METHOD OF STATEMENT

Method Statement for Butt and Wrap Joint Lamination

Equipment Number: UG FIREWATER FRP LINE

Document Appraisal Stamp

Name Title Sign Date

RP Engineer 03/01/2024

Review Grade
Description Code Result
Accepted A

Proceed with Deviation; Revised submission required C

Affiliate End User Sign Off:

Name: Date:

Rev. No. Rev Date Revision Details Revised by Approved by

 Contents
1.0 Introduction

2.0 Scope

3.0 Materials

4.0 Specification & Standards

5.0 Tools

6.0 Consumables

7.0 Material Inspection

8.0 Environment Control & Conditioning of Laminate surface

9.0 Preparation of Surface

10.0 Installation & Lamination

11.0 Joint Lamination Recipe

12.0 Curing & Finishing

13.0 Lining Dimensions

14.0 Barcol Hardness Inspection

15.0 Raw materials

16.0 Workmanship & Crew

17.0 Quality Control for FRP Work

18.0 References
1.0 Introduction:
The purpose of this document is to outline a Method Statement for the detailed execution
of replacing the damaged 10” RTR Pipe for the Firewater Line.

2.0 Scope:
This method statement defines the minimum requirements step-by-step for makeup of
replacing the damaged RTR Firewater Pipeline.

3.0 Materials:

• As per Job Details provided by End user.

• Lamination Material – Lamination kit as per required Lamination Joint.

4.0 Standards & Specifications:

• SES-P14-T02 Rev.4 Quality Assurance of FRP Piping
• SES-P13-C05 Rev.4 Installation Requirements for FRP Piping
System Manufacturer’s Lamination
Procedure and Recipe
• SES-P01-E28-01 Rev.6 Qualification of FRP Pipe and
• Manufacturer Components

5.0Tools:

 Heating Blanket
 Measuring tape
 Level Bar / Spirit Level
 Grooved steel roller
 disc grinder
 Small electrical grinding machine
 Mixing Bucket
 Lamb wool Rollers
 Paint Brush
 Tenting (depends on weather conditions)
6.0 Consumables:

 Cutting disks
 Emery disks, emery paper, emery cloth, flapper wheels (all grade P40 to P60)
 Lamb wool roller, lamb wool refill
 Spatula (rubber scraper plate, filling knife), marker pen, dust (paint) brush
 Rubber gloves, Polyethylene gloves, working gloves, dust masks, safety goggles
 Cover-all, safety shoes, safety helmet
 Mixing bucket
 Measuring can
 Cleaning rags, cleaning fluid such as acetone and (IPD- Isophoronediamine) Catalyst.
7.0 Material Inspection:

Perform visual inspection for any sign of damages or defects of the pipes.
Likewise with the lamination kits shall be inspected prior to use. Do not use it when
containers showing evidence of damage or leakage. The resin and curing agents shall be
used before its expiration date that shown on the respective containers. Ensure that
storage of lamination kits complies with the recommended storage requirements.

8.0 Environment control and conditioning of laminate surfaces:

Perform and check the relative humidity should be within 75% and the temperature of the
laminate surfaces, during the laminate procedure, should be kept between 15 – 40 °C, and
also at least 3 °C above the dew point.

9.0 Preparation of Surface:

Ensure Proper Isolation of the Existing pipeline to be repaired and laminated. Water or any
source of liquid shall be avoided to avoid impurities and to enhance the bonding of the
Joint to be laminated. The surface to be laminated will be made rough by using grinding
machine. Grinding the surface to be laminated is important to remove the glossy and
smooth surface protection of the FRP and to have an excellent adhesion between the
fiberglass lamination and the existing FRP.
10.0 Installation & Lamination:

RESINSELECTION:(SES-P01-E28-01 Rev.5; 5.1)

The resin to be used for joint lamination shall be Epoxy resin(suitable for firewater
line)use for structural wall build up with suitable curing agents recommended by the
resin manufacturer in order to meet its performance requirements and temperature
limits.
REINFORCEMENTS:(SES-P01-E28-01 Rev.5; 5.2)
Structural reinforcements for the joint lamination shall be E- fiberglass woven roving (for
joint lamination).
JOINTSTYPE:(SES-P01-E28-01 Rev.5;7)
Joint type to be used shall be Butt & Wrap method (Butt and Strap in other terms). GRE
laminate and reinforcements are applied to the exterior of plain end pipe. It is considered
as the strongest and most reliable type of jointing. The laminate end shall be tapered with
6:1 ratio.

