Manual No.

F6000
April 1, 2007

Matched Tapered Bell &

Spigot Joints

• RED THREAD® II
• GREEN THREAD®
• SILVER STREAK®
• F-CHEM®

PIPE
INSTALLATION
HANDBOOK
 FIBER GLASS SYSTEMS L. P.
PIPE INSTALLATION HANDBOOK
Matched Tapered Bell & Spigot Joints

This fabrication manual is offered to assist you in the proper

fabrication and installation procedures when assembling your
Fiber Glass Systems (FGS) piping system.

If you do not find the answer to your questions in the

manual, feel free to contact us or your local FGS distributor.

FGS products must be installed and used in accordance

with sound, proven practice and common sense.
The information supplied by FGS in its
literature must be considered as an expression of guidelines
based on field experience rather than a warranty for which FGS
assumes responsibility. FGS offers a limited warranty of its
products in the Terms and Conditions of Sale. The information
contained in the literature and catalogs furnished by FGS
cannot ensure, of itself, a successful installation and is offered
to customers subject to these limitations and explanations.
It is the policy of FGS to improve its products continually.
Therefore, the company reserves the right, without notice, to
change specifications and/or design at any time without incurring
an obligation for equipment previously sold. Descriptions
contained in this catalog are for the purpose of identification and
neither limit nor extend the standard product limited warranty set
forth in the Terms and Conditions of Sale and Trade Customs.


 Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Fabrication & Installation Assistance . . . . . . . . . . . . . . . . . . iv

Part I
Pipe Products
Pipe Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description of Pipe Products . . . . . . . . . . . . . . . . . . . . . 1
Pipe Grades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fabrication Accessories . . . . . . . . . . . . . . . . . . . . . . . . . 6
Joining Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Part II
SITE CONSIDERATIONS
Storage and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Tools, Equipment, and Supplies . . . . . . . . . . . . . . . . . . . . 10
Suggested Crew Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Adverse Weather Recommendations . . . . . . . . . . . . . . . . 14
Burial Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . 15
Anchors, Guides and Supports . . . . . . . . . . . . . . . . . . . . . 22

Part III
general installation
Read This First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Cutting FGS Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Part IV
Fabrication of RED THREAD II, GREEN THREAD, AND
SILVER STREAK Pipe and Fittings

Tapering FGS Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Tapering Tool Reference Chart . . . . . . . . . . . . . . . . . . . . . 28
Joint Prep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Adhesive Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Joint Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Close Tolerance Piping . . . . . . . . . . . . . . . . . . . . . . . . . 31
Take-Off Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1”-6” Bell x Spigot Joints . . . . . . . . . . . . . . . . . . . . . . . . 37
8”-24” Bell x Spigot Joints . . . . . . . . . . . . . . . . . . . . . . . 38
T.A.B. Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Joint Cure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Heat Collars & Heat Packs . . . . . . . . . . . . . . . . . . . . . . 42
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

ii
 PIPE PRODUCTS
PART V
FABRICATION OF F-CHEM PIPE AND FITTINGS
Joint Prep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Joint Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Joint Cure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

CONSIDERATIONS
Heat Blankets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Tapping into a Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

SITE
Part VI
Installation Considerations
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

INSTALLATION
Water Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

GENERAL
Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Connecting to Other Systems . . . . . . . . . . . . . . . . . . . . . . 73
Painting Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Part VII
Helpful Information

FABRICATION
Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

RT, GT, SS
Decimal Equivalents of Fractions . . . . . . . . . . . . . . . . . . . 77
Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
How To Read Flanged or Reducing Fittings . . . . . . . . . . . 83
How To Figure a 45° Offset . . . . . . . . . . . . . . . . . . . . . . . 84
FABRICATION

Standard Abbreviations
F-CHEM

RT RED THREAD® II piping systems

RTPP RED THREAD II Performance Plus
piping systems
GT GREEN THREAD® piping systems
CONSIDERATIONS
INSTALLATION

GTPP GREEN THREAD Performance Plus

piping systems
SS SILVER STREAK® piping systems
FC F-CHEM® piping systems

© 2005, NATIONAL OILWELL VARCO

INFORMATION
HELPFUL

® Trademark of Varco I/P, Inc.

iii
 FABRICATION AND INSTALLATION ASSISTANCE

Installing FGS fiberglass pipe is different from installing

carbon steel, stainless steel, lined steel and even other
fiberglass piping systems. Learning the proper methods to
prepare and make-up bell & spigot joints can help ensure the
reliability and long-term performance of your piping system.

FGS offers the TQI Plus (ASME B31.3) Fabrication

and Assembly certification program. Qualified Field Service
Representatives train fabrication and assembly crews, conduct
and supervise fabrication work, and inspect work in progress.

For complete information concerning these training

seminars, contact your local FGS distributor or FGS .

SAFETY
This safety alert symbol indicates an important
! safety message. When you see this symbol, be
alert to the possibility of personal injury.

CAUTION
As this pipe may carry hazardous material and/or operate
at a hazardous pressure level, you must follow instructions
in this manual to avoid serious personal injury or property
damage. In any event, improper installation can cause
injury or damage. In addition, installers should read and
follow all cautions and warnings on adhesive kits, heat
packs, propane torches, etc. to avoid personal injury.
Also, observe general safety practices with all saws,
tools, etc. to avoid personal injury. Wear protective
clothing when necessary. Make sure work surfaces
are clean and stable and that work areas are properly
ventilated.

iv
 PIPE PRODUCTS
PART I
PIPE PRODUCTS

Description of Pipe Products

The performance characteristics of a fiberglass pipe

system depend on several important elements including the
resin and curing agent, as well as the manufacturing process
and type and thickness of the pipe’s corrosion barrier.
FGS piping systems are manufactured using epoxy, vinyl
ester, or isophthalic polyester resin systems. All are heat cured
for optimum chemical resistance and physical properties.
Match your temperature, pressure and chemical resistance
requirements to the piping system.


PIPE PRODUCTS

FGS PIPE GRADES

RED THREAD II &

RED THREAD II Performance Plus
Epoxy pipe grade that provides long service life, lightweight
and corrosion resistance. Used for light chemical services
in salts, solvents and pH 2 to 13 solutions up to 210° F and
pressures to 450 psig. Available in 2”-24” pipe sizes. T.A.B.
(Threaded and Bonded bell & spigot) is the primary joining
method for 2”-6” diameter pipe. Matched tapered bell & spigot
joining method is used for 8”-24” pipe.

GREEN THREAD &

GREEN THREAD Performance Plus
Epoxy pipe with 15-35 mil resin-rich liner that provides
excellent chemical resistance to dilute acids and caustics.
Rated for temperatures up to 225°F and pressures to 450
psig. Matched tapered bell & spigot connection is provided on
all 1”-24” pipe sizes.

SILVER STREAK
Custom filament wound pipe is specially designed for abrasive
and corrosive services found in flue gas desulfurization. It
is a proprietary blend of epoxy resin and abrasion-resistant
additives. Rated for temperatures to 225°F and 150 psig.
Available in 2”-24” pipe sizes.

F-CHEM
Custom filament wound construction offers more flexibility
in resin systems, corrosion barriers and wall thickness than
our standard products. Rated for temperatures to 250°F and
150 psig. Let us assist you in selecting the right pipe for a
specific application. Available in 1”-72” pipe sizes. Joining
methods include plain end butt and wrap, O-ring bell & spigot
or matched tapered bell & spigot.


 PIPE PRODUCTS
FITTINGS

FGS fittings are color coded. GREEN THREAD fittings are

green and may be used with RED THREAD II and GREEN
THREAD pipe. SILVER STREAK fittings are black. F-CHEM
fittings are color matched to the pipe. Be sure to use the
correct grade of pipe and fittings for your service. Consult FGS
Fittings & Accessories Bulletins for pressure rating limits on
various fittings. The lowest rated fitting determines the system
pressure rating.
Most compression-molded fittings have a center line dot or
cross which will assist you in making measurements.


PIPE PRODUCTS

ADHESIVES

FGS adhesives are formulated for specific use with

the companion pipe grades. Use only the recommended
adhesive with each pipe grade - do not mix systems! Standard
adhesives are a two-component system (Parts A and B) which
must be mixed prior to use. Detailed instructions for adhesives
are provided with each kit. Read these instructions thoroughly
and follow the recommended procedures. The cure time and
pot-life of the adhesive is dependent on temperature. Refer
to the adhesive instructions. Ambient temperatures above
100°F require extra care by the fabricator to assure sufficient
working time of the adhesive. Refer to Adverse Weather
Recommendations on page 14.

ADHESIVE SELECTION

FGS standard adhesive kits are designed to be used with

specific piping systems as shown in Table 2.

ADHESIVE WORKING LIFE

Working life or pot life is the time it takes for the adhesive
to harden in the mixing can. Refer to Table 1 below.

TABLE 1. Fiber Glass Systems Adhesives Estimated Pot Life

Pipe Pot Life Pot Life
Resin @ 70°F (min.) @ 90°F (min.)
Systems Adhesive (see note) (see note)

Epoxy 7000 25 15
Epoxy 8000 15 8
Vinyl Ester CL-100 20 10
NOTE: Pot life is the time available for fabrication. Times may vary
depending upon temperature, humidity, quantity mixed, etc.


 TABLE 2. Adhesive Selection Refer to Bulletin No. D4000 for more information

Use with these Max. Kit Number of Bonds per kit

Piping Systems Temp. Nbr.r 1" 11/2" 2" 3" 4" 6" 8" 10" 12" 14" 16" 18" 20" 24"
2014 18 15 13 5 2 1 1/2 1/2
RTII/GT
200°F
PERF. PLUS 2069 8 4 3 2 2 1 1 3/4 1/2

7014 25 18 10 6 3 2 1
RED THREAD II
150°F 7024 9 6 4 2 1
(Joints Per Can)


7069 8 4 3 2 2 1
8014 45 27 21 15 8 5 3 2 1 1/2 1/2
RED THREAD II
GREEN THREAD 225°F 8024 20 12 9 6 4 2 1
SILVER STREAK 3/4 1/2
8069 8 4 3 2 2 1 1
Number of Bonds per kit
14" 16" 18" 20" 24" 30" 36" 42" 48" 54"-72"
F-CHEM 200°F CL-100 11/2 11/2 1 1 3/4 1/2 1/3 1/4 1/5 Contact the factory

PIPE PRODUCTS
PIPE PRODUCTS

FABRICATION ACCESSORIES

Heat Collars and Heat Blankets:

FGS offers high temperature heat
collars and silicone heat blankets
for use in curing of adhesive joints.
The blankets and collars have a pre-
set thermostat which controls the
temperature of the unit. See page
44 for heat collar page 54 for heat
blanket cure times for adhesive joint
fabrications.

Heat Guns: High wattage electric

heat guns are also available to
heat F-CHEM adhesive joints. The
heat guns are 1600 watt capacity.

FGS Heat Packs: A heat pack unit consisting of ties and

reactants in a plastic bag attached to foil paper is also
available. Heat packs will cure joints within one hour.

Tapering Tools: FGS matched tapered joints require various

tools for making the tapered spigot in the field (RT, GT, SS).
Refer to Table 6 on page 28 for selection of proper tapering
tool.

Come-Along: Specifically
designed hydraulic come-alongs
are available for 8”-24” piping
systems (RT, GT, SS). Especially
useful for long straight runs of
pipe.
Manual Come-Along: Kit consists
of two manual cable puller come-
alongs and one strap clamp kit. It is
a mechanical aid used to join larger
diameter piping. The come-along
is most useful for 8”-16” pipe sizes
to aid in the alignment and landing of the spigot end into the
bell.

Strap Clamp Kit: FGS offers

Strap Clamp Kits that can be
used in conjunction with come-
alongs for bonding 8”-24” fittings.

 PIPE PRODUCTS
JOINING SYSTEMS

Bell and Spigot Joint: The adhesive bonded, tapered bell

and spigot joint is a primary joining method for the following
products:
1"-24" GREEN THREAD piping and pipe to fittings
2"-24" RED THREAD II piping and pipe to fittings
2”-24” SILVER STREAK pipe to fittings
4”-72” F-CHEM piping*

*Pipe to pipe joints

also available in butt
& wrap.

Pipe is supplied
with one end
tapered (the spigot)
and the other end
belled (integral bell
or factory bonded
coupling) to accept a tapered spigot. The joint is made by
applying adhesive which, when cured, is compatible with the
piping systems for joint strength and corrosion resistance.

T.A.B. (Threaded and Bonded) Joint: The T.A.B. joint is the

primary joining method for the following product:

2"-6" RED
THREAD II piping
and pipe to cou-
plings.

The joining sys-

tem combines
both threads and
adhesives on the
bonding surfaces.
The mechanical locking action of these promotes positive
makeup which prevents backout during adhesive curing.
Standard tapered bell fittings are used with this system.


 PART II
SITE CONSIDERATIONS

STORAGE AND HANDLING

CONSIDERATIONS

A. Pipe and Fittings

Fiberglass reinforced pipe, fittings, and adhesives require
SITE

special storage and handling. Care should be taken in

transporting, unloading, handling, and storing FGS products
to prevent impact and other damage.
When transporting pipe, the spacers under and between
the pipe joints must be of sufficient width to avoid point
loading, which could produce cracking or buckling damage.
A minimum of four spacers should be used for supporting 14"
and larger 40' long pipe joints. More spacers should be used
for smaller pipe or if pipe is stacked over eight feet high.
Due to its light weight, lifting equipment is usually not
required for 1" - 14" pipe. When lifting equipment is required,
use nylon slings or chokers. Do not allow chains or cables
to contact the pipe during transport or handling. If a pipe or
fabrication is more than 20 feet long, use at least two support
points.
For storage, a board (2 x 4 minimum) should be placed
under each layer of pipe approximately every five feet. The
intent is to support the pipe and distribute the load evenly.
The pipe should also be braced on either side of the pipe rack
to prevent unnecessary pipe movement. Avoid placing FGS
pipe on sharp edges, narrow supports, or other objects that
could cause damage to the pipe wall. When storing FGS pipe
directly on the ground, select a flat area free of rocks and other
debris that could damage the pipe.
FGS pipe is furnished factory packaged in compact, easy-
to-handle bundles complete with protective end caps. Leave
these caps in place until installation time to protect the pipe
ends as well as to prevent dirt or other material from getting
into the pipe. Fittings are packaged in cardboard boxes and
should be stored in a dry area. If fittings are removed from
the boxes, protect machined bells and spigots from exposure
to direct sunlight.
FGS pipe can be damaged when joints or bundles of pipe
are dropped during handling or shipping. Severe localized
impact blows may result in damage to the fiberglass reinforced
structure in the pipe wall. Before installation, inspect the
pipe's outer surface for any damage. Do not use damaged
pipe unless inspected and approved by a FGS representative.
If impact damage occurs, the damaged areas may be

recognized by a star type fracture on the pipe. Pipe that has
been damaged should have a length cut away approximately
one foot either side of the impacted site.

Note:

CONSIDERATIONS
weight.

SITE
straps.

B. Adhesive
FGS vinyl ester adhesives can be damaged by storage in
warm places. FGS recommends that CL-100 adhesive be
stored in a dry area where temperatures do not exceed 80° F.
Refer to adhesive instructions included in each kit for storage
life recommendations.

