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Ameron International Corporation is a multinational manufacturer of

highly-engineered products for the construction, industrial, chemical


and energy markets. The company operates businesses in Europe,
the Middle East, Africa, North America, South America and
Australasia. Traded on the New York Stock Exchange (AMN), Ameron
is a leading producer of high-performance coatings; fiberglass pipe
and composites, concrete and steel pipe systems and specialised
construction products.
With Bondstrand, Centron, Dualoy and Bondstrand SSL
(Steel Strip Laminate) Ameron offers the worlds most comprehensive
line of Glassfiber Reinforced Epoxy (GRE) and phenolic pipe products,
representing a cost-effective alternative to corrosion-prone metallic
piping and (reinforced) thermo plastics. The corrosion resistance and
chemical inertness of Glassfiber Reinforced Epoxy (GRE) and phenolic
pipe make it especially suitable for service in hostile and corrosive
environments. The special characteristics of phenolic pipe with its fire
resistance and low smoke generation, making it less toxic, demonstrate
a significant safety advantage in case of fire on for example platforms.
Furthermore, it is much lighter in weight than comparable steel pipe
and easier to install.
Ameron Fiberglass-Composite Pipe Group/Europe serves industrial,
military, marine, offshore and oilfield markets in Europe, Africa and
the CIS countries (former Russia) with high-performance Glassfiber
Reinforced Epoxy (GRE) and phenolic piping systems of up to 100
mm (40 inch) in diameter and pressure classes of up to 245 bar
(3500 psi).
High standards of performance
Ameron Fiberglass-Composite Pipe Group/Europe is a leader in
Glassfiber Reinforced Epoxy (GRE) and phenolic piping technology.
All pipes are manufactured using state-of-the- art computer-controlled
equipment. In order to meet industrys ever more exacting needs for
quality products and services. Ameron is certified in accordance with
ISO 9001.
Ameron 2004 - FP562 A_intro. Printed in The Netherlands.
BONDSTRAND

GLASSFIBER REINFORCED
EPOXY AND PHENOLIC PIPE SYSTEMS
FOR OFFSHORE APPLICATIONS
BONDSTRAND
EPOXY AND PH
FOR OFFSHOR
SPECIFICATIONS
UKOOA
In 1994, the United Kingdom Offshore Operators
Association (UKOOA) issued a Document Suite on
behalf of and under the guidance of the Fibre
Reinforced Plastic (FRP) workgroup of the UKOOA.
This Document Suite provides the offshore oil & gas
industry with mutually agreed specifications and
recommended practices for the design, purchase,
manufacturing, qualification testing, handling,
storage, installation, commissioning and operation
of Glass Reinforced Epoxy (GRE) piping systems
offshore.
Ameron was a member of the advisory group that
was formed to review the documents during their
development.
ISO
This Document Suite formed the basis of the ISO
14692 Standard.
Although, the ISO 14692 Standard is primarily
intended for offshore applications on both fixed and
floating topsides facilities, it may also be used as
guidance for the specification, manufacture, testing
and installation of GRE piping systems in other
similar applications found onshore, e.g. produced-
water and firewater systems.
IMO
In 1993, the International Maritime Organisation
(IMO) issued a resolution (A.18/Res. 753) covering
acceptance criteria for plastic materials in piping
systems, appropriate design and installation
requirements and fire test performance criteria for
assuring ship safety. Major certifying bodies (such as
Lloyds Registre, Bureau Veritas, Det Norske Veritas,
American Bureau of Shipping and United States
Coast Guard) have adopted and implemented these
Guidelines in their respective Rules and Regulations
for the Classification of Ships.
All Bondstrand pipe series that are used in the
marine/offshore industry are type-approved by these
major certifying bodies.
Historically, offshore production
platform, drilling rig and FPSO owners
and operators have had to face the grim
reality of replacing most metal piping.
This has resulted in piping systems costing
two or three times the original
investment.
Bondstrand

Glassfiber Reinforced Epoxy


(GRE) pipe systems offer the cost-
effective, maintenance-free and
lightweight solution that provides
problem-free operation during the
service life of the installation.
The many advantages of Ameron
Glassfiber Reinforced Epoxy (GRE)
pipe systems
Durable and corrosion resistant
Bondstrand GRE piping is inert to internal
corrosion caused by (salt) water,
chemicals, residues and bacteria.
Similarly, it resists exterior corrosion even
in aggressive environments. Cathodic
protection is not required.
Lightweight easy to install
Bondstrand GRE pipe systems, being just
a quarter to an eighth the weight of
comparable steel pipes, are easy to install
without the need of heavy installation
equipment, welding or protective
coating. For installation of GRE piping
systems no hot work is required.
Low installation and operating costs
The installation cost of Bondstrand GRE
pipe systems is typically 80% of the cost
of carbon steel. The smooth internal
surface reduces the head loss resulting in
lower pump energy consumption.
Wide range of pipe systems
Ameron offers a complete range of pipe
systems in a variety of diameters and
pressure classes for many different
applications. Pipe systems are available in
diameters up to 1000 mm (40 inch),
pressure classes up to 245 bar (3500 PSI)
and standard lengths up to
12 m (40-feet).
No contamination
Bondstrand GRE does not produce rust or
scale, which could foul steam traps, valves
and other components.
ENGINEERING CAPABILITIES
PREFABRICATION
The Ameron Fiberglass-Composite Pipe Group can
assist in converting layout- or isometric drawings
into spool drawings, which in turn are used by
Ameron for the manufacture of the spools .
Amerons Engineering Service can include:
G General engineering calculations such as support
span, thrust loads, joint strength, collapse
pressure and internal pressure ratings, etc.
G Design drawings, stress- and hydraulic analyses
G Pipe Spool drawings from piping isometrics
G Pipe support detailing
G Material take offs (MTO)
G Supervision and/or survey of installation
G Project Management
G Special product design for custom made parts
G Expertise on international specification work
towards approval authorities
G Field service
G Training to certify installers.
Ameron has highly skilled and trained pipe
spool fabricators to provide spool
prefabrication services to our customers.
These spools are fabricated based on spool
drawings issued by the Ameron Fiberglass-
Composite Pipe Group.
Where pipe spacing is a constraint, Ameron can
offer custom made spools to meet specific
dimensions.
Amerons team of piping engineers and
fabricators can assist to ensure that custom-made
spools are designed and fabricated to meet the
design requirements.
Supply of pre-fabricated spools by Ameron is
recommended as it will reduce the number of
field joints and provide greater reliability
because of the high quality joints and testing of
joints made at the Ameron factory.
TESTING
FIRE ENDURANCE
Bondstrand fittings are tested to 1.5 times their
pressure rating before they leave the factory or are
used in spools. Small diameter fittings, to
150 mm (6 inch) are air tested, when possible. All
others and the large diameter fittings are
hydrotested. Ameron is the only manufacturer to
conduct unrestrained hydro-test of fittings above
500 mm (20 inch) in diameter using self-energizing
test plugs. Unrestrained testing is a more
representative test as it simulates the actual
condition the pipeline is subjected to in most
offshore installations.
Ameron has extensive testing capabilities to meet
special testing requirements. Comprehensive
qualification testing is done on representative sizes
before manufacturing. Qualification test includes
long-term hydrostatic test in accordance with
ASTM D-2992, medium term survival test
(1000-hour survival test) and short time burst test in
accordance with ASTM D-1599. Mechanical and
physical property tests of Bondstrand pipe can also
be conducted.
Epoxy pipe
Bondstrand epoxy offshore products can be used for systems
which are normally water filled without additional passive fire
protection. Fire exposure will cause the outer surface of the pipe
to char, but the inner piping is able to perform, stabilized by the
water.
Epoxy pipe with intumescent coating
For dry services where epoxy pipe is preferred, an outer layer of
passive fire protection can be used.
Intumescent coatings can be applied in the field (unreinforced)
or in the factory (reinforced or unreinforced) to provide the fire
endurance needed.
The coating also provides very high resistance to damage and
may be considered for areas where the piping is vulnerable to
impact.
Phenolic pipe
Bondstrand PSX-L3 pipe can also be used in normally wet service
and in those locations where smoke density and toxicity are of
concern. The PSX-JF pipe is used in normally dry service (such as
deluge lines). Both products include an exterior jacket for impact
resistance and enhanced fire performance.
Our corrosion-resistant piping systems can be
used in a wide range of applications.
Typical application areas are:
WIDE RANGE OF
APPLICATIONS
G Ballast water
G Caissons
G Cooling water
G Disposal
G Drains
G Drilling mud
G Fresh water
G Potable water
G Produced water
G Fire mains
G Saltwater / seawater
G Sanitary / sewage
G Column piping
G Vent lines
WIDE RANGE OF
SYSTEMS
*
As a leading producer Ameron off ers
the worlds most comprehensive
range of glassf iber reinf orced epoxy
and phenolic pipe systems. Whether
you need corrosion protection, f ire
protection, or a conductive system,
Ameron off ers the right choice.
Bondstrand

Glassf iber Reinf orced


Epoxy (GRE) and Phenolic pipe series
Sizes: 25-1000 mm (140 inch)
Pressure classes: up to 25 bar (365 psi)
Internal liners: available if needed
Conductive systems: available if
needed
J oining systems: Quick-Lock and
Taper/Taper adhesive bonded joints.
* Depending on requirements
COST COMPARISON
WITH CONVENTIONAL
STEEL MECHANICAL
SYSTEMS
BONDSTRAND

CONDUCTIVE PIPING SYSTEMS


Bondstrand conductive piping
systems have been developed to
prevent accumulation of potentially
dangerous levels of static electrical
charges. Pipe and flanges contain
high strength conductive filaments;
fittings include a conductive liner.
Together with a conductive adhesive this
provides an electrically continuous system. If
required, grounding saddles may be installed
on the pipe once the piping system is installed.
Integral grounding cables are then bolted to
the ships structure to drain accumulated
charges.
TOTAL INSTALLED COST
EQUALS
TRADITIONAL STEEL PIPING
A comparison of costs
clearly shows the typical
savings during the service
life of the piping system.
WORLDWI DE
OPERATI ON
W ith
m anufacturing
facilities in the
U SA , Europe and
A sia-Pacific,
A m eron offers
the w orlds m ost com prehensive line of
G RE pipe products for industry, oil & gas,
offshore, m arine and fuel handling.
Ameron
Fiberglass-Composite Pipe
Group
Headquarters
P.O. Box 801148
Houston, TX 77280
USA
Phone (+1) 713 690 7777
Fax (+1) 713 690 2842
www.ameron.com
E-mail: marcom@ameronfpd.com
Ameron
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone (+31) 345 587 587
Fax (+31) 345 587 561
www.ameron-fpg.nl
E-mail: info@ameron-fpg.nl
Ameron
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd.
N0. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone (+65) 8616118
Fax (+65) 8621302/861 7834
www.ameron.com.sg
E-mail: info@ameron.com.sg
Ameron
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, TX 76364
USA
Phone (+1) 940 569 1471
Fax (+1) 940 569 2764
This literature and the inform ation and recom m en-
dations it contains are based on data reasonably
believed to be reliable. H ow ever, such factors as
variations in environm ent, application or installa-
tion, changes in operating procedures, or extrapo-
lation of data m ay cause different results. A m eron
m akes no representation or w arranty, express or
im plied, including w arranties of m erchantability
or fitness for purpose, as to the accuracy, adequacy
or com pleteness of the recom m endations or in-
form ation contained herein. A m eron assum es no
liability w hatsoever in connection w ith this litera-
ture or the inform ation or recom m endations it
contains.
LEADING PRODUCER
AMERON OFFERS THE WORLDS MOST COMPREHENSIVE
SELECTION OF J OINING SYSTEMS FOR OFFSHORE PIPE
SYSTEMS
FITTINGS
Standard filament-wound Couplings; 30,
45, 60, and 90 Elbows; Tees and Reducing
Tees; Concentric Reducers; Flanges and
Nipples.
Standard Flanges are available with the
following drilling: ANSI B16.5 Class 150 &
300, DIN, ISO and JIS. Other drilling patterns
are available on request.
Available in sizes 50-1000 mm (2-40 inch)
Ameron is a leading
producer of glassfiber-
reinforced epoxy (GRE) pipe
systems with manufacturing
facilities in the Americas,
Europe and Asia-Pacific.
Ameron offers the worlds
most comprehensive line of
GRE pipe products for
industry, oil & gas, offshore,
marine and fuel handling
applications.
CUSTOMER SUPPORT
Ameron provides a high
degree of customer support
through a network of sales
offices, supply houses,
stocking distributors and
sales representatives in
more than 100 countries.
This is supported by central
research and development
facilities, to meet customer
requirements.
EXPERTISE AT EVERY
STAGE
Ameron offers advice at
every stage, from project
planning to installation.
With advanced software,
Ameron can offer assistance
in design, calculations and
engineering.
WORLDWIDE APPROVALS
Ameron is committed to
Total Quality Management
and conforms to the
international ISO 9001
standard and holds many
type approvals such as
Lloyds, DNV, ABS, BV,
United States Coast Guard
and UKOOA.
Ameron 2003 FP 287 D 04/03 supersedes FP 287 C 11/95. Printed in The Netherlands.
QUICK-LOCK

An adhesive-bonded joint with straight spigot and tapered


bell. The integral pipe stop in the Quick-Lock bell
provides accurate laying lengths in close
tolerance piping.
Available in sizes 50-400 mm (2-16 in).
TAPER-TAPER
An adhesive-bonded joint with matching tapered
male and female ends offering superior joint
strength by controlled adhesive thickness.
Available in sizes 50-1000 mm (2-40 in).
DOUBLE O-RING
A mechanical joint offering quick assembly between
male and female ends. Two O rings are
employed to provide sealing.
Available in sizes 50-900 mm (2-36 in).
FLANGES
One-piece flanges and Stub-end flanges with
movable rings.
Available in sizes 50-1000 mm (2-40 in).
Comparison of the life cycle cost of a
GRE seawater lift caissonfor a new built
platform versus steel
Cutting the cast
A comparison of costs clearly shows the
savings made in materials. during
fabrication and installation. and later
during the lifetime of the caissons.
The inspection of steel caissons and
maintenance of corrosion protection
coatings or claddings greatly increases the
totallife span costs tor the platform
operator. A number of steel caissons have
required replacement at several times the
original installation cost.
These direct costs do not allow tor
perhaps greater additional costs resulting
trom production shutdown losses during
maintenance or replacement operations.
Easy ta install
Caissons can vary in size from 250 mm
(10 inch) to 1200 mm (48 inch) in diameter
and from 20 to 100 rn in length. Import
caissons typically incorporate a central
riser system for the transportation of sea
water on to the platform for process and
utility applications. Export caissons
normally contain a number of smaller
pipes within the external housing for the
disposal of effluent produced by the
insta!lation.
The lightweight GRE caissons are easily
and conveniently set in place without the
need for major handling equipment.
Ameron and S lP Engineering can offer a
complete turn-key service for the design,
manufacture, fabrication and installation
of GRE caissons, including the interna!
column pipes. The Ameron-SlP association
brings together years of combined
experience in materials, engineering and
installation.
. .
Ameron Bondstrand@
glassfiber reinforced epoxy
systems for caissons
Caissons, large diameter pi ping transportation systems, are used on
offshore oil and gas platforms for importing sea water and
discharging treated effluent. Until recent I y these caissons have been
fabricated from steel, but when subjected to the extreme
environmental conditions of the North Sea they are susceptible to
severe corrosion problems.
The necessity to conform with safety requirements, particularly for
the fire water caisson system, has lead to rigorous inspection and
maintenance procedures. These procedures, and subsequent repair
and replacement work, are very costly and can amount to up to
seven times the original installation costs when calculated over the
life span of the caissons. Glassfiber reinforced epoxy (GRE) caissons
from Ameron have been accepted by Lloyd's Register and certified
for oil and gas platforms not only because of platform lifetime
durability but also because of the ease of installation.
Glassfiber reinforced epoxy can stand the wear
In 1989 Ameron and the London-based offshore design and
construction company S LP Engineering began a joint programme to
develop lightweight maintenance-free glassfiber reinforced epoxy
caisson housing systems that would last the platform lifetime.
In 1994 the first complete GRE caissons and diver protection cages
were instalied on the Hamilton Oil Douglas Accommodation
platform in the UK Liverpool Bay Development.
The 700 and 900 mm diameter caissons were manufactured using
Bondstrand(!) glassfiber reinforced filament wound epoxy, chosen
because of its flexural strength properties, and more.
Filament-wound GRE caissons offer the
following advantages:
During installation
.Ease af installatian, na welding an site
.Lightweight, 40% less than metal,
means easier handling
.Installatian casts reduced by half
In use
.Maintenance-free, means major cost
savings, no down time losses
.Long lasting, platform lifetime durability
Design
In-house software has been specifically developed by
Ameron and S LP for the finite element analysis of GRE
caissons.
Testing
An extensive testing programme has been completed on
prototype GRE caissons to verify their performance under
conditions that simulate the worst environment likely to be
encountered offshore. Particular emphasis was given to
verification of pipe jointing by axial tensile testing and
static flexural strength testing under a simulated one in
fifty year wave loading condition. Cyclic flexural strength
testing has also been undertaken to produce a fatigue
curve for the GRE caisson system.
Cyclic tlexural strength testing has been carried out to
produce a tatigue curve tor the GRE caisson system
Certification
Lloyd Register Certifying Authority played a major role
throughout the testing programme on GRE caisson
prototypes. In 1994, Lloyd's approval was granted for the
use of Bondstrand GRE caissons on offshore platforms.
Prototype GRE caissons have been thoroughly tested in the
worst environment likely to be experienced in offshore
conditions.
S-N plot of fatigue data under flexural bending
Bondstrand@
Glassfiber reinforced epoxy systems for caissons
Ameron
Fiberglass Pipe Division
Group Headquarters
P.O. Box 801148
Houston
Texas 77280-1148
USA
Telephone 1-713-690-7777
Fax 1-713-690-2842
Ameron
Fiberglass Pipe Division
The Americas
P.O. Box 878
Burkburnett
Texas76364
USA
Telephone 1-817-669-1471
Fax 1-817-669-4012
Ameron
Fiberglass Pipe Division
Asia
Ameron (Pte) Ltd.
No.7 A, Tuas Avenue 3
Jurong
Singapore 2263
Telephone 65-8621301
Fax 65-8621302
Telex 38960 AMERON RS
Ameron
Fiber91ass Pipe Division
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Telephone 31345573341
Fax 31 345575254
Telex 40257 BONDS NL
ISQ_~QO1
I! .,'i) !{j)
Accredlted b the Dutch
~nlln"il fnr ~ertlflcatlon
-
Certlfled Flrm
Manufacturing plants: Burkburnett, Texas; Spartanburg, South
Carolina; Geldermalsen, The Netherlands and Singapore.