Step Procedure:

Surface Preparation.
Remove sand, dust, any foreign debris on the surface of the pipe. Ensure no traces of
water drop at the surface of the pipe. Grind the surface of the existing FRP pipe where
lamination will take place using grinder to remove any smooth surface and to expose the
glass fiber part of the pipe.
Prepare the required materials for lamination procedure. Resin, hardener, lamination kit,
lamination materials, etc.
The mixing of the resin will be done carefully and to the possible extent it will be single
handedly mixed to avoid changes in mixing mode. Hardener percentage will be
maintained according to the recipe. Thorough mixing will be ensured to obtain uniform
mixing. RATIO (pbw)- Resin: 100 Parts; Hardener: 24parts) Manufacturers
recommendation.
Laminationarea shall be properly grinded using grinding machine suitable with proper
sanding disc.

1. New GRE Pipe, 2m long shall be provided to replace the damaged portion of the
existing line. Cut the damaged GRE fittings that required replacement using cutting
disc suitable for FRP Materials.
2. Pipe shall be aligned accordingly. Once finish, initial lamination shall proceed.
3. The surface to be laminated will be made rough by Grinding followed by cleaning
with clean cotton rags or paint brush. Remove all dust on the surface before mixing
the resin and do lamination. Align the new pipe to the existing line. If the surface is
idle for more than 1 hour after grinding process, regrinding shall be done before
applying lamination.
4. Resin mixing shall be started once all preparation done. Apply resin on the grinded
area. Applying resin putty on the edge of the joint is necessary to seal all possible
gaps and to have a uniform surface during the lamination.All edges of the pipe
shall be covered with resin putty, this serves as corrosion barrier of the joint as it
cover the damage and exposed liner. Apply adhesive mixture in order to protect
the pipe against penetration of the medium. Coat the external surfaces of the pipe
ends at least 100mm in width and join them together. Wet out the boat tape with
adhesive and apply a minimum of 3 layers circumferentially.
5. Use aluminum serrated roller to remove air bubbles on lamination. Let it get dry
and cured for 30 to 60mins.
6. Before curing, use a heat source (hot-air blower, flood light etc.) to allow
thelaminate to gel and dry immediately. All fit layer shall be done first on all joints
prior to do final to rectify easily if there is some misalignment on proceeding joints.
7. Use heating blankets, to cure the butt-and-wrap joint laminate for 1 Hour.
8. Once all Fit layer is done and have a perfect alignment. Structural wall lamination
shall be done on all joints.
9. For Pipes bigger than 3” NPD, use boat tape in the sequence as per the provided
recipe below. With 50% overlap until the minimum required laminate thickness is

6th Joint.
 achieved. Make sure that the applied layers of boat tape and roving is thoroughly
impregnated with the resin mixture. Use aluminum serrated roller to remove air
bubbles on lamination. During the wrapping procedure, tension must be applied so
that the resin under the layer being laid could be pressed out.
10. For final layer and to give smooth finish, apply one final layer of boat tape spirally
wrapped onto the whole surface of the laminated joint.
11. Check if the heating blanket is working properly. Temperatures in excess of 120°C
should be easily achieved if the heating blanket works properly. The surface
contact between the heating blanket and the laminate should be as large as
possible; fit the blanket as snugly as possible to the joint. Cure the laminate for 1.5-
4 hours. Wherever possible, apply a heating blanket on the inside as well and
close the pipe ends to avoid drafts.
12. In cold weather, insulate the heating blanket to trap the heat, but do not cover the
blanket’s thermostat housing. After curing, use sandpaper to remove the rough
edges of the laminate and to generally smooth out the external surface.

Do proper sanding again on the laminated area after curing.

Note: While applying the lamination, make sure it is applied properly and tightened.

2 3
1
Application of Layers Curing by heating and
Initial Grinding
Fit Layer Rough Grinding

6 4
5
QC Testing Application of Layers
Final Curing
Second Round & So on
11.0 Joint Lamination Recipe:

Diameter:10” (250mm)

Length of Lamination of the joint:250mm

Thickness:10.2mm

See below attached recipe.