Material Safety Data Sheets (MSDS) are available from

FGS at http://www.smithfibercast.com


 TOOLS, EQUIPMENT and SUPPLIES
REQUIRED FOR INSTALLATION

For maximum efficiency, the following tools and equipment are

CONSIDERATIONS

recommended prior to any installation:

SITE

clamp kit
• Hand Tools
- Level - Marking Pen - Tape Measure - Pipe Wrap
- Hacksaw (22-28 teeth/inch)
- Tapering tool (See pages 26-28)

RT, GT, SS)

• Power Tools
- Power tapering tools (See pages 26-28)

aluminum oxide, carbide or diamond

cutting blade
- Heat gun, heat blanket or collar
- T.A.B. wrenches (for 2”-6” T.A.B. joint piping systems)
• Expendables
-Clean, Dry, Lint-Free Shop Cloths

SS), (30-60 grit for F-Chem)

- Impermeable gloves
- Chemical splash goggles

NOTE: You must use the proper tool for tapering each size
and type of pipe (see pages 26-28).

Equipment for Cool Weather (Below 70°F) pipe assembly:

• Heat source
- Portable torch with spreader tip, or
- Portable electric heat lamp, or
- Industrial hot air gun
• A means of maintaining adhesive kits at 70°-80°F:
- A box with a 25 watt light bulb, or
- Inside of a vehicle.
• Heat assisted curing
- Electric heating collars or blankets
- Chemical heat packs

10
 Additional equipment for 8”-24” pipe assembly (RT, GT, SS):
• Hydraulic come-along or two come-alongs with manila rope
or nylon slings (for reduced slippage)
• Strap clamp kit

CONSIDERATIONS
• Sledge hammer, 12-16 lbs., and a 4 x 4 block of wood

Additional equipment for applying saddles:

SITE
• Power sander with 30-60 grit sanding disc (preferred
for 6” and larger saddles).
• Hose clamps

SUGGESTED LABOR TIMES FOR FGS

BELL X SPIGOT PIPING SYSTEMS

Placing Scribe &

Joint
Pipe in Set Up Cutting Hand Power
(Min/Jt) Tapering Tapering Makeup
Size Hangers (Min.)
(10) Hand/ (Min Jt) (Min/Jt) (Min)
(Min/Ft) (7/8)
(1) power
1" .7 3.0 1.33/1.25 1.0 .25 (2) 1.0
11/2" .7 3.0 1.33/1.25 1.5 .25 (2) 1.0
2" .7 3.0 1.50/1.25 2.0 .25 1.5
3" .7 3.0 2.0/1.33 3.0 .25 2.0
4" .8 4.0 5.0/2.5 4.0 .25 3.0
6" 1.0 5.0 7.0/3.0 5.0 2.5 (3) 4.0
8" 1.2 7.0 4.5/3.5 22.0 8.0 (4,5,9) 5.0
10" 1.4 7.0 NA/5.0 35.0 10.0(9) 6.0
12" 1.7 8.0 NA/5.0 40.0 12.0(9) 8.0
14" 2.3 9.0 NA/5.0 NA 12.0 (5,9) 10.0
16" 2.3 10.0 NA/6.0 NA 12.0(9) 12.0
18" 2.5 12.0 NA/8.0 NA 25.0 (6) 14.0
20" 3.0 12.0 NA/8.0 NA 28.0 (6) 16.0
24" 3.0 14.0 NA/10.5 NA 30.0 (6) 20.0

Table 2.1
(1) Placing in hangers figures are based on one-worker
operation for 1"-4"; two workers for 6"-10"; three workers for
12"-24". Total times should be figured by multiplying figures
given by workers needed per operation.
(2) 2000 series Power Tools
11
 (3) 2"-6"Hand Tapering Tool
(4) IndividualTapering Tool
(5) 8"-16" Grinding Tapering Tool
(6) 18"-24" Grinding Tapering Tool
(7) Each joint makeup calculation includes cleaning, sand-
CONSIDERATIONS

ing, applying adhesive and proper engagement. Allow three

minutes for mixing adhesive.
(8) The units (time) listed above are based on using experi-
SITE

enced crews on fitting intensive runs. For straight run pipe,

contact your local FGS representative.
(9) Time doubles for Performance Plus products.
(10) Includes set up for hydraulic or manual come-along and
setting pipe stand levels.

These numbers are based on installations using experi-

enced crews in typical installation conditions. They do
not include extreme weather conditions, time used for
gathering supplies and tools, break time, manpower is-
sues, etc. Assume 6 hours of productive labor for every
8 hours worked. Adjustment factors should be applied to
these base units to compensate for prevailing production
and job conditions. Because of all the variables involved,
Fiber Glass Systems is not responsible for any differen-
tial between these numbers and actual results.

SUGGESTED CREW SET-UP AND ASSEMBLY

Manpower requirements change depending on whether
the installation is simple, consisting of long, straight runs, or
complex. It also depends on pipe size, installation tem-
perature, and other similar influences. Following are some
general guidelines that are applicable to most installations. If
you have any questions, please contact an FGS representa-
tive for information.

A. Suggested Crew Size for 1” - 6” straight run pipe

(long runs)
A three-worker crew is the minimum recommended crew
size. A four-worker crew is sometimes more efficient, even
when installing 1” - 6” diameter pipe.
12
 Man # Crew Description
#1 Clean/prep/align
Removes end caps, sands and cleans joint and aligns
pipe for bonding.

CONSIDERATIONS
#2 Adhesive mixer/bonder
Mixes adhesive and applies to bell and spigot.

SITE
#3 Assembly man
Helps make up joint and checks for lock up.

#4 Pre-heat/prep/supplies
(optional through 4"; recommended on 6”)
Pre-heats joints and helps keep pipe aligned. Also applies
heat collars during cool weather. (All help in moving sup-
plies and equipment from joint to joint.)

B. Suggested Crew Size for 8” - 48” straight run pipe

(long runs)
A six or seven crew members is recommended.

Man # Crew Description

#1 Clean/prep/align
Removes end caps, sands and cleans joint and helps
align joint for insertion.

#2 Adhesive mixer/bonder
Mixes adhesive and applies to bell and spigot. Marks
insertion depth and determines when joint is locked up.
Assists with come-along.

#3 Adhesive mixer/Bonder
Helps #2 with adhesive and assists with come-along.

#4 Pre-heat/alignment man
Pre-heats joints, helps align joints and assists with come-
along.

#5 Alignment man
Sets level of pipe and aligns joint for proper insertion;
directs tractor driver.

#6 Truck driver/Supply man (optional)

Drives supply truck and assists with all aspects of instal-
lation. Also coordinates heat collars during cool weather
and ice chest during hot weather.
13
 #7 Tractor Operator
Operates side boom tractor, trac hoe or backhoe.
(All help in moving supplies and equipment from joint to
joint.)
CONSIDERATIONS

C. In more complex pipe assemblies, the crew size will

depend on the amount of tapering and prefabrication
SITE

needed. In most cases, a three-worker crew is the mini-

mum for any size piping installation. In some instances
(small jobs with only a few joints) only one or two crew-
men will be required.

RECOMMENDATIONS FOR FABRICATION IN ADVERSE

WEATHER CONDITIONS

FGS piping can be installed in adverse weather condi-

tions when the necessary precautions are taken.
Actual work will often be more quickly completed in high
temperature conditions. Low temperatures can increase the
work time 20%-35% over normal shop conditions. A similar
increase is common for high moisture conditions.

Hot Weather Installation Tips

Hot weather conditions, temperatures above 90°F, will
greatly reduce the working time of the adhesive. The follow-
ing steps are recommended when fabricating in hot weather
conditions:
1. Avoid direct sunlight on the joining surfaces.
2. Store adhesive in a cool area.
3. Keep F-CHEM adhesive in ice chest prior to mixing.
4. Keep mixed adhesive in an ice chest with sealed bag of
ice or ice pack.
4. Refer to the field fabrication instructions supplied in the
adhesive kit for the proper amount of catalyst in CL-100.

Cold Weather Installation Tips

Adhesive cure time is directly related to the temperature.
Colder temperatures result in longer cure times.
The following steps should be used when fabricating in
colder temperatures:
1. Adhesive kits should be placed in a warm room for six to
twelve hours before application in order to reach tempera-
tures of 80°F-100°F. This will make mixing much easier and
speed cure times. Or use a box with a 25-watt light bulb to
warm adhesive kits.

14
2. When possible, piping should be bonded indoors into
subassemblies. The warmer conditions of these areas will
allow faster cure times.
3. Pre-warm bonding surfaces to 80°F-100°F when tempera-
ture falls below 70°F.
4. Refer to the field fabrication instructions supplied in the adhe-

CONSIDERATIONS
sive kit for the proper amount of catalyst for vinyl ester kits.
5. A heat gun, collar or blanket may be used to obtain a

SITE
faster cure time. Apply a layer of fiberglass insulation or a
welding blanket around the heat collars or blankets when
installation temperatures are below 50°F.

Extreme Moisture

Adhesive Joints
• If fittings or pipe have moisture on the bonding surface,
wipe them dry prior to sanding.
• Sand pipe or fittings immediately before applying the
adhesive to bond the joint. Sand surfaces until a fresh, dry
surface is present, then remove dust with a clean dry cloth,
and apply adhesive.
• Cure per the previous recommendations for normal, ex-
treme heat or extreme cold temperatures.

BURIED INSTALLATIONS

These are general guidelines only. For more details see

FGS Engineering and Design Guide E5000. For installations
using UL listed RED THREAD IIA piping see special instruc-
tions contained in Manual No. B2160.

15
 Pipe Bending Allowance for Standard RED THREAD
X (Ft) Y (Ft)
Size
(Straight run from (Offset from straight
(In)
pipe) run)
10 0.80
20 3.70
CONSIDERATIONS

2
30 9.00
40 18.10
SITE

10 0.55
20 2.50
3
30 5.90
40 11.10
10 0.42
20 1.90
4
30 4.40
40 8.20
20 1.22
30 2.90
6
40 5.40
50 8.60
20 0.89
40 4.00
8
60 9.40
80 17.50
20 0.71
40 3.20
10
60 7.50
80 13.80
20 0.60
40 2.70
12
60 6.30
80 11.60
20 0.53
40 2.40
14
60 5.50
80 10.00
20 0.46
40 2.10
16
60 4.80
80 8.80
16
 X (Ft) Y (Ft)
Size
(Straight run from (Offset from straight
(In)
pipe) run)
20 0.41
40 1.90

CONSIDERATIONS
18
60 4.30
80 7.90

SITE
20 0.37
40 1.70
20
60 3.90
80 7.10
20 0.31
40 1.40
24
60 3.20
80 5.90

TABLE 3. Burial Depths*

Minimum Maximum
Product
(Ft.) (Ft.)
1" - 4" RED THREAD II 2 15
6" - 24" RED THREAD II 3 15
1" - 12" GREEN THREAD 2 15
14" - 24" GREEN THREAD 3 15
1" - 12" SILVER STREAK 2 15
14" - 24" SILVER STREAK 3 15
F-CHEM Custom Piping** 3-5 12 - 20

* Based on 1000 psi soil modulus. Contact the factory for

detailed information for your specific application.
** F-CHEM is designed for specific burial applications ac-
cording to AWWA C950.

A. Burial Depth
1. Minimum Burial Depth
Minimum depth in unpaved areas for pipe subjected
to vehicular loads depends on pipe grade, pipe size,
vehicle axle weight, and the bedding material. With a
standard legal axle load of 34,000 lbs., the mini-
mum depth of cover (from the top of the pipe to the

17
 surface) for moderately compacted non-clay bearing
soils is shown in Table 3.

The pipe should always be buried below the frost line.

2. Maximum Burial Depth

CONSIDERATIONS

Maximum burial depth is dependent on the backfill

material. For moderately compacted soils that do not
SITE

contain large amounts of highly expansive clays, the

maximum burial depth is shown in Table 3.

B. Trench Preparation
Final bedding of the trench must be as uniform and con-
tinuous as possible. Before backfilling, fill all gaps under
the pipe with proper bedding material. Avoid sharp bends
and sudden changes in slope. It is important to remove all
sharp rocks, cribbage, or other foreign objects that could
come in contact with the piping.

C. Bedding Requirements
Fiberglass pipe can be damaged by point contact or wear
with the trench bottom and walls, improper bedding mate-
rials, or adjacent pipe. Use recommended bedding mate-
rial a minimum of 6 inches thick at the bottom, sides, and
top of the piping (refer to Table 4). Adjacent pipes should
be spaced the greater of 6 inches or one pipe diameter.
The piping can be laid directly on the undisturbed trench
bottom if the native soil meets the requirements of a
recommended bedding material (refer to Table 4). Never
lay fiberglass piping directly against native rock or shale.
Always use dry, unfrozen bedding materials that do not
contain foreign objects or debris. Never use water flood
for compaction. Slurries can be used that are intended
for burial of flexible piping systems. When using slurries,
care must be taken to prevent floating or deformation of
the piping.

18
 Compacted Native Fill

6" Min.
Backfill

CONSIDERATIONS
6" Min. Bedding

SITE
Areas “a” must firmly support pipe haunches

TABLE 4. Recommended Bedding Materials

Bedding Material Compaction Proctor
Density
Crushed rock or pea gravel 3/4” Not Required
maximum size
Coarse-grained sand or soil 75-85%
with little or no fines
Coarse-grained sand or soil 85-95%
with more than 12% fines
Sand or gravel with more than 85-95%
30% coarse-grained particles
Sand or gravel with less than Greater than 95%
30% coarse-grained particles

D. Pipe Support
Fiberglass pipe is flexible and requires the support of the
bedding material to keep the pipe round in burial applica-
tions. It is very important that a recommended bedding
material is properly compacted around the entire circum-
ference of the pipe. (Refer to Table 4) Tamp the bedding
material under the bottom half of the piping to prevent
voids or areas of low compaction. Vibratory or similar
tamping equipment can drive small stones or debris into
the pipe wall if they are present in the bedding material.
Avoid striking the pipe with tamping equipment as the
pipe may be fractured.

19
 Consult the factory if the pipe will be subject to
vacuum or high water tables.
Ensure Firm
Compaction
CONSIDERATIONS

No Voids
SITE

Select
Bedding
Proper Bedding Improper Bedding

E. Road Crossings
When laying fiberglass
pipe under road cross-
ings, it may be neces-
sary to pass the pipe
through conduit to pro-
tect the pipe. Pad the
pipe to prevent rubbing
or point loads against
the conduit.

F. Wall Penetrations
Where the pipe goes through or passes under a concrete
structure, precautions must be taken to prevent bending
or point loading of the pipe due to settling. A minimum 2"
thick pad of resilient material should be wrapped around
the pipe to provide flexibility and prevent contact with the
concrete. If bolts are used in the resilient material, care
should be taken that the bolts, nuts, or washers cannot
come into point load contact with the pipe. Bedding depth
under the pipe should be increased to a minimum of 12"
or one pipe diameter, whichever is greater, for one pipe
joint length away from the concrete.

“O” Ring Bell & Spigot

Thick Pad of Re-

silient Material

Thick Protective Layer of

Resilient Material

20
G. Timing
Test and cover the pipe as soon as possible to reduce the
chance of damage to the pipe, floating of the pipe due to
flooding, or shifting of the line due to cave-ins.