Bondstrand pipe is also manufactured in Japan and Saudi Arabia.
Cl Ameron 1995 FP604 2/95 Printed in The Netherlal
Ameron 2004. FP 918 09/04. Page 1 of 28. Printed in The Netherlands.
Bondstrand

2000M/7000M
Glassfiber Reinforced Epoxy
(GRE) pipe systems for
marine service
with external pressure requirements
In 1993, IMO (International Maritime Organisation) issued a resolution (A.18/Res. 753)
covering acceptance criteria for assuring ship safety. Major certifying bodies have adopted
and implemented these Guidelines in their respective Rules and Regulations for the
Classification of Ships.
All Bondstrand pipe series used in the marine industry are designed and type-approved
by the below major certifying bodies. (A complete list is available, on request)
- American Bureau of Shipping (ABS), U.S.A.;
- Bureau Veritas, France;
- Det Norske Veritas, Norway;
- Germanischer Lloyd, Germany;
- Lloyd's Register, United Kingdom;
- Nippon Kaiji Kyokai, Japan;
- Registro Italiano Navale (RINA), Italy;
- United States Coast Guard (USCG), U.S.A.
Maximum operating temperature: up to 121C.
Pipe diameter: 1-40 inch (25-1000 mm).
Pipe system design for pressure ratings up to 16 bar.
ASTM D-2992 Hydrostatic Design Basis (Procedure B - service factor 0.5);
ASTM D-1599 Safety factor of 4:1. Design criteria for external pressure requirements are
in accordance with IMO regulations.
Bondstrand 2000M
ASTM D-2310 Classification: RTRP-11FW for static hydrostatic design basis;
ASTM D-2310 Classification: RTRP-11FX for static hydrostatic design basis;
Complies with ASTM F-1173 Classification.
Bondstrand 7000M
ASTM D-2310 Classification: RTRP-11AW for static hydrostatic design basis;
ASTM D-2310 Classification: RTRP-11AX for static hydrostatic design basis;
Complies with ASTM F-1173 Classification.
Approvals
Quick-Lock
Uses and applications
Characteristics
Taper/Taper
18-40 inch
1-16 inch
A complete library of Bondstrand pipe and fittings in TRIBON,
PDS and PDMS-format is available on CD-ROM. Please contact Ameron for details.
For specific fire protection requirements, an outher layer of passive fire protection is
available.
For pipe systems without external pressure requirements, please refer to
Bondstrand 3400 product data (FP 835) or contact your Ameron representative.
! Ballast ! Portable discharge line
! Chlorination ! Stripping lines
! Draining ! Tankcleaning (salt water)
! Cargo line ! Fire protection mains
! Sanitary service & sewage ! Various other applications
Ameron 2004. FP 918 09/04. Page 2 of 28. Printed in The Netherlands.
Table of Contents GENERAL DATA
Adhesives ................................................................................................................. 27
Conversions .............................................................................................................. 28
Engineering design & installation data ..................................................................... 28
Hydrostatic testing .................................................................................................... 28
Important notice ........................................................................................................ 28
Joining system and configuration ............................................................................... 3
Mechanical properties ................................................................................................. 4
Physical properties ..................................................................................................... 4
Pipe series .................................................................................................................. 3
Pipe length .................................................................................................................. 4
Pipe dimensions and weights ..................................................................................... 7
Pipe performance .................................................................................................... 5-6
Span length ................................................................................................................. 9
Surge Pressure ......................................................................................................... 28
Ultimate Collapse Pressures ...................................................................................... 8
FITTINGS DATA
Adaptors............................................................................................................... 26-27
Bell mouth ................................................................................................................. 25
Couplings .................................................................................................................. 22
Elbows ................................................................................................................... 9-11
Expansion coupling ................................................................................................... 26
Flanges ................................................................................................................ 20-22
Joint dimensions Quick-Lock ................................................................................... 8
Joint dimensions Taper/Taper ..................................................................................... 8
Laterals ..................................................................................................................... 17
Nipples ...................................................................................................................... 23
Reducers.............................................................................................................. 18-19
Saddles ............................................................................................................. 17 & 24
Tees ..................................................................................................................... 11-16
Ameron 2004. FP 918 09/04. Page 3 of 28. Printed in The Netherlands.
Pipe series Pipe
Filament-wound Glassfiber Reinforced Epoxy (GRE) pipe for Bondstrand adhesive-
bonding systems. MDA (diaminodiphenylmethane) or IPD (isophoronediamine) cured.
Fittings
A wide range of lined filament-wound Glassfiber Reinforced Epoxy (GRE) fittings for
Bondstrand adhesive-bonding systems. For special fittings, not listed in this product
guide, please contact your Ameron representative.
Flanges
Filament-wound Glassfiber Reinforced Epoxy (GRE) heavy-duty flanges, hubbed and stub-
end flanges for Quick-Lock adhesive bonding systems. Standard flange drilling patterns
as per ANSI B16.5 (150 Lb). Other flange drilling patterns, such as ANSI B16.5 (> 150 Lb),
DIN, ISO and JIS are also availabe.
Bondstrand2000M
Glassfiber Reinforced Epoxy (GRE) pipe system; IPD or MDA cured.
Standard 0.5 mm internal resin-rich reinforced liner.
Maximum operating temperature: 121C.; for higher temperatures, please contact Ameron.
Maximum pressure rating: 16 bar.
Minimum pressure: full vacuum.
External Pressure Requirements: In accordance with IMO Regulations.
Bondstrand7000M (* conductive)
Glassfiber Reinforced Epoxy (GRE) pipe system; IPD or MDA cured.
Maximum operating temperature: 121C.; for higher temperatures, please contact Ameron.
Maximum pressure rating: 16 bar.
Minimum pressure: full vacuum.
External Pressure Requirements: In accordance with IMO Regulations.
* Conductive
Our conductive pipe systems have been developed to prevent accumulation of potentially
dangerous levels of static electrical charges. Pipe, fittings and flanges contain high strength
conductive filaments. Together with a conductive adhesive this provides an electrically
continuous system.
Description Bondstrand 2000M Bondstrand 7000M
Pipe diameter 1-40 inch 1-40 inch
Joining system Quick-Lock 1-16 inch Quick-Lock 1-16 inch
Taper/Taper 18-40 inch Taper/Taper 18-40 inch
Liner 0.5 mm -
Temperature 121C. 121C.
Pressure Rating 16 bar 16 bar
Pipe
25-400 mm (1-16 inch):
Quick-Lock (straight/taper) adhesive joint with integral pipe stop in bell end.
End configuration: Integral Quick-Lock bell end x shaved straight spigot.
450-1000 mm (18-40 inch):
Taper/Taper adhesive joint.
End configuration: Integral Taper bell x shaved taper spigot
Fitting
25-400 mm (1-16 inch):
Quick-Lock (straight/ taper) adhesive joint with integral pipe stop in bell end.
End configuration: Integral Quick-Lock bell ends.
450-1000 mm (18-40 inch):
Taper/Taper adhesive joint.
End configuration: Integral Taper bell ends.
Flanges
25-1000 mm (1-40 inch):
Quick-Lock (straight/ taper) adhesive joint with integral pipe stop in bell end.
End configuration: Integral Quick-Lock bell end.
Note: * Pipe nipples, saddles and flanged fittings have different end configurations.
Joining system &
configuration
Ameron 2004. FP 918 09/04. Page 4 of 28. Printed in The Netherlands.
Typical mechanical
properties
Nominal Joining Approximate overall Length*
Pipe Size System Europe Plant Asia Plant
[mm] [inch] [m] [m]
25-40 1-1 Quick-Lock 5.5 3.0
50-125 2-5 Quick-Lock 6.15 5.85/9.0
150 6 Quick-Lock 6.1 5.85/9.0
200 8 Quick-Lock 6.1/11.8 5.85/9.0
250 10 Quick-Lock 6.1/11.8 5.85/11.89
300-400 12-16 Quick-Lock 6.05/11.8 5.85/11.89
450-1000 18-40 Taper/Taper 11.8 11.89
* Tolerance +/- 50 mm.
Pipe property Units Value Method
Thermal conductivity pipe wall W(m
.
K) .33 Ameron
Thermal expansivity (lineair) 10
-6
mm/mm C 18.0 Ameron
Flow coefficient Hazen-Williams 150
Absolute roughness 10
-6
m 5.3
Density kg/m
3
1800
Specific gravity - 1.8 ASTM D-792
Pipe property IPD cured Units 21C. 93C. Method
Bi-axial
Ultimate hoop stress at weeping N/mm
2
300 ASTM D-1599
Circumferential
Hoop tensile strength N/mm
2
380 ASTM D-2290
Hoop tensile modulus N/mm
2
23250 18100 ASTM D-2290
Poisson's ratio axial/hoop 0.93 1.04 Ameron
Longitudinal
Axial tensile strength N/mm
2
65 50 ASTM D-2105
Axial tensile modulus N/mm
2
10000 7800 ASTM D-2105
Poisson's ratio hoop/axial 0.40 0.45 ASTM D-2105
Axial bending strength 80 Ameron
Beam
Apparent elastic modulus N/mm
2
9200 7000 ASTM D-2925
Hydrostatic Design Basis
Static N/mm
2
148* ASTM D-2992
(Proc. B.)
Pipe property MDA cured Units 21C. 93C. Method
Bi-axial
Ultimate hoop stress at weeping N/mm
2
250 ASTM D-1599
Circumferential
Hoop tensile strength N/mm
2
220 ASTM D-2290
Hoop tensile modulus N/mm
2
25200 ASTM D-2290
Poisson's ratio axial/hoop 0.65 0.81 Ameron
Longitudinal
Axial tensile strength N/mm
2
80 65 ASTM D-2105
Axial tensile modulus N/mm
2
12500 9700 ASTM D-2105
Poisson's ratio hoop/axial 0.40 0.44 ASTM D-2105
Axial bending strength 85 Ameron
Beam
Apparent elastic modulus N/mm
2
12500 8000 ASTM D-2925
Hydrostatic Design Basis
Static N/mm
2
124* ASTM D-2992
(Proc. B.)
* At 65C.
Typical physical
properties
Typical pipe length
Ameron 2004. FP 918 09/04. Page 5 of 28. Printed in The Netherlands.
.
Typical pipe performance Bondstrand 2000M (MDA cured) at 21C.
Nominal STIS Stifness Pipe
Pipe Factor Stiffness
Size
[mm] [inch] [kN/m
2
] [lb.in] [psi]
25 1 3142.4 502 16187
40 1 949.6 502 4812
50 2 534.7 554 2729
80 3 157.3 554 796
100 4 154.4 1281 863
125 5 80.5 1281 449
150 6 46.7 1377 279
200 8 35.5 3092 276
250 10 36.6 6375 285
300 12 35.9 10627 280
350 14 36.8 13548 286
400 16 36.9 20308 287
450 18 36.2 28265 282
500 20 36.3 38976 283
600 24 36.6 67877 285
700 28 36.9 121531 288
750 30 36.8 148680 286
800 32 37.1 182139 289
900 36 36.8 256919 286
1000 40 37.7 361759 294
Bondstrand 2000M (IPD-cured) at 21C.
25 1 2087.4 504 16251
40 1 620.6 504 4831
50 2 352.0 556 2740
80 3 102.6 556 799
100 4 111.3 1286 866
125 5 57.9 1286 451
150 6 35.9 1382 280
200 8 35.6 3104 277
250 10 36.8 6400 286
300 12 36.1 10669 281
350 14 36.9 13602 287
400 16 37.1 20389 289
450 18 36.3 28378 283
500 20 36.5 39130 284
600 24 36.6 68147 285
700 28 36.9 122013 289
750 30 36.8 149270 288
800 32 37.1 182862 290
900 36 36.8 257939 288
1000 40 37.7 363195 295
Ameron 2004. FP 918 09/04. Page 6 of 28. Printed in The Netherlands.
Typical pipe performance Bondstrand 7000M (MDA-cured) at 21C.
Nominal STIS Stifness Pipe
Pipe Factor Stiffness
Size
[mm] [inch] [kN/m
2
] [lb.in] [psi]
25 1 3142.4 797 24464
40 1 949.6 797 7393
50 2 534.7 867 4162
80 3 157.3 867 1225
100 4 154.4 1809 1202
125 5 80.6 1809 627
150 6 46.7 1809 363
200 8 39.4 3092 276
250 10 38.2 6375 285
300 12 37.2 10627 280
350 14 38.0 13548 286
400 16 37.2 20308 287
450 18 38.0 28265 282
500 20 37.2 38976 283
600 24 36.7 67877 285
700 28 37.1 121531 288
750 30 36.9 148680 286
800 32 37.3 182139 289
900 36 36.9 256919 286
1000 40 37.9 361759 294
Bondstrand 7000M (IPD-cured) at 21C.
25 1 3154.9 800 24561
40 1 953.3 800 7422
50 2 536.8 871 4179
80 3 157.9 871 1230
100 4 155.0 1816 1207
125 5 80.9 1816 630
150 6 46.9 1816 365
200 8 35.6 3104 277
250 10 36.8 6400 286
300 12 36.1 10669 281
350 14 36.9 13602 287
400 16 37.1 20389 289
450 18 36.3 28378 283
500 20 36.5 39130 284
600 24 36.7 68147 286
700 28 37.1 122013 289
750 30 36.9 149270 288
800 32 37.3 182862 290
900 36 36.9 257939 288
1000 40 37.9 363195 295
Ameron 2004. FP 918 09/04. Page 7 of 28. Printed in The Netherlands.
Bondstrand 2000M
Nominal Pipe Minimum Average Designation
Pipe Inside Struct. Wall Pipe per ASTM
Size Diameter Thickness [t] Weight D-2966
mm] [inch] [mm] [mm] [kg/m] MDA IPD
25 1 27.1 3.0 0.7 RTRP-11 FW1-2112 FX1-3112
40 1 42.1 3.0 1.3 RTRP-11 FW1-2112 FX1-3112
50 2 53.0 3.1 1.3 RTRP-11FW1-2112 FX1-3112
80 3 81.8 3.1 1.8 RTRP-11FW1-2112 FX1-3112
100 4 105.2 4.1 3.1 RTRP-11FW1-2113 FX1-3113
125 5 131.9 4.1 3.5 RTRP-11FW1-2113 FX1-3113
150 6 159.0 4.2 4.6 RTRP-11FW1-2113 FX1-3113
200 8 208.8 5.5 7.4 RTRP-11FW1-2116 FX1-3116
250 10 262.9 7.0 12 RTRP-11FW1-2116 FX1-3116
300 12 313.7 8.3 17 RTRP-11FW1-2116 FX1-3116
400 14 337.6 9.0 19 RTRP-11FW1-2116 FX1-3116
400 16 385.8 10.3 25 RTRP-11FW1-2116 FX1-3116
450 18 433.8 11.5 32 RTRP-11FW1-2116 FX1-3116
500 20 482.1 12.8 39 RTRP-11FW1-2116 FX1-3116
600 24 578.6 15.4 56 RTRP-11FW1-2116 FX1-3116
700 28 700.0 18.7 75 RTRP-11FW1-2116 FX1-3116
750 30 750.0 20.0 93 RTRP-11FW1-2116 FX1-3116
800 32 800.0 21.4 102 RTRP-11FW1-2116 FX1-3116
900 36 900.0 24.0 132 RTRP-11FW1-2116 FX1-3116
1000 40 1000.0 26.9 165 RTRP-11FW1-2116 FX1-3116
Bondstrand 7000M
25 1 27.1 3.5 0.7 RTRP-11AW1-2112 AX1-3112
40 1 42.1 3.5 1.3 RTRP-11AW1-2112 AX1-3112
50 2 53.0 3.6 1.3 RTRP-11AW1-2112 AX1-3112
80 3 81.8 3.6 1.8 RTRP-11AW1-2112 AX1-3112
100 4 105.2 4.6 3.1 RTRP-11AW1-2113 AX1-3113
125 5 131.9 4.6 3.5 RTRP-11AW1-2113 AX1-3113
150 6 159.0 4.6 4.6 RTRP-11AW1-2113 AX1-3113
200 8 208.8 5.5 7.4 RTRP-11AW1-2116 AX1-3116
250 10 262.9 7.0 12 RTRP-11AW1-2116 AX1-3116
300 12 313.7 8.3 17 RTRP-11AW1-2116 AX1-3116
350 14 337.6 9.0 19 RTRP-11AW1-2116 AX1-3116
400 16 385.8 10.3 25 RTRP-11AW1-2116 AX1-3116
450 18 433.8 11.5 32 RTRP-11AW1-2116 AX1-3116
500 20 482.1 12.8 39 RTRP-11AW1-2116 AX1-3116
600 24 578.6 15.4 56 RTRP-11AW1-2116 AX1-3116
700 28 700.0 18.7 75 RTRP-11AW1-2116 AX1-3116
750 30 750.0 20.0 93 RTRP-11AW1-2116 AX1-3116
800 32 800.0 21.4 102 RTRP-11AW1-2116 AX1-3116
900 36 900.0 24.0 132 RTRP-11AW1-2116 AX1-3116
1000 40 1000.0 26.9 165 RTRP-11AW1-2116 AX1-3116
Typical pipe dimensions
and weights
Ameron 2004. FP 918 09/04. Page 8 of 28. Printed in The Netherlands.
Ultimate collapse pressure Ultimate collapse pressure (ultimate short term external failure pressure) at 21 C.
Nominal Internal 2000M 2000M 7000M 7000M
Pipe Pressure MDA IPD MDA IPD
Size static*
[mm] [inch] [bar] [bar] [bar] [bar] [bar]
25 1 16 674 733 1019 1108
40 1 16 200 218 308 335
50 2 16 115 125 175 191
80 3 16 33.2 36.0 51.0 55.5
100 4 16 35.9 39.1 50.1 54.4
125 5 16 18.7 20.3 26.1 28.3
150 6 16 11.6 12.6 15.1 16.5
200 8 16 11.5 12.5 11.5 12.5
250 10 16 11.9 12.9 11.9 12.9
300 12 16 11.7 12.7 11.7 12.7
350 14 16 11.9 13.0 11.9 13.0
400 16 16 12.0 13.0 12.0 13.0
450 18 16 11.7 12.8 11.7 12.8
500 20 16 11.8 12.8 11.8 12.8
600 24 16 11.9 12.9 11.9 12.9
700 28 16 12.0 13.0 12.0 13.0
750 30 16 11.9 13.0 11.9 13.0
800 32 16 12.0 13.1 12.0 13.1
900 36 16 11.9 13.0 11.9 13.0
1000 40 16 12.2 13.3 12.2 13.3
* Up to 93.
