Inspection, Handling & Storage

Inspection Upon receipt of ordered items, check the shipment as follows: Make overall inspection of load. If the load arrives intact, ordinary inspection while unloading will normally be sufficient to make sure the pipe and/or fittings have arrived without damage. If the load has shifted or indicates rough treatment, then carefully inspect each pipe section for damage. Check quantity of each item against bill of lading. Note on the bill of lading any transit damage or loss and have the carrier representative sign your copy of the receipt. Make prompt claim against the carrier in accordance with their instructions. Do not dispose of any damaged items. The carrier will notify you of proper disposal procedure. If any defect other than transit damage is found, immediately telephone your Ameron representative. DO NOT USE PIPE THAT APPEARS DEFECTIVE. Unloading and Handling Unloading large diameter fiberglass pipe is the responsibility of the customer. Be sure to maintain control of the pipe during unloading. Do not drop, impact or bump the pipe, particularly at pipe ends. Use pliable straps, slings or rope to lift. DO NOT USE STEEL CABLES OR CHAINS TO LIFT OR TRANSPORT THE PIPE. Pipe lengths to 40 ft. can be lifted with only one support point (Fig. 1). However, it is good field practice to lift at two support points 15 ft. apart (Fig. 2). Storage Pipe less than 4 ft. in diameter may be stored directly on sandy soil. When storing pipe directly on the ground, be sure that the ground is flat and free of rocks larger than 1/2 in diameter, and other potentially damaging debris (Fig.3).

Fig. 1

Fig. 2

Fig. 3.CORRECT.

Fig. 4.INCORRECT: Pipe stored on objects, uneven surfaces.

Pipe 4 ft. in diameter and larger shall be placed on a minimum of two (2) cradles (90 - same as used in shipping) placed so that they support the pipe at the wall. Narrow flat supports are not adequate substitutes. All ribbed pipe shall be stored in a way that will avoid point loading of the rib area. Pipe should not be stacked. If at any time during handling or installation of the pipe, any minor damage, such as gouges or scratches should occur to the interior surface of the pipe, such damage should be coated with catalyzed resin before the section is installed. Any damage beyond this kind of minor occurrence may be cause to repair or replace the pipe section. If in doubt, dont use the pipe; contact your Ameron Representative for further advice and coordination of repair or replacement.