CONSIDERATIONS
H. Two Point Lifting of Red Thread II

SITE
This table provides information concerning safe lift
points for RTII during installation. The following table has
been compiled for two lift points and the maximum length
of pipe that may be safely lifted and the critical location of
the lift points.

TABLE 4.H
Cantilever Mid-Span
Pipe Lengths
Nominal Length Lengths
(Feet)
Size (In) (Feet) (Feet)
Number Length Min. Max. Min. Max.
8 3 120 24 26 68 72
10 3 120 20 28 64 80
12 3 120 22 31 58 76
14 3 120 22 31 58 76
16 3 120 20 35 50 80
18 3 120 19 36 48 82
20 4* 160 31 37 86 98
24 4* 160 29 40 80 102

21
 ANCHORS, GUIDES AND SUPPORTS

A. Pipe Hangers
Pipe hangers such as those shown are often used to
support FGS pipe in buildings and pipe racks. However,
CONSIDERATIONS

the use of too many hangers in

succession can result in an un-
stable line when control valves
SITE

operate, and during pump start-

up and shutdown. To avoid this
condition, the designer should
incorporate auxiliary guides
periodically in the line to add
lateral and axial stability.

B. Pipe Guides
Guides are rigidly fixed to the supporting structure and
allow the pipe to move in the axial direction only. Proper
guide placement and spacing are important to ensure
proper movement of expansion joints or loops and to pre-
vent buckling of the line.
1/16” Min.-1/8” Max.
The guiding mechanism clearance per side
should be loose so it will allow
free axial movement of the
pipe. “U” bolts, double-nutted
so they cannot be pulled down
tight, are often utilized for
guides.

Primary and secondary guides, i.e., those immediately

adjacent to expansion joints, are spaced more closely
than intermediate guides. Refer to FGS Manual No.
E5000, Engineering & Piping Design Manual, for details.

Piping entering expansion joints or expansion loops re-

quire additional guides. Refer to FGS Manual No. E5000,
Engineering & Piping Design Manual for details.

C. Pipe Supports:
Piping supports for FGS pipe should
be spaced at intervals as shown in
the product bulletins.

22
NOTE: Properly spaced supports do not alleviate the need for
guides as recommended in the
preceding section. Supports that
make only point contact or that
provide narrow supporting areas
should be avoided. Some means

CONSIDERATIONS
of increasing the supporting area
should be used; sleeves made

SITE
from half of a FGS coupling
or pipe are suitable. Support
pumps, valves and other heavy equipment independent of
the pipe. Refer to pump and valve connection instructions on
page 74.

D. Pipe Anchors: Pipe anchors divide a pipeline into

individual expanding sections. In most applications, major
pieces of connected equipment, such as pumps and
tanks, function as anchors. Additional anchors are usually
located at valves,
near changes in Anchor Sleeves
direction of the
piping, at blind
ends of pipe, and
at major branch Snug fit
connections. Provi-
sions for expansion Clamp, snug
but not tight
should be designed
into each of the
individual pipe sec- Weld or Bolt Anchor
tions. to support member

Caution: Do not install more than one expansion joint be-

tween the same two anchors in any straight pipe section.

Do not anchor FGS pipe by applying external pres-

! sure as point loads, such as a "U"-bolt, directly to

the bare pipe. Refer to FGS Manual No. E5000,
Engineering & Piping Design Guide, for a thorough
discussion on supports, anchors and guides.

23
 PART III
GENERAL INSTALLATION
INSTRUCTIONS

IMPORTANT • READ THIS FIRST

Before beginning the actual assembly procedures, read

and make sure all installers thoroughly understand the follow-
ing instructions.

All bonding surfaces must be clean, dry and factory

fresh in appearance before applying adhesive. When end
caps have been lost, surfaces will weather and result in loss
of bond strength When surfaces are weathered, re-taper (RT,
GT, SS) spigots. Sand bells and F-CHEM spigots to achieve a
factory fresh appearance. (Note: T.A.B.™ couplings that have
weathered must be replaced.)

Matching tapered bell and spigot joints require a very

FABRICATION

thin adhesive bond line for maximum strength and du-

RT, GT, SS

rability. The adhesive used with tapered joints is very strong

when used in bond lines a few thousandths of an inch thick.
The same adhesive may be brittle in thick sections result-
ing in poor bond strength. To achieve a thin bond line, the
matched tapered angles of the joint are designed to mechani-
cally “lock-up” when wedged together.

Using mechanical force assures “lock up” and a thin

bond line. Hammering a wooden block placed against the
bell end of pipe, or using mechanical devices such as come-
alongs should be used to “lock up” the joint.
Note: For T .A. B joints, special T.A.B. wrenches are
required to achieve the mechanical lock up in the joint.

Adverse weather conditions require special precau-

tions when bonding pipe. (See page 14, Recommendations
for Fabrication in Adverse Weather Conditions) The adhesive
is very viscous (thick) when cool or when applied to cool pipe.
The thick adhesive can actually be stiff enough to prevent
joint “lock up.” When the adhesive is hot or when it is applied
to hot pipe, the available working time may be significantly
reduced.

Matched tapered bell and spigot joints that are not

“locked up” can fail prematurely.

24
 CUTTING FIBERGLASS PIPE

FGS pipe should be cut using one of the methods referred to

under Tools and Equipment on page 10.

1. Measure pipe, remembering to allow for spigot and fitting

dimensions.
2. Scribe a cutting guide around the pipe to ensure a per-
pendicular cut for proper fit.
3. Hold the pipe firmly but not to the point of crushing. If
chain vises or other mechanical holding devices are used,
care should be taken to prevent crushing or point loading
of the pipe. To prevent damage to the pipe, 180 degree
sections of FGS pipe can be used for protective covers.
4. Saw the pipe as smoothly as possible. The pipe ends
should be square within 1/8 inch.
PART IV

FABRICATION
RT, GT, SS

Note: For integral joint (IJ) bell ends, the bell end must be cut
off before tapering. Measure the O.D. of the pipe near the bell
end until you see the O.D. start to get larger. Cut the pipe at
this point. Depending on pipe size the distance from the end
of the bell can vary anywhere from 12" to 36".

25
 Fabrication of RED THREAD II, GREEN THREAD AND
SILVER STREAK Pipe and Fittings

TAPERING FGS PIPE

Various tools are available from FGS for making the ta-
pered spigot in the field.
To reproduce a standard taper, the tapering tool must be
marked or adjusted. The process varies depending on the tool
being used and the product being tapered. Please refer to indi-
vidual tool instructions for tapering.

Refer to Table 6 on page 28 for specific bulletin number and

proper taper angle for each size and type of pipe.

Do not taper over the bell end of integral joint pipe. See
page 25 for cutting instructions.

A. 1"-6" Tool (Bulletin F6600) - A

hand-held tool that can be adapted for
power when a large number of tapers
FABRICATION
RT, GT, SS

is necessary. Different piping systems

require different mandrels.

B. Model
2100/ 2102
Tool (Bulletin F6625/ F6624)
- Power tool for tapering and
scarfing RED THREAD II and RED
THREAD IIA piping.

C. Model 2300 Tool (Bulletin

F6627) - Power tool especially
designed for tapering 1” - 4” GREEN
THREAD piping.

D. 8", 10", or 12" Tapering Tool

(Bulletin F6608 or F6612) - These
tools are designed for manual or
power (i.e., Ridgid 300 or 700 power
drive or equal) operation; there is a
tool for each size pipe.

26
E. 8"-16" Grinding Tapering
Tool (Bulletin F6616) - This is an
electrically powered grinding tool.
The tool comes with different size
mandrels to taper 8"-16" pipe.

Additional material will be needed:

1. Sturdy work bench (preferably
with a metal top) or stand to hold
the tool
2. Two 20" long pieces of 1" diameter steel pipe. Mount these
on top of the bench parallel to each other, on a 2-foot center,
extending off the bench 12".
3. Two adjustable pipe stands with hard rubber rollers at 90
degree angle to pipe, i.e. the stand must allow the pipe to
rotate.
4. This tool requires approximately 3,000 watts of 115 vac
power for operation (30 amp breaker). We recommend 5,000
watts (50 amp breaker). As the length of extension cords in-
creases, the power lost in the cord increases. Table 5 shows

FABRICATION
maximum allowable lengths for various size cords:

RT, GT, SS
F. 8"-16" Taper/Scarf Tool (Bulletin
F6622) - This is an electrically pow-
ered tapering tool. The tool comes
with different size mandrels to taper
8"-16" pipe.

G. 18"-24" Tapering Tool (Bulletin F6621) - This is an elec-

trically powered tapering tool. The tool comes with different
size mandrels to taper 18"-24" pipe.

Note: Some tools may be used with other pipe systems with
special-order tooling. In these cases, supplemental tool instruc-
tions are also available. Be sure to specify which pipe system
you will be tapering when ordering tools.

TABLE 5. Extension Cord Length

Wire Size Suggested Length Maximum Length
(AWG) (Ft.) (Ft.)
12 20 22
10 30 36
8 50 57

27
 Tool Product Tool Taper Angle Bulletin # Comments
Specify product to receive correct mandrels. Power adapter
1" - 6" Hand RT 1" = 3°;11/2 = 21/2°
F6600 separate. Uses Ridgid® 700 or equivalent power drive with a
Tapering GT 2" - 6" = 13/4°
Ridgid 774 adapter.
RT/GT
2" - 6" Modular 13/4° F6603 Specify the product to receive correct mandrels.
TABLE 6.

2100 Power RT 13/4° F6625 Tapers 2” & 3”; Scarfs 3” & 4”

2102 Power RT 13/4° F6624 Tapers 2” - 4”; Scarfs 3”
1" = 3°; 2 = 21/2° Tapers 1” - 4”
2300 Power GT F6627
3" - 4" = 13/4°
2700 Power SS 13/4° F6632 Tool for 2"-4" Silver Streak

28
2”-6” taper angle =13/4°. Set tool on 11/2° to cut correct taper.
2" - 6" (Unique) SS Adjustable F6605
Uses Ridgid 700 or equiv. with 772 adapter.
RT F6608 (Taper) Tapers and scarfs. Uses Ridgid 700 or equivalent power drive
8" Tapering 0 or 1°
GT F6609 (Scarf) with a Ridgid 774 adapter.
10" & 12" RT F6612 (Taper) Tapers and scarfs. Order scarfing adapter kit for Secondary
Cutting Tool Reference Chart

0 or 1°
Tapering GT F6613 (Scarf) Containment. Use 774 adapter.
RT/GT F6616 (Taper)
8" - 16" Tapers and scarfs. Some SILVER STREAK and Performance
SS
Tapering, Scarfing and

0 or 1° F6617 (Scarf)
Tapering/Scarf Plus will have to be double cut.
MOS F6622
1° - Standard
8" - 24" Tapering RT F6621 Tapers 18” - 24”
11/4° - MOS
 JOINT PREP for
RED THREAD II, GREEN THREAD and SILVER STREAK

All bonding surfaces must be clean and dry before bonding.

• For T.A.B. joints, clean with an acceptable solvent and
clean rag. Wire brushes may also be used for cleaning
T.A.B. surfaces; however, they must be clean and free of
oily contaminates.
• For smooth tapers, sandpaper or solvent (or both) may
be used. Sand just light enough to remove any contami-
nates.
• Use caution as oversanding can change the taper angle
or end dimension, and create flat spots on the spigot.
• When surfaces have weathered, sand or retaper spigots
and sand bells to achieve a factory fresh appearance.
Cut at least 1” from spigots before retapering. T.A.B.
couplings must be replaced.
• Bonding surfaces must be dry, so be sure all solvent has
evaporated before applying adhesive.

FABRICATION
Note: Use of a solvent as a cleaning method is optional.

RT, GT, SS
Some alternate cleaning solvents are acetone, methylene
chloride, and methyl ethyl ketone. After cleaning, be sure any
residual solvent has evaporated before applying adhesive. DO
NOT USE SOLVENTS THAT LEAVE AN OILY FILM ON THE
BONDING SURFACES.

WARNING: Some degreasers and solvents are

!
extremely flammable. Do not smoke or use near an
open flame. Wear eye protection. Be sure to read
warning labels on containers.

Never use gasoline, turpentine, or diesel fuel to clean joints.

Solvent containers may be under pressure. Use caution

when removing inner seals, especially in warm weather. Use
with adequate ventilation.

29
 ADHESIVE MIXING

When the weather is cool or the adhesive has been

stored in a cool environment (below 70°F), prewarm the
adhesive kits. (Do not heat above 100°F!)
1. For epoxy empty all of the contents of the hardener bottle
into the can of base adhesive.
2. Mix all of the base epoxy adhesive with all of the hardener.
NEVER ATTEMPT TO SPLIT A KIT. Cut through the adhe-
sive with the edge of the mixing stick to assist in mixing the
two components.
3. Mix until the adhesive has a uniform color and a consistent
flow off the mixing stick. Wipe down the sides, bottom, and
under the rim of the can with the mixing stick to assure com-
plete mixture.

Complete information and safety precautions are packaged

with each adhesive kit. Review all safety precautions thor-
oughly before mixing the adhesive.
FABRICATION

ADHESIVE DISPOSAL: Once the adhesive and hardener have

RT, GT, SS

been mixed and reacted, nothing can be extracted, and it is

classified as non-hazardous material. Dispose of in a nor-
mal manner as other solid waste. Excess adhesive and
hardener can be mixed, allowed to react, and disposed of as
above. If extra jars of adhesive or hardener have accumulated
without the other component to mix and react, contact your FGS
regional manager. Hardener jars, when empty are not subject to
EPA regulation and can be disposed of in a normal manner. These
guidelines are based on federal regulations. State and local regula-
tions and ordinances should be reviewed.

30
 JOINT ASSEMBLY for
RED THREAD II, GREEN THREAD and SILVER STREAK

A. Close Tolerance Piping

The tapered bell and spigot system employed by FGS
can be readily used to achieve dimensional accuracy where
required by a particular pipe layout. As with any matched
taper, minor variations in tolerance in the bell or spigot will af-
fect the insertion depth. In applications where the final make-
up length of an assembly is not critical, these variations are of
no consequence. However, when the installation is such that
close tolerances must be maintained, you must compensate
for these variations. It is possible to accurately reproduce
tapers (spigots) in the field with the field tapering tools. This
provides a means of achieving dimensional accuracy.
Calculation to Achieve a Desired Length
Most close tolerance installations are made to prints call-
ing out CL to CL (centerline to centerline) dimensions.
When fabricating to these dimensions, follow these pro-
cedures per the figure below .

FABRICATION
1. Obtain the centerline to face dimension (A) of fittings

RT, GT, SS

to be used from Tables 8 or 9 on pages 33-36.