Nominal Insertion Spigot Diameter Spigot Length
Pipe Depth Min. Max. Min. Max.
Size (Ds) Sd Sd L L
[mm] [inch] [mm] [mm] [mm] [mm] [mm]
25 1 27 32.6 32.9 28.5 31.0
40 1 32 47.5 47.8 33.5 36.0
50 2 46 59.2 59.6 49.0 52.0
80 3 46 87.6 88.0 49.0 52.0
100 4 46 112.5 112.9 49.0 52.0
125 5 57 139.5 139.9 58.5 61.5
150 6 57 166.2 166.6 59.0 62.0
200 8 64 217.1 217.5 65.0 68.0
250 10 70 271.3 271.7 71.0 74.0
300 12 76 322.2 322.6 78.0 81.0
350 14 89 353.8 354.2 89.0 93.0
400 16 102 404.1 404.5 103.0 106.0
Dimensions for Quick-Lock Spigots for bonding HD Flanges Dia of Straight
Spigot [Sd]
450 18 111 455.8
500 20 111 506.6
600 24 127 608.2
700 28 152 736.3
750 30 165 788.4
800 32 178 840.5
900 36 163 943.4
1000 40 230 1051.4
Dimensions for adhesive Taper spigots for adhesive Taper/Taper joints
Nominal Taper Insertion Nominal Dia of
Pipe Angle Depth Spigot Spigot
Size Nose Thickn. at Nose
X Ds nose Sd
[mm] [inch] [degrees] [mm] [mm] [mm]
450 18 2.5 114 4.6 443.0
500 20 2.5 127 5.0 492.2
600 24 3.5 178 3.8 586.3
700 28 1.75 178 6.4 712.9
750 30 1.75 178 4.2 758.4
800 32 1.75 178 8.9 817.8
900 36 1.75 203 5.6 911.3
1000 40 1.75 410 8.1 1016.3
Quick-Lock dimensions
Taper/Taper dimensions
Ameron 2004. FP 918 09/04. Page 9 of 28. Printed in The Netherlands.
Span length
Filament-wound 90 elbows with integral Quick-Lock (1-16 inch) or
Taper/Taper (18-40 inch) socket ends for adhesive bonding
Nominal Laying Overall Max. Working Average
Pipe Size Length (LL) Length (OL) Pressure Weight
[mm] [inch] [mm] [mm] [bar] [kg]
25 1 65 92 20 0.3
40 1 81 113 20 0.4
50 2 76 122 20 0.5
80 3 114 160 20 1.1
100 4 152 198 20 1.6
125 5 195 252 16 2.7
150 6 229 286 16 3.6
200 8 305 369 16 6.8
250 10 381 451 16 11.0
300 12 457 533 16 18.0
350 14 359 448 16 26.0
400 16 397 499 16 31.0
450 18 458 572 16 53.0
500 20 508 635 16 65.0
600 24 584 762 16 122.0
700 28 711 889 16 205.0
750 30 762 940 16 243.0
800 32 813 991 16 330.0
900 36 915 1118 16 417.0
1000 40 1040 1450 16 489.0
Elbows 90
Bondstrand 2000M
Nominal Single MDA Contininuous Single IPD Continuous
Pipe Size Span* Span* Span* Span*
[mm] [inch] [m] [m] [m] [m]
25 1 2.6 3.3 2.4 3.0
40 1 2.9 3.7 2.7 3.4
50 2 3.1 4.0 2.9 3.7
80 3 3.5 4.5 3.3 4.2
100 4 4.0 5.1 3.7 4.7
125 5 4.3 5.4 4.0 5.0
150 6 4.5 5.7 4.2 5.3
200 8 5.1 6.5 4.8 6.1
250 10 5.8 7.3 5.3 6.8
300 12 6.3 8.0 5.8 7.4
350 14 6.5 8.3 6.0 7.7
400 16 7.0 8.8 6.4 8.2
450 18 7.4 9.3 6.8 8.7
500 20 7.7 9.8 7.2 9.1
600 24 8.5 10.8 7.9 10.0
700 28 9.3 11.8 8.6 11.0
750 30 9.6 12.2 8.9 11.3
800 32 10.0 12.7 9.2 11.7
900 36 10.5 13.4 9.8 12.4
1000 40 11.1 14.1 10.3 13.1
Bondstrand 7000M MDA IPD
25 1 2.5 3.3 2.4 3.0
40 1 2.9 3.8 2.7 3.4
50 2 3.1 4.1 2.9 3.7
80 3 3.5 4.5 3.3 4.2
100 4 4.0 5.2 3.7 4.7
125 5 4.3 5.6 4.0 5.0
150 6 4.5 5.9 4.2 5.3
200 8 5.0 6.5 4.7 5.9
250 10 5.7 7.3 5.3 6.7
300 12 6.2 8.0 5.7 7.3
350 14 6.4 8.3 6.0 7.6
400 16 6.9 8.8 6.4 8.1
450 18 7.3 9.3 6.7 8.6
500 20 7.7 9.8 7.1 9.0
600 24 8.4 10.8 7.8 9.9
700 28 9.3 11.8 8.6 10.9
750 30 9.6 12.2 8.9 11.3
800 32 9.9 12.7 9.2 11.7
900 36 10.5 13.4 9.7 12.4
1000 40 11.1 14.1 10.3 13.0
* Span recommendations are based on pipes filled with water having a density of 1000 kg/m
3
and include no provisions for weights caused by valves, flanges or other heavy objects.
At 21C. At 93C., span lengths are approx. 10% lower.
Ameron 2004. FP 918 09/04. Page 10 of 28. Printed in The Netherlands.
Elbows ANSI 45
Filament-wound 90 elbows with integral Quick-Lock male ends*
Nominal Laying Maximum Average
Pipe Length Working Weight
Size (LL) Pressure
[mm] [inch] [mm] [bar] [kg]
50 2 110 12 0.4
80 3 135 12 0.7
100 4 160 12 1.0
150 6 198 12 2.4
200 8 224 12 3.9
250 10 275 12 6.3
300 12 300 12 13.3
* Also available with flanges.
Filament-wound 45 Quick-Lock (1-16 inch) or
Taper/Taper (18-40 inch) socket ends for adhesive bonding
Nominal Laying Overall Maximum Average
Pipe Length Length Working Weight
Size (LL) (OL) Pressure
[mm] [inch] [mm] [mm] [bar] [kg]
25 1 22 49 16 0.2
40 1 29 61 16 0.3
50 2 35 81 16 0.4
80 3 51 97 16 0.8
100 4 64 110 16 1.1
125 5 84 141 16 1.8
150 6 95 152 16 2.4
200 8 127 191 16 4.3
250 10 159 229 16 7.3
300 12 191 267 16 11.0
350 14 121 210 16 17.0
400 16 137 239 16 20.0
450 18 191 305 16 33.0
500 20 210 337 16 40.0
600 24 252 430 16 82.0
700 28 295 473 16 140.0
750 30 322 500 16 164.0
800 32 337 515 16 283.0
900 36 400 603 16 283.0
1000 40 450 860 16 334.0
Filament-wound 45elbows with integral Quick-Lock male ends*
Nominal Laying Maximum Average
Pipe Length Working Weight
Size (LL) Pressure
[mm] [inch] [mm] [bar] [kg]
50 2 60 12 0.2
80 3 71 12 0.4
100 4 97 12 0.9
150 6 121 12 1.9
200 8 134 12 3.9
250 10 159 12 8.3
300 12 186 12 10.0
* Also available with flanges.
Elbows ANSI 90
short radius
Elbows 45
Quick-Lock
Taper/Taper
Ameron 2004. FP 918 09/04. Page 11 of 28. Printed in The Netherlands.
Elbows 22 Filament-wound 22elbows with integral Quick-Lock socket ends for adhesive
bonding
Nominal Laying Overall Maximum Average
Pipe Length Length Working Weight
Size (LL) (OL) Pressure
[mm] [inch] [mm] [mm] [bar] [kg]
25 1 9 36 16 0.1
40 1 9 41 16 0.2
50 2 13 59 16 0.5
80 3 21 67 16 0.7
100 4 29 75 16 1.0
125 5 43 100 16 1.4
150 6 43 100 16 1.9
200 8 57 121 16 3.9
250 10 67 137 16 5.9
300 12 76 152 16 10.4
350 14 83 172 16 12.0
400 16 89 191 16 14.0
Filament-wound equal Tee with integral Quick-Lock (1-16 inch) or
Taper/Taper (18-40 inch) socket ends for adhesive bonding
Nominal Laying Overall Laying Overall Maximum Average
Pipe Length Length Length Length Working Weight
Size total run total run branch branch Pressure
(LL1) (OL1) (LL2) (OL2)
[mm] [inch] [mm] [mm] [mm] [mm] [bar] [kg]
25 1 54 108 27 54 16 0.2
40 1 60 124 30 62 16 0.4
50 2 128 220 64 110 16 1.0
80 3 172 264 86 132 16 1.8
100 4 210 302 105 151 16 2.5
125 5 254 368 127 184 16 5.0
150 6 286 400 143 200 16 6.7
200 8 356 484 178 242 16 10.0
250 10 432 572 216 286 16 18.0
300 12 508 660 254 330 16 29.0
350 14 534 712 267 356 16 37.0
400 16 584 788 292 394 16 56.0
450 18 648 876 324 438 16 69.0
500 20 712 966 356 483 16 92.0
600 24 838 1194 419 597 16 168.0
700 28 964 1320 482 660 16 285.0
750 30 1016 1372 508 686 16 337.0
800 32 1090 1446 545 723 16 459.0
900 36 1220 1626 610 813 16 581.0
1000 40 1416 2236 708 1118 16 686.0
Equal Tees
Quick-Lock
Taper/Taper
Ameron 2004. FP 918 09/04. Page 12 of 28. Printed in The Netherlands.
Filament-wound standard and fabricated reducing tees with integral
Quick-Lock (1-16 inch) socket ends for adhesive bonding
Nominal Laying Overall Laying Overall Maximum Average
Pipe Length Length Length Length Working Weight
Size (LL1) (OL1) (LL2) (OL2) Pressure
(runxrunxbranch) half run half run branch branch
[mm] [inch] [mm] [mm] [mm] [mm] [bar] [kg]
40x40x25 1x1x1 30 62 30 57 20 0.6
50x50x25 2x2x1 64 110 57 84 20 0.9
50x50x40 2x2x1 64 110 57 89 20 1.0
80x80x25 3x3x1 86 132 76 103 20 1.6
80x80x40 3x3x1 86 132 76 108 20 1.6
80x80x50 3x3x2 86 132 76 122 20 1.7
100x100x25 4x4x1 72 118 194 221 20 7.5
100x100x40 4x4x1 89 136 194 226 20 9.0
100x100x50 4x4x2 105 151 89 135 20 2.1
100x100x80 4x4x3 105 151 98 144 20 2.3
125x125x50 5x5x2 127 184 102 148 16 3.4
125x125x80 5x5x3 127 184 111 157 16 4.0
125x125x100 5x5x4 127 184 118 164 16 4.6
150x150x25 6x6x1 83 140 221 248 16 11.7
150x150x40 6x6x1 101 158 221 253 16 13.8
150x50x50 6x6x2 143 200 114 160 16 5.4
150x150x80 6x6x3 143 200 124 170 16 6.0
150x150x100 6x6x4 143 200 130 176 16 6.2
150x150x125 6x6x5 143 200 136 193 16 6.5
200x200x25 8x8x1 84 148 245 272 16 15.0
200x200x40 8x8x1 101 165 246 278 16 17.5
200x200x50 8x8x2 116 180 246 292 16 19.9
200x200x80 8x8x3 178 242 149 195 16 9.1
200x200x100 8x8x4 178 242 162 208 16 9.7
200x200x125 8x8x5 178 242 168 225 16 10.6
200x200x150 8x8x6 178 242 168 225 16 11.4
250x250x25 10x10x1 83 153 273 300 16 18.1
250x250x40 10x10x1 100 170 273 305 16 21.0
250x250x50 10x10x2 115 185 273 320 16 24.0
250x250x80 10x10x3 115 185 273 320 16 24.0
250x250x100 10x10x4 216 286 184 230 16 14.8
250x250x125 10x10x5 216 286 194 251 16 15.2
250x250x150 10x10x6 216 286 194 251 16 15.5
250x250x200 10x10x8 216 286 203 267 16 16.5
300x300x25 12x12x1 84 160 298 325 16 21.2
300x300x40 12x12x1 102 178 298 330 16 25.0
300x300x50 12x12x2 117 193 298 344 16 29.0
300x300x80 12x12x3 117 193 298 344 16 29.0
300x300x100 12x12x4 254 330 206 252 16 21.0
300x300x150 12x12x6 254 330 219 276 16 22.0
300x300x200 12x12x8 254 330 229 293 16 23.0
300x300x250 12x12x10 254 330 241 311 16 24.0
350x350x25 14x14x1 81 170 314 341 16 24.0
350x350x40 14x14x1 99 188 314 346 16 28.0
350x350x50 14x14x2 114 203 314 361 16 31.0
350x350x80 14x14x3 114 203 314 361 16 31.0
350x350x100 14x14x4 114 203 314 361 16 31.0
350x350x150 14x14x6 267 356 244 301 16 29.0
350x350x200 14x14x8 267 356 254 318 16 30.0
350x350x250 14x14x10 267 356 267 337 16 32.0
350x350x300 14x14x12 267 356 279 355 16 34.0
400x400x25 16x16x1 85 187 338 365 16 29.0
400x400x40 16x16x1 103 205 338 370 16 33.0
400x400x50 16x16x2 118 220 338 384 16 37.0
400x400x80 16x16x3 118 220 338 384 16 37.0
400x400x100 16x16x4 118 220 338 384 16 37.0
400x400x150 16x16x6 292 394 264 321 16 37.0
400x400x200 16x16x8 292 394 273 337 16 38.0
400x400x250 16x16x10 292 394 283 353 16 41.0
400x400x300 16x16x12 292 394 295 371 16 45.0
400x400x350 16x16x14 292 394 292 381 16 49.0
Note: Regular numbers are filament wound tees; Italic numbers are fabricated tees.
Reducing Tees
Standard
Fabricated
Ameron 2004. FP 918 09/04. Page 13 of 28. Printed in The Netherlands.
Filament-wound standard and fabricated reducing tees with integral
Taper/Taper (18-40 inch) socket ends for adhesive bonding
Nominal Laying Overall Laying Overall Maximum Average
Pipe Length Length Length Length Working Weight
Size (LL1) (OL1) (LL2) (OL2) Pressure
(runxrunxbranch) half run half run branch branch
[mm] [inch] [mm] [mm] [mm] [mm] [bar] [kg]
450x450x25 18x18x1 88 202 358 385 16 31.0
450x450x40 18x18x1 88 202 358 390 16 31.0
450x450x50 18x18x2 88 202 358 404 16 22.0
450x450x80 18x18x3 100 214 358 404 16 35.0
450x450x100 18x18x4 113 227 358 404 16 38.0
450x450x150 18x18x6 138 252 367 424 16 45.0
450x450x200 18x18x8 324 438 306 370 16 53.0
450x450x250 18x18x10 324 438 319 389 16 60.0
450x450x300 18x18x12 324 438 319 395 16 67.0
450x450x350 18x18x14 324 438 317 406 16 66.0
450x450x400 18x18x16 324 438 319 421 16 69.0
500x500x25 20x20x1 88 215 382 409 16 35.0
500x500x40 20x20x1 88 215 382 414 16 35.0
500x500x50 20x20x2 88 215 382 428 16 36.0
500x500x80 20x20x3 100 227 382 428 16 39.0
500x500x100 20x20x4 113 240 382 428 16 43.0
500x500x150 20x20x6 138 265 391 448 16 50.0
500x500x250 20x20x10 356 483 344 414 16 77.0
500x500x300 20x20x12 356 483 345 421 16 82.0
500x500x350 20x20x14 356 483 343 432 16 85.0
500x500x400 20x20x16 356 483 344 446 16 85.0
500x500x450 20x20x18 356 483 350 464 16 89.0
600x600x25 24x24x1 88 266 430 457 16 51.0
600x600x40 24x24x1 88 266 430 462 16 51.0
600x600x50 24x24x2 88 266 430 476 16 52.0
600x600x80 24x24x3 100 278 430 476 16 56.0
600x600x100 24x24x4 113 291 430 476 16 61.0
600x600x150 24x24x6 138 316 439 496 16 69.0
600x600x200 24x24x8 419 597 412 476 14 78.0
600x600x250 24x24x10 419 597 386 456 16 85.0
600x600x300 24x24x12 419 597 408 484 16 85.0
600x600x350 24x24x14 419 597 394 483 16 101.0
600x600x400 24x24x16 419 597 395 497 16 123.3
600x600x450 24x24x18 419 597 413 527 16 137.0
600x600x500 24x24x20 419 597 406 533 16 156.0
700x700x25 28x28x1 88 266 491 518 16 59.0
700x700x40 28x28x1 88 266 491 523 16 59.0
700x700x50 28x28x2 88 266 491 537 16 59.0
700x700x80 28x28x3 100 278 491 537 16 64.0
700x700x100 28x28x4 113 291 491 537 16 70.0
700x700x150 28x28x6 138 316 500 557 16 80.0
700x700x350 28x28x14 482 660 490 579 16 147.0
700x700x400 28x28x16 482 660 500 602 16 166.0
700x700x450 28x28x18 482 660 500 614 16 189.0
700x700x500 28x28x20 482 660 506 633 16 210.0
700x700x600 28x28x24 482 660 506 684 16 252.0
750x750x25 30x30x1 88 266 516 543 16 63.0
750x750x40 30x30x1 88 266 516 548 16 63.0
750x750x50 30x30x2 88 266 516 562 16 63.0
750x750x80 30x30x3 100 278 516 562 16 69.0
750x750x100 30x30x4 113 291 516 562 16 74.0
750x750x150 30x30x6 138 316 525 582 16 85.0
750x750x300 30x30x12 508 686 756 832 16 118.0
750x750x350 30x30x14 508 686 722 811 16 157.0
750x750x400 30x30x16 508 686 698 800 16 178.0
750x750x450 30x30x18 508 686 488 602 16 202.0
750x750x500 30x30x20 508 686 495 622 16 225.0
750x750x600 30x30x24 508 686 481 659 16 270.0
Note: Regular numbers are filament wound tees; Italic numbers are fabricated tees
Reducing Tees
Ameron 2004. FP 918 09/04. Page 14 of 28. Printed in The Netherlands.