Instructions for Underground Installation

This recommended practice describes procedures for installing fiberglass reinforced thermosetting resin pipe produced by Ameron. Piping can support large earth loads and traffic without excessive deflection through a combination of the pipes stiffness and the mobilization of lateral passive soil forces. Proper installation techniques in accordance with the type of burial classification recommended by Amerons Engineering Department insures that the necessary passive soil pressure at the sides of the pipe will be developed and maintained. To achieve proper installation, trenches should be dug to at least 12 inches below the pipe base bedding, and the backfilling and bedding shall be maintained in accordance with this specification. Description and identification procedures for suitable backfill materials are found under Soil Types (pg. 13) and type of burial classifications are described under Classes of Trench Conditions (pg. 14). Attention is called to the following list of specifications and methods: ASTM D-698 ASTM D-883 ASTM D-2310 ASTMD-2412 ASTM D-2487-66T ASTM D-2487-66T Trenching Trench Width - The width of the trench at any point should be sufficient to provide adequate room for joining the pipe in the ditch with bell holes permissible at the joints. The pipe O.D. plus 24 inches per side is the normal trench width for large pipe diameters. Trench Contour - The trench bottom should be continuous, relatively smooth, shaped and compacted in accordance with the bedding and backfilling classification specified. Where ledge rock, hardpan, large rocks, timbers or other foreign materials are encountered, it is advisable to pad the trench bottom using sand or compacted fine grained soils at least 6 inches thick. Unstable Trench Conditions - Where an unstable soil condition is encountered such as may be caused by excavation below ground water, the bottom of the trench must be stabilized before laying the pipe. This can usually be accomplished by lowering the water table at least 12 inches below grade with well-points, shoring the sides, overexcavating the bottom material, and replacing with a mixture of sand and coarse gravel or crushed stone or by a combination of the above methods. In the case where shoring or sheeting is required, the width of the trench need only be sufficient to provide adequate working room. When shoring or sheeting is to be removed, the backfill should be placed and compacted as the sheeting is being pulled to avoid the occurrence of voids beneath the sheeting. Should soft plastic soil incapable of supporting pipe and pavement be encountered when the excavation is opened, it should be removed and replaced with suitable materialpreferably granularto a depth that will provide a firm, stable bedding. If dewatering is required, the use of well points is recommended. Bedding, Backfilling & Compaction Bedding Grade - The pipe should be uniformly and continuously supported over its entire length on firm, stable material. Blocking should not be used to change pipe grade or to intermittently support pipe across excavated sections. Backfilling - Pipe is installed in a wide range of subsoils. These soils should be not only stable but also applied in such a manner as to physically shield the pipe from damage. Attention should be given to local pipe laying experience which may indicate solutions to particular pipe bedding problems. Backfill materials according to the requirements under Soil Types (pg. 13) with a particle size of 1/2 inch or less should be used to surround the pipe; it should be placed in layers. Each soil layer should be sufficiently compacted to uniformly develop lateral passive soil forces during the backfill operation. Compaction - Both the bedding and backfill must be compacted to the specified percent of its maximum density as described in Methods D-698. Care should be taken when Moisture-Density Relations of Soils Nomenclature Relations of Soils Reinforced Thermosetting Resin Plastic Pipe External Loading Properties of Plastic Pipe by Parallel Plate Loading Tentative Method for Classification of soils for Engineering Purposes Description of Soils (Visual Manual Procedure)

Instructions for Underground Installation (contd)

compacting sidefill to avoid shifting the pipe. During compaction the moisture content of the backfill material should be within 2 percent of its optimum in accordance with Methods D-698 Test for Moisture-Density Relations Soils using 5.5 lb. rammer and 12 inch drop. In cases where soil test data are not available, the required moisture for satisfactory compaction of clay soils may be determined by checking the least amount necessary to hand roll a sample into a 1/8 round thread. Vibratory methods are preferred for compaction. The compaction within 6 inches to 18 inches of the pipe is usually done with hand tampers. After the side fills have been compacted to required density, a 12 inch layer of the same material should be placed over the top of the pipe and lightly tamped. Excessive tamping of this top layer should be avoided as it may result in distortion of the pipe. In wide, deep trenches, lightweight tractor powered track-mounted equipment of less than 5 psi pressure is permitted at least 24 inches away from the pipe and not across the pipe until 4 ft. of overburden is compacted. Wet puddling or water flooding for consolidating the backfill is not recommended, since this may lead to trapped air cavity around the perimeter of the pipe. Water addition may be used to obtain the optimum compaction of the backfill material. Lateral Pipe Deflection During Backfillng - Compacting each soil layer by means of a mechanical tamper, or similar tool will produce an inward horizontal eccentricity in the pipe. This lateral displacement during compaction is acceptable provided it does not exceed 7 percent of the nominal pipe inside diameter. If over 7 percent horizontal eccentricity is encountered, the compaction density should be decreased to 85 percent of the Modified Proctor maximum dry density, and also notify Ameron of this condition. Less eccentricity is expected and allowable in the joint area due to the increased stiffness with an additional wall thickness. Pipe strutting to produce a prescribed increased vertical deflection prior to pipe backfilling is sometimes used. Pipe Sleeving at Rigid Penetrations The optimum sleeve length shall be at least one nominal pipe diameter. The clearance between the O.D. of the pipe and I.D. of the sleeve shall be at least 3 inches. The use of a low density filler such as flexible foam, treated rags, or equivalent at the end of the sleeve between it and the pipe will prevent the trench fill from entering the sleeve. Soil Types A soil is considered stable if it provides dependable support to the pipe and undergoes only slight volume change with variation in its moisture content. The ability of a soil to provide support depends upon its resistance to consolidation and its shear strength. In general, coarse grained soils are considered stable. In ASTM D-2487- 66T, these are defined as soils of which 50 percent or less pass U.S. Standard No. 200 sieve. The particle passing through No. 200 sieve is about the smallest size visible to the naked eye. Using the group symbols of ASTM D-2487-66T (under Soil Classification Symbols, pg. 14), the following are considered stable backfill: GW, GP, GM, GC, SW, SP, provided that maximum particle size is not greater than 1/2 inch. In terms of overall use, gravel with fines and sand are the best backfill material for pressure pipe. Sand or gravel mixed with silts or clays, in which the sand or gravel constitutes at least 50 percent of the mixture, is also suitable. Certain soils should not be used as backfill material; these include highly organic soils, identified by odor or spongy feel, and fat, highly plastic expansive clay. Frozen soil should not be placed in contact with the pipe. Field Identification of Soils Gravel - Minimum grain size 1/4 inch. Sand - Individual grains visible to the naked eye with maximum particle size about 0.25 inch. Fine sand displays dilitancy and is nonplastic. Note: To test for dilitancy, place pat of moist soil on palm of hand. If the soil displays dilitancy, water will appear at the surface of the pat on shaking and disappear when the pat is compressed by the fingers. Silt - Individual grains difficult to see with the naked eye. May be slightly plastic. Displays dilitancy. Easily washed from fingers. Low dry strength. Lean Clay - Individual grains difficult to see with the naked eye. Dry lumps have moderate to high strength. Can be rolled into a 1/8 inch thread having low to moderate strength. Does not display dilitancy.

