
streaks. Scrape the sides and bottom to make certain there is a
complete blend of hardener and paste. The colder the material,
the more mixing you must do.
NOTE: The smaller kits can be mixed by hand fairly easy, but the
larger kits will require a drill motor and a mixing blade to help
mix the two (2) components more thoroughly.
When applying the A Liner Repair Paste, use a putty knife
or trowel to cover the outlined area with a 3mm (1/8)
thick (minimum) layer of paste. Smooth and feather out
all edges.
Ambient Temperature at least 16C. (60F.)
Allow the A Liner Repair Paste to cure for a minimum of

two (2) hours.
After two (2) hours, check the cure by scratching the paste
with a knife or nail. It should be as hard as the pipe or
fitting surface. If slightly rubbery or soft, allow the paste
to cure for another two (2) hours. If after four (4) at 16C.
(60F.) or higher, the paste remains soft; the paste should
be removed and the repair redone.
Cold Weather Curing Below 16C. (60F.): If

the ambient temperature is below 16C. (60F.), pre-heat the
repair area with heating collars, heat lamp, or hot air (oil and
moisture free). The paste and hardener must be warmed
Apply the paste. Cure it with a heat lamp or hot air. In general,
for cold weather curing, the A Liner Repair Work should be
carried out in a heated shelter.
Tips and Warnings

a) DO NOT use A Liner Repair Paste after expiration date on label.
b) Always store A Liner Repair Paste Kits in a cool, dry place (10 to
27C. or 50 to 80F.).
c) If stored at low temperature, the A Liner Repair Paste and
Hardener may become too hard for mixing. In that case, heat
the closed can above 35C. (95F.) until the contents are liquid.
60
Installation Manual
Do not exceed 100C. (210F.). Cool below 29C. (85F.)
before using.

d) The working time or pot life of catalyzed paste varies

with the temperature. The warmer it is, the shorter the working
time. At 24C. (75F.), you have 10 to 20 minutes; and at 16C.
(60F.), you have 25 to 35 minutes before the paste starts to
harden in the can. See chart for approximate temperature
times. DO NOT use the paste once it has started to harden.
61
Installation Manual
SADDLES
drilled hole in the pipe to aid in

the corrosion protection of the
pipe structure.
Purpose
RPS belled, flanged, and plain-ended saddles have been factory
prepared to allow simple field assembly of a stub-in after the piping
system has been installed. Since a hole must be cut through the
pipe wall exposing the structure and liner, RPS Engineering should
be contacted to determine if the service is suited to this method of
fabrication and what type of adhesive should be used. Operating
conditions such as temperature, pressure, and fluid components are
to be considered in determining the correct adhesive; or if a field
installed stub-in would be more appropriate.
Installation
a) Drill the required diameter hole in the pipe.
b) Thoroughly sand an area
where the pipe saddle is to be
bonded. Remove brushcoat
only, or any high spots that
prevent pipe saddle from
fitting flush to pipe exterior.
The sanded area should
equal the length and width of the pipe saddle plus 13mm ().
For dimensions, see RPS Design Graphics Manual Doc. No. DGM1,
Sections 4.9 and 4.10. For proper safety procedures, see Safety
Section, Page 6, and MSDS, Page 9.
c) Remove PEEL-A-BOND
material from pipe saddle.
Refer to RPS Pipe and
Fittings Installation Manual,
Page 51.
d) Mix RPS Adhesive (Refer
to RPS Pipe and Fittings
Installation Manual, Page 21, on general use of P1500,
H1500, or E1500 adhesive).
e) Apply 1.5mm to 3mm (1/16 to
1/8) thick layer of RPS adhesive
to bonding area of pipe saddle
and sanded surface of pipe.
Also apply a smooth layer of
adhesive to the cut edge of
62
f) Position saddle over pipe;