Reducing Tees (C'tnd)
Filament-wound standard and fabricated reducing tees with integral
Taper/Taper (18-40 inch) socket ends for adhesive bonding
Nominal Laying Overall Laying Overall Maximum Average
Pipe Length Length Length Length Working Weight
Size (LL1) (OL1) (LL2) (OL2) Pressure
(runxrunxbranch) half run half run branch branch
[mm] [inch] [mm] [mm] [mm] [mm] [bar] [kg]
800x800x25 32x32x1 88 266 541 568 16 66.0
800x800x40 32x32x1 88 266 541 573 16 67.0
800x800x50 32x32x2 88 266 541 587 16 67.0
800x800x80 32x32x3 100 278 541 587 16 73.0
800x800x100 32x32x4 113 291 541 587 16 79.0
800x800x150 32x32x6 138 316 550 607 16 90..0
800x800x500 32x32x20 545 723 523 650 16 257.0
800x800x600 32x32x24 545 723 523 701 16 310.0
800x800x700 32x32x28 545 723 532 710 16 348.0
800x800x750 32x32x30 545 723 534 712 16 387.0
900x900x25 36x36x1 88 291 591 618 16 78.0
900x900x40 36x36x1 88 291 591 623 16 78.0
900x900x50 36x36x2 88 291 591 637 16 78.0
900x900x80 36x36x3 100 303 591 637 16 85.0
900x900x100 36x36x4 113 316 591 637 16 92.0
900x900x150 36x36x6 138 341 600 657 16 105.0
900x900x400 36x36x16 610 813 563 665 16 270.0
900x900x450 36x36x18 610 813 563 677 16 290.0
900x900x500 36x36x20 610 813 563 690 16 323.0
900x900x600 36x36x24 610 813 541 719 16 387.0
900x900x700 36x36x28 610 813 570 748 16 459.0
900x900x750 36x36x30 610 813 584 762 16 484.0
1000x1000x40040x40x1 120 530 641 668 16 92.0
1000x1000x45040x40x1 120 530 641 673 16 92.0
1000x1000x50040x40x2 120 530 641 687 16 92.0
1000x1000x60040x40x3 132 542 641 687 16 100.0
1000x1000x60040x40x24 708 1118 593 771 16 457.0
1000x1000x70040x40x28 708 1118 632 810 16 541.0
1000x1000x75040x40x30 708 1118 633 811 16 571.0
1000x1000x80040x40x32 708 1118 652 830 16 605.0
1000x1000x90040x40x36 708 1118 652 855 16 634.0
Note: Regular numbers are filament wound tees; Italic numbers are fabricated tees.
Standard
Fabricated
Ameron 2004. FP 918 09/04. Page 15 of 28. Printed in The Netherlands.
Fabricated Reducing tees with integral Quick-Lock (1-16 inch) socket ends and
flanged branch
Nominal Laying Overall Laying Maximum Average
Pipe Length Length Length Working Weight
Size (LL1) (OL1) (LL2) Pressure with flange
(runxrunxbranch) half run half run branch CL150
[mm] [inch] [mm] [mm] [mm] [bar] [kg]
100x100x25 4x4x1 72 118 225 16 8.0
100x100x40 4x4x1 89 135 230 16 9.7
150x150x25 6x6x1 83 140 252 16 12.2
150x150x40 6x6x1 101 158 257 16 14.5
200x200x25 8x8x1 84 148 276 16 15.5
200x200x40 8x8x1 101 165 281 16 18.2
200x200x50 8x8x2 116 180 295 16 21.4
250x250x25 10x10x1 83 153 303 16 18.6
250x250x40 10x10x1 100 170 308 16 22.0
250x250x50 10x10x2 115 185 322 16 25.6
250x250x80 10x10x3 115 185 323 16 26.3
300x300x25 12x12x1 84 160 329 16 22.3
300x300x40 12x12x1 102 178 334 16 26.1
300x300x50 12x12x2 117 193 348 16 30.2
300x300x80 12x12x3 117 193 349 16 30.9
350x350x25 14x14x1 81 170 344 16 24.3
350x350x40 14x14x1 99 188 349 16 28.4
350x350x50 14x14x2 114 203 363 16 32.7
350x350x80 14x14x3 114 203 369 16 33.4
350x350x100 14x14x4 114 203 364 16 34.2
400x400x25 16x16x1 85 187 369 16 29.1
400x400x40 16x16x1 103 205 374 16 33.8
400x400x50 16x16x2 118 220 388 16 38.5
400x400x80 16x16x3 118 220 389 16 39.2
400x400x100 16x16x4 118 220 389 16 39.9
Note: Other sizes, or multiple size branched tees available on request. Please contact Ameron.
Fabricated Reducing Tees
with Flanged Branch
Ameron 2004. FP 918 09/04. Page 16 of 28. Printed in The Netherlands.
Fabricated Reducing tees with integral Taper/Taper (18-40 inch) socket ends and
flanged branch
Nominal Laying Overall Laying Maximum Average
Pipe Length Length Length Working Weight
Size (LL1) (OL1) (LL2) Pressure with flange
(runxrunxbranch) half run half run branch CL150
[mm] [inch] [mm] [mm] [mm] [bar] [kg]
450x450x25 18x18x1 88 202 388 16 31.7
450x450x40 18x18x1 88 202 394 16 32.0
450x450x50 18x18x2 88 202 408 16 33.0
450x450x80 18x18x3 100 214 409 16 37.0
450x450x100 18x18x4 113 227 409 16 41.2
450x450x150 18x18x6 138 252 430 16 49.9
500x500x25 20x20x1 88 215 412 16 35.8
500x500x40 20x20x1 88 215 418 16 36.0
500x500x50 20x20x2 88 215 432 16 37.0
500x500x80 20x20x3 100 227 433 16 41.4
500x500x100 20x20x4 113 240 433 16 45.9
500x500x150 20x20x6 138 265 454 16 54.8
600x600x25 24x24x1 88 266 460 16 51.9
600x600x40 24x24x1 88 266 467 16 52.0
600x600x50 24x24x2 88 266 480 16 53.0
600x600x80 24x24x3 100 278 481 16 58.2
600x600x100 24x24x4 113 291 481 16 63.4
600x600x150 24x24x6 138 316 502 16 73.7
700x700x25 28x28x1 88 266 521 16 59.3
700x700x40 28x28x1 88 266 527 16 59.3
700x700x50 28x28x2 88 266 541 16 60.5
700x700x80 28x28x3 100 278 542 16 66.5
700x700x100 28x28x4 113 291 542 16 72.6
700x700x150 28x28x6 138 316 563 16 84.5
750x750x25 30x30x1 88 266 546 16 63.2
750x750x40 30x30x1 88 266 552 16 63.4
750x750x50 30x30x2 88 266 566 16 64.4
750x750x80 30x30x3 100 278 567 16 70.8
750x750x100 30x30x4 113 291 567 16 77.1
750x750x150 30x30x6 138 316 588 16 89.8
800x800x25 32x32x1 88 266 571 16 66.9
800x800x40 32x32x1 88 266 576 16 67.2
800x800x50 32x32x2 88 266 590 16 68.1
800x800x80 32x32x3 100 278 590 16 74.9
800x800x100 32x32x4 113 291 590 16 81.6
800x800x150 32x32x6 138 316 610 16 94.9
900x900x25 36x36x1 88 291 621 16 78.3
900x900x40 36x36x1 88 291 627 16 78.6
900x900x50 36x36x2 88 291 641 16 79.6
900x900x80 36x36x3 100 303 642 16 87.0
900x900x100 36x36x4 113 316 642 16 94.4
900x900x150 36x36x6 138 341 663 16 109.2
1000x1000x25 40x40x1 120 530 672 16 92.3
1000x1000x4040x40x1 120 530 677 16 92.6
1000x1000x50 40x40x2 120 530 691 16 93.7
1000x1000x80 40x40x3 132 542 692 16 103.0
Note: Other sizes, or multiple size branched tees available on request. Please contact Ameron.
Fabricated Reducing Tees
with Flanged Branch
Ameron 2004. FP 918 09/04. Page 17 of 28. Printed in The Netherlands.
!
Bushing Saddles Filament-wound pipe saddles with stainless steel, 1/2 inch and 3/4 inch threaded
bushings *
Nominal Angle Saddle Saddle Maximum Average Required
Pipe Length Thickn. Working Weight Adhesive
Size (B) (ts) Pressure Kits
[mm] [inch] [degree] [mm] [mm] [bar] [kg] [3 Oz] [6 Oz]
50 2 180 100 14 16 0.5 1 -
80 3 180 100 14 16 0.6 1 -
100 4 180 100 14 16 0.8 1 -
125 5 180 100 14 16 0.9 - 1
150 6 180 100 14 16 1.0 - 1
200 8 180 100 14 16 1.2 - 1
250 10 180 100 14 16 1.6 1 1
300 12 180 100 14 12 1.9 1 1
350 14 180 100 14 12 2.1 1 1
400 16 180 100 14 12 2.5 - 2
450 18 90 100 14 12 3.3 - 1
500 20 90 100 14 12 3.7 1 1
600 24 90 100 14 12 4.4 - 2
* Consult Ameron for other type material, or other sized bushings.
Filament-wound 45 laterals with integral Quick-Lock socking ends
Nominal Laying Overall Laying Overall Maximum Average
Pipe Length Length Length Length Working Weight
Size (LL1) (OL1) (LL2) (OL2) Pressure
[mm] [inch] [mm] [mm] [mm] [mm] [bar] [kg]
50 2 64 110 203 249 16 1.6
80 3 76 122 254 300 16 3.0
100 4 76 122 305 351 16 3.9
125 5 89 146 337 394 16 5.8
150 6 89 146 368 425 16 6.8
200 8 114 178 445 509 16 12.0
250 10 127 197 521 591 12 21.0
300 12 140 216 622 698 12 30.0
350 14 140 229 622 711 12 39.0
400 16 140 242 622 724 12 54.0
45 Laterals
Ameron 2004. FP 918 09/04. Page 18 of 28. Printed in The Netherlands.
Filament-wound concentric reducers with integral Quick-Lock (1-16 inch) or
Taper/Taper (18-40 inch) socket ends
Nominal Laying Overall Maximum Average
Pipe Size Length Length Working Weight
(runxrun) (LL) (OL) Pressure
[mm] [inch] [mm] [mm] [bar] [kg]
40x25 1x1 32 91 16 0.2
50x25 2x1 64 137 16 0.3
50x40 2x1 32 110 16 0.5
80x40 3x1 76 154 16 0.5
80x50 3x2 54 146 16 0.5
100x50 4x2 76 168 16 1.1
100x80 4x3 73 165 16 0.9
125x80 5x3 74 177 16 1.4
125x100 5x4 74 177 16 1.5
150x80 6x3 97 200 16 1.8
150x100 6x4 94 197 16 1.8
150x125 6x5 110 224 16 1.8
200x100 8x4 138 248 16 2.9
200x125 8x5 126 247 16 2.8
200x150 8x6 98 219 16 2.7
250x150 10x6 117 244 16 3.7
250x200 10x8 105 239 16 3.6
300x200 12x8 149 289 16 5.0
300x250 12x10 137 283 16 4.6
350x250 14x10 184 343 16 7.2
350x300 14x12 178 343 16 7.3
400x300 16x12 165 343 16 8.9
400x350 16x14 152 343 16 9.0
450x400 18x16 103 319 16 12.7
500x400 20x16 225 454 16 22.6
500x450 20x18 123 364 16 18.9
600x400 24x16 453 733 16 48.4
600x450 24x18 353 645 16 44.3
600x500 24x20 230 535 16 38.5
700x400 28x16 765 1045 16 79.0
700x450 28x18 661 953 16 74.0
700x500 28x20 542 847 16 69.0
700x600 28x24 311 667 16 67.3
750x400 30x16 876 1156 16 111.6
750x450 30x18 775 1067 16 106.6
750x500 30x20 653 958 16 99.6
750x600 30x24 422 778 16 87.2
750x700 30x28 111 467 16 57.2
800x400 32x16 1023 1303 16 139.4
800x450 32x18 920 1212 16 125.4
800x500 32x20 798 1103 16 108.8
800x600 32x24 570 926 16 94.3
800x700 32x28 259 615 16 81.8
800x750 32x30 148 504 16 70.9
900x500 36x20 1029 1359 16 210.0
900x600 36x24 799 1180 16 176.1
900x700 36x28 487 868 16 140.2
900x750 36x30 375 756 16 125.9
1000x900 40x36 285 898 16 182.0
Concentric Reducers
Quick-Lock
Taper/Taper
Ameron 2004. FP 918 09/04. Page 19 of 28. Printed in The Netherlands.
Eccentric Reducers Filament-wound Eccentric Reducers with integral Quick-Lock (1-16 inch) or
Taper/Taper (18-40 inch) socket ends
Nominal Laying Overall Eccentricity Maximum Average
Pipe Size Length Length Working Weight
(runxrun) (LL) (OL) (X) Pressure
[mm] [inch] [mm] [mm] [mm] [bar] [kg]
40x25 1x1 56 115 7 16 0.2
50x25 2x1 100 173 13 16 0.3
50x40 2x1 44 122 6 16 0.5
80x40 3x1 150 228 20 16 0.5
80x50 3x2 108 200 14 16 0.5
100x50 4x2 200 292 27 16 1.1
100x80 4x3 93 185 12 16 0.9
125x100 5x4 101 204 14 16 1.5
150x80 6x3 293 396 39 16 1.8
150x100 6x4 200 303 27 16 1.8
150x125 6x5 100 214 13 16 1.8
200x100 8x4 390 500 52 16 2.9
200x150 8x6 190 311 25 16 2.7
250x150 10x6 392 519 53 16 3.7
250x200 10x8 202 336 27 16 3.6
300x200 12x8 390 530 53 16 5.0
300x250 12x10 190 336 26 16 4.6
350x250 14x10 308 467 42 16 7.2
350x300 14x12 118 283 16 16 7.3
400x300 16x12 306 484 41 16 8.9
400x350 16x14 188 379 25 16 9.0
450x300 18x12 450 640 63 16 15.6
450x350 18x14 322 525 43 16 14.2
450x400 18x16 197 413 18 16 12.7
500x400 20x16 324 553 39 16 23.0
500x450 20x18 197 438 22 16 18.9
600x400 24x16 580 860 93 16 48.0
600x450 24x18 450 742 73 16 44.0
600x500 24x20 325 630 48 16 39.0
750x400 30x24 451 807 86 16 87.0
900x400 36x24 832 1213 161 16 176.0
Quick-Lock
Taper/Taper
Ameron 2004. FP 918 09/04. Page 20 of 28. Printed in The Netherlands.
Hub Flanges
Heavy-Duty Flanges Filament-wound Heavy-Duty flanges with integral Quick-Lock (1-40 inch) socket end
Nominal Laying Overall Maximum Average weight DIN 2632DIN 2633
Pipe Length Length Working ANSI ANSI
Size (LL) (OL) Pressure B16.5 B16.5
CL.150 CL.300 PN10 PN16
[mm] [inch] [mm] [mm] [bar] [kg] [kg] [kg] [kg]
25 1 3 29 16 0.5 0.6 0.5 0.5
40 1 3 35 16 1.1 1.1 1.0 1.0
50 2 4 51 16 1.3 1.7 1.8 1.8
80 3 5 51 16 1.8 2.6 2.4 2.4
100 4 5 51 16 2.8 3.8 2.7 2.7
125 5 5 62 16 3.8 5.4 4.0 4.0
150 6 6 63 16 4.5 6.7 4.9 4.9
200 8 6 70 16 5.0 9.9 7.1 6.9
250 10 6 76 16 9.5 13.2 9.1 9.8
300 12 5 81 16 14.5 19.2 11.2 12.7
350 14 8 97 16 20.5 29.8 18.6 20.5
400 16 8 110 16 27.0 40.0 25.0 27.4
450 18 10 114 16 32.0 - - -
500 20 10 121 16 40.0 - - -
600 24 11 138 16 58.0 - - -
700 28 14 165 16 73.0 - - -
750 30 14 178 16 88.0 - - -
800 32 14 192 16 112.0 - - -
900 36 14 178 16 116.0 - - -
1000 40 15 245 16 162.0 - - -
Note: Other drillings may be possible. Please consult Ameron.
1) Full-face elastomeric gaskets may be used suitable for the service pressure, service
temperature and fluid. Shore A durometer hardness of 60 +5 is recommended (3 mm thick).
Compressed fibre gaskets (3 mm thick), compatible with pressure, temperature and medium
may also be used.
Mechanical properties should be in accordance with DIN 3754 (IT 400) or equal.
2) For maximum bolt torque refer to the appropriate Bondstrand literature.
A torque-wrench must be used, since excessive torque may result in flange damage.
3) Size 18-40 inch can be bonded directly to a fitting by using a Quick-Lock to Taper/Taper
transition nipple.
For bonding to pipe, a Quick Lock (straight) spigot has to be shaved on the pipe.
Filament-wound Hubbed flanges with integral Quick-Lock (1-36 inch) socket end
Nominal Laying Overall Flange Maximum Average weight DIN 2632DIN 2633
Pipe Length Length Thickness Working ANSI ANSI
Size Pressure B16.5 B16.5
(LL) (OL) (E) CL.150 CL.300 PN10 PN16
[mm] [inch] [mm] [mm] [mm] [bar] [kg] [kg] [kg] [kg]
50 2 4 51 30 12 0.9 1.1 1.0 1.0
80 3 5 51 30 12 1.5 1.8 1.6 1.1
100 4 5 51 33 12 2.2 2.9 2.1 2.1
125 5 5 62 47 12 3.7 4.9 3.6 3.6
150 6 6 63 47 12 3.7 5.4 3.9 3.9
200 8 6 70 54 12 6.2 8.4 6.0 6.0
250 10 6 76 54 12 8.4 11.1 7.6 8.2
300 12 5 81 56 12 12.3 15.3 9.0 10.2
350 14 8 97 72 12 17.3 22.6 14.1 15.5
400 16 8 110 85 12 26.0 32.9 20.6 22.6
450 18 10 114 89 12 30.0 - - -
500 20 10 121 96 12 35.0 - - -
600 24 11 138 113 12 48.0 - - -
700 28 14 165 114 12 67.0 - - -
750 30 14 178 121 12 77.0 - - -
800 32 14 192 124 12 85.0 - - -
900 36 14 178 140 12 93.0 - - -
Note: As per above heavy-duty flanges.
Ameron 2004. FP 918 09/04. Page 21 of 28. Printed in The Netherlands.