2. Create an insertion gauge by cutting a short section
of pipe; 12” long for small diameters and 18” long for
larger diameters. Taper the pipe using the instruc-
tions supplied with each tool. Check dry insertion.
The insertion length should be within +1/8” of a factory
spigot insertion.
3. Obtain insertion length (IL) by inserting the gauge
(made with the tool being used) into a fitting and
measuring. (Note: Measure each end of each fitting,
because the insertion may vary for each bell.) You can
prepare and use a short nipple as a standard insertion

31
 gauge. (Note: You must prepare a new gauge if you
change tapering tools or make any changes to the tool
you are using.) Always add a make-up dimension (refer
to Table 7) to this measurement, since the adhesive will
act as a lubricant and allow greater penetration than
when the surfaces are dry.
TABLE 7. Approximate Make-up Dimensions (M)*
Approximate Make-up
Pipe Diameter (In.)
Dimensions* (In.)
1 and 11/2 1/16

2 1/8

3 and 4 3/16

6 1/4

8 3/8

10 and 12 5/8

14 3/4

16 1
18
FABRICATION
RT, GT, SS

20 Use field developed dimensions

24
*CAUTION: Make-up dimensions depend on the tightness of the dry fit. If
the field developed dimensions vary, use field developed dimensions.
4. To achieve a specified CL to CL dimension, the length
of pipe to cut is equal to the CL to CL distance minus
the sum of the centerline to face dimension of the
fittings (“A” dimension) plus the sum of the measured
insertion lengths (IL) plus the sum of the
make-up allowance (M), or

Length of Pipe to Cut =

(CL to CL ) - (A + A) + (IL + IL) + (M + M)

Note: Each bell of each fitting may have a slight-

ly different insertion depth with a standard taper.
Each bell of each fitting should be checked
with a standard taper and
marked.

Consult FGS Fittings

Bulletins No. A1350 or
A1355 for complete fit-
ting dimensions.

32
 TABLE 8. Take-off Dimensions for RT, GT Fittings (Contact FGS for SS Dimensions)

Dimensions are
used to calculate pipe
length requirements to
meet pipeline center
line to center line
dimensions.

Lateral (In.)
Size (In.) 45° Elbow 90° Elbow Tee Cross
A B
1 23/8 23/4 23/4 37/8 21/2 23/4
11/2 27/8 33/8 33/8 51/4 31/4 33/8

33
2 25/8 33/8 33/8 65/8 23/4 33/8
3 33/4 45/8 45/8 73/4 41/4 45/8
4 37/8 51/8 51/8 9 43/8 51/8
6 43/8 61/8 61/8 121/2 53/4 61/8
8 81/8 115/8 115/8 161/4 73/8 115/8
10 85/8 131/8 131/8 195/8 83/4 131/8
12 91/2 14 14 243/4 113/4 14
14 121/2 19 19 321/2 153/4 16
16 131/4 201/4 201/4 353/4 173/4 171/4
FABRICATION
RT, GT, SS
 Table 8.1
Take off and nominal dry insertion dimensions for low pressure, 150/225 psig, RED THREAD and GREEN THREAD products.
For information on fittings not listed in this table, contact Fiber Glass Systems Technical Service Dept. or refer to Bulletin A1350
on our web site at http://www.smithfibercast.com
Size 45 º Elbow (In) 90 º Elbow (In) Tee (In) Flanges (In)
(In) A x-RT x-GT A x-RT x-GT A x-RT x-GT Molded FW x-RT x-GT
1 2⅜ NA 1⅛ 2¾ NA 1⅛ 2¾ NA 1⅛ 1⅜ NA 1⅛
1.5 2 ⅞ NA 1 ¼ 3 ⅜ NA 1 ¼ 3 ⅜ NA 1 ¼ 1 ⅜ NA
2 2 ⅝ 1⅝ 1 ⅝ 3 ⅜ 1⅝ 1 ⅝ 3 ⅜ 1⅝ 1 ⅝ 2 ⅜ 1⅝
3 3 ¾ 1⅞ 1 ⅞ 4 ⅝ 1⅞ 1 ⅞ 4 ⅝ 1⅞ 1 ⅞ 2 ¾ 1⅞

34
4 3 ⅞ 1⅞ 1 ⅞ 5 ⅛ 1⅞ 1 ⅞ 5 ⅛ 1⅞ 1 ⅞ 2 ¾ 1⅞
6 4 ⅜ 2½ 2 ⅜ 6 ⅛ 2½ 2 ⅜ 6 ⅛ 2½ 2 ⅜ 2 ½ 2½
8 8⅛ 4¼ 3½ 11 ⅝ 4¼ 3½ 11 ⅝ 4¼ 3½ 3¼ 3
10 8⅝ 4¼ 3⅝ 13 ⅝ 4¼ 3⅝ 13 ⅝ 4¼ 3⅝ 4⅞ 3¾
12 9½ 4 3⅞ 14 4 3⅞ 14 4 3⅝ 4½ 4
14 12 ½ 6 6 19 6 6 19 6 6 2 3⅛ 2⅛
16 13 ¼ 6⅛ 6⅛ 20 ¼ 6⅛ 6⅛ 20 ¼ 6⅛ 6⅛ 2 3⅛ 2⅛
Contact Fiber Glass Systems Technical Service Dept. for 18"-24" dimensions.
(1) Refer to Bulletin A1350 for information on 2"-12" filament wound flanges.
X dimensions are nominal dry insertion lengths. Pipe must be driven together and fully locked up to assure full joint strength. Actual insertions
should be +1/8" of a field measured factory insertion for 1"-6" and ¼" for 8" and larger. Insertion depths are for tool set up only. Do not use
insertion depths (x) for close tolerance piping. Refer to joint assembly instructions for complete information on joint lock up.
Table 8.2
Take off and nominal dry insertion dimentions for low pressure,
150/225 psig, SILVER STREAK products. Refer to Bulletin
A2000 or www.smithfibercast.com for more information.

INSERTION DEPTHS FOR SILVER STREAK

Coupled/Mitered Filament Wound
Size Fittings Fittings
2 1.84 2.64
3 2.36 2.86
4 1.99 3.13
6 2.87 2.76
8 3.47 5.28
10 4.34 5.12
12 4.82 6.40

FABRICATION
14 5.47 4.55

RT, GT, SS
16 6.27 5.61

35
 X dimensions are nominal dry insertion lengths. Pipe must be driven together and
fully locked up to assure full joint strength. Actual insertions should be + ¼" for 8"
and larger joints. Insertion depths are for tool set up only. Do not use insertion
depths (x) for close tolerance piping. Refer to joint assembly instructions for
compelte information on joint lock up.

A-Van Stone
Flanges (In)

10 ½
12 ½
15 ½
6¼

7¾
7

8
9
Take-off Dimensions for RT/ GT Performance Plus Fittings

x-GT
5⅛
6½

5¾
5¾
7
Tee (In)

x-RT

6½

5¾
5¾
6

7
13 ½
15 ¾
17 ¾
19 ½
21 ½
26 ⅜
31 ¼
35
A
FABRICATION
RT, GT, SS

x-RT x-GT
5⅛
14½ 6½ 6 ½ 23 ¼ 6 ½ 6 ½

5¾
5¾
(Long Radius) (In) (Long Radius) (In)

7
90 º Elbow

5¾
5¾
6

7
5⅛ 19 ½

47 ¼
27
30
34
40

57
x-RT x-GT A

5¾
5¾
7
45 º Elbow

5¾
5¾
6

7
TABLE 9.

29 ⅝
35 ⅞
12½

16½
17¾

24⅞
20
A

10
12
14
16
18
20
24
Size

8
(In)

Dimensions are used to cal-

culate pipe length requirements
to meet pipeline center line to
center line dimensions.

36
B. 1” - 6” Bell & Spigot Joint
THE SPIGOT MUST BE ALIGNED AND LOCKED IN
THE BELL. A cocked or misaligned joint will result in false
“lock up” and premature joint failure either during testing or
at a later date.
1. When ambient temperature is below 70°F, prewarm the
bonding surfaces. Use a hot air gun, propane torch or
other clean burning heat source that has a spreader
type tip, and apply heat uniformly
to bell and spigot until warm to the
touch. Check temperature by touch-
ing outside of the bell and inside of
the spigot to avoid contact with clean
bonding surfaces. If hot to the touch,
let cool before applying adhesive.
When using a torch to preheat, warm
the bell first. It is thicker and will hold
heat longer. If an electric heating
collar is used to prewarm, place the joint together
dry, then heat the O.D. of the bell to avoid contami-
nating the spigot. CAUTION: Do not use chemical

FABRICATION
RT, GT, SS
heat packs for prewarming.
2. Brush adhesive on both the bell and spigot bonding
surfaces, applying a thin uniform coating to each . To
minimize contamination, apply adhesive
to the bell first. Adhesive should always
be worked into the machined surface
by applying pressure during application.
This will “wet out” the machined surface
and maintain the required thin bond line.
Be sure that adhesive is deep down into
the bell past the insertion depth and that
all machined taper surfaces on the spigot
and the cut end of the pipe are uniformly covered.
Excess adhesive will make the joint more difficult to
lock.
3. Align and lock the joint. For 2" or smaller pipe, insert
the spigot into the bell until surfaces touch, then push
and turn at the same time until a lock is
achieved. Only a quarter to a half turn is
usually needed. On 3”-6” diameter pipe
or on fittings, pushing and turning to lock
the joint is impractical and driving force
must be used. A hammer may be used to
assist in joint lock-up. Place a 2x4 board
flat across the bell. The first few raps should be light
to prevent any tendency of the joint to back out.
37
 If the adhesive or the
pipe surfaces are cool,
push and hold for a few
seconds to allow time for
the adhesive to start flow-
ing out of the tapered joint.

4. Check lock up by moving free end of the pipe in an

up and down or side to side motion. The movement
must be sufficient to move the joint being checked. No
movement should be visible in the joint. If any move-
ment exists, the joint is not properly locked up. Avoid
excess movement as this could damage the spigot.

C. 8” - 24” Bell & Spigot Joint

1. Long runs (ditch piping) must be supported at the joint
section at all times until fully cured. Lifting near the
center of the pipe with a backhoe or side boom tractor
without proper support under the joint can cause dam-
age to joints that are not cured. Lifting near the center
FABRICATION

of the pipe for alignment is acceptable as long as the

RT, GT, SS

joint does not support the weight of the piping section.

Blocks or skids should be used to support the entire
joint section until the joint is fully cured. Install pipe in
straight alignment; never install pipe in a bind.

2. 8"-24" hydraulic come-along is recommended for

pipe to pipe connections. All joints pulled together with
this type of device must be vibrated during installation to
help align the spigot in the bell and prevent a false lock
up or cocking of the joint. Refer to Bulletins No. F6618
or F6619 for detailed instructions on hydraulic come-
alongs.

a. When using a hydraulic come-along on 8”-24” pipe,

make sure pipe is resting on blocks before come-
along collars are removed. Do not remove collars
while pipe is still attached to cable or tractor. If
collars are resting on blocks after bonding, leave
pressure on come-along and lift gently with the
chains, just enough to remove collars. Do not place
excessive bending stress across the joint.

38
 3. Strap clamp kits are available from FGS for pipe to
fitting connections. When used in conjunction with the
hydraulic come-along, a heavy duty band (strap) clamp
and two ring belt straps are used to pull the joint togeth-
er. Refer to Bulletin No. F6641 for detailed instructions
on Strap Clamp Kits.

4. Ratchet-type come-alongs can be used as an alterna-

tive to the hydraulic
come-alongs. Use two,
one on each side of the
joint. Use a heavy-duty
strap clamp kit to attach
the come-alongs to the
pipe. Slings, or 5/8” or
larger manila ropes,
are also acceptable. A series of half-hitches will grip
the pipe when using rope. Allow room to operate
the come-alongs by placing the strap clamps, slings

FABRICATION
RT, GT, SS
or ropes 18”-24” on each side of the joint. Take up
come-alongs together so that the joint stays in align-
ment. Force the joint together until it is solid. Rap the
joint together with a 12-15 lb. sledge hammer and a
board while keeping pressure on the come-alongs to
ensure the joint is fully engaged.

5. Fitting to pipe joints can be made by placing the

fitting against a solid structure such as a wall, side of
the trench, truck bumper, etc. Drive the spigot end of
the pipe into the fitting using a 12-16 lb. sledge ham-
mer and a large block of wood. Place the block against
the pipe end away from the fitting. Care should be
taken while hammering as excessive force can damage
the pipe end or fitting.

TABLE 10. Hydraulic Come-Along Pressures

Pipe Pipe Size Hydraulic Pressure
Grade (In.) (psig)
RT, GT, SS 8-10 1500-1750
12-16 1750-2000
RT PP, GT PP 8-10 1500-2000
12-16 2000-2500

39
 D. T.A.B. Joint:
T.A.B. Joint installation proce- T.A.B. Wrenches
dures follow the normal bell and
spigot operations of cleaning, ad-
hesive mixing, etc. as described
above. Two T.A.B. wrenches are
required when joining T.A.B. pipe.
Separate wrenches are available
from FGS for each size pipe. The
wrenches lock around the pipe
and force the pipe into a very slight oval shape. Therefore,
the wrenches must be 6" to 12" away from the joint to assure
good joint make up.
1. Cover all machined areas on the spigot and at least
one-half inch beyond the last thread in the bell with the proper
adhesive.
2. Screw the pipe together until firm using T.A.B. joint
wrenches. DO NOT OVERTIGHTEN.
FABRICATION

Connections into fittings are made using the normal bell

RT, GT, SS

and spigot methods. A threaded spigot can be bonded into a

smooth bell (fitting), or a smooth spigot can be bonded into a
threaded bell.

E. Saddles and Reductions

Note: 3033 Adhesive is recommended for saddles.

Position the saddle on the pipe and mark around the saddle
base. Use a file, a sander, or rough sandpaper (16 to 40
grit) to remove all surface gloss from the pipe O.D. where
the saddle is to be bonded. (For large diameter pipe, a disc
sander is usually more practical.) Use circular or random pat-
tern motion during sanding to eliminate grooves on the pipe
surface. After sanding, position the saddle on the pipe and
mark the hole to be cut in the pipe. Cut a hole the same size
as the saddle outlet using a pilot drill and circular hole saw or
sabre saw. Do not force the cutter or it will fray the edges of
the hole excessively. Clean all bonding surfaces as required.
Note: Be sure cleaner (if used) has evaporated before ap-
plying adhesive to the bonding surfaces. Apply a heavy coat
of adhesive to the O.D. of the pipe, I.D. of the saddle, and
the edges of the pipe wall exposed by the hole. Place the
saddle over the hole and clamp with two hose clamps or a
banding tool. (Note: Banding tool must be a type that does
not leave slack in the bands when the tool is removed. Use

40
metal banding.) Using a large
screw driver, hand tighten the hose
clamps alternately until secure
and adhesive squeezes out all the
way around the saddle. This will
ensure that the pipe O.D. conforms
to the saddle I.D. You can remove
the clamps or leave them in place
after the adhesive is cured. Allow
adhesive to cure before bonding
in the side run. Use two banding
tools to pull the sides of the saddle
down alternately. If two tools are
not available, tighten the first band
snug, the second band tight, and
add a third band, pulled tight, on
the first side. Three-quarter inch
banding is recommended. If the
saddles are used on non-standard
pipe (pipe not listed in FGS litera-
ture), contact your FGS represen-

FABRICATION
RT, GT, SS
tative for special instructions.

F. Reducer Bushings
Install reducer bushings using a block of wood and a hammer
and the same procedures as for bell and spigot pipe. The
wood block should be sized to allow the reducer bushing to be
counter-sunk in the bell. Some reducer bushings will be coun-
ter-sunk before they are actually locked up. For maximum
chemical resistance with 8" and larger Green Thread reducer
bushings, coat all machined surfaces with adhesive just before
assembly.