Instructions for Underground Installation (contd)

Fat Clay - Shows no or very slow dilitancy and should not be used unless mixed with coarse grained material. Has high dry strength. Has soapy feel and shiny streak results if fingernail is run over damp surface. Can be rolled into 1/8 inch threads having relatively high strength. Soil Classification Symbols GW - Well-graded gravel, gravel-sand mixtures, little or no fines. GP - Poorly graded gravel, gravel-sand mixtures, little or no fines. GM - Silty gravel, poorly graded gravel-sand-silt mixtures. GC - Clay gravel, poorly graded gravel-sand-clay mixtures. SW - Well-graded sands, gravelly sands, little or no fines. SP - Poorly graded sands, gravelly sands, little or no fines. SM - Silty sands, poorly graded sand-silt mixtures. Classes of Trench Conditions Class A is that method of bedding conduits in which the lower part of the conduit exterior is bedded in a cradle, constructed of 2,000 lb. concrete or better, having a minimum thickness under the pipe of 1/4 of the nominal internal diameter and extending up the sides of the pipe for a height equal to 1/4 of the outside diameter. Class B for trench conduits is that method in which the trench conduit is set on fine granular materials in an earth foundation carefully shaped to fit the lower part of the conduit exterior for a width of at least 60 percent of the conduit breadth. The remainder of the conduit is entirely surrounded to a height of at least one foot above its top by granular materials carefully placed by hand to fill all spaces under and adjacent to the conduit completely. The fill is tamped thoroughly on each side and under the conduit, as far as practical, in layers not exceeding 6 inches in thicknessall under the direction of a competent engineer represented by a competent inspector constantly present during the operation. Class B for embankment conduits is that method of bedding projecting conduits, having a projection ratio not greater than 0.70, in which the conduit is carefully bedded on fine granular materials in an earth foundation carefully shaped to fit the lower part of the conduit exterior for at least 10 percent of its overall height. The earth fill material is thoroughly rammed and tamped in layers not more than 6 inches deep around the conduit for the remainder of the lower 30 percent of its height. In the case of rock foundations, the pipe is bedded on an earth cushion having a thickness under the pipe of not less than 1/2 inch per foot of height of fill with a minimum allowable thickness of 8 inches, and with the earth foundation carefully shaped and filled around the conduit the same as for first class projecting embankment bedding on an earth foundation. Class C is that method of bedding in which the conduit is bedded with ordinary care in an earth foundation shaped to fit the lower part of the conduit exterior with reasonable closeness for at least 10 percent of its overall height (for at least 50 percent of the conduit breadth in the case of the trench conduit). The remainder of the conduit is surrounded by granular materials, placed by shovel to fill all spaces completely under and adjacent to the conduitall under the general embankment conduit pipe is bedded on an earth cushion having a thickness under the pipe of not less than 1/2 inch per foot of height of fill, with a minimum allowable thickness of 8 inches and the earth foundation carefully shaped and filled around the conduit the same as for ordinary projecting embankment bedding on an earth foundation. Class D is that method of bedding in which little or no care is exercised either to shape the foundation surface to fit the lower part of the conduit exterior or to fill all spaces under and around the conduit with granular materials. This type of bedding also includes the case of conduits on rock foundations in which an earth cushion is provided under the conduit, but is so shallow that the conduit, as it settles under the influence of vertical load, approaches contact with the rock.