Stub-end Flanges
Steel Ring Flange for
Stub-end
Taper/Taper
Quick-Lock
Filament-wound O-ring sealed stub-end flanges with integral Quick-Lock (1-16 inch) or
Taper/Taper (18-40 inch) socket ends with loose steelrings
Nominal Laying Overall Face Ring Maximum Average
Pipe Length Length Diameter to Face Working Weight
Size (LL) (OL) (RF) (H) Pressure Stub-end
[mm] [inch] [mm] [mm] [mm] [mm] [bar] [kg]
25 1 10 37 51 10 16 0.1
40 1 10 42 73 10 16 0.2
50 2 10 56 92 10 16 0.2
80 3 10 56 127 10 16 0.4
100 4 10 56 157 16 16 0.6
125 5 10 67 186 16 16 1.0
150 6 10 67 216 16 16 1.2
200 8 10 74 270 16 16 1.8
250 10 10 80 324 23 16 2.5
300 12 10 86 378 23 16 3.3
350 14 10 98 413 27 16 3.8
400 16 10 112 470 27 16 5.7
450 18 20 134 532 35 16 11.1
500 20 20 147 580 39 16 13.2
600 24 20 198 674 47 16 17.2
700 28 20 198 800 51 16 21.0
750 30 20 198 850 46 16 24.4
800 32 20 198 900 48 16 21.8
900 36 20 223 1000 53 16 30.8
1000 40 20 430 1100 58 16 470
Note: Up to 12 bar flat faced stub-ends suitable for elastomeric gaskets can be used.
From 12 bar and above O-ring sealed stub-ends should be used.
Make sure that when using O-ring sealed stub-end, its counter flange is compatible,
e.g. use a flat faced stub-end (without O-ring groove) or another flat surface flange as
counter flange.
Nominal ANSI Average ANSI Average DIN 2632 Average DIN 2633 Average
Pipe B16.5 Weight B16.5 Weight Weight Weight
Size CLASS.150 CLASS.300 PN 10 PN 16
(D) (D) (D) (D)
[mm] [inch] [mm] [kg] [mm] [kg] [mm] [kg] [mm] [kg]
25 1 14.3 0.8 17.5 1.3 16 1.0 16 1.0
40 1 17.5 1.2 20.6 2.3 16 1.7 16 1.7
50 2 19.0 1.8 22.2 2.5 18 2.2 18 2.2
80 3 23.8 3.2 28.6 4.8 20 3.0 20 3.0
100 4 23.8 4.2 31.7 7.0 20 3.1 20 3.1
125 5 23.8 4.4 34.9 9.5 22 3.6 23 3.8
150 6 25.5 5.2 36.5 12.2 22 4.9 23 5.1
200 8 28.8 8.5 41.3 18.3 25 7.1 27 7.3
250 10 35.6 13.5 47.6 26.0 28 9.3 32 11.8
300 12 40.0 23.0 50.8 38.7 29 10.7 35 15.4
350 14 41.6 32.0 54.0 56.3 36 21.3 40 26.3
400 16 47.9 42.0 58.2 70.1 40 26.6 44 33.0
450 18 50.2 39.7 63.6 86.5 42 27.2 50 40.9
500 20 52.0 50.6 66.5 104.1 45 34.7 54 59.8
600 24 63.7 86.1 78.4 182.9 52 55.3 63 72.2
700 28 69.0 100.5 95.6 213.4 57 78.8 59 101.9
750 30 71.6 117.0 99.9 229.3 - - - -
800 32 76.9 153.5 106.2 289.0 62 95.3 66 105.7
900 36 85.4 197.2 117.7 424.1 66 111.8 71 125.1
1000 40 93.7 - 102.8 - 74 - 82 -
Note: Other materials and/or drillings are available. Please consult Ameron.
Ameron 2004. FP 918 09/04. Page 22 of 28. Printed in The Netherlands.
Couplings
Filament-wound blind flanges
Nominal Flange Maximum Average weight Average weight
Pipe Thickness Working ANSI B16.5 ANSI B16.5 DIN 2632 DIN 2633
Size (D) Pressure CLASS 150 CLASS 300 PN 10 PN 16
[mm] [inch] [mm] [bar] [kg] [kg] [kg] [kg]
25 1 25 16 0.4 0.5 0.4 0.5
40 1 25 16 0.5 0.9 0.7 0.8
50 2 30 16 0.7 1.2 1.1 1.2
80 3 30 16 1.1 1.9 1.6 1.7
100 4 35 16 1.7 3.6 2.6 2.7
125 5 35 16 2.6 3.8 3.0 3.1
150 6 40 16 2.9 5.7 4.4 4.6
200 8 45 16 5.2 9.2 7.1 7.3
250 10 50 16 7.2 13.8 10.6 11.5
300 12 60 16 11.4 23.0 16.3 17.8
350 14 65 16 16.4 31.0 23.0 25.0
400 16 70 16 23.0 41.0 31.0 33.0
450 18 70 16 43.0 52.0 40.0 43.0
500 20 70 16 52.0 63.0 48.0 54.0
600 24 85 16 85.0 106.0 79.0 91.0
700 28 85 16 110.0 136.0 104.0 106.0
750 30 90 16 132.0 160.0 129.0 116.0
800 32 95 16 145.0 184.0 155.0 125.0
900 36 100 16 206.0 239.0 191.0 192.0
Note: Other drillings are available. Please consult Ameron.
Filament-wound couplings with integral Quick-Lock (1-16 inch) or
Taper/Taper (18-40 inch) socket ends
Nominal Laying Overall Outside Maximum Average
Pipe Length Length Diameter Working Weight
Size (LL) (OL) (OD) Pressure
[mm] [inch] [mm] [mm] [mm] [bar] [kg]
25 1 10 64 42 16 0.1
40 1 10 74 58 16 0.1
50 2 10 102 72 16 0.3
80 3 10 102 100 16 0.4
100 4 10 102 129 16 0.6
125 5 10 124 153 16 0.9
150 6 10 124 183 16 1.1
200 8 10 138 235 16 1.7
250 10 10 150 289 16 2.3
300 12 10 162 340 16 2.8
350 14 19 197 372 16 4.6
400 16 19 223 422 16 7.2
450 18 70 298 460 16 10.7
500 20 70 324 514 16 13.0
600 24 70 426 619 16 18.8
700 28 70 426 742 16 23.5
750 30 70 426 795 16 24.5
800 32 70 426 848 16 27.0
900 36 70 476 950 16 34.5
1000 40 70 890 1057 16 40.7
Blind Flanges
Taper/Taper
Quick-Lock
Ameron 2004. FP 918 09/04. Page 23 of 28. Printed in The Netherlands.
Nipples
Transition Nipples
Filament-wound nipples with integral Quick-Lock (1-16 inch) or
Taper/Taper (18-40 inch) male ends
Nominal Laying Gap* Maximum Average
Pipe Length Working Weight
Size (LL) Pressure
[mm] [inch] [mm] [mm] [bar] [kg]
25 1 57 3 16 0.1
40 1 67 3 16 0.1
50 2 95 3 16 0.1
80 3 95 3 16 0.1
100 4 95 3 16 0.2
125 5 117 3 16 0.3
150 6 118 3 16 0.4
200 8 130 3 16 0.6
250 10 143 3 16 0.9
300 12 156 3 16 1.1
350 14 184 3 16 3.1
400 16 210 3 16 4.4
450 18 278 50 16 5.9
500 20 304 50 16 7.8
600 24 406 50 16 12.0
700 28 406 50 16 21.0
750 30 406 50 16 22.0
800 32 406 50 16 24.0
900 36 456 50 16 36.0
1000 40 870 50 16 51.0
* Remaining gap after bonding.
Taper/Taper
Quick-Lock
Filament-wound transition nippels with integral Taper/Taper (18-40 inch) male ends
Nominal Laying Gap* Maximum Average
Pipe Length Working Weight
Size (LL) Pressure
[mm] [inch] [mm] [mm] [bar] [kg]
450 18 238 19 16 6
500 20 263 25 16 7
600 24 338 33 16 9
700 28 374 44 16 15
750 30 386 44 16 22
800 32 400 44 16 30
900 36 410 43 16 40
1000 40 685 45 16 45
* Remaining gap after bonding.
Ameron 2004. FP 918 09/04. Page 24 of 28. Printed in The Netherlands.
!
Grounding Saddles
Filament-wound pipe saddles for wear, support and anchor
Nominal Saddle Saddle Saddle Required Saddle Required
Pipe Angle Thickn. Weight Adhesive Weight Adhesive
Size t
s
B=100mm Kits B=150mm Kits
[mm] [inch] [degree] [mm] [kg] [3 and 6Oz] [kg] [3 and 6 Oz]
25 1 180 14 0.2 1 - 0.3 1 -
40 1 180 14 0.3 1 - 0.5 1 -
50 2 180 14 0.4 1 - 0.6 1 -
80 3 180 14 0.5 1 - 0.8 - 1
100 4 180 14 0.7 1 - 1.1 - 1
125 5 180 14 0.8 - 1 1.2 - 1
150 6 180 14 0.9 - 1 1.4 1 1
200 8 180 14 1.1 - 1 1.7 1 1
250 10 180 14 1.5 1 1 2.3 - 2
300 12 180 14 1.8 1 1 2.7 1 2
350 14 180 14 2.0 1 1 3.0 1 2
400 16 180 14 2.4 - 2 3.6 - 3
450 18 180 16 - - - 3.2 - 2
500 20 180 16 - - - 3.6 - 2
600 24 180 16 - - - 4.3 - 2
700 28 180 16 - - - 5.1 - 3
750 30 180 16 - - - 5.5 - 3
800 32 180 16 - - - 5.8 - 3
900 36 180 16 - - - 6.5 - 4
1000 40 180 16 - - - 8.2 - 4
Notes:
1) Filament-wound support saddles are intended for protection of pipe at supports and clamps,
as well as for anchoring purposes. Support and anchor saddles are standard 180.
Saddles are supplied in standard lengths of 100 mm and 150 mm.
2) For special saddle -lengths, -thickness and/or angles consult Ameron.
3) Wear saddles are standard 90. Weights of 90 degree saddles are 50% of value shown.
Filament-wound pipe saddles for grounding in conductive piping systems.
Nominal Saddle Saddle Saddle Average Required
Pipe Angle Length Thickness Saddle Adhesive
Size B t
s
Weight Kits
[mm] [inch] [degree] [mm] [mm] [kg] [3Oz]
25 1 90 76 14 0.1 1
40 1 90 76 14 0.1 1
50 2 90 76 14 0.1 1
80 3 90 76 14 0.1 1
100 4 90 76 14 0.2 1
125 5 90 76 14 0.3 1
150 6 90 76 14 0.3 1
200 8 45 76 14 0.2 1
250 10 45 76 14 0.2 1
300 12 45 76 14 0.2 1
350 14 45 76 14 0.3 1
400 16 45 76 14 0.3 1
450 18 22
1/2
76 16 0.2 1
500 20 22
1/2
76 16 0.2 1
600 24 22
1/2
76 16 0.3 1
700 28 22
1/2
76 16 0.3 2
750 30 22
1/2
76 16 0.4 2
800 32 22
1/2
76 16 0.4 3
900 36 22
1/2
76 16 0.4 3
1000 40 22
1/2
76 16 0.5 3
Notes:
1) Bondstrand conductive adhesive should be used for mounting.
2) Saddles are supplied with integrated stainless steel cable with a length of 600 mm.
Support Saddles
Ameron 2004. FP 918 09/04. Page 25 of 28. Printed in The Netherlands.
Filament-wound bell mouths with adhesive-bonded HD-flange
Nominal Overall Length of Internal Internal Average
Pipe Length Bell Mouth Diameter Diameter Weight*
Size (OL) (H1) (D1) (D2)
[mm] [inch] [mm] [mm] [mm] [kg]
50 2 269 115 110 110 3.1
80 3 274 120 220 220 5.0
100 4 289 135 275 275 8.4
125 5 323 158 400 400 12.7
150 6 324 158 450 450 14.7
200 8 533 340 750 418 26.0
250 10 594 395 850 518 39.0
300 12 569 365 850 510 51.0
350 14 605 375 850 510 60.0
400 16 588 345 850 510 67.0
450 18 627 360 900 548 90.0
500 20 724 450 1100 548 119.0
600 24 831 540 1300 648 171.0
* Weights provided are for bell mouth with CL150 flange.
Bell Mouths
Ameron 2004. FP 918 09/04. Page 26 of 28. Printed in The Netherlands.
Filament-wound Key-Lock expansion coupling with integral double O-ring Key-Lock
female end one side and double O-ring female end on other side
Nominal Laying Overall O-ring Key Average
Pipe Length Length Size Size Weight
Size (LL) (OL)
[mm] [inch] [mm] [mm] [mm] [mm] [kg]
50 2 50 222 7 x 59.7 6 x 305 1.3
80 3 50 222 7 x 88.3 6 x 400 1.7
100 4 50 222 7 x 113.7 6 x 483 3.5
125 5 50 264 9 x 135 8 x 580 4.6
150 6 50 270 10 x 161.3 8 x 660 6.6
200 8 50 337 10 x 225.5 10 x 840 15.4
250 10 50 356 12.5 x 302 12 x 1270 19.9
300 12 50 410 12.5 x 342.3 15 x 1270 21.0
350 14 50 430 12.5 x 342.3 15 x 1360 25.0
400 16 50 450 12.5 x 393.1 18 x 1585 32.0
450 18 50 416 15.0 x 445.0 15x1750 27.0
500 20 50 433 15.0 x 490.0 15x1930 32.0
600 24 50 479 18.0 x 580.0 18x2240 52.0
700 28 50 560 20.0 x 685.0 20x2700 99
Filament-wound double O-ring male Key-Lock adapter with integral Quick-Lock
(2-16 inch) or Taper/Taper (18-40 inch) socket end
Nominal Laying Overal Pressure Weight
Pipe Length Length
Size (LL) (OL)
[mm] [inch] [mm] [mm] [bar] [kg]
50 2 85 131 16 0.4
80 3 85 131 16 0.6
100 4 85 131 16 0.9
125 5 102 159 16 1.6
150 6 105 162 16 1.8
200 8 138 202 16 5.1
250 10 148 218 16 11.8
300 12 175 251 16 14.6
350 14 185 274 16 10.7
400 16 195 297 16 15.9
450 18 193 307 16 19.5
500 20 201 328 16 23.5
600 24 224 402 16 25.0
700 28 265 443 16 29.0
750 30 272 450 16 34.0
800 32 307 485 16 42.0
900 36 362 465 16 50.0
1000 40 355 765 16 64.0
Key-Lock Adapter for
Expansion Coupling
Expansion Coupling
Taper/Taper
Assembly of double
O-ring expansion joint
Quick-Lock
Ameron 2004. FP 918 09/04. Page 27 of 28. Printed in The Netherlands.
Filament-wound double O-ring male adapter with integral Quick-Lock (1-16 inch) or
Taper/Taper (18-40 inch) socket end
Nominal Laying Overall Average
Pipe Length Length Weight
Size (LL) (OL)
[mm] [inch] [mm] [mm] [kg]
50 2 85 131 0.4
80 3 85 131 0.7
100 4 85 131 0.9
125 5 102 159 1.6
150 6 105 162 1.8
200 8 138 202 5.1
250 10 148 218 11.8
300 12 175 251 14.6
350 14 185 274 10.7
400 16 195 297 15.9
450 18 193 307 19.5
500 20 201 328 23.5
600 24 224 402 25.0
700 28 265 443 29.0
750 30 272 450 34.0
800 32 307 485 42.0
900 36 362 465 50.0
1000 40 355 765 64.0
Number of Adhesive Kits per joint
Nominal Required Minimum number
Pipe Adhesive Kit of Adhesive Kits
Size Size required per joint
[mm] [inch] [cm
3
] [Oz] nr.
25 1 88.7 3 1/5
40 1 88.7 3 1/5
50 2 88.7 3 1/4
80 3 88.7 3 1/3
100 4 88.7 3 1/2
125 5 88.7 3 1
150 6 88.7 3 1
200 8 88.7 3 1
250 10 177.4 6 1
300 12 177.4 6 1
350 14 177.4 6 2
400 16 177.4 6 2
450 18 177.4 6 2
500 20 177.4 6 3
600 24 177.4 6 4
700 28 177.4 6 4
750 30 177.4 6 5
800 32 177.4 6 5
900 36 177.4 6 6
1000 40 177.4 6 6
Notes:
1) Adhesive Kits should never be split. If remainder is not used for other joints made at the same
time, the surplus must be discarded.
2) Required adhesive for saddles is shown in the dimension table of the respective saddles.
3) For type of adhesive to be used, please refer to the Bondstrand Corrosion Guide.
Double O-ring Adapter
for Expansion Coupling
Adhesive
Taper/Taper
Quick-Lock
Ameron 2004. FP 918 09/04. Page 28 of 28. Printed in The Netherlands.
Field testing
Surge pressure
Engineering design &
installation
Conversions
Important notice
Consult de following literature for recommendations pertaining design, installation and
use of Bondstrand pipe, fittings and flanges:
Assembly Instructions for Quick-Lock adhesive-bonded joints FP 170
Assembly Instructions for Taper/Taper adhesive-bonded joints FP 564
Assembly Instructions for Bondstrand fiberglass flanges FP 196
Bondstrand Corrosion Guide for fiberglass pipe and tubing FP 132
Bondstrand Pipe Shaver Overview FP 599
Bondstrand Marine Design Manual FP 707
Please consult Ameron for the latest version of the above mentioned literature.
Pipe system is designed for hydrostatic testing with water at 150% of rated pressure.
Maximum allowable surge pressure is max. 150% of rated pressure.
1 psi = 6895 Pa = 0.07031 kg/cm
2
1 bar = 10
5
Pa = 14.5 psi = 1.02 kg/cm
2
1 MPa = 1 N/mm
2
= 145 psi = 10.2 kg/cm
2
1 inch = 25.4 mm
1 Btu.in/ft
2
hF = 0.1442 W/mK
C = 5/9 (F-32)
This product literature and the recommendations for usage it contains are based on test
data reasonably believed to be reliable. It is intended that this literature be used by personnel
having specialised training in accordance with currently acceptable industry practice and
normal operating conditions. Variation in environment, changes in operating procedures,
or extrapolation of data may cause unsatisfactory results. We recommend that your
engineers verify the suitability of this product for your intended application. Since we have
no control over the conditions of service, we expressly disclaim responsibility for the results
obtained or for any consequential or incidental damages of any kind incurred.
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.nl
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet:www.ameron.com
email: marcom@ameronfpd.com
Ameron 1999 FP 835 08/99. Page 1 of 4 - Printed in the Netherlands.