squeeze tightly against pipe
until adhesive squeezes out
around all of the edges; then
hold in place with clamps, soft
wire, or steel strapping.
g) Using a mixing stick - smooth
out excess adhesive forming
a neat fillet at the edges of
the saddle, and remove any
adhesive that may block the
hole in the pipe.
h) Apply two (2) heating collars;
one (1) to each side of
pipe saddle for 105 minutes.
Do not attempt to combine
steps h) and i), as overlapping
may damage a heating collar
thermostat and lead to an
uncured or overheated joint.
i) Apply two (2) heating
collars longitudinally to
each side of pipe saddle
for 105 minutes.
Installation Manual
Number of Bonds per Adhesive Kit*
PIPE SADDLE
SIZE
ADHESIVE KIT
(P1500-1, H1500-1, or E1500-1)
1 into 3
1 into 4 - 12
1 into 3
1 into 4 - 12
2 into 4 - 12
3 into 6 - 12
4 into 8 - 12
* The number of bonds per kit may be limited by time between

applications
63
Installation Manual
PEEL-A-BOND is a trademark of RPS

RPS Composites Inc.
740 Main Street
P.O. Box 299
Mahone Bay, Nova Scotia
Canada B0J 2E0
Tel: (902) 624.8383 | (800) 343.9355
Fax: (902) 624.6395
www.rpscomposites.com
RPS Installation Manual 10/12
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Installation Manual

Pipe & Fittings Installation Manual

RPS Composites Inc.

RPS continually endeavours to improve its products. These changes

2) Cover forklift forks with wood or carpeting to protect pipe

3) Use metal or nylon strapping to tie down load and isolate

1) On arrival inspect load for:

damaged cartons or crates

4) Supports for pipe and headers to be located at about length

2) Immediately report any problems to the carrier and to RPS

2) Prior to storing, check that all spool pieces, headers, manifold,

1) Handle FRP products with care to prevent damage

hand (small light sizes only)

slings or ropes attached in 2 places, lifted by hoist or

forklift (for 12 dia. and smaller only - not stacked)

3) Prevent items from receiving any damage such as deep

hand (small crates only)

4) Ensure that mixing instructions, catalysts, etc. are not discarded

slings or ropes using hoists

1) ENSURE THAT CATALYSTS & PROMOTERS ARE NEVER PLACED

3) Pipe, fittings, or headers shipped crated should only be

4) Do not lift pipe by inserting forks into ends of pipe.

2) Avoid careless stacking of pipes or headers.

6) Pipe ends are fragile; HANDLE WITH CARE.

4) Prevent point loading from supports; if necessary, cover

8) NO SMOKING when handling resin, paste, adhesives, or chemicals

5) STORE JOINING MATERIALS INSIDE IN COOL, DRY AREAS, 5C. to

1) Avoid point loading to prevent damage. If necessary, cover

Field Polyester Resins & Paste

7) HEADERS, MANIFOLDS, OR OTHER STRUCTURES OF CRITICAL

NOTE: Shelf life of Polyester Resins & Paste vary depending on

8) Heating Blanket Storage

Blankets should be stored flat, or wrapped on a paper or

Blanket storage should be such that blankets do not receive

9) Do not remove protective coverings until items are ready for

plastic end caps from tapered ends of pipe

protective cover from flanges

plastic covers from joining kits

crates or covers from cans or containers of resin or chemicals

See Note Below

10) CAUTION: NEVER STORE RESINS, ADHESIVES, PASTES,

5) Positively NO SMOKING, WELDING, OR OPEN FLAME IS TO BE

6) Never store resins, adhesives, pastes, promoters, catalysts, or

7) Explosion proof electric motors or air motors must be used for

All local safety regulations must be followed.

2) Never work in small confined spaces without the buddy

40% Methyl Ethyl Ketone Peroxide in Dimethyl Phthalate

A strong oxidizing material; an organic peroxide.

Use only with Polyester/Vinyl ester Resins per formula

1) Fire - Use CO , dry chemical, or foam to fight fire. Use water to

2) If resins are over catalyzed, they will generate excessive heat

3) Discard all materials if exposed to water or other fire

IMPORTANT, NEVER MIX DIRECTLY WITH ACCELERATORS SUCH

4) NEVER torch-cut or weld empty cans/drums of resins, acetone,

Safety Data Sheets.

6) Acetone Cleaner - 2 propanone

Flammable & Explosive: Do Not store, expose near, or allow direct

7) Epoxy Resin, Paste, & Adhesive (E1500)

IMPORTANT, NEVER MIX DIRECTLY WITH ACCELERATORS SUCH

Flammable: Do Not store or expose near open flame, sparks, or hot