Instructions for Butt and Strap Joints

Each weld kit is supplied with a premeasured quantity of glass strips for making the butt and strap joint for a particular pipe size with a desired pressure rating. Therefore, it is extremely important that all materials be properly applied to the joint to insure that the finished product will have the required wall thickness and pressure rating of the pieces that are joined. Tools Power disc sander, with 12-24 grit grinding discs Saber saw, with 24 tooth metal-cutting blade or tungsten carbide blade 10 scissors or retractable razor knife Serrated aluminum or teflon rollers, 1 diameter x 3 wide Wrap-a-round or straight-edged gasket material Supplies

Precut Strips

Cleaning solvent - acetone or methylene chloride 3 wide stiff bristle brushes, for wetting out glass strips Cellophane, mylar film or unwaxed paper, for pre-wetting glass strips Mixing sticks (wooden tongue depressors) Paper or plastic mixing cups Milliliter graduates for measuring resin and catalyst Safety goggles or glasses Protective gloves, neoprene or polyethylene

Application

All butt welds are to be made in accordance with NBS Specification PS 15-69. The actual procedure will be performed as follows: 1. Measure off length of pipe (or duct) required and using a marker and straight edge, draw a line completely around surface to be cut (Fig.1). 2. Cut pipe (or duct) with a saber saw using a fine toothed blade or a circular saw with an abrasive blade. Cut ends will be coated with resin so as to cover any exposed fibers (Fig. 2). 3. Pipe ends to be joined will be sanded back one foot beyond the required weld dimension. (Fig. 3)

Cross section after entrapped air is rolled out

Fig.1

Fig.2

Fig.3

Instructions for Butt and Strap Joints (contd)

4. Pipe will be placed in the position in which they are to be welded. A catalyzed thixotrophic polyester paste will be applied to the joint seam. This will eliminate resin flow through the crack as the actual weld is applied. (Fig. 4) Make certain work area and surfaces are as clean as possible and dry. 5. The precut fiberglass kit is then saturated with catalyzed resin along side of joint area (Fig. 5). 6. The saturated weld is then picked up like a bandage and wrapped around the joint (Fig. 6).

Fig. 4

Fig. 5

Fig. 6

7. A serrated roller is then used to smooth the weld and remove any air bubbles that may have been trapped beneath the weld when applied (Fig.7). 8. The joint should be made in steps not to exceed 1/4 inch thickness. The outer surface of each strip should be lightly sanded prior to the next being applied. 9. An inside weld, consisting of 2 layers of chopped strand mat may be used in larger diameter pipe. 10. A final gel coat is applied after the weld has taken its initial cure (Fig. 8).

Fig. 7

Fig. 8