Uses and applications
Description
Series 3400 Fiberglass
Epoxy Pipe Systems
for marine applications
using Taper/Taper adhesive-bonded joint
Air cooling circulation water
Auxiliairy equipment cooling
Ballast / segregated ballast
Brine
Drainage / sanitary service / sewage
Eductor service
Electrical conduit
Exhaust piping
Fresh water / saltwater service (non-essential)
Inert gas effluent
Main engine cooling
Sounding pipes / vent lines
Steam condensate
Tank cleaning (saltwater system)
Laminate meets all IMO requirements.
Pipe wall design using a 148 N/mm
2
Hydrostatic Design Basis (Procedure B.)
A 0.5 mm liner is available on request.
Maximum operating temperature: 93C.
This system is designed to provide minimal 4:1 safety factor in accordance with
IMO Regulations.
Classification: Fire Endurance L3 meets all IMO requirements.
Pipe
Filament-wound fiberglass reinforced epoxy with Taper/Taper male and female
adhesive-bonded joint.
Fittings
Standard filament-wound couplings, 22.5, 45 and 90 Elbows, Tees and Reducing
Tees, Concentric Reducers, Flanges and Nipples. Special fittings are available on
request.
* Flanges are available with the following drillings: ANSI B16.5 Class 150 & 300, DIN,
ISO & JIS. Other drilling patterns are available on request.
For dimensional data and standard configurations for fittings, please refer to the
respective Bondstrand Fittings Guide for Taper/Taper adhesive-bonded joints
(Ref. FP 657-10 to FP 657-25).
* Taper/Taper integral filament-wound male and female adhesive-bonded joint.
* Van Stone type flanges with movable flange rings for easy bolt aligment.
* Flanges hubless (heavy-duty)
* Viking-Johnson, Dresser, Straub or similar type mechanical couplings.
* Double O-ring Expansion Joints.
Performance
Joining systems
Ameron 1999 FP 835 08/99. Page 2 of 4 - Printed in the Netherlands.
Physical properties
Pipe sizes
Mechanical properties
Typical pipe dimensions
Bondstrand pipe is produced in different lengths depending on pipe size and location
of manufacture. Pipe can be cut to specified lengths at the factory.
Consult your Ameron representative for details.
From 50-150 mm (2-6") : 6.1 m. random length.
From 200-600 m. (8-24") : 6.1 or 12.2 m. random lengths.
From 700-1000 mm (28-40") : 11.8 m. random length.
Pipe property Units Value Method
Thermal conductivity W/mK .33 Ameron
Thermal expansivity (lineair) 10
-6
mm/mm/C 18.0 Ameron
Flow coefficient Hazen-Williams 150
Absolute roughness 10
-6
m 5.3
Density g/cm
3
1.8
Pipe property Unit 21C 93C Method
Bi-axial
Ultimate hoop stress at weeping N/mm
2
300 ASTM D-1599
Circumferential
Hoop tensile strength N/mm
2
300 ASTM D-2290
Hoop tensile modulus N/mm
2
25300 22000 ASTM D-2290
Poisson's ratio axial/hoop 0.50 0.65 Ameron
Longitudinal
Axial tensile strength N/mm
2
65 50 ASTM D-2105
Axial tensile modulus N/mm
2
10000 7800 ASTM D-2105
Poisson's ratio hoop/axial 0.40 0.45 ASTM D-2105
Axial bending strength N/mm
2
80 Ameron
Beam
Apparent elstic modulus N/mm
2
9200 7000 ASTM D-2925
Hydrostatic Design Basis
Static N/mm
2
148* ASTM D-2992
(Proc. B)
Cyclic N/mm
2
50* ASTM D-2992
(Proc. A)
* a 65C
Nominal Pipe Minimal total wall thickness (mm)
Pipe Size ID
(mm) (in) (mm) 3410 3412 3414 3416 3420 3425
50 2 53.2 2.3 2.3 2.3 2.3 2.3 2.3
80 3 81.8 2.3 2.3 2.3 2.3 2.3 2.4
100 4 105.2 2.3 2.3 2.3 2.5 2.5 2.9
150 6 159.0 2.5 2.7 2.8 3.0 3.4 3.9
200 8 208.8 3.1 3.1 3.3 3.5 4.0 5.0
250 10 262.9 3.5 3.5 3.7 4.3 4.8 6.0
300 12 313.7 3.9 4.1 4.3 5.0 5.7 7.1
350 14 344.4 4.1 4.5 4.9 5.4 6.1 7.9
400 16 393.7 4.4 4.8 5.3 6.1 7.0 8.9
450 18 433.8 4.6 5.5 5.8 6.7 7.6 9.7
500 20 482.1 5.4 6.0 6.5 7.4 8.3 10.7
600 24 578.6 6.0 7.0 7.5 8.7 10.1 12.8
700 28 700.0 7.0 7.6 9.0 10.5
750 30 750.0 7.2 8.1 9.7 11.2
800 32 800.0 7.4 8.6 10.3 11.9
900 36 900.0 7.9 9.6 11.4 13.3
1000 40 1000.0 8.6 10.6 12.7 14.7
Note: Pipe series designation: First two digits indicate product serie.
final two digits indicate internal pressure class (bar).
Ameron 1999 FP 835 08/99. Page 3 of 4 - Printed in the Netherlands.
Nominal Ultimate Collapse (bar) at 21C
Pipe Size
(mm) (in) 3410 3412 3414 3416 3420 3425
50 2 24.5 24.5 24.5 24.5 24.5 24.5
80 3 6.7 6.7 6.7 6.7 6.7 7.9
100 4 3.2 3.2 3.2 4.4 4.4 7.5
150 6 1.3 1.7 1.9 2.5 3.8 6.2
200 8 1.2 1.2 1.5 1.9 3.0 6.3
250 10 0.9 0.9 1.1 1.9 2.8 5.8
300 12 0.8 1.0 1.1 1.9 2.9 5.9
350 14 0.7 1.0 1.3 1.8 2.7 6.3
400 16 0.6 0.8 1.2 1.8 2.9 6.1
450 18 0.5 1.0 1.2 1.9 2.8 6.0
500 20 0.7 0.9 1.2 1.9 2.7 6.0
600 24 0.5 0.9 1.1 1.8 2.9 6.1
700 28 0.5 0.7 1.1 1.8
750 30 0.5 0.7 1.2 1.8
800 32 0.4 0.7 1.2 1.8
900 36 0.4 0.7 1.1 1.8
1000 40 0.3 0.7 1.2 1.8
Nominal Minimum weight empty pipe in kg/m
Pipe Size
(mm) (in) 3410 3412 3414 3416 3420 3425
50 2 0.7 0.7 0.7 0.7 0.7 0.7
80 3 1.0 1.0 1.0 1.0 1.0 1.1
100 4 1.3 1.3 1.3 1.4 1.4 1.7
150 6 2.1 2.3 2.4 2.6 3.0 3.4
200 8 3.5 3.5 3.8 4.0 4.6 5.9
250 10 5.0 5.0 5.3 6.3 7.0 8.9
300 12 6.7 7.1 7.4 8.7 10.0 12.6
350 14 7.8 8.6 9.4 10.4 11.8 15.4
400 16 9.5 10.5 11.6 13.4 15.5 19.9
450 18 11.0 13.3 14.0 16.3 18.6 23.9
500 20 14.4 16.1 17.5 20.0 22.6 29.4
600 24 19.3 22.6 24.3 28.4 33.1 42.3
700 28 27.3 29.8 35.4 41.5
750 30 30.1 34.0 41.0 47.5
800 32 33.0 38.6 46.4 53.9
900 36 39.7 48.5 57.9 67.8
1000 40 48.1 59.6 71.8 83.4
Note: Excluding integral joints.
Nominal Specific Tangential Initial Stiffness (STIS) in N/m
2
a 21C
Pipe Size
(mm) (in) 3410 3412 3414 3416 3420 3425
50 2 73904 73904 73904 73904 73904 73904
80 3 21044 21044 21044 21044 21044 24662
100 4 10037 10037 10037 13691 13691 23396
150 6 4042 5359 6113 7821 12117 19347
200 8 3922 3922 4885 5991 9447 19797
250 10 3028 3028 3667 6098 8787 18142
300 12 2599 3079 3615 5963 9141 18446
350 14 2334 3191 4232 5820 8636 19622
400 16 1990 2659 3684 5816 9033 19221
450 18 1730 3119 3707 5899 8804 18884
500 20 2148 3026 3916 5923 8509 18752
600 24 1760 2891 3601 5753 9166 19016
700 28 1642 2134 3641 5891
750 30 1493 2128 3752 5867
800 32 1318 2123 3737 5847
900 36 1144 2115 3612 5814
1000 40 1094 2108 3692 5787
Note: Pipe series designation: First two digits indicate product serie.
final two digits indicate internal pressure class (bar).
External pressure
performance
Pipe weight
Specific Tangential
Initial Stifness
Nominal Partial span recommendations* (in meters) for
Pipe Size horizontal support arrangements at 21C
(mm) (in) 3410 3412 3414 3416 3420 3425
50 2 3.2 3.2 3.2 3.2 3.2 3.2
80 3 3.6 3.6 3.6 3.6 3.6 3.6
100 4 3.8 3.8 3.8 3.9 3.9 4.1
150 6 4.4 4.4 4.5 4.6 4.7 4.9
200 8 5.0 5.0 5.0 5.1 5.3 5.6
250 10 5.4 5.4 5.5 5.7 5.9 6.2
300 12 5.9 5.9 6.0 6.3 6.5 6.8
350 14 6.1 6.2 6.4 6.5 6.7 7.2
400 16 6.4 6.6 6.7 7.0 7.2 7.7
450 18 6.7 7.0 7.1 7.3 7.6 8.0
500 20 7.1 7.3 7.5 7.7 7.9 8.5
600 24 7.7 8.0 8.1 8.4 8.8 9.3
700 28 8.4 8.6 8.9 9.3
750 30 8.6 8.9 9.3 9.6
800 32 8.8 9.2 9.6 9.9
900 36 9.2 9.7 10.1 10.5
1000 40 9.7 10.2 10.7 11.1
* Note: For continuous span use of above values: plus 20%
For simple span use of above values: minus 20%
1) Span recomendations are based on pipes filled with water with a specific
gravity of 1000 kg/m
3
and include no provision for weights caused by valves,
flanges or heavy objects.
2) Span recommendations are calculated for a maximum long time deflection
of 13 mm to ensure good appearance and adequate drainage.
Maximum allowable surge pressure is 150% of rated pressure.
Pipe system is designed for field testing with water at 150% of rated pressure.
1 psi = 6895 Pa = 0,07031 kg/cm
2
1 bar = 10
5
Pa = 14,5 psi = 1,02 kg/cm
2
1 MPa = 1 N/mm
2
= 145 psi = 10,2 kg/cm
2
1 po = 25,4 mm
1 Btu.po/ft
2
hF = 0,1442 W/mK
C = 5/9 (F-32)
This product literature and the recommendations for usage it contains are based on test
data reasonably believed to be reliable. It is intended that this literature be used by
personnel having specialised training in accordance with currently acceptable industry
practice and normal operating conditions. Variation in environment, changes in operat-
ing procedures, or extrapolation of data may cause unsatisfactory results. We recom-
mend that your engineers verify the suitability of this product for your intended application.
Since we have no control over the conditions of service, we expressly disclaim responsi-
bility for the results obtained or for any consequential or incidental damages of any kind
incurred
Span lengths
Surge pressure
Conversions
Important notice
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.n
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet:www.ameron.com
email:marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Fittings & Flanges for
pipe series 2410 and 3410
using the Taper/Taper adhesive-bonded joint
Bondstrand Taper-Taper fittings & flanges are glassfiber reinforced filament-wound epoxy
pipe fittings in diameters 50 through 1000 mm (2-40 inch) designed to be used with
Bondstrand pipes. Pipe is standard with integral Taper-Taper spigot and socket ends for
adhesive bonding or with integral Key-Lock male and female ends for mechanical joining.
Fittings are filament-wound with integral taper socket ends. Pipes and fittings are
available in several pressure classes from 10 bar upwards.
For intended services and performance capabilities refer to product data sheet FP 452 and
FP 158 pertaining to Bondstrand Series 2400 and 3400 pipe data.
For recommendations pertaining to design, installation and use of Bondstrand Pipe,
Fittings and Flanges reference is made to the following literature:
FP 564 Assembly Instructions for Taper-Taper adhesive bonded joints.
FP 161 Installation Instructions using the Key-Lock mechanical joint.
FP 453 M86 Pipe Shaver operating instructions for Taper-Taper joints in sizes
50 to 150 mm (2-6 inch).
FP 454 M87 Pipe Shaver operating instructions for Taper-Taper joints in sizes
150 to 400 mm (6-16 inch).
FP 455 M87XL Pipe Shaver operating instructions for Taper-Taper joints in
sizes 400 to 600 mm (16-24 inch).
FP 204 M95 Pipe Shaver operating instructions for Taper-Taper joints in sizes
600 to 1000 mm (24-40 inch).
FP 196 Flange Assembly Instructions.
FP 132 Corrosion Guide.
General Bondstrand engineering and installation guides.
Dimensional data for Taper-Taper adhesive bonded fittings are contained in individual
dimensional sheets per pressure class:
FP No. Fitting Pipe System Pressure
549-10 T-10 2410 and 3410 10 bar
549-12 T-12 2412 and 3412 12 bar
549-14 T-14 2414 and 3414 14 bar
549-16 T-16 2416 and 3416 16 bar
549-20 T-20 2420 and 3420 20 bar
549-25 T-25 2425 and 3425 25 bar
549-32 T-32 2432 and 3432 32 bar
549-40 T-40 2440 and 3440 40 bar
549-50 T-50 2450 and 3450 50 bar
Ameron 1998 FP657-10 (8/98). Printed in The Netherlands. Page1 of 12.
Description
Uses and Application
Design and Installation
How to use this product
data sheet
FP657-10 (8/98). Fittings & Flanges for 2410/3410. Page 2 of 12.
Nominal Pipe Size Taper Insertion Spigot Spigot
Angle Depth Nose Diameter
Thickness at Nose
Ds t
mm inch degrees mm mm mm
50 2 1.75 50 1.0 55.2
80 3 1.75 50 1.0 83.8
100 4 1.75 50 1.0 107.2
150 6 2.50 50 1.0 161.0
200 8 2.50 80 1.0 210.8
250 10 2.50 80 1.0 264.9
300 12 2.50 80 1.0 315.7
350 14 2.50 80 1.5 347.4
400 16 2.50 110 1.5 396.7
450 18 2.50 110 1.5 436.8
500 20 2.50 110 2.0 486.1
600 24 2.50 110 2.0 582.6
700 28 1.75 140 4.0 708.0
750 30 1.75 140 4.0 758.0
800 32 1.75 170 4.0 808.0
900 36 1.75 200 4.0 908.0
1000 40 1.75 200 4.5 1009.0
Dimensions of the
Taper-Taper joint
Nominal Adhesive Minimum number of
Pipe Size Kit Size adhesive kits per joint
fluid
mm inch cm
3
ounce nr.
50 2 89 3 0.2
80 3 89 3 0.2
100 4 89 3 0.4
150 6 89 3 0.4
200 8 89 3 0.6
250 10 177 6 1.0
300 12 177 6 1.0
350 14 177 6 1.0
400 16 177 6 2.0
450 18 177 6 2.0
500 20 177 6 2.0
600 24 177 6 2.0
700 28 177 6 4.0
750 30 177 6 4.0
800 32 177 6 5.0
900 36 177 6 6.0
1000 40 177 6 7.0
Note:
Adhesive kits should never be split. If remainder is not used for other joints made at the
same time, the surplus must be discarded.
Quantity of Adhesive
FP657-10 (8/98). Fittings & Flanges for 2410/3410. Page 3 of 12.
Filament-wound 90 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 87 137 50 0.6
80 3 126 176 50 1.1
100 4 155 205 50 2.1
150 6 240 290 50 4.2
200 8 315 395 80 8.6
250 10 391 471 80 14.2
300 12 463 543 80 21.0
350 14 364 444 80 30.0
400 16 402 512 110 35.0
450 18 472 582 110 49.0
500 20 523 633 110 72.0
600 24 625 735 110 112.0
700 28 726 866 140 123.0
750 30 777 917 140 196.0
800 32 828 998 170 252.0
900 36 929 1129 200 348.0
1000 40 1031 1231 200 480.0
Elbows 90
Filament-wound 45 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 45 95 50 0.5
80 3 61 111 50 0.9
100 4 73 123 50 1.3
150 6 106 156 50 2.5
200 8 137 217 80 6.9
250 10 169 249 80 9.8
300 12 196 276 80 18.1
350 14 125 205 80 19.1
400 16 142 252 110 21.0
450 18 204 314 110 31.0
500 20 225 335 110 42.0
600 24 268 378 110 63.0
700 28 310 450 140 90.0
750 30 331 471 140 107.0
800 32 352 522 170 139.0
900 36 394 594 200 193.0
1000 40 436 636 200 257.0
Elbows 45
FP657-10 (8/98). Fittings & Flanges for 2410/3410. Page 4 of 12.
Filament-wound 22
1
/2 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 29 79 50 0.4
80 3 37 87 50 0.6
100 4 43 93 50 0.9
150 6 60 110 50 1.4
200 8 76 156 80 4.6
250 10 68 148 80 6.0
300 12 77 157 80 8.9
350 14 71 151 80 12.5
400 16 85 195 110 13.6
450 18 106 216 110 19.7
500 20 116 226 110 24.0
600 24 136 246 110 45.0
700 28 157 297 140 60.0
750 30 167 307 140 70.0
800 32 177 347 170 94.0
900 36 197 397 200 137.0
1000 40 217 417 200 153.0
Elbows 22
1
/2
Filament-wound tees with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Laying Overall Insertion Weight
Length Length Length Length Depth
total total branch branch
run run
L1 OL1 L2 OL2 Ds
mm inch mm mm mm mm mm kg
50 2 148 248 74 124 50 1.3
80 3 192 292 96 146 50 2.9
100 4 230 330 115 165 50 4.0
150 6 306 406 153 203 50 8.7
200 8 376 536 188 268 80 17.5
250 10 452 612 226 306 80 25.0
300 12 528 688 264 344 80 44.0
350 14 544 704 272 352 80 47.0
400 16 590 810 295 405 110 56.0
450 18 678 898 339 449 110 67.0
500 20 740 960 370 480 110 99.0
600 24 868 1088 434 544 110 130.0
700 28 994 1274 497 637 140 240.0
750 30 1046 1326 523 663 140 285.0
800 32 1118 1458 559 729 170 363.0
900 36 1248 1648 624 824 200 518.0
1000 40 1382 1782 691 891 200 683.0
Tees
FP657-10 (8/98). Fittings & Flanges for 2410/3410. Page 5 of 12.