41
 JOINT CURE
TABLE 11. Adhesive Ambient Cure Time
Adhesive Type Temperature (°F) Cure Time (hrs.)
110 2
90 3
80 5
7000
70 8
60 18
55 24
110 1
90 2
FABRICATION

80 4
RT, GT, SS

8000
70 6
60 12
55 18
NOTE: Cure time is the time before the line can be tested. Times may
vary depending upon temperature, humidity, etc.

A. Ambient Cure
Cure time is the time required for the adhesive in the
assembled joint to harden. Cure time depends on the type of
adhesive and the ambient temperature, as shown in Table 11.
You can shorten cure time by applying heat. Although
all of the adhesives will cure at ambient temperatures above
70°F, it is recommended they be heat-cured at temperatures
of at least 275°F to maximize physical properties and corro-
sion resistance. See page 43 for instructions for using FGS
heat collars for heat-curing joints.

B. High Temperature Heat Collar

Refer to Bulletin No. F6640 for complete operating
instructions.

42
NOTE: Do not bend or fold heating collar as this may break
the heating elements and cause the collar to work improperly
or not at all.

For Pipe and Fittings:

1. Use the same size heating collar as the pipe size you
are installing, with the exception of flanges. Do not use a
heating collar that is designed for a larger size pipe.
2. With the un-insulated flap on the bottom (next to the
fitting), carefully wrap the heating collar around the joint.
Feed the strap through the square ring. CAUTION: The
un-insulated flap is extremely hot when the collar is on.
DO NOT TOUCH with bare hands.
3. Tighten the straps until the heating collar is snug against
the joint.

For Flanges:
1. For 1", 11/2" and 2" flanges, an industrial heat gun may be
used to cure the joint. Be sure that the end of the gun is at
least six inches from the opening of the flange.
2. For 3" through 16" flange joints, use a heating collar that

FABRICATION
is one pipe size smaller. Remove the straps from the

RT, GT, SS
heating collar.
3. Carefully turn the collar inside out with the heated area
facing the I.D. of the pipe. Place the heating collar in the
I.D. of the flange. A split ring of pipe may be used to hold
the collar in place while the joint is curing.

For Saddles:
1. Place the heating collar over the saddle outlet. During
cool weather, a wind shield is recommended to keep heat
on the joint. Saddles must be heat cured for two hours.
Allow the joint to return to ambient temperature before apply-
ing stress to the joint.

NOTE: FGS High Temperature electric heating collars are de-

signed to fit around fittings, and will overlap on pipe joints and
couplings. Exceeding the recommended cure time on pipe
joints where the heating collar overlaps may shorten the life of
the heating collar and/or damage the pipe.
The use of insulation may be necessary below 40°F to prevent
heat loss.

43
TABLE 12. High Temperature Heat Collar Cure Times for Adhesive Joint Fabrication

Pipe (1) Fitting Flange (2) Perf. Plus

N/A

N/A
120
120
120

120
120
120
30
35
40
45
60

30
35
40
45
60
Cure Time (Minutes)

15
20
27
30
34
38
70
80
90
15
20
27
30
34
38
70
80
90
20
20
27
30
34
38
70
80
90
20
20
27
30
34
38
70
80
90
10
20
27
30
34
38
70
80
90
12
20
27
30
34
38
70
80
90
Pipe Size (In.)

18 (3)
20 (3)
24 (3)

18 (3)
20 (3)
24 (3)
2-6

2-6
10
12
14
16

10
12
14
16
8

8
Adhesive Grade

Series Adhesive
Pipe System &

Green Thread
Red Thread II
7000 or 8000

Silver Streak
8000 Series
Adhesive

NOTE: Heat blanket cure time refers to that time when the
heat source can be removed and the pipe installed and tested
at recommended pressures. Heat blanket hours pertain to
70°F-100°F fabrication environment. Cure times will be longer
for colder temperatures. For temperatures below 70°F, see
“Cold Weather Installation Tips” on page 14 or consult FGS
Technical Services. If no heat source is available, adhesives
will cure at ambient temperatures of 70°F-100°F in 24 hours.
(1) Includes sleeve couplings.

250°F
(3) 18" joints require the use of one 8" and one 10" heating collar
20" joints require the use of two 10" heating collars
24" requires the use of two 12" heating collars
C. FGS Heat Packs
FGS heat packs that cure joints in approximately one hour
are also available. Refer to Bulletin No. D4500 for complete
instructions that are included with each kit. Observe all safety
precautions listed on the instruction sheets that accompany the
heat packs.
44
 Caution: The adhesive bead will cure faster than
! the adhesive in the joint. It is important that the joint
not be pressurized until it has been subjected to the
proper time-temperature cycle. A temperature versus time to
pressure curve is indicated in the instructions packaged with
each adhesive kit.

REPAIRS for RED THREAD, GREEN THREAD & SILVER

STREAK Piping Systems

Fiberglass piping systems are relatively simple to repair.

Normally, repair means cutting out a fitting or a damaged sec-
tion of pipe and replacing it with new material.

Caution: Always determine exactly what fluid has

! been in the piping system. Contact may be harmful to
humans. Take necessary precautions.

Always use the same pipe grade, fittings, and adhesive on new
parts as is in the existing system. Do not mix pipe grades.

FABRICATION
RT, GT, SS
Inspecting for Potential Causes of Joint Failure

Joint Backout – If the bead is no longer next to the edge

of the bell, the joint backed out before the adhesive cured.
Cocked Joint – If a joint is cocked or misaligned, there
will usually be a large gap between the bell and spigot on one
side.
Improperly Cured Joint – If the adhesive bead is soft or
flexible, the adhesive is not sufficiently cured.
Weathered Joint – If the machined area appears yellow,
the joint may have been exposed to UV degradation.

All damaged or improperly assembled joints must be repaired

or replaced as indicated below.

REPAIRING WEATHER DAMAGE

If machined surfaces of pipe or fittings are exposed to
direct sunlight prior to installation, a loss of joint bonding
strength may occur. If ultraviolet exposure is greater than two
hours, the following steps must be taken:

1. For exposed spigot ends, use 80 to 120 grit sand paper

or Emery cloth and lightly sand to remove UV degrada-
tion. Avoid oversanding as this may alter the taper angle
of the spigot and may result in voids in the bond line.
If UV degradation is too severe, cut 1” from the end of the
pipe and retaper.
45
 2. For exposed bell ends (pipe or fittings), sand thoroughly
until the entire surface appears fresh. Hand sanding with
40 grit sandpaper is recommended. Use a light sanding
operation to prevent changing the taper angle.

NOTE: COUPLINGS OR INTEGRAL BELLS WITH T.A.B.

THREADS THAT HAVE BEEN OVEREXPOSED MUST BE
REPLACED.

REPAIRING MINOR DAMAGE

For damaged areas less than one inch in diameter in light
chemical or water service.

A. Flanged Systems: If possible, simply replace the entire

flanged length. Otherwise, cut out the damaged section,
then bond new flanges to the remaining pipe ends accord-
ing to recommended procedures. Next, fabricate a new
flange-by-flange spool to the length required. Bolt in the
new pipe section.
Flanged fittings should be removed from the system when
FABRICATION

damaged and replaced with a new fitting.

RT, GT, SS

B. Tapered Systems: Make a patch to cover damaged

area.
1. Cut a length of good pipe to adequately cover the
damaged area and extend 3”-4” on either side of the
damaged area.

2. Slit this “patch” length-

wise twice and remove
a section so that about
three-fourths of the
circumference remains for 1"-4" pipe and one-half the
circumference for 6" and larger pipe.
3. Thoroughly sand the inner surface of the patch and
sand a corresponding area on the pipe around the
damaged section.
4. Clean the bonding
surfaces, then ap-
ply a thick coating
of adhesive to both surfaces, snap the patch in place,
and apply pressure with hose clamps. The clamps
may be left on or removed after curing.
46
 REPAIRING EXTENSIVE DAMAGE
When the damaged area in the pipe wall is larger than one
inch in diameter, or for repair of pipe in severe chemical ser-
vice that requires a lined product, follow these instructions:

1. When damage is local (less than one inch long, but more
than two inches around
the circumference of the
pipe), check to see if there
is enough slack in the pipe
to cut out the damaged sec-
tion, re-taper the cut ends,
and bond a sleeve coupling
between the tapered ends.
2. When damage is extensive (too large for replacement by
a single sleeve coupling), cut out the damaged section,
taper the cut ends, and install two sleeve couplings and a
pipe nipple. This procedure requires sufficient slack
in the line to make the final joint by lifting the pipe (or
moving the pipe to one side) to engage the bell and

FABRICATION
spigot joint.

RT, GT, SS
3. If the line cannot be moved sufficiently to install a sleeve
coupling or a sleeve coupling spool piece, taper both
ends of the pipe and install flanges.
4. If it is impossible to taper the pipe in the ditch, you can
install a new section of pipe by overwrapping the plain cut
ends.
a. Clean an area large enough for installers to work on
both sides and under the pipe. Cut out the damaged
section of pipe and measure the gap. Cut a section
of good pipe that is not more than one-half inch
shorter than the length to be replaced (1/4" maximum
gap on each end).
b. Sand the ends of the pipe to remove all resin gloss.
Align the replacement pipe section with the pipeline
and block up all sections to maintain alignment. All
sections must be rigid so they will not move during
the overwrapping procedure. Tack welds should be
used by placing 1" x 2" patches of glass cloth and ad-
hesive (four patches spaced at 90° intervals around
the pipe). See Overwrapping.

47
 REPAIRING LEAKING JOINTS
Overwrapping – If a joint leaks because of improper instal-
lation, you can repair it by overwrapping with glass cloth and
resin. The temperature in the work area should be 75°F-90°F.
Be sure to protect the overwrap from the sun.

1. Use 7-10 oz. glass cloth from FGS. Components for the
epoxy overwrap are available in an 8088 repair kits (see
Table 13).
TABLE 13. WELDFAST 8088-S Overwrap Repair Kits
Pipe Layers Glass Width Number of kits
Size (In.) of Glass (In.) Required per Joint
1 4 8 0.25
11/2 4 8 0.25
2 6 8 0.75
3 6 8 0.75
4 6 8 1.00
6 6 8 1.50
FABRICATION

8 8 8 2.50
RT, GT, SS

10 10 8 3.50
12 12 8 5.00
14 14 8 6.50
16 16 8 8.00

2. Use a grinder
or sander with
coarse sandpaper
(40 grit or less) to
remove gloss five
inches on either
side of the joint.
3. Bevel the shoulder to blend in with the pipe wall and add
putty to make a smooth
transition from fitting to
pipe. The length of this
putty should be held to
a minimum, because the
putty has limited pressure
capabilities.

48
 CAUTION: There must not be any pressure on

! the line or any fluid leaking from the joint when

performing this procedure.

4. Re-sand and clean surfaces including bevel.

5. Thoroughly mix the adhesive and hardener with the stir
stick until there is a uniform color and a consistent flow off
the stir stick.
6. Using a paint brush, apply
the mixed adhesive to all
sanded areas.
7. Each piece of glass cloth
must be slightly longer
than the previous piece,
because the O.D. of the
pipe becomes larger as
you add glass cloth. Cut
the first piece to allow for two inches of overlap. When
this length is no longer sufficient to overlap at least one-
half inch on the ends, determine a new length with two

FABRICATION
inches of overlap.

RT, GT, SS
8. Center a piece of glass cloth over the joint. Pull on the
cloth while positioning it and wet it out by painting with
adhesive. Brush to remove any trapped air bubbles in
the wrap. Start at one end of the cloth and work around
the circumference, wetting the cloth with resin. Work the
cloth away from the starting end and from the center of
the cloth to the sides. The cloth must be thoroughly wet-
ted with adhesive, but do not spend a lot of time in one
area as the cloth will wet out (lose its shiny, white appear-
ance) with time. By the time the cloth has been worked
down smoothly with no air beneath it, most of it will be
wetted out.
9. To prevent thick sections or humps in the overwrap, cen-
ter the next piece of glass cloth on the joint starting from
a new point on the circumference. Repeat Step 8 until all
layers are applied.
10. Should the overwrap start to give off heat, discontinue
wrapping and let the joint cure and cool with a fan. Sand
the cured layers to remove the gloss before restarting the
overwrap procedure.
11. Pay particular attention to the bottom of the overwrap as
this is the area that may sag and is most difficult to see.
12. In temperatures above 90°F, protect the overwrap from
direct sunlight.

49
 PART V
FABRICATION OF F-CHEM PIPE AND FITTINGS

A. Matched Tapered Bell and Spigot Joint Prep

Note: It is essential that pipe and fitting surfaces be
sanded, clean, dry, and free of oil, grease, and solvent con-
tamination.
1. Prepare the bell and spigot
ends of the pipe by sanding
the bonding surfaces with
36 to 60 grit abrasive.
The sanded area should
extend at least 1/2" beyond
the length of the bell.
2. Never sand more than two
(2) hours before making the joint.
3. Wipe the sanded area with a clean, dry, lint-free cloth,
and avoid touching the surfaces with bare hands or
dirty gloves.

Do not use solvents.

Note: F-CHEM fittings are available with flanged or plain

ends only. See Manual No. F6080, Pipe Installation Hand-
book for Socket Joints and Butt & Wrap Joints, for joining
F-CHEM fittings and pipe with butt & wrap joints.
FABRICATION

B. Joint Assembly
F-CHEM

1. Coupler Instructions
Attach the bands or chains
to the pipe. Have the jacks
and all other material
ready, prior to mixing the
resin and catalyst.

Place band clamps or chains approximately 3 to 4 feet

from the joint on both the bell and the spigot pieces.
Slip the "D" rings into place on the horizontal center-
line, on both sides of the pipe, prior to attaching the
coupler hooks.

Unreel the couplers and hook the jacks into place. The
cables may be left unattached to allow working room
for the application of the adhesive.

50
 2. Mixing Weldfast CL-100 Adhesive
a. Mix the can of Part "A"
resin to fully disperse any
liquid which may have
separated during storage.
It should be a light purple
color.
b. Add the recommended
tubes of Part "B" catalyst to the Part "A" resin can.
c. Mix thoroughly for a minimum of
two minutes or until the color is a
consistent light green.

3. Pot Life
Pot life (working time) may vary with changes in tempera-
ture and humidity.
TABLE 14. CL-100 Adhesive Estimated Pot Life

Pipe Pot Life Pot Life

Resin @ 70°F @ 90°F
System Adhesive (min.) (min.)

Vinyl Ester CL-100 20 10

4. Applying Weldfast CL-100 and Bonding Pipe

a. Use the brush to apply gen-
erous amounts of catalyzed
resin to the bell end first,
FABRICATION

then apply to the spigot end.

F-CHEM

b. Align the joint and guide the

spigot end into the bell.
c. Attach coupler hooks and
jack the joint into firm engagement. Check around
the joint line to be sure that it is even, which indicates
proper alignment.
d. Use brush to fill in any gaps in adhesive. Leave
coupler in place during initial cure (approximately
one hour).

