bonding manual (22.6.05)0 - asut · pdf filethis method statement explained machine made...

www.asutfiberglass.com

ASUT FIBERGLASS LTD.

EPI-DUR® (GRE) Epoxy Base

VIN-DUR® (GRV) Vinylester Base

ISO-DUR® (GRP) Isophthalic Base

Assembly InstructionFOR EPOXY ADHESIVE HOT CURING BONDED JOINTS

A ASUTF I B E R G L A S S

L

(Assembly Dimension)

FLAT COLLAR

TAILED COLLAR

COUPLING

TAILED FIX FLANGE

FIBERGLASS

ASUTAsut Fiberglass Ltd.

Tarsus - Mersin Industrial Zone

Cumhuriyet Bulv. No:23

Voice = (+ 90 - 324 ) 6764262

Fax = (+ 90 - 324 ) 6764261

E mail = info @ asutfiberglass


fd - 0 / 06 - 05 - S1

BONDING SPOOL

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EPI-DUR , VIN-DUR & ISO-DUR Bonding System

PURPOSE

This Method Statement Explained Machine Made GRE-GRP Plain End & Male-Female

Pipe and Double socket End Fittings Joint Installation.

SCOPE

This Method Statement cover Requirements for ASUT Fiberglass™ EPI-DUR® , VIN-DUR® & ISO-DUR®

Pipe and Fittings Workshop and Field ,Coupling 5565 Adhesive™ (with R6500™ or F5500™

Hardener) Bonding.They show you how to cut the pipe,prepare the ends,use the

adhesive,stab the joint and cure the adhesive to produce a strong and reliable bond

joint.

NECESSARY TOOLS & EQUIPMENTS FOR BONDING

· Tape Measure

· Level

· Infinitive

· Marking Pen

· Marking Band

· ½ - 2 - 3” Putty Spatula

· Rubber Piece (2-3 mm thick)

· Card Board (30x30 cm)

· Rubber - Clote Gloves

· Safety Glasses

· Small Disk Grinder Power Tools

· Big Disk Grinder Power Tools

· Hand Drilling Medium Power Tools

· Cutting (wheels) Blade 115x3

· Cutting (wheels) Blade 180x3

· Plastic Disc Pad 115

· Plastic Disc Pad 180

· Disk Sand Paper 115

· Disk Sand Paper 180

· Abrasive Flapper Roller and Sandpaper

· 2 - 3” Brushes

· Cleaner (Methylene Chlorite)

· Shaver-Taper Tools

· Curing Heating Box or Blanket

· Puller (winch) and Pipe Clip

NECESSARY RAW MATERIAL FOR BONDING

· 5565 Adhesive™ Standard (for R6500 or F5500 Hardener)

· R6500™ Hardener (for 2 hrs. handling)

· F5500™ Hardener (for 3 hrs. handling)

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PREPARING THE EPI-DUR® , VIN-DUR® & ISO-DUR® PIPE AND FITTINGS

Pipes delivery to site already shaved end

Fittings delivery to site Coupling end

Collar and Fix Flange delivery to site Taper end

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Check first Fitting Dimension catalogue for assemble length.

Measure required length and scribe the pipe using a pipefitter’s wrap-around.Cut the

pipe with cutting blade.Do not crush pipe if clamping to hold.Use pipe vise and protect

surface from point loading.

Prepare the outside surface of the pipe with Shaver-Taper Tool or Disk Grinder power sand

paper,approximately 5 mm longer than required by the socket depth.This is primarily to

remove the surface glaze and insure proper sizing of the pipe outside if available.Dust off

sanded area a clean with Brushes.

Do not touch tapered surface with hands or greasy gloves.Do not use solvent.Do not use

air to blow sanding dust of the prepared ends as it may contain contaminates

detrimental to bond strength.Never sand the joint surface more than two (2) hours

before making the joint.

Remove the outside surface glaze

ØB2

ØB

ØB1

ØDN

A

LC

167.5168.0150

350

500

400

250

300

200

363.0

515.0

413.0

324.0

273.0219.0

362.5

514.5

412.5

323.5

272.5218.5

40

80100

50

DN

2548.0

114.089.0

60.0

33.4

(mm)

B

47.5

113.588.5

59.5

32.9

B2(mm)

32691235168.5

363.5

515.5

413.5

324.5

273.5219.5

500

600

586

355

450

307

104

132

106

110

10994

604

732

692

560

464401

48.5

114.589.5

60.5

33.9

B1(mm)

55

100140

67

(mm)

38

L

36

7359

42

36

(mm)

C

91

213159

109

74

(mm)

A

3.900

17.200

30.000

22.000

9.000

13.000

6.200

1.100

0.455

0.320

Weight

1.800

(kg)

0.175

Design:

PN 16 DN 25-40-50-80-100-150-200-250-300

PN 10 DN 350-400-500

90° ELBOW

EPI-DUR / VIN-DUR / ISO-DUR Adhesive Bonded Type

Asut Fiberglass Ltd.