Filament-wound 45 lateral with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Laying Overall Insertion Weight
Length Length Length Length Depth
L1 OL1 L2 OL2 Ds
mm inch mm mm mm mm mm kg
50 2 74 124 209 259 50 2.3
80 3 86 136 264 314 50 4.1
100 4 86 136 315 365 50 6.3
150 6 99 149 378 428 50 12.3
200 8 124 204 455 535 80 27.0
250 10 137 217 531 611 80 43.0
300 12 150 230 632 712 80 52.0
350 14 150 230 632 712 80 69.0
400 16 150 260 632 742 110 95.0
Lateral 45
Filament-wound cross with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Laying Overall Insertion Weight
Length Length Length Length Depth
run run branch branch
L1 OL1 L2 OL2 Ds
mm inch mm mm mm mm mm kg
50 2 148 248 74 124 50 1.9
80 3 192 292 96 146 50 3.3
100 4 230 330 115 165 50 5.7
150 6 306 406 153 203 50 13.2
200 8 376 536 188 268 80 21.0
250 10 452 612 226 306 80 37.0
300 12 528 688 264 344 80 58.0
350 14 544 704 272 352 80 68.0
400 16 590 810 295 405 110 105.0
Cross
FP657-10 (8/98). Fittings & Flanges for 2410/3410. Page 6 of 12.
Filament-wound reducing tees with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Laying Overall Insertion Weight
Length Length Depth Length Length Depth
half half run branch branch branch
run x run x branch run run
L1 OL1 Ds1 L2 OL2 Ds2
mm inch mm mm mm mm mm mm kg
80x80x50 3x3x2 96 146 50 86 136 50 2.7
100x100x50 4x4x2 115 165 50 99 149 50 3.8
100x100x80 4x4x3 115 165 50 108 158 50 4.0
150x150x50 6x6x2 153 203 50 124 174 50 8.0
150x150x80 6x6x3 153 203 50 134 184 50 9.6
150x150x100 6x6x4 153 203 50 140 190 50 9.6
200x200x80 8x8x3 188 268 80 159 209 50 15.6
200x200x100 8x8x4 188 268 80 172 222 50 16.2
200x200x150 8x8x6 188 268 80 178 228 50 17.0
250x250x100 10x10x4 226 306 80 194 244 50 23.0
250x250x150 10x10x6 226 306 80 204 254 50 24.0
250x250x200 10x10x8 226 306 80 213 293 80 26.0
300x300x100 12x12x4 264 344 80 216 266 50 32.0
300x300x150 12x12x6 264 344 80 229 279 50 32.0
300x300x200 12x12x8 264 344 80 239 319 80 33.0
300x300x250 12x12x10 264 344 80 251 331 80 34.0
350x350x150 14x14x6 272 352 80 254 304 50 34.0
350x350x200 14x14x8 272 352 80 264 344 80 35.0
350x350x250 14x14x10 272 352 80 277 357 80 38.0
350x350x300 14x14x12 272 352 80 289 369 80 39.0
400x400x150 16x16x6 295 405 110 274 324 50 47.0
400x400x200 16x16x8 295 405 110 283 363 80 51.0
400x400x250 16x16x10 295 405 110 293 373 80 47.0
400x400x300 16x16x12 295 405 110 305 385 80 53.0
400x400x350 16x16x14 295 405 110 315 395 80 54.0
450x450x200 18x18x10 339 449 110 316 396 80 66.0
450x450x250 18x18x12 339 449 110 329 409 80 66.0
450x450x300 18x18x12 339 449 110 329 409 80 71.0
450x450x350 18x18x14 339 449 110 330 410 80 72.0
450x450x400 18x18x16 339 449 110 330 440 110 75.0
500x500x250 20x20x10 370 480 110 355 435 80 93.0
500x500x300 20x20x12 370 480 110 355 435 80 96.0
500x500x350 20x20x14 370 480 110 356 436 80 97.0
500x500x400 20x20x16 370 480 110 356 466 110 107.0
500x500x450 20x20x18 370 480 110 365 475 110 102.0
600x600x300 24x24x12 434 544 110 405 485 80 112.0
600x600x350 24x24x14 434 544 110 406 486 80 123.0
600x600x400 24x24x16 434 544 110 406 516 110 126.0
600x600x450 24x24x18 434 544 110 428 538 110 130.0
600x600x500 24x24x20 434 544 110 428 540 110 137.0
Reducing Tees
FP657-10 (8/98). Fittings & Flanges for 2410/3410. Page 7 of 12.
Nominal Pipe Size Laying Overall Insertion Laying Overall Insertion Weight
Length Length Depth Length Length Depth
half half run branch branch branch
run x run x branch run run
L1 OL1 Ds1 L2 OL2 Ds2
mm inch mm mm mm mm mm mm kg
700x700x350 28x28x14 497 637 140 475 555 80 202
700x700x400 28x28x16 497 637 140 483 593 110 207
700x700x450 28x28x18 497 637 140 483 593 110 209
700x700x500 28x28x20 497 637 140 491 601 110 212
700x700x600 28x28x24 497 637 140 491 601 110 217
750x750x400 30x30x16 523 663 140 501 611 110 245
750x750x450 30x30x18 523 663 140 509 619 110 247
750x750x500 30x30x20 523 663 140 509 619 110 250
750x750x600 30x30x24 523 663 140 517 627 110 256
750x750x700 30x30x28 523 663 140 517 657 140 268
800x800x400 32x32x16 559 729 170 537 647 110 303
800x800x450 32x32x18 559 729 170 537 647 110 306
800x800x500 32x32x20 559 729 170 545 655 110 309
800x800x600 32x32x24 559 729 170 545 655 110 315
800x800x700 32x32x28 559 729 170 553 693 140 329
800x800x750 32x32x30 559 729 170 553 693 140 332
900x900x450 36x36x18 624 824 200 603 713 110 427
900x900x500 36x36x20 624 824 200 603 713 110 430
900x900x600 36x36x24 624 824 200 611 721 110 437
900x900x700 36x36x28 624 824 200 611 751 140 452
900x900x750 36x36x30 624 824 200 618 758 140 458
900x900x800 36x36x32 624 824 200 618 788 170 468
1000x1000x500 40x40x20 691 891 200 669 779 110 570
1000x1000x600 40x40x24 691 891 200 669 779 110 578
1000x1000x700 40x40x28 691 891 200 677 817 140 596
1000x1000x750 40x40x30 691 891 200 677 817 140 601
1000x1000x800 40x40x32 691 891 200 685 855 170 614
1000x1000x900 40x40x36 691 891 200 685 885 200 632
Reducing Tees (cont.)
FP657-10 (8/98). Fittings & Flanges for 2410/3410. Page 8 of 12.
Filament-wound concentric reducers with integral Taper-Taper adhesive bonded
socket ends
Nominal Pipe Size Laying Overall Overall Insertion Weight
Length Length Length Depth
L OL Ds1 Ds2
mm inch mm mm mm mm kg
80x50 3x2 74 174 50 50 0.8
100x50 4x2 96 196 50 50 1.1
100x80 4x3 94 194 50 50 1.3
150x80 6x3 117 217 50 50 1.5
150x100 6x4 124 224 50 50 1.8
200x100 8x4 163 293 80 50 3.3
200x150 8x6 129 259 80 50 3.7
250x150 10x6 148 278 80 50 6.2
250x200 10x8 135 295 80 80 6.2
300x200 12x8 180 340 80 80 7.8
300x250 12x10 167 327 80 80 8.5
350x250 14x10 214 374 80 80 10.2
350x300 14x12 208 368 80 80 11.0
400x300 16x12 195 385 110 80 13.7
400x350 16x14 183 373 110 80 12.8
450x400 18x16 128 348 110 110 20.0
500x400 20x16 249 469 110 110 21.0
500x450 20x18 151 371 110 110 23.0
600x400 24x16 486 706 110 110 27.0
600x450 24x18 388 608 110 110 26.0
600x500 24x20 267 487 110 110 24.0
700x400 28x16 796 1046 140 110 62.0
700x450 28x18 698 948 140 110 60.0
700x500 28x20 577 827 140 110 58.0
700x600 28x24 340 590 140 110 52.0
750x400 30x16 915 1165 140 110 74.0
750x450 30x18 817 1067 140 110 73.0
750x500 30x20 696 946 140 110 70.0
750x600 30x24 459 709 140 110 64.0
750x700 30x28 149 429 140 140 58.0
800x400 32x16 1038 1318 170 110 94.0
800x450 32x18 940 1212 170 110 92.0
800x500 32x20 819 1099 170 110 90.0
800x600 32x24 582 862 170 110 83.0
800x700 32x28 272 582 170 140 77.0
800x750 32x30 153 463 170 140 72.0
900x450 36x18 1186 1496 200 110 133.0
900x500 36x20 1065 1375 200 110 130.0
900x600 36x24 828 1138 200 110 122.0
900x700 36x28 518 858 200 140 116.0
900x750 36x30 399 739 200 140 111.0
900x800 36x32 276 646 200 170 111.0
1000x500 40x20 1313 1623 200 110 173.0
1000x600 40x24 1076 1386 200 110 165.0
1000x700 40x28 766 1106 200 140 157.0
1000x750 40x30 647 987 200 140 152.0
1000x800 40x32 524 894 200 170 152.0
1000x900 40x36 278 678 200 200 146.0
Note: Eccentric Reducers are available on request.
Concentric Reducers
FP657-10 (8/98). Fittings & Flanges for 2410/3410. Page 9 of 12.
Filament-wound couplings with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Outside Weight
Length Length Depth Diameter
L OL Ds OD
mm inch mm mm mm mm kg
50 2 70 170 50 70 0.4
80 3 70 170 50 100 0.7
100 4 70 170 50 124 0.9
150 6 70 170 50 180 1.5
200 8 70 230 80 230 2.5
250 10 70 230 80 286 3.4
300 12 70 230 80 339 4.5
350 14 70 230 80 370 4.8
400 16 70 290 110 419 6.4
450 18 70 290 110 460 7.3
500 20 70 290 110 524 14.4
600 24 70 290 110 606 9.8
700 28 70 350 140 734 16.3
750 30 70 350 140 783 16.6
800 32 70 410 170 840 27.0
900 36 70 470 200 937 29.0
1000 40 70 470 200 1038 33.0
Couplings
Filament-wound pipe nipples with integral Taper-Taper adhesive bonded spigot ends
Nominal Pipe Size Laying gap Insertion Weight
Length Depth
L Ds
mm inch mm mm mm kg
50 2 125 25 50 0.1
80 3 125 25 50 0.1
100 4 125 25 50 0.1
150 6 125 25 50 0.2
200 8 190 30 80 0.6
250 10 190 30 80 0.8
300 12 200 40 80 1.1
350 14 200 40 80 1.4
400 16 260 40 110 2.2
450 18 280 60 110 2.7
500 20 280 60 110 3.4
600 24 280 60 110 4.4
700 28 340 60 140 8.5
750 30 340 60 140 9.4
800 32 400 60 170 12.4
900 36 460 60 200 17.2
1000 40 460 60 200 21.0
Nipples
FP657-10 (8/98). Fittings & Flanges for 2410/3410. Page 10 of 12.
Heavy-Duty filament-wound flanges with Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overal Insertion Weight
Length Length Depth
L D Ds
1) 2)
mm inch mm mm mm kg
50 2 5 55 50 1.5
80 3 5 55 50 2.2
100 4 5 55 50 2.9
150 6 5 55 50 3.7
200 8 6 56 50 5.5
250 10 6 86 80 10.6
300 12 6 86 80 15.3
350 14 6 86 80 18.7
400 16 6 86 80 23.0
450 18 6 86 80 24.0
500 20 6 116 110 38.0
600 24 6 116 110 49.0
700 28 6 146 140 67.0
750 30 6 146 140 73.0
800 32 6 176 170 117.0
Notes:
1) Bold insertion depth for subsequent flanges deviates from other fittings.
2) The weights shown are for ANSI B16.5 Class 150 drilled flanges. Weights for other
drilling classes may be different. For more detailed information reference is made to
the appropriate product data.
* Heavy Duty Flanges are standard available in drillings according to ANSI and ISO (DIN).
** Full-face elastomeric gaskets may be used, suitable for the service pressure, service
temperature and fluid. Shore A durometer hardness of 60 5 is recommended and a
thickness of 3 mm.
Compressed fibre gaskets, 3 mm thick, compatible with the pressure, temperature
and medium, may also be used. The mechanical properties should be in accordance
with DIN 3754 (IT 400) or equal.
*** For maximum bolt torque refer to the appropriate Bondstrand literature. Please be
aware that excessive torque may result in flange failure and, therefore a torque-
wrench is required.
Heavy-Duty Flanges
FP657-10 (8/98). Fittings & Flanges for 2410/3410. Page 11 of 12.
Filament-wound Stub-end flanges with Taper-Taper adhesive bonded socket ends
and steel backing rings
Nominal Pipe Size Laying Overall Insertion Ring Weigth Weight
Length Length Depth to GRE steel
Face stub- ring
L OL Ds H end
1)
mm inch mm mm mm mm kg kg
50 2 15 65 50 10 0.2 1.8
80 3 15 65 50 10 0.5 3.2
100 4 15 65 50 12 0.8 4.2
150 6 15 65 50 13 1.3 5.2
200 8 15 95 80 20 2.6 8.5
250 10 15 95 80 16 3.1 13.5
300 12 15 95 80 18 3.9 23.0
350 14 15 95 80 19 3.8 32.0
400 16 20 130 110 21 6.9 42.0
450 18 20 130 110 24 11.4 40.0
500 20 20 130 110 23 12.3 51.0
600 24 20 130 110 28 13.0 86.0
700 28 20 160 140 29 17.8 100.0
750 30 20 160 140 32 19.7 117.0
800 32 20 190 170 33 24.0 154.0
900 36 20 220 200 36 30.0 197.0
1000 40 20 220 200 46 35.0 303.0
Notes:
1) The weight shown is for ANSI B16.5 Class 150 drilled flanges. Weights for other
drilling classes may be different. For more detailed information reference is made to
the appropriate product data.
* Stub-End Flange Rings are standard available in drillings according to ANSI and ISO
(DIN).
** Stub-End Flanges are available with and without O-ring groove in the face.
Up to 10 bar stub-ends without grooves can be used with flat elastomeric or
compressed fibre gaskets.
For pressures 12 bar and above suitable O-ring seals should be used, available on
request.
*** Make sure that the O-ring grooved stub-end is compatible with its counter flange,
e.g. use a stub-end without groove or another flat surface flange as counter flange.
**** Maximum bolt-torque for use with O-rings seals may be calculated based on
pressure, size and number of bolts. If using flat face gaskets (maximum pressure 10
bar) refer to the appropriate Bondstrand literature for hubbed flanges.
Stub-end Flanges
(Van Stone)
Filament wound adapters and couplings with Key-lock ends.
Nominal Pipe Qty Laying Overall Insertion Weight Laying Overall Weight
Size of Length Length Depth Length Length
Keys L OL Ds L OL
mm inch mm mm mm kg mm mm kg
adapter KLM x TBF coupling KLF x KLF
50 2 1 5 100 50 0.3 100 140 0.8
80 3 1 5 100 50 0.5 100 140 1.0
100 4 1 5 100 50 0.7 100 140 2.2
150 6 1 4 110 50 1.0 127 181 4.3
200 8 1 2 150 80 1.9 152 225 6.3
250 10 1 3 155 80 2.7 163 242 9.6
300 12 1 5 170 80 4.0 186 278 11.6
350 14 1 13 180 80 6.4 191 289 15.8
400 16 1 15 215 110 8.2 197 302 21.0
450 18 1 16 220 110 11.5 204 296 17.8
500 20 1 33 240 110 13.9 210 308 22.0
600 24 1 34 250 110 16.9 229 340 31.0
700 28 2 119 385 140 34.0 277 547 65.0
750 30 2 118 385 140 34.0 279 558 83.0
800 32 2 130 445 170 49.0 315 629 105.0
900 36 2 147 515 200 67.0 356 737 154.0
1000 40 2 122 475 200 68.0 330 724 103.0
Key-lock Adapters
& Couplings
Pipe system is designed for field testing with water at 150% of rated pressure.
Maximum allowable surge pressure is 150% of rated pressure.
Field Testing
Surge Pressure
1 psi = 6895 Pa = 0.07031 kg/cm
2
1 bar = 105Pa = 14.5 psi = 1.02 kg/cm
2
1 MPa = 1 N/mm
2
= 145 psi = 10.2 kg/cm
2
1 inch = 25.4 mm
1 Btu.in/ft2hF = 0.1442 W/mK
C = 5/9 (F-32)
This product literature and the recommendations for usage it contains are based on test data
reasonably believed to be reliable. It is intended that this literature be used by personnel
having specialised training in accordance with currently accepted industry practice and
normal operating conditions. Variation in environment, changes in operating procedures, or
extrapolation of data may cause unsatisfactory results. We recommend that your engineers
verify the suitability of this product for your intended application. Since we have no control
over the conditions of service, we expressly disclaim responsibility for the results obtained
or for any consequential or incidental damages of any kind incurred.
Conversions
Important Notice
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.n
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet:www.ameron.com
email:marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Fittings & Flanges for
pipe series 2412 and 3412
using the Taper/Taper adhesive-bonded joint
Bondstrand Taper-Taper fittings & flanges are glassfiber reinforced filament-wound epoxy
pipe fittings in diameters 50 through 1000 mm (2-40 inch) designed to be used with
Bondstrand pipes. Pipe is standard with integral Taper-Taper spigot and socket ends for
adhesive bonding or with integral Key-Lock male and female ends for mechanical joining.
Fittings are filament-wound with integral taper socket ends. Pipes and fittings are
available in several pressure classes from 10 bar upwards.
For intended services and performance capabilities refer to product data sheet FP 452 and
FP 158 pertaining to Bondstrand Series 2400 and 3400 pipe data.
For recommendations pertaining to design, installation and use of Bondstrand Pipe,
Fittings and Flanges reference is made to the following literature:
FP 564 Assembly Instructions for Taper-Taper adhesive bonded joints.
FP 161 Installation Instructions using the Key-Lock mechanical joint.
FP 453 M86 Pipe Shaver operating instructions for Taper-Taper joints in sizes
50 to 150 mm (2-6 inch).
FP 454 M87 Pipe Shaver operating instructions for Taper-Taper joints in sizes
150 to 400 mm (6-16 inch).
FP 455 M87XL Pipe Shaver operating instructions for Taper-Taper joints in
sizes 400 to 600 mm (16-24 inch).
FP 643 M95 Pipe Shaver operating instructions for Taper-Taper joints in sizes
600 to 1000 mm (24-40 inch).