51
 ADHESIVE DISPOSAL: Once the adhesive and catalyst have
been mixed and reacted, nothing can be extracted, and it is classi-
fied as non-hazardous material. Dispose of in a normal manner as
other solid waste. Excess adhesive and catalyst can be mixed, al-
lowed to react, and disposed of as above. If extra cans of adhesive
or tubes of catalyst have accumulated without the other compo-
nent to mix and react, contact your FGS regional manager. Cata-
lyst tubes, when empty are not subject to EPA regulation and can
be disposed of in a normal manner. These guidelines are based
on federal regulations. State and local regulations and ordinances
should be reviewed.

C. Joint Cure
Cure time is the time required for the adhesive in the
assembled joint to harden and depends on the ambient tem-
perature. Cure Time for CL-100 Adhesive is 24 hours. Cure
time can be decreased and joint strength increased by heating
the joint from 175°F to 225°F. Heat cure is strongly recom-
mended for piping systems carrying fluids at temperatures
above 120°F.
FABRICATION
F-CHEM

52
 INSTRUCTIONS FOR USING FGS
SILICON RUBBER HEAT BLANKET

Caution: Read Operating Instructions Before Using.

• Use only with 120 volt power outlet.
• Blanket should not be used in wet conditions.
• Tears, cuts or punctures in the blanket can create a
potential safety hazard.
• The thermostat must be wrapped in the blanket to prevent
overheating.

1. Use only the proper size heat blanket for the pipe being
joined.
2. After the adhesive fillet has hardened, wrap the blanket
around the joint by first placing the thermostat end of the
blanket against the joint with the thermostat facing out.
Wrap the remainder of the blanket tightly around the pipe.
Hold it in place during the heating process.

NOTE: Check heat blanket temperature to be sure it is

heating properly.

3. Avoid excess flexing of the blanket. Abnormal flexing can

cause breakage and shorten the service life of the blanket.
DO NOT crease the heat blanket.
4. Use aluminum foil to protect heat blanket from adhesive.
5. DO NOT use cleaning solvents. Solvents penetrate the
rubber and damage the heating wires.
6. DO NOT carry or move the blanket by lifting it with the
FABRICATION

cord alone. Support the weight of the blanket separately

F-CHEM

from the cord to avoid abusing the cord-to-blanket con-

nection.

Improper sizing or use of the heat blankets can cause excess

heating which can damage both the piping and heat blankets.

TABLE 15. 110 Volt Silicon Rubber Heat Blanket Models

(For use with F-CHEM pipe)
Pipe Size 4”-8” 10”-14” 16”-20”

Model C D E

53
 TABLE 16. Silicon Rubber Heat Blanket Cure Times for
Adhesive Joint Fabrication

Piping System/ Pipe Size B&S Joints

Adhesive Grade (In.) (hrs.)
4 - 14 1
F-CHEM CL-100
16 - 20 4

NOTE: Heat blanket cure time refers to that time when the
heat source can be removed and the pipe installed and tested
at recommended pressures. Heat blanket hours pertain to
70°-100°F fabrication environment. Cure times will be longer
for colder temperatures. For temperatures below 70°F, see
"Cold Weather Installation Tips" on page 14 or consult FGS
Technical Services. If no heat source is available, adhesives
will cure at ambient temperatures of 70°-100°F in 24 hours.
FABRICATION
F-CHEM

54
 REPAIR & MODIFICATION
for F-CHEM PIPING SYSTEMS

Fiberglass piping systems are relatively simple to repair.

Normally, repair means cutting out a fitting or a damaged sec-
tion of pipe and replacing it with new material.

Caution: Always determine exactly what fluid has

! been in the piping system. Contact may be harmful
to humans. Take necessary precautions.

Always use the same pipe grade, fittings, and adhesive

when repairing or replacing damaged sections, or modifying
the system.
If you have any questions about the chemical service,
pipe grade selection, or system operating conditions, call your
local FGS Distributor or Fiber Glass Systems direct.

NOTE:
When making repairs, be sure all surfaces to be bonded
are dry, clean and thoroughly sanded. Good adhesive
connections cannot be made on wet or contaminated
surfaces.

REPLACING DAMAGED PIPE

Pipe leaks through the pipe wall are almost always the
result of physical damage to the pipe from impact, vacuum,
excessive bending, or other abusive conditions. The dam-
FABRICATION

aged section should always be replaced using the following

F-CHEM

procedures:

Flanged Systems:
If possible, simply replace the entire flanged length. Other-
wise, cut out the damaged section, then bond new flanges to
the remaining pipe ends according to recommended proce-
dures. Next, fabricate a new flange-by-flange spool to the
length required. Bolt in the new pipe section.

Flanged fittings should be removed from the system when

damaged and replaced with a new fitting

55
 Tapered Bell & Spigot Systems:
Cut out the section of pipe which leaks, making sure cuts are
square. Dry the pipe ends. Cut a new length of pipe the same
length as the piece that was cut out. Use two FGS butt &
wrap kits to bond the new pipe into place. Refer to Manual
No. F6080 for Butt & Wrap Joint detailed instructions.

Butt Wrap Butt Wrap

REPLACING DAMAGED FITTINGS

If a leak develops in an F-CHEM fitting, it will usually be
necessary to cut out the leaking part and replace it. Use FGS
butt & wrap kits to bond the new fitting into place. Refer to
Manual No. F6080 for detailed instructions.
TEMPORARY FIXES, OVERWRAP
FABRICATION
F-CHEM

Step 1
Problem - Cut out
Fitting Section

Butt Wrap
Joint

56
 As a temporary repair, a leaking fitting, pipe or joint can
be overwrapped with a resin and glass lay-up. This requires
resin, catalyst, fiberglass reinforcement, tools, and a clean,
dry work area. Many times an overwrap is the preferred
method, particularly when fittings are in a close, complex
manifold or assembly. Custom overwrap kits are available for
each pipe size and pressure classification. Contact FGS.

Application Procedure: Before making the over-wrap, read

these instructions carefully.
1. Sand the surface area thoroughly for an equal distance
on each side of the leak. The sanded surface should
extend at least 1/2” beyond the widest layer of glass sup-
plied with the kit. Remove all surface glazes, paint, oil,
grease, scale, moisture, or other foreign material to en-
sure proper bonding of the resin material to the surface.
2. Use the applicator brush to remove all dust from the
sanded area.
3. If repairing a bell & spigot pipe joint, use the WELDFAST
adhesive putty sup- Bell
End
plied in the kit to form
a tapered bead as
shown in this sketch. Spigot
End
The bead will provide
a smooth transition
from fitting to pipe.
4. Lay out the precut Veil & Tapered
Weldfast
fabmat and surfacing Fabmat
Overlay Bead
FABRICATION

veil on a flat, clean, dry

F-CHEM

surface (i.e., cardboard, plywood, etc.).

5. Add contents of Part "B" tube(s) to container of Part "A"
(resin). Using one of the wooden stirrers, mix the contents
thoroughly for at least one minute.
6. Use the applicator brush to apply a liberal, even coating
of the resin mixture to the entire sanded surface.
7. Using the 3" roller, thoroughly saturate the fabmat laid out
on your working surface. Apply wet-out fabmat to the joint
to be overlaid placing the mat side down. Using the 3"
roller, continue to roll out the material until all entrapped
air has been rolled out and the fabmat is contoured
smoothly to the surface.
8. For joint sizes 4" and larger, repeat Step #7 above.

57
 9. Place surfacing veil over the fabmat and, again using the
3" roller, apply a liberal amount of resin and work out all
air as in Step #7.
Be sure that the pipe surface is thoroughly wet out with
catalyzed resin.

Some guidelines on the overwrap are:

1. The overwrap should be equally spaced on each side of
the point of the leak.
2. The overwrap should be around the entire circumference
of the pipe or fitting.
3. The pressure rating and pipe diameter will determine the
overwrap thickness. Consult FGS technical services to
determine specific information about design of the over-
wrap.
4. The resin system of the overwrap should be compatible
with the resin system of the existing pipe or fittings.
5. Cure the overwrap completely before pressure testing.

Refer to Manual No. F6080 Butt & Wrap Joint Section for
detailed instructions.

TAPPING INTO AN F-CHEM LINE

The most common method for
adding a branch or tapping into an
existing F-CHEM line is the use of
a T-Miter. For complete instruc-
tions, see Bulletin Nos. D4235,
FABRICATION

D4240 or D4242, supplied with

F-CHEM

each T-Miter kit.

Application of a T-Miter:
1. Cut the end of the new branch pipe with a contour to
match the existing line pipe outside diameter.
2. Trial fit the branch pipe to the line pipe to ensure minimal
gaps and mark for the hole in the line pipe.
3. Cut a hole in the line pipe the same diameter as the
branch pipe inside diameter.
4. Sand both pipes with a 36-60 grit abrasive to complete
roughen the bonding surface
1/2” beyond the widest layer of
fiberglass to be applied.
5. Use the adhesive supplied in
the kit to seal the edges of the
pipe and bond the branch to the
existing pipe.

58
6. Mix the resin supplied in the
kit and wet out the sanded
pipe surfaces and supplied
fiberglass.
7. Apply the fiberglass to the
pipe joint according to the
instructions supplied in the
T-Miter kit.
8. Cure the fiberglass layup.

FABRICATION
F-CHEM

59
 PART VI
INSTALLATION CONSIDERATIONS

TESTING RECOMMENDATIONS

THESE PROCEDURES MUST BE FOLLOWED IN OR-

DER TO AVOID SERIOUS PERSONAL INJURY OR PROP-
ERTY DAMAGE. FAILURE TO DO SO WILL RESULT IN
LOSS OF WARRANTY, AND BUYER, INSTALLER, OR ANY
EMPLOYEE, AGENT, OR REPRESENTATIVE THEREOF,
ASSUMES THE RISK OF ANY DAMAGE OR INJURY TO
PERSON OR PROPERTY.

NOTE: Follow all applicable local codes and prudent

engineering practices.

HYDROSTATIC TESTING
Wherever possible, FGS piping systems should be hydro-
statically tested prior to being put into service. Care should
be taken when testing, as in actual installation, to avoid water
hammer. Locate all test equipment away from the end of the
piping system.
Above Ground: All anchors, guides and supports must be
in place prior to testing.
Buried Systems: Before testing, make sure the piping sys-
tem is secure in the ditch with complete bedding under the pipe
and enough backfill material in the middle of the pipe to hold the
pipe in place. Joints should be left open for visual inspection
during test.
To hydrostatically test the line, observe the following: Water
should be introduced at the lowest point in the system and the
air bled off through a partially open valve or loose flange at all
the high points. Slowly close the valve, and bring the system
gradually up to the desired pressure.
CONSIDERATIONS
INSTALLATION

A. Test Procedures (RT, GT, SS)

The normal recommended procedure is to conduct a
cyclic pressure test. The piping system is subjected to 10
pressurization cycles at 11/2 times the anticipated or design
operating pressure. Pressure is then kept on the system
for 1-8 hours while the line is inspected for leaks. When
higher test pressures are desired, the test pressure should
not exceed 11/2 times the maximum rated cyclic pressure
for the lowest rated component in the system. For low
pressure applications, such as drain lines, the cyclic test
may be replaced by a steady pressure test. Lines that
can be subjected to severe temperature cycles, such as
60
 steam condensate lines, hot water lines, and cold water
lines, should be tested using the cyclic test procedure at
11/2 times the cyclic pressure rating, even if the system is
to operate at relatively low pressure. Vacuum or external
pressure testing must not exceed the external pressure
rating.
B. Test Procedures (F-CHEM)
Test pressure should not be more than 1-1/2 times the
working pressure of the piping system, and never exceed
1-1/2 times the rated operating pressure of the lowest
rated component in the system. When testing is complet-
ed, open all of the air bleeds before draining the piping.
This will prevent vacuum collapse of the pipe.

WARNINGS:
Air Testing: Hydrostatic test should be used instead of air
or compressed gas if possible. When air or compressed gas
is used for testing, tremendous amounts of energy can be
stored in the system. If a failure occurs, the energy may be re-
leased catastrophically, which can result in property damage
and personal injury. In cases where system contamination or
fluid weight prevents the use of hydrostatic test, air test may
be used with extreme caution. To reduce the risk of air testing,
use the table below to determine maximum pressure. When
pressurizing the system with air or compressed gas, the
area surrounding the piping must be cleared of personnel to
prevent injury. Hold air pressure for one hour, then reduce the
pressure to one half the original. Personnel can then enter the
area to perform soap test of all joints. Again, extreme caution
must be exercised during air testing to prevent property dam-
age or personnel injury. If air or compressed gas testing is
used, FGS will not be responsible for any resulting injury
to personnel or damage to property, including the piping
system. Air or compressed gas testing is done entirely at the
discretion and risk of management at the job site.
CONSIDERATIONS
INSTALLATION

Pipe Diameter
1” 11/2” 2” 3” 4” 6” 8” 10” 12” 14” 16”

psig 25 25 25 25 25 25 14 9 6 5 4

For larger diameters, contact Fiber Glass Systems.

61
 C. Test Frequency
It is strongly suggested that pressure tests be per-
formed on small sections of the installation as they
are completed to assure that the installation tech-
niques are satisfactory.

•READ THIS CAREFULLY•

D. SAFETY PRECAUTIONS
As in any system where pressure is employed, adequate
safety precautions should be exercised.
Locate pressure gauges in close proximity to

!
the pressurizing equipment, not directly on the pip-
ing system. Stay away from the ends of the pipeline.
Do not straddle pipe. Use of a pressure gauge, with
the test pressure at mid-scale, is recommended.
In buried applications, it is suggested that long pipe runs
be partially backfilled at various points to secure them in
place. All joints and connections should be left exposed
for inspection.
In exposed pipe systems, standard pipe guides and hang-
ers will normally be sufficient to restrain the pipe during
testing.
CONSIDERATIONS
INSTALLATION

62
 SYSTEM STARTUP

On any pressurized piping system, the initial start-up

should be gradual to prevent excessive loads and pressure
surges which may damage or weaken the piping.
One method is to slowly fill the system while bleeding off
all air before starting any pumps or opening valves into pres-
surized piping. An alternate method is to start the centrifugal
pump against a closed, adjacent valve; then slowly open the
valve to gradually build up system pressure. The air should be
bled off while the line is filling as in the first method.
For positive displacement pumps, consult FGS Engineer-
ing for recommendations.

WATER HAMMER - AVOIDING PROBLEMS

Water Hammer is a term generally used to describe situ-

ations where a pressure surge in the piping system causes
violent movement of the system. Usually this pressure surge
is caused by a sudden valve closing, electrical outage, pump
failure, or some other out-of-the ordinary situation. The pres-
sure surge is usually brief, but damage can be severe. In FRP
piping, water hammer usually results in failed fittings due to
pipe system movement caused by pressure. Insufficient sys-
tem anchors, guides and supports allow excessive movement
of the piping and creates fitting failures.
Installing slow operating valves, a pump bypass or surge
protectors in the system is recommended.
Air in a system can also cause water hammer. Be sure to
bleed air out of the piping prior to full pressure operation. Any
pipe system which moves suddenly, creates a lot of noise, or
is unstable is susceptible to water hammer.
CONSIDERATIONS
INSTALLATION

63
 FIBERGLASS FLANGES

Before bonding the flange onto the pipe, make sure the bolt
holes line up with the mating bolt holes on the other sys-
tem. Do not bolt the flange before bonding, unless insertion
depth of the spigot is previously checked to be certain that
the spigot does not bottom out or extend through the flange.
The use of flat washers on all nuts and bolts is required. The
maximum allowable torque is indicated on each flange and is
also shown in Table 6.3.