Tarsus - Mersin Industrial Zone


Voice = (+ 90 - 324 ) 6764262

Fax = (+ 90 - 324 ) 6764261

E mail = info @ asutfiberglass


FIBERGLASS

ASUT

fd - 0 / 06 - 05 - 9

363.5362.5363.0350

500

400 413.0

515.0

412.5

514.5

413.5

515.5

150

250

300

200

80

100

50

40

168.0

219.0

273.0

324.0

60.0

89.0

114.0

48.0

DN

25

B

(mm)

33.4

168.5167.5

272.5

323.5

218.5

273.5

324.5

219.5

88.5

113.5

59.5

47.5

89.5

114.5

60.5

48.5

(mm)(mm)

32.9

B2

33.9

B1

1108104

132

106 1207

1319 90.000

54.000

97 464

109

110

97

768

820

624

58

74

43

37

316

368

266

234

4.400

16.450

11.600

32.000

7.800

0.650

1.100

1.800

2.500

(mm)(mm)

37

C

224

A

0.470

(kg)

Weight

A/2

C

A

ØDN

ØB2

ØB

ØB1

180

200

270

220

550

600

900

995

430

1055

L

(mm)

150

160

Design:

PN 16 DN 25-40-50-80-100-150-200-250-300

PN 10 DN 350-400-500

ASUTFI BERGLASS

Asut Fiberglass Ltd.

Tarsus - Mers in Industria l Zone


Voice = (+ 90 - 324 ) 6764262

Fax = (+ 90 - 324 ) 6764261

E mail = info @ asutfiberglasswww.asutfiberglass.com

EQL. TEEEPI-DUR / VIN-DUR / ISO-DUR Adhesive Bonded Type

CC L

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Flapper sander and/or hand sanding at field for factory taper end pipes

Sanding cut end

Make 45 deg. Triming to cut end corner

First check bonding space pipe and fittings before shaving

Prepare the inside surface of the socket (coupling) with power drilling tools with abrasive

flapper grinding roller and,or circular sandpaper (if necessary).Dust off sanded area with

a clean brush.Do not touch surface with hands or greasy gloves.Do not use solvent.Do

not use compressor air to blow sanding dust off the prepared ends as it may contain

contaiminated detrimental to bond strength.Never sand the joint surfaces more than

two (2) hours before making the joint.

Prepare the inside surface of fittings coupling and finished end with flapper sander

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Please read first Adhesive & Hardener MSDS and Application Manual

Use a flat and clean piece of card board.Flat surface to mix the two component 5565

Adhesive™ and R6500™ Hardener or F5500™ Hardener. Using a putty spatula,mix the

two components together using turning and spreading motions,making sure all unmixed

components are folded into the bulk and mixed. The two components are different

colors,to easy to see streaks indicating unmixed adhesive.Continue scraping,turning and

folding and spreading until a consistent color is reached.Spread the mixed adhesive

over the surface of the mixing cardboard to remove any thick area.

5565 Adhesive™ (white color) and R6500™ Hardener (Black Color) and F5500™

Hardener (Black Color).Good mixed bonding material becoming grey.

Check first hardener useable life

and determining bonding quantities

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The first application of the adhesive to coupling must be as thin layer worked in

scrubbed into the pores and to get wet of the coupling surface with the stick,steel spatula or

rubber piece.Seal the surface of the coupling.

Apply an even layer of adhesive the coupling not to exceed 1 mm

Do not overload the coupling as this will cause "push in" of excess material and could

cause flow restrictions.

Seal the cut end of pipe with a positive coating of adhesive.This is vital with the open cut

section of any fiberglass laminated structure.Use a pressuring and scrubbing action to

properly seal the surface.Apply a thin coating of adhesive to the exterior of the pipe rub

or scrub the material into the surface of the pipe to wet the surface.Now apply a

generous coat of the adhesive making sure by visual inspection that the thickness of the

adhesive exceeds the tolerance between the pipe and fittings so that all the air will be

displaced.Lack of adhesive could cause trapped air in the coupling,which would cause

channeling and leaking.