AMIANTIT Recommended layering Sequence

For the Laminate Structure: 16-Bar Pressure Rating
ND = Inch 1 1½ 2 3 4 6 8 10 12 14 16 18 20 24
ND = mm 25 40 50 80 100 150 200 250 300 350 400 450 500 600
Lamination
Length 120 120 120 120 120 120 120 125 150 175 200 225 250 300
(mm)
Lamination
Thickness 4.6 4.6 4.6 4.6 5.0 6.8 8.4 10.2 12.0 13.2 14.8 16.2 17.8 21.2
(mm)
Sequence
Number of
Layers
1 BT BT BT BT BT BT BT BT BT BT BT BT BT BT
2 BT BT BT BT BT BT BT BT BT BT BT BT BT BT
3 BT BT BT BT WR WR WR WR WR WR WR WR WR WR
4 BT BT BT BT WR WR WR WR WR WR WR WR WR WR
5 BT BT BT BT WR WR WR WR WR WR WR WR WR WR
6 BT BT BT BT WR WR WR WR WR WR WR WR WR WR
7 BT BT BT BT BT WR WR WR WR WR WR WR WR WR
8 BT BT BT BT BT BT BT BT BT BT BT BT BT
9 BT BT BT BT WR WR WR WR WR WR WR WR
10 BT BT BT BT BT WR WR WR WR WR WR WR
11 BT BT BT BT WR WR WR WR WR WR WR
12 BT BT BT BT BT WR WR WR WR WR WR
13 BT WR WR WR WR WR
14 BT BT BT BT BT
15 WR WR WR WR
16 BT WR WR WR
17 BT WR WR
18 WR WR
 19 BT WR
20 BT
21 WR
22 WR
23 BT

Note:
1. BT = Boat tape, 2” or 4” wide; WR = Woven Roving
2. L = Lamination Length; 2L = Total Length of Joint Lamination
3. Overlapping shall be 50% of each layer. Use layering sequence as in the above table until
the minimum laminate thickness is achieved.

12.0 Curing & Finishing:

After completing the lamination on all joints, curing time must be 8 hrs.

13.0 Lining Dimensions:

• Lamination dimension for the 10” diameter pipe will be 250mm long and 10.2mm
thickness

14.0 Barcol Hardness Inspection:

• Barcol hardness test shall be carried out after completing the curing time on the
lamination. The specimen is place under the indentor of Barcoal hardness tester and a
uniform pressure applied to the specimen until the dial indicator reaches a maximum.
The minimum Barcol hardness value is 35 Barcol. (SES-P13-C-05 Rev.4; 6.4.8).

• At least 5 readings shall be done every joint. All readings shall be recorded

15.0 Raw materials:

The following materials listed below are commonly used for fiberglass repairs.

• The resin system will be Epoxy resin.

• Boat tape
• Woven Roving
 • (IPD- Isophoronediamine) Catalyst

Note: Above is based on the manufacture recommendation.

• Raw material Storage:

Upon receiving the FRP materials, it is important to store them in proper place at
factory storage & material shall be delivered on site as per requirement.

Resin: Resin shall be stored in shelter/shaded area, preferably 15-25 °C and no

exposure to moisture & direct sunlight for longer duration. The supplied promoted
resin required to have atleast three (3) months self-life upon receipt at site.

Hardener:Hardener shall be stored in a cool maintained room (20-25 °C).

Glass Mat & CSM: shall be stored in a close room to avoid dust, damp and direct
sunlight.

Styrene: Styrene shall be stored in same condition as resin.

The Entire storage area shall be marked with “NO SMOKING SIGN BOARDS”

16.0 Workmanship & Crew:

• The crew proposed to be deployed for the subject job will be highly skilled with
richexperience in the executed of similar jobs. The team will be under the
guidance ofskilledandexpertteamleaderswith goodrecords.

17.0 Quality Control for FRP Works:

• Approved ITP shall be referenced while inspection of piping activities.

• QC Inspector shall perform visual inspection for laminated joints external/internal
works. Hardness shall be checked using Barcol Tester.
• QC inspector shall keep the thickness using the PI tape. Lamination width shall
be measured.
• QC inspector shall keep all record of laminated joints as per approved ITP.
18.0 References:
 S ES-P01-E28-01 Rev.6
 S ES-P01-E28-02 Rev.5
 S ES-P13-C05_Rev.4
 S ES-P13-C05_Rev.4
 AS TM D2996
 AWWAC950
AWWA M45