FGS flanges are designed to meet ANSI B16.5, Class 150

bolt hole standards. Full-face gasketing materials, 1/8" thick,
with a Shore A hardness of 60 to 70 durometer, are recom-
mended for fiberglass flanges. Gaskets made from Teflon®
and PVC usually have high durometer ratings and are not
acceptable.

Connecting to Flat-Face Flanges:

Fiberglass flanges may be joined to flat-face flanges at the
recommended torque levels (See Table 6.3) when using
proper gasketing material.

Connecting to Raised-Face Steel Flanges:

When connecting to a raised-face steel flange, one of the fol-
lowing must be utilized:

a. Use filament wound fiberglass flanges,

b. Use molded fiberglass flanges and machine the steel

flange face until it is flat or use a metal spacer ring to fill the
void between the raised-face steel
flange and the fiberglass flat-face
flange (normally more difficult than
machining the steel flange face). If
CONSIDERATIONS
INSTALLATION

metal spacer rings are not available, it

is acceptable to use spacer rings made
from materials that are at least as hard FIGURE 8.3

as the fiberglass flange.

c. Use metal back-up rings behind molded fiberglass flanges

(See Figs. 8.4 and 8.5).

Connecting to Lug or Wafer Valves:

Most lined valves need a flat surface to seal against and a
sealing surface that is close to their own I.D. to properly seat
the lining. Unlined valves with sealing components in the face
are in the same category as lined valves. Sometimes the
64
sealing ridges on the valve face can fall in the wrong place
for the grooves in fiberglass flange faces, or they can be too
close to the I.D. to seal. When connecting to valves with
other than flat-faced flanges, follow these recommendations:
1) For unlined lug and wafer valves without integral seals,

Back-up Ring Thickness

Pipe Size Ring Thickness
1" - 8" 1/2"

10" - 12" 3/4"

FIGURE 8.4 FIGURE 8.5

use filament wound flanges with no back-up rings or molded

flanges with metal back-up rings. (See Fig. 8.3, 8.4, and 8.5)

2) For lug and wafer valves that are

lined or have integral seals, use a ¼"
steel spacer plate with an I.D. equal
to Schedule 40 steel or as required by
the valve manufacturer. (See Fig. 8.6)
FIGURE 8.6
SUMMARY
• FGS molded flanges are designed to be used against
flat-face flanges. When joining to raised-face flanges and
lug or wafer valves, steel back-up rings should be used, or
spacers fabricated from any material capable of preventing
the flange face from bending.
• FGS filament wound flanges may be mated to raised-
face flanges and lug or wafer valves with no back-up rings
or spacers if the bolt torque limits shown in Table 6.4 are not
exceeded.
• When using lug and wafer valves with integral seals, it
CONSIDERATIONS
INSTALLATION

may be necessary to use a ¼" thick steel flange between the

valve and the fiberglass flange to achieve a proper seal. A
⅛" thick full-face gasket should be used between the steel
flange face and the fiberglass flange.
• When using smooth-face flanges (non-standard) for
pressures above 25 psig, it is necessary to glue a 0.20" to a
0.35" diameter, 80 durometer O-ring to the full-face gasket.
A composite retainer O-ring gasket may also be used to seal
smooth-face flanges.

65
 Standard Bolting Conditions
FGS flanges are designed to meet ANSI B16.5 Class
150 bolt hole standards. For RT, GT & SS, full-face gasket-
ing materials, 1/8" thick, with a Shore A hardness of 60 to 70
durometer, are recommended. F-CHEM flanges require full-
face gasketing material 1/4" thick or O-ring seals depending on
pressure ratings. Refer to Table 17.
Flat gaskets made from Teflon® and PVC usually have
high durometer ratings and are not acceptable.
CONSIDERATIONS
INSTALLATION

66
 TABLE 17. Gasket & O-Ring Requirements for
F-CHEM Stub Flanges & Flanged Fittings

Pipe Pressure Gasket(1) O-Ring(2)

Size Rating I.D. O.D. Cross I.D.
(In.) (psig) (In.) (In.) Section
14 50-100 14 3/16 21 - -
125-150 - - .275 15.475
16 50-100 16 3/16 23½ - -
125 - - .275 17.455
18 50-100 18 3/16 25 - -
125 - - .275 19.455
20 50-75 20 3/16 27½ - -
100 - - .275 21.629
24 50-75 24 3/16 32 - -
100 - - .275 26.129
30 50-75 30 3/16 38¾ - -
100 - - .375 31.975
36 50-75 36 3/16 46 - -
100 - - .375 36.180
42 50 42 3/16 53 - -
75-100 - - .375 44.620
48 50 48 1/16 59½ - -
75-100 - - .500 50.680
54 50-75 - - .500 56.770
60 50-75 - - .750 62.590
72 50-75 - - .750 75.340
CONSIDERATIONS

(1)Use ANSI 16.5 Class 150 lb. drilling gasket with a hardness
INSTALLATION

of 50 to 70 durometer on the Shore A scale.

(2)Use O-ring with a hardness of 50-70 durometer on the
Shore A scale.

67
 TABLE 18. Bolt, Washer & Torque Requirements for
RT, GT, SS Flanges & Flanged Fittings(1)
Maximum
Flange Number Machine Stud Allowable
Size of Bolt(2) Bolt(2) Torque in
(In.) Bolts(3) Size Size Ft. Lbs.
1 4 ½ - 13x3 ½ - 13x4 25
1½ 4 ½ - 13x3 ½ - 13x4 25
2 4 ⅝ - 11x3 ⅝ - 11x4 30
3 4 ⅝ - 11x4½ ⅝ - 11x5½ 30
4 8 ⅝ - 11x4½ ⅝ - 11x5½ 30
6 8 ¾ - 10x5½ ¾ - 10x6 30
8 8 ¾ - 10x5½ ¾ - 10x6½ 100
10 12 ⅞ - 9x6 ⅞ - 9x7½ 100
12 12 ⅞ - 9x6 ½ ⅞ - 9x7½ 100
14 12 1 - 8x7 1 - 8x8 100
16 16 1 - 8x7 1 - 8x8 100
18 16 1⅛ - 7x7½ 1⅛ - 7x8¾ 100
20 20 1⅛ - 7x7½ 1⅛ - 7x8¾ 100
24 20 1¼ - 7x7¾ 1¼ - 7x9½ 100
(1)
Most flanged fittings are available with molded flanges.
Filament wound flanges are available on request.
(2)
Bolt lengths are nominal. When joining FGS flanges to
flanges of other material or manufacturers products, bolt
length must be calculated.
(3)
1"-24" flanges are ANSI B16.5 Class 150 lb. bolt hole
standard.
CONSIDERATIONS
INSTALLATION

NOTE: Washers are required with all nuts and bolts.

Recommended Bolt Torquing Sequence for FGS Flanges

Before bonding the flange onto the pipe, make sure the
bolt holes line up with the mating bolt holes on the other
system. Do not bolt the flange before bonding unless insertion
depth of the spigot is previously checked to be certain that the
spigot does not bottom out or extend through the flange. The
maximum allowable torque is indicated on each flange and is
also shown in Tables 18, 20, and 21.

68
TABLE 19. Recessed Bolt Hole Data for RT, GT, SS(1)

Flange Stud Recess Washer No.

Size Size Depth O.D. of
(In.) (In.) (In.) (In.) Studs

3 5
/8 1
/4 1 5/16 4
8 3
/4 1
/2 1 1/2 4
10 7
/8 5
/8 1 3/4 4
12 7
/8 3
/4 1 3/4 4
14 1 1
/2 2 4
16 1 1
/2 2 4

TABLE 20. Bolt, Washer & Torque Requirements for

RTPP and GTPP Van Stone-Type Flanges(2)

Flange Machine Stub Maximum Allowable

Size No. of Bolt (3) Bolt Torque in Ft. Lbs.
(in.) Bolts Size Size RTPP, GTPP

8 12 7
/8-9x11 7
/8-9x12 100
10 16 1-8x12 1-8x13 100
12 16 11/8-7x131/2 11/8-7x15 100
14 20 11/8-7x15 11/8-7x161/2 100
16 20 1 /4-7x17 /2
1 1
11/4-7x19 100
18 24 11/4-7x201/2 11/4-7x22 200
20 24 11/2-6x23 11/2-6x25 200
24 24 1 /2-6x27
1
1 /2-6x28 /2
1 1
200

(1) On 3”, 14” and 16” 45° flanged elbows and on all 8”, 10”
CONSIDERATIONS
INSTALLATION

and 12” flanged fittings, four holes are recessed for clearance
during assembly. Studs are recommended for assembly. Stud
length is dependent on adjacent flange.
(2) Flanges are ANSI B16.5 Class 300-lb. bolt hole standard.
(3) Bolt lengths are nominal. When joining FGS flanges to

flanges of other material or manufactures, bolt length must be

calculated.

Note: Washers are required with all nuts and bolts.

69
 TABLE 21. Bolt, Washer & Torque Requirements for
F-CHEM Flanges & Flanged Fittings
Pipe Pressure No. of Machine Stub Bolt Torque
Size Rating Bolt Bolt Bolt (ft.lbs.)
(in.) (psig) Holes Size Size (Nom) (Max)
14 50 12 1-8x41/2 1-8x6 75 100
75 12 1-8x5 1-8x6 85 110
100 12 1-8x5 1-8x7 90 120
125 12 1-8x51/2 1-8x7 50 100
150 12 1-8x6 1-8x7 50 100
16 50 16 1-8x41/2 1-8x6 75 100
75 16 1-8x5 1-8x6 85 110
100 16 1-8x51/2 1-8x7 90 120
125 16 1-8x6 1-8x7 50 100
18 50 16 11/8-7x5 11/8-7x6 75 100
75 16 11/8-7x51/2 11/8-7x7 85 110
100 16 11/8-7x6 11/8-7x7 90 120
125 16 11/8-7x61/2 11/8-7x8 50 100
20 50 20 11/8-7x5 11/8-7x7 90 120
75 20 11/8-7x51/2 11/8-7x7 105 140
100 20 11/8-7x6 11/8-7x8 75 125
24 50 20 11/4-7x51/2 11/4-7x7 90 120
75 20 11/4-7x6 11/4-7x8 105 140
100 20 11/4-7x61/2 11/4-7x8 75 125
30 50 28 11/4-7x6 11/4-7x8 105 140
75 28 11/4-7x61/2 11/4-7x8 120 160
100 28 11/4-7x7 11/4-7x9 75 125
36 50 32 11/2-6x61/2 11/2-6x9 105 140
75 32 11/2-6x71/2 11/2-6x9 120 160
100 32 11/2-6x8 11/2-6x10 100 150
42 50 36 11/2-6x7 11/2-6x9 120 160
75 36 11/2-6x8 11/2-6x10 100 150
100 36 11/2-6x81/2 11/2-6x10 100 150
48 50 44 11/2-6x71/2 11/2-6x9 120 160
75 44 11/2-6x8 11/2-6x10 100 150
100 44 11/2-6x9 11/2-6x11 100 150
CONSIDERATIONS

54 50 44 13/4-5x8 13/4-5x10 100 175

INSTALLATION

75 44 13/4-5x9 13/4-5x11 100 175

60 50 52 13/4-5x81/2 13/4-5x11 100 175
75 52 13/4-5x91/2 13/4-5x12 100 175
72 50 60 13/4-5x91/2 13/4-5x11 125 200
75 60 13/4-5x11 13/4-5x13 125 200
(1) Use two washers with each bolt. Use SAE standard washers under
all nuts and bolt heads up to 48” size. Use USS wrought washers for
54” and larger sizes.
(2) Bolt lengths are nominal. When joining flanges to flanges of other
material or manufacturer, bolt length must be calculated. Note: Special
bolt lengths are required for blind flanges.
70
Recommended Bolt Torquing Sequence for
FGS Flanges

CONSIDERATIONS
INSTALLATION

71
 INSTALLATION
CONSIDERATIONS

72
 CONNECTING TO OTHER SYSTEMS
It is often necessary to connect a fiberglass piping to another
piping system or make a connection that will not be possible
using flanges. Two types of adapters are available: bell or
spigot by grooved ends and bell or spigot by threaded ends.

CONSIDERATIONS
INSTALLATION

73
 ADAPTERS
Note: When using adapters with spigot ends, it may be nec-
essary to cut off a portion of the factory pipe bell if the groove
or threads are not fully exposed.

A. Grooved Adapters
RT, GT, SS Product: Do Grooved Adapters
not use couplings designed
for plastic or cement-lined
steel as they can leak due
to a difference in groove
dimensions. Grooved
adapters are machined to ES dimensions. Use
standard high pressure (Victaulic Style 77) coupling
or equivalent.

B. Threaded Adapters
When using threaded
Threaded Adapters
adapters, thread them
into the other system
before bonding onto
FGS pipe. Otherwise,
unless a union is used,
it may be impossible to
turn the adapter into the
mating thread. Use soft
set, nonmetallic thread
lubricant or two wraps of
Teflon tape. Caution: Do not overtighten. Tighten
the adapters as if they were brass or other soft mate-
rial.

NOTES:
1. The use of FGS adhesive to bond a steel or metal pipe
into a fiberglass flange is not recommended.
CONSIDERATIONS
INSTALLATION

2. If mating a fiberglass system to steel, the preferred

method is with flanges. Terminate the old system with
their flange and bolt the FGS flange on the new system.
3. Be sure to check the anchors, guides, and supports of
an existing system to avoid transfer of any stresses or
thermal expansion loads into the fiberglass system.
4. Do not try to thread pipe or fittings.

74
SPECIAL BOLTING CONDITIONS
It is often necessary to mate fiber-
glass flanges with other compo-
nents which do not have a full flat-
face surface such as raised face
flanges, butterfly or check valves
having partial liner facings, and
Van Stone flange hubs. The addi-
tion of a hard spacer ring or steel
back-up ring placed between the
raised face and the outer edge of the flange to form a full flat
face on the mating flange is recommended. The purpose of the
spacer is to fill the gap outside the raised face to prevent bolt
loads from bending and breaking the fiberglass flange.

Pump & Equipment Connection

Fiberglass pipe connections to pumps or other equipment that
involve vibration, shock loads or other mechanical move-
ments should include flexible connectors. These flexible con-
nectors allow for the absorption of vibration and eliminate the
placing of undue strain on the pipe and fittings. A bellows-type
expansion joint is recommended.