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Plain taper end pipe & Coupling ready for Life bonding.

Move the pipe into the coupling until it firmly bottom,which should push a uniform

squeeze out of adhesive to the outside of coupling opening.Do not withdraw pipe after

insertion.Do not twist.Any back movement or withdrawal could draw air into the glue line

and cause leakage.Make any slight adjustments for plub and level,then use a ¾ or 1”

putty spatula or rubber piece to pull a fillet around the joint.

Make sure adhesive cleaned around the joint ends with Methylene Chlorite

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Please check after bond insertion and pull with the winch for overal length and level

for next bonding step overal length and level

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If necessary ,use puller winch with pipe clamp

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If necessary, use curing heating box or blanket with winch or without winch

for fast handling to spool

Must be ; Curing for Epoxy adhesive

work life.

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INSTALLATION CONSIDERATIONS

Experience has shown us that highly rellable piping system joints can be made even

under extreme weather conditions whenever the necessary precautions are taken.The

actual works will often be more quickly completed in high temperature condition.Low

temperatures can increase the work time 20% - 35% over normal shop conditions.A similar

increase is common for wet condition.

Hot Weather Installation Tips ;

Hot weather conditions,with temperature above 32 deg. C, will greatly the working time

of the bonding.The following steps are recommended when fabricating in hot weather

conditions.

· Avoid direct sunlight on the joining surfaces.

· Cool adhesive avoid direct sunlight

· Plan and organize job to reduce working time

Cold Weather Installation Tips ;

The curing time for bond is direckly related to the temperature.Colder temperature result

in longer curing times.The following steps should be used when appliying a field adhesive

bonding in colder temperature.

· Field adhesive kits should be placed in warm room before application in order to

reach temperatures of 21 to 26 deg. C. This will make mixing much easier and

speed cure times.The adhesive should not be applied at temperatures in

excess of 14 deg. C.

· When possible,piping should be field bonded indoors into subassemblies.The

warmer conditions of these areas will allow faster curing times and,in most

cases,save installation time and labor.

· It is helpful to warm the pipe ends and fittings before joint makeup.Warm parts will

contribute to faster curing times.

· A heating box or blanket may be used to obtain a faster cure time.

·

EXTREME MOISTURE

· If fittings or pipe have moisture on the bonding surface wipe them dry prior to

sanding.

· Sand pipe and fittings immediately before appliying the adhesive to bond the

joint.Sand surface until a fresh,dry surface is present then remove dust and apply

adhesive.

· Cure per the previous recommendations for normal extreme heat or extreme cold

temperature.

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ADHESIVE MATERIAL (CURING TYPE)

5565 Adhesive™ (White & Green pot)

Bisphenol-A (BPA) Epoxy resin Adhesive

R6500™ Hardener (Yellow & Red pot)

Aromatic polyamine , Diamino Diphenyl Methane (DDM) Hardener.

Excellent Chemical Resistance and 140 deg C. Operating temperature.

Useable life 20 mins.

Gel time 30 mins.

Handling 60 mins at 23 deg. C applications.

Application good for Internall,Night and low temperature

R5500™ Hardener (Grey & Purple Pot)

Aromatic polyamine , Diamino Diphenyl Methane (DDM) Hardener.

Good Chemical Resistance and 100 deg C. Operating temperature.

Useable life 30 mins.

Gel time 45 mins.

Handling 90 mins at 23 deg. C applications.

Application good for Outside,day and above 35 C° temperature

Mixing Volume

* 5565 Adhesive (150 g) mixing with R6500 Hardener (150 g) = total volume 300 g

* 5565 Adhesive (150 g) mixing with F5500 Hardener (150 g) = total volume 300 g

* We have 2 type bonding material,each mixture total 300 g

* Adhesive mixing shal be one and one (all timing datum for 23 deg. C application)

Dia. 25 40 50 65 80 100 150 200 250 300 350 400 500

Qnty. 12 10 8 7 5 3 2 1.5 1.2 1 0.8 0.7 0.6

Man # 4 4 4 4 4 4 4 5 5 5 5 5 5

Appr. Number of Pipe Coupling Bonds per 300 g Kit and Installation Crew Man #

Ep Bonding 06.05-R0

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bonding manual (22.6.05)0 - asut · pdf filethis method statement explained machine made...

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