PAINTING PIPE
All piping O.D. surfaces should be clean and dry before paint-
ing. Use a fast-drying solvent such as acetone or trichloroeth-
ylene to clean the O.D. of RT, GT, or SS. For longer lasting
results, and for F-Chem pipe, the O.D. should be thoroughly
sanded or sand blasted. If sand blasting, be careful not to cut
or groove the pipe O.D. with an aggressive spray. FGS pipe
can be painted with any good quality epoxy ether or two-part
epoxy paint. Contact your local paint supplier for a detailed
recommendation.
CONSIDERATIONS
INSTALLATION

75
 PART VII
HELPFUL INFORMATION
CONVERSIONS
Metric Units U.S. Equivalents
Lengths 1 millimeter . . . . . . . . . . . 0.03937 inch
1 centimeter . . . . . . . . . . 0.3937 inch
1 meter . . . . . . . . . . . . . . 39.37 inches or 1.094 yards
1 kilometer . . . . . . . . . . . 1093.61 yards or 0.6214 mile
Areas 1 square millimeter . . . . . 0.00155 square inch
1 square centimeter . . . . . 0.155 square inch
1 square meter . . . . . . . . 10.764 square feet
or 1.196 sq. yards
1 square kilometer 0.3861 square mile

Volumes 1 cubic millimeter . . . . . . 0.000061 cubic inch

1 cubic centimeter . . . . . . 0.061 cubic inch
1 liter . . . . . . . . . . . . . . . . 61.025 cubic inches
1 cubic meter . . . . . . . . . 35.314 cubic feet
or 1.3079 cubic yards

Capacities 1 milliliter (0.001 liter) 0.0338 U.S. fluid ounce

1 liter . . . . . . . . . . . . . . . . 2.1134 U.S. liquid pints
1 liter . . . . . . . . . . . . . . . . 1.0567 U.S. liquid quarts
1 liter . . . . . . . . . . . . . . . . 0.2642 U.S. gallon
Weights 1 gram . . . . . . . . . . . . . . 0.03527 avoir. ounce
or 15.4324 grains
1 kilogram(1000 grams) . 2.2046 avoir. pounds

U.S. System Units Metric Equivalents

Lengths 1 inch 25.4 millimeters
or 2.54 centimeters
1 foot . . . . . . . . . . . . . 0.3048 meter
1 yard . . . . . . . . . . . . 0.9144 meter
1 mile . . . . . . . . . . . . 1.6093 kilometers
Areas 1 square inch . . . . . . 645.16 square millimeters
or 6.452 square centimeters
1 square foot . . . . . . 0.0929 square meter
1 square yard . . . . . . 0.8361 square meter
1 square mile . . . . . . 2.59 square kilometers
Volumes 1 cubic inch . . . . . . . . 16,387.2 cubic millimeters
or 16.3872 cubic centimeters
1 cubic foot . . . . . . . . 0.02832 cubic meter
1 cubic yard . . . . . . . 0.7646 cubic meter

Capacities 1 U.S. fluid ounce . . . 29.573 milliliters

1 U.S. liquid pint . . . . 0.47317 liter
1 U.S. liquid quart . . . 0.94633 liter
1 U.S. gallon . . . . . . . 3.78533 liters
INFORMATION
HELPFUL

Weights 1 grain . . . . . . . . . . . . 0.0648 gram

1 avoir. ounce . . . . . . 28.35 grams
1 avoir. pound . . . . . . 0.4536 kilogram
1 Troy ounce . . . . . . . 31.1035 grams
76
 DECIMAL EQUIVALENTS OF FRACTIONS

Inches Decimal of an Inch Inches Decimal of an Inch

1/64 .015625 29/64 .453125

1/32 .03125 15/32 .46875
3/64 .046875 31/64 .484375
1/20 .05 1/2 .5
1/1 6 .0625 33/64 .515625
1/13 .0769 17/32 .53125
5/64 .078125 35/64 .546875
1/12 .0833 9/16 .5625
1/11 .0909 37/64 .578125
3/32 .09375 19/32 .59375
1/10 .10 39/64 .609375
7/64 .109375 5/8 .625
1/9 .111 41/64 .640625
1 /8 .125 21/32 .65625
9/64 .140625 43/64 .671875
1/7 .1429 11/16 .6875
5/32 .15625 45/64 .703125
1/6 .1667 23/32 .71875
11/64 .171875 47/64 .734375
3/16 .1875 3/4 .75
1/5 .2 49/64 .765625
13/64 .203125 25/32 .78125
7/32 .21875 51/64 .796875
15/64 .234375 13/16 .8125
1/4 .25 53/64 .828125
17/64 .265625 27/32 .84375
9/32 .28125 55/64 .859375
19/64 .296875 7/8 .875
5/16 .3125 57/64 .890625
21/64 .328125 29/32 .90625
1/3 .333 59/64 .921875
11/32 .34375 15/16 .9375
23/64 .359375 61/64 .953125
3/8 .375 31/32 .96875
25/64 .390625 63/64 .984375
INFORMATION

13/32 .40625 1 1.0

HELPFUL

7/16 .4375

77
 DEFINITION OF TERMS

ADAPTER – A fitting used to join two pieces of pipe, or two

fittings, which have different joining systems.
ADHESIVE – A material formulated to bond together pipe and fit-
tings resulting in high strength and corrosion resistant fabrications.
ANCHORS – Device to positively restrain the movement of
the pipe against all lateral and axial forces.
BELL AND SPIGOT – A joining system in which two trun-
cated conical surfaces come together and bond adhesively.
The bell is the female end. The spigot is the male end.
BUSHING – A fitting used to join two different sizes of pipe
by reducing the size of the female end of the joint. Joints may
come threaded or tapered.
CATALYST – See hardener.
COLLAR – See coupling.
COMPRESSIVE FORCE – The force that occurs when op-
posing loads act on a material, crushing, or attempting to
crush it. In pipe, circumferential compressive forces result
from external collapse pressure, actual compressive forces
from heating of an end-restrained fiberglass pipe.
COMPRESSION MOLDING – A process for making fittings
in which a molding compound is formed and cured into the
finished part configuration through pressure and heat in a die.
CONCENTRIC REDUCER – A pipe fitting used to join two differ-
ent sizes of pipe while maintaining the same centerline.
CONTACT MOLDING – A process for making fittings in which
cut pieces of fiberglass reinforcement are laid on a mold,
saturated with resin, and cured to the finished part shape.
COUPLING (collar) – A short heavy wall cylindrical fitting
used to join two pieces of the same size pipe in a straight line.
The coupling always has female connection ends which can
be bell, threaded or a mechanical joining method.
CURE – The hardening of a thermoset resin system by the
action of heat or chemical action.
CURE STAGES – Stages describe the degree to which a
thermoset resin has crosslinked. Three stages, in order of
increasing crosslinking, include B-stage, gelled, fully cured.
CURE TIME – The time required for a thermoset material to
react and develop full strength. The time is dependent upon
INFORMATION
HELPFUL

the temperature of the material.

78
CURING AGENT – See hardener.
CUT AND MITERED FITTINGS – Fittings manufactured by
cutting, assembling and bonding pipe sections into a desired
configuration. The assembled product is then overwrapped
with resin-impregnated roving or glass cloth, to provide added
strength.
EPOXY RESIN – A thermosetting resin, usually made from
Bisphenol A and epichlorhydrin, cured by a variety of agents
such as anhydrides and amines. These resins contain cyclic
ether groups. See thermoset.
FRP – Fiberglass Reinforced Plastic.
FILAMENT WOUND – A manufacturing method for pipe and
fittings in which resin impregnated continuous strand roving
wraps around a mandrel to achieve high reinforcement con-
centration and precise filament placement.
FILLERS (extender, pigments, inerts; i.e., sand, etc.) –
Materials added to a resin which do not affect the cure of the
resin but may influence the physical properties of the resin
system.
FITTING TYPES – The classification of fittings by the method
of manufacture; i.e., molded, cut and mitered, filament wound,
contact molded.
GEL TIME – The time it takes for a resin system to harden to
a rubber-like state.
GUIDE – Device that allows free axial movement of the pipe,
but restrains lateral movement.
HAND LAY-UP – The forming of resin and fiberglass into fin-
ished pipe products or fittings by manual procedures. These
procedures include overwrap techniques, contact molding,
hand molding and others.
HARDENER (accelerator, catalyst, curing agent, promoter) –
Chemicals added to the resin, single or in combination, which
speed up the hardening process, or cause hardening to occur.
HEAT BLANKET or HEAT COLLAR – An electrical device
used to heat a fabrication to reduce cure time.
HYDROSTATIC TEST – A pressure test of a completed fab-
rication to confirm good quality. Typically, the system is filled
with water and held at the selected pressure while checking
for leaks.
INFORMATION
HELPFUL

79
 IMPACT RESISTANCE – The ability of a part to absorb a
striking blow without damage.
JOINING (connecting systems) – Any of a variety of methods
for connecting two separate components of a piping system
together. Included are bell and spigot, threaded and coupled,
mechanical devices, etc.
JOINT – A term used to describe an individual length of pipe
or the actual joining mechanism; i.e., adhesive bonded bell
and spigot, threaded and coupled, etc.)
LINER – A generic term used to describe the interior surface
in pipe. Generally, liners are resin-rich regions from 0.005 to
0.100 in. thick. Liners may be reinforced with fibrous mate-
rial such as veil or mat. Liners can provide extra corrosion
protection for severe chemical service. They also form a leak
barrier (elastomer bladder). The manufacturer may add a liner
before, during, or after construction of the pipe wall depend-
ing on the manufacturing process.
LOCK-UP –A bell and spigot joint engaged sufficiently to
eliminate pivot action in the joint.
MATRIX – The material used to bind reinforcement and fillers
together. This material may be thermoplastic or thermosetting
and dictates to a large extent the temperature and chemical
service conditions allowable for a pipe or fitting.
MECHANICAL FORCE – Physical exertion of power used to
achieve lock-up in tapered bell and spigot joints.
MOLDED FITTINGS – Pipe fittings formed by compressing
resin, chopped fiber and other ingredients in a mold under
heat and pressure.
MOLDING – Any of several manufacturing methods where
pressure or compression molding shapes resin and reinforc-
ing materials into final products.
POLYESTER RESIN – Any of a large family of resins which
are normally cured by crosslinking with styrene. The physi-
cal and chemical properties of polyester resins vary greatly.
Some have excellent chemical and physical properties while
others do not. Vinyl esters are a specific type of polyester
resin. Other polyester resins with properties suitable for use
in the manufacture of fiberglass pipe include: isophthalic
Bisphenol A fumarate and HET acid polyesters. Each type
of resin has particular strengths and weaknesses for a given
piping application.
INFORMATION

POT LIFE – The time available to use thermoset adhesives

HELPFUL

after the reactive materials have been mixed.

80
PRESSURE RATING – The maximum anticipated long term
operating pressure a manufacturer recommends for a given
product. Also referred to as working pressure, pressure class
or design pressure.
REINFORCEMENT – Typically, fibers of glass, carbon or
synthetic material used to provide strength and stiffness to a
composite material. The type of fiber used as reinforcement
plays a major role in determining the properties of a composite,
as does the fiber diameter and the type of sizing used. Terms
relating to the physical form of the reinforcement include:
Chopped Fiber - Continuous fibers cut into short (0.125 to
2.0-in.) lengths.
Filament - A single fiber of glass; e.g., a monofilament.
Mats - Coarse fabric sheets made from chopped strands
randomly placed and held together by resin binders.
Milled Fibers - Glass fibers, ground or milled, into short
(0.032 to 0.125-in.) lengths.
Roving - A collection of one or more filaments wound into
a cylindrical package. The typical form of glass fiber used
in the manufacture of filament wound pipe.
Veil - Surfacing mat of porous fabric made from glass or
synthetic filaments. Used to provide a resin rich layer or
liner.
Yarn - Glass fiber filaments twisted together to form
textile-type fibers.
Yield - The number of yards of material made from one
pound of the product.
Resin (polymer) - As applied to fiberglass pipe, resin is
the polymer or plastic material used to bind the glass
fibers together.
RESIN – The polymer (liquid plastic) material which hardens
with cure to provide a solid form, holding the fiberglass rein-
forcement in place. Resins provide the corrosion resistance in
FRP parts.
SADDLE – A fitting which is bonded to the exterior of a pipe
to make a branch connection.
SHELF LIFE – The storage time for a material until it be-
comes unusable.
SOCKET JOINT – A joining system in which two straight
cylindrical surfaces come together and bond adhesively.
INFORMATION
HELPFUL

SPACERS – Wooden strips used to support pipe during stor-

age and handling.

81
 STRESS – The force per unit of cross sectional area. Mea-
sured in pounds per square inch (psi). This should not be
confused with hydraulic pressures, measured as psig or psia,
which can induce stress.
SUPPORT SPACING (span) – The recommended maximum
distance between pipe supports to prevent excessive pipe
deformation (bending).
SURGE PRESSURE – A transient pressure increase due to
rapid changes in the momentum of flowing fluids. Water ham-
mer is one type of surge pressure. Rapid opening or closing
of valves often result in a surge pressure or water hammer.
THERMAL CONDUCTIVITY – The rate at which a material
(pipe) transmits heat from an area of high temperature to an
area of lower temperature. Fiberglass pipe has low thermal
conductivity.
THERMAL EXPANSION – The increase in dimensions of a
material (pipe) resulting from an increase in temperature. A
decrease in temperature results in thermal contraction.
THERMOSET – A polymeric resin cured by heat or chemical
additives. Once cured, a thermoset resin becomes essentially
infusible, (cannot be re-melted) and insoluble. Thermoset-
ting resins used in pipe generally incorporate reinforcements.
Typical thermosets include:
• Vinyl esters • Novolac or epoxy Novolac
• Epoxies • Unsaturated polyesters
THRUST FORCES – Commonly used to describe the forces
resultant from changes in direction of a moving column of
fluid. Also used to describe the axial or longitudinal end loads
at fittings, valves, etc., resultant from hydraulic pressure.
TORQUE – Used to quantify a twisting moment (torsion) in
pipe. Torque is measured as a force times the distance from
the force to the axis of rotation. Torque is expressed in foot-
pounds (ft-lb) or inch-pounds (in-lb).
TWO HOLING – A method of aligning flanges onto pipe or fit-
tings so that the bolt circle will mate with the adjoining flange.
VINYL ESTER – A premium resin system with excellent corro-
sion resistance. Vinyl ester exhibits high versatility, tempera-
ture resistance and excellent corrosion resistance to acids.
WATER HAMMER – Pressure surges in a piping system
caused by sudden change in fluid velocity, such as operation
INFORMATION

of a valve, pump, or other component.

HELPFUL

WORKING LIFE – Same as POT LIFE.

82
HOW TO READ FLANGED OR REDUCING FITTINGS

TEE

Run x Run x Branch

LATERAL
Run x Run x Branch

CROSS
Run x Run x Branch X Branch

The above sequence should be used when describ-

ing fitting outlets. Drawings or sketches showing outlet
types, locations, sizes and dimensional requirements
are required for more complicated fitting configurations.
INFORMATION
HELPFUL

83
 HOW TO FIGURE A 45° OFFSET

True
Length
Offset
Length
45 ˚

Offset
Length

True Length = offset x 1.414

Offset = true length x .707

EXAMPLES:
IF: offset = 12"
12" x 1.414 = 16.968 = 1'-5"
true length = 1'-5"
(to nearest 1/16")

IF: true length = 24"

24 x .707 = 16.968 = 1'-5"
offset length = 1'-5"
(to nearest 1/16")
INFORMATION
HELPFUL

84
 2700 W. 65th Street
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Phone: (501) 568-4010 • Fax: (501) 568-4465

25 S. Main Street
Sand Springs, OK 74063
Phone: (918) 245-6651 • Fax: (918) 245-7566

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