FP 196 Flange Assembly Instructions.
FP 132 Corrosion Guide.
General Bondstrand engineering and installation guides.
Dimensional data for Taper-Taper adhesive bonded fittings are contained in individual
dimensional sheets per pressure class:
FP No. Fitting Pipe System Pressure
549-10 T-10 2410 and 3410 10 bar
549-12 T-12 2412 and 3412 12 bar
549-14 T-14 2414 and 3414 14 bar
549-16 T-16 2416 and 3416 16 bar
549-20 T-20 2420 and 3420 20 bar
549-25 T-25 2425 and 3425 25 bar
549-32 T-32 2432 and 3432 32 bar
549-40 T-40 2440 and 3440 40 bar
549-50 T-50 2450 and 3450 50 bar
Ameron 1998 FP657-12 (8/98). Printed in The Netherlands. Page 1 of 12.
Description
Uses and Application
Design and Installation
How to use this product
data sheet
FP657-12 Fittings & Flanges for 2412/3412. Page 2 of 12.
Nominal Pipe Size Taper Insertion Spigot Spigot
Angle Depth Nose Diameter
Thickness at Nose
Ds t
mm inch degrees mm mm mm
50 2 1.75 50 1.0 55.2
80 3 1.75 50 1.0 83.8
100 4 1.75 50 1.0 107.2
150 6 2.50 50 1.0 161.0
200 8 2.50 80 1.0 210.8
250 10 2.50 80 1.0 264.9
300 12 2.50 80 1.0 315.7
350 14 2.50 80 1.5 347.4
400 16 2.50 110 1.5 396.7
450 18 2.50 110 1.5 436.8
500 20 2.50 140 2.0 486.1
600 24 2.50 170 2.0 582.6
700 28 1.75 170 4.0 708.0
750 30 1.75 200 4.0 758.0
800 32 1.75 230 4.0 808.0
900 36 1.75 260 4.0 908.0
1000* 40 1.75 290 4.5 1009.0
1000** 40 1.75 200 4.5 1009.0
Dimensions of the
taper-taper joint
Nominal Adhesive Minimum number of
Pipe Size Kit Size adhesive kits per joint
fluid
mm inch cm
3
ounce nr.
50 2 89 3 0.2
80 3 89 3 0.2
100 4 89 3 0.4
150 6 89 3 0.4
200 8 89 3 1.0
250 10 177 6 1.0
300 12 177 6 1.0
350 14 177 6 1.0
400 16 177 6 2.0
450 18 177 6 2.0
500 20 177 6 3.0
600 24 177 6 4.0
700 28 177 6 4.0
750 30 177 6 5.0
800 32 177 6 6.0
900 36 177 6 8.0
1000* 40 177 6 9.0
1000** 40 177 6 7.0
* For Bondstrand 2412 only
** For Bondstrand 3412 only
Note:
Adhesive kits should never be split. If remainder is not used for other joints made at the
same time, the surplus must be discarded.
Quantity of Adhesive
* For Bondstrand 2412 only
** For Bondstrand 3412 only
FP657-12 Fittings & Flanges for 2412/3412. Page 3 of 12.
Filament-wound 90 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 87 137 50 0.6
80 3 126 176 50 1.1
100 4 155 205 50 2.1
150 6 240 290 50 4.2
200 8 315 395 80 8.6
250 10 391 471 80 14.2
300 12 463 543 80 21.0
350 14 364 444 80 30.0
400 16 402 512 110 35.0
450 18 472 582 110 49.0
500 20 523 663 140 101.0
600 24 625 795 170 155.0
700 28 726 896 170 188.0
750 30 777 977 200 228.0
800 32 828 1058 230 290.0
900 36 929 1189 260 402.0
1000* 36 1031 1321 290 568.0
1000** 40 1031 1231 200 522.0
Elbows 90
Filament-wound 45 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 45 95 50 0.5
80 3 61 111 50 0.9
100 4 73 123 50 1.3
150 6 106 156 50 2.5
200 8 137 217 80 6.9
250 10 169 249 80 9.8
300 12 196 276 80 18.1
350 14 125 205 80 19.1
400 16 142 252 110 20.0
450 18 204 314 110 31.0
500 20 225 365 140 67.0
600 24 268 438 170 91.0
700 28 310 480 170 101.0
750 30 331 531 200 131.0
800 32 352 582 230 200.0
900 36 394 654 260 282.0
1000* 40 436 726 290 324.0
1000** 40 436 636 200 262.0
* For Bondstrand 2412 only
** For Bondstrand 3412 only
Elbows 45
* For Bondstrand 2412 only
** For Bondstrand 3412 only
FP657-12 Fittings & Flanges for 2412/3412. Page 4 of 12.
Filament-wound 22
1
/2 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 29 79 50 0.4
80 3 37 87 50 0.6
100 4 43 93 50 0.9
150 6 60 110 50 1.4
200 8 76 156 80 4.5
250 10 68 148 80 6.0
300 12 77 157 80 8.9
350 14 71 151 80 12.5
400 16 85 195 110 13.6
450 18 106 216 110 19.7
500 20 116 256 140 32.0
600 24 136 306 170 73.0
700 28 157 327 170 68.0
750 30 167 367 200 89.0
800 32 177 407 230 138.0
900 36 197 457 260 195.0
1000* 40 217 507 290 224.0
1000** 40 217 417 200 165.0
Elbows 22
1
/2
Filament-wound tees with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Laying Overall Insertion Weight
Length Length Length Length Depth
total total branch branch
run run
L1 OL1 L2 OL2 Ds
mm inch mm mm mm mm mm kg
50 2 148 248 74 124 50 1.3
80 3 192 292 96 146 50 2.9
100 4 230 330 115 165 50 4.0
150 6 306 406 153 203 50 8.7
200 8 376 536 188 268 80 17.5
250 10 452 612 226 306 80 25.0
300 12 528 688 264 344 80 44.0
350 14 544 704 272 352 80 47.0
400 16 590 810 295 405 110 56.0
450 18 678 898 339 449 110 67.0
500 20 740 1020 370 510 140 127.0
600 24 868 1208 434 604 170 138.0
700 28 994 1334 497 667 170 303.0
750 30 1046 1446 523 723 200 377.0
800 32 1118 1578 559 789 230 567.0
900 36 1248 1768 624 884 260 799.0
1000* 40 1382 1962 691 981 290 914.0
1000** 40 1382 1782 691 891 200 813.0
* For Bondstrand 2412 only
** For Bondstrand 3412 only
Tees
* For Bondstrand 2412 only
** For Bondstrand 3412 only
FP657-12 Fittings & Flanges for 2412/3412. Page 5 of 12.
Filament-wound 45 lateral with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Laying Overall Insertion Weight
Length Length Length Length Depth
L1 OL1 L2 OL2 Ds
mm inch mm mm mm mm mm kg
50 2 74 124 209 259 50 2.3
80 3 86 136 264 314 50 4.1
100 4 86 136 315 365 50 6.3
150 6 99 149 378 428 50 12.3
200 8 124 204 455 535 80 27.0
250 10 137 217 531 611 80 43.0
300 12 150 230 632 712 80 52.0
350 14 150 230 632 712 80 69.0
400 16 150 260 632 742 110 95.0
Lateral 45
Filament-wound cross with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Laying Overall Insertion Weight
Length Length Length Length Depth
run run branch branch
L1 OL1 L2 OL2 Ds
mm inch mm mm mm mm mm kg
50 2 148 248 74 124 50 1.9
80 3 192 292 96 146 50 3.3
100 4 230 330 115 165 50 5.7
150 6 306 406 153 203 50 13.2
200 8 376 536 188 268 80 21.0
250 10 452 612 226 306 80 37.0
300 12 528 688 264 344 80 58.0
350 14 544 704 272 352 80 68.0
400 16 590 810 295 405 110 105.0
Cross
FP657-12 Fittings & Flanges for 2412/3412. Page 6 of 12.
Filament-wound reducing tees with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Laying Overall Insertion Weight
Length Length Depth Length Length Depth
half half run branch branch branch
run x run x branch run run
L1 OL1 Ds1 L2 OL2 Ds2
mm inch mm mm mm mm mm mm kg
80x80x50 3x3x2 96 146 50 86 136 50 2.7
100x100x50 4x4x2 115 165 50 99 149 50 3.8
100x100x80 4x4x3 115 165 50 108 158 50 4.0
150x150x50 6x6x2 153 203 50 124 174 50 8.0
150x150x80 6x6x3 153 203 50 134 184 50 9.6
150x150x100 6x6x4 153 203 50 140 190 50 9.6
200x200x80 8x8x3 188 268 80 159 209 50 15.6
200x200x100 8x8x4 188 268 80 172 222 50 16.2
200x200x150 8x8x6 188 268 80 178 228 50 17.3
250x250x100 10x10x4 226 306 80 194 244 50 23.0
250x250x150 10x10x6 226 306 80 204 254 50 24.0
250x250x200 10x10x8 226 306 80 213 293 80 26.0
300x300x100 12x12x4 264 344 80 216 266 50 32.0
300x300x150 12x12x6 264 344 80 229 279 50 32.0
300x300x200 12x12x8 264 344 80 239 319 80 33.0
300x300x250 12x12x10 264 344 80 251 331 80 34.0
350x350x150 14x14x6 272 352 80 254 304 50 34.0
350x350x200 14x14x8 272 352 80 264 344 80 35.0
350x350x250 14x14x10 272 352 80 277 357 80 38.0
350x350x300 14x14x12 272 352 80 289 369 80 39.0
400x400x150 16x16x6 295 405 110 274 324 50 47.0
400x400x200 16x16x8 295 405 110 283 363 80 51.0
400x400x250 16x16x10 295 405 110 293 373 80 47.0
400x400x300 16x16x12 295 405 110 305 385 80 53.0
400x400x350 16x16x14 295 405 110 315 395 80 55.0
450x450x200 18x18x8 339 449 110 316 396 80 66.0
450x450x250 18x18x10 339 449 110 329 409 80 66.0
450x450x300 18x18x12 339 449 110 329 409 80 71.0
450x450x350 18x18x14 339 449 110 330 410 80 72.0
450x450x400 18x18x16 339 449 110 330 440 110 75.0
500x500x250 20x20x10 370 510 140 355 435 80 98.0
500x500x300 20x20x12 370 510 140 355 435 80 100.0
500x500x350 20x20x14 370 510 140 356 436 80 106.0
500x500x400 20x20x16 370 510 140 356 466 110 121.0
500x500x450 20x20x18 370 510 140 365 475 110 126.0
600x600x300 24x24x12 434 604 170 405 485 80 149.0
600x600x350 24x24x14 434 604 170 406 486 80 168.0
600x600x400 24x24x16 434 604 170 406 516 110 172.0
600x600x450 24x24x18 434 604 170 428 538 110 190.0
600x600x500 24x24x20 434 604 170 428 568 140 224.0
Reducing Tees
FP657-12 Fittings & Flanges for 2412/3412. Page 7 of 12.
Nominal Pipe Size Laying Overall Insertion Laying Overall Insertion Weight
Length Length Depth Length Length Depth
half half run branch branch branch
run x run x branch run run
L1 OL1 Ds1 L2 OL2 Ds2
mm inch mm mm mm mm mm mm kg
700x700x400 28x28x16 497 667 170 483 593 110 270
700x700x450 28x28x18 497 667 170 483 593 110 273
700x700x500 28x28x20 497 667 170 491 631 140 280
700x700x600 28x28x24 497 667 170 491 661 170 292
750x750x400 30x30x16 532 732 200 501 611 110 330
750x750x450 30x30x18 532 732 200 509 611 110 334
750x750x500 30x30x20 532 732 200 509 649 140 341
750x750x600 30x30x24 532 732 200 517 679 170 355
750x750x700 30x30x28 532 732 200 517 687 170 365
800x800x400 32x32x16 559 789 230 537 647 110 406
800x800x450 32x32x18 559 789 230 537 647 110 409
800x800x500 32x32x20 559 789 230 545 685 140 505
800x800x600 32x32x24 559 789 230 545 715 170 521
800x800x700 32x32x28 559 789 230 553 723 170 444
800x800x750 32x32x30 559 789 230 553 753 200 456
900x900x450 36x36x18 624 884 260 603 713 110 572
900x900x500 36x36x20 624 884 260 603 743 140 699
900x900x600 36x36x24 624 884 260 603 743 170 705
900x900x700 36x36x28 624 884 260 611 781 170 719
900x900x750 36x36x30 624 884 260 618 818 200 625
900x900x800 36x36x32 624 884 260 618 848 230 770
1000x1000x500 40x40x20* 691 981 290 669 809 140 956
1000x1000x600 40x40x24* 691 981 290 669 839 170 977
1000x1000x700 40x40x28* 691 981 290 677 847 170 826
1000x1000x750 40x40x30* 691 981 290 677 877 200 841
1000x1000x800 40x40x32* 691 981 290 685 915 230 1038
1000x1000x900 40x40x36* 691 981 290 685 945 260 1068
1000x1000x500 40x40x20** 691 891 200 669 809 140 875
1000x1000x600 40x40x24** 691 891 200 669 839 170 896
1000x1000x700 40x40x28** 691 891 200 677 847 170 758
1000x1000x750 40x40x30** 691 891 200 677 877 200 773
1000x1000x800 40x40x32** 691 891 200 685 915 230 956
1000x1000x900 40x40x36** 691 891 200 685 945 260 987
* For Bondstrand 2412 only
** For Bondstrand 3412 only
Reducing Tees (cont.)
FP657-12 Fittings & Flanges for 2412/3412. Page 8 of 12.
Concentric Reducers
* For Bondstrand 2412 only
** For Bondstrand 3412 only
Filament-wound concentric reducers with integral Taper-Taper adhesive bonded
socket ends
Nominal Pipe Size Laying Overall Overall Insertion Weight
Length Length Length Depth
L OL Ds1 Ds2
mm inch mm mm mm mm kg
80x50 3x2 74 174 50 50 0.8
100x50 4x2 96 196 50 50 1.1
100x80 4x3 94 194 50 50 1.3
150x80 6x3 117 217 50 50 1.5
150x100 6x4 124 224 80 50 1.8
200x100 8x4 163 293 80 50 3.3
200x150 8x6 129 259 80 80 3.7
250x150 10x6 148 278 80 80 6.2
250x200 10x8 135 295 80 80 6.2
300x200 12x8 180 340 80 80 7.8
300x250 12x10 167 327 80 80 8.5
350x250 14x10 214 374 80 80 10.2
350x300 14x12 208 368 80 80 11.0
400x300 16x12 195 385 110 80 13.7
400x350 16x14 183 373 110 80 12.8
450x400 18x16 128 348 110 110 20.0
500x400 20x16 249 499 140 110 29.0
500x450 20x18 151 401 140 110 28.0
600x400 24x16 486 766 170 110 57.0
600x450 24x18 388 668 170 110 49.0
600x500 24x20 267 577 170 140 43.0
700x400 28x16 796 1076 170 110 83.0
700x450 28x18 698 978 170 110 81.0
700x500 28x20 577 887 170 140 82.0
700x600 28x24 340 680 170 170 80.0
750x400 30x16 915 1225 200 110 105.0
750x450 30x18 817 1127 200 110 103.0
750x500 30x20 696 1036 200 140 104.0
750x600 30x24 459 829 200 170 102.0
750x700 30x28 149 519 200 170 91.0
800x400 32x16 1038 1378 230 110 131.0
800x450 32x18 940 1280 230 110 129.0
800x500 32x20 819 1189 230 140 157.0
800x600 32x24 582 982 230 170 155.0
800x700 32x28 272 672 230 170 116.0
800x750 32x30 153 583 230 200 118.0
900x450 36x18 1186 1556 260 110 184.0
900x500 36x20 1065 1465 260 140 223.0
900x600 36x24 828 1258 260 170 220.0
900x700 36x28 518 948 260 170 175.0
900x750 36x30 399 859 260 200 172.0
900x800 36x32 276 766 260 230 209.0
1000x500* 40x20 1313 1743 290 140 310.0
1000x600 40x24 1076 1536 290 170 307.0
1000x700 40x28 766 1226 290 170 240.0
1000x750 40x30 647 1137 290 200 242.0
1000x800 40x32 524 1044 290 230 294.0
1000x900 40x36 278 828 290 260 288.0
1000x500** 40x20 1313 1653 200 140 269.0
1000x600 40x24 1076 1446 200 170 266.0
1000x700 40x28 766 1136 200 170 206.0
1000x750 40x30 647 1047 200 200 208.0
1000x800 40x32 524 954 200 230 253.0
1000x900 40x36 278 738 200 260 247.0
Note: Eccentric Reducers are available on request
FP657-12 Fittings & Flanges for 2412/3412. Page 9 of 12.
Filament-wound couplings with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Outside Weight
Length Length Depth Diameter
L OL Ds OD
mm inch mm mm mm mm kg
50 2 70 170 50 70 0.4
80 3 70 170 50 100 0.7
100 4 70 170 50 124 0.9
150 6 70 170 50 180 1.5
200 8 70 230 80 230 2.5
250 10 70 230 80 286 3.4
300 12 70 230 80 339 4.5
350 14 70 230 80 370 4.8
400 16 70 290 110 419 6.4
450 18 70 290 110 460 7.3
500 20 70 350 140 524 16.7
600 24 70 410 170 619 21.0
700 28 70 410 170 734 18.3
750 30 70 470 200 783 20.0
800 32 70 530 230 840 32.0
900 36 70 590 260 937 34.0
1000* 40 70 650 290 1044 38.0
1000** 40 70 470 200 1036 30.0
Couplings
Filament-wound pipe nipples with integral Taper-Taper adhesive bonded spigot ends
Nominal Pipe Size Laying gap Insertion Weight
Length Depth
L Ds
mm inch mm mm mm kg
50 2 125 25 50 0.1
80 3 125 25 50 0.1
100 4 125 25 50 0.1
150 6 125 25 50 0.2
200 8 190 30 80 0.6
250 10 190 30 80 0.8
300 12 200 40 80 1.1
350 14 200 40 80 1.4
400 16 260 40 110 2.4
450 18 280 60 110 3.0
500 20 340 60 140 4.9
600 24 400 60 170 8.3
700 28 400 60 170 11.2
750 30 460 60 200 14.6
800 32 520 60 230 18.6
900 36 580 60 260 25.0
1000* 40 640 60 290 27.0
1000** 40 460 60 200 21.0
* For Bondstrand 2412 only
** For Bondstrand 3412 only
Nipples
* For Bondstrand 2412 only
** For Bondstrand 3412 only
FP657-12 Fittings & Flanges for 2412/3412. Page 10 of 12.
Heavy-Duty filament-wound flanges with Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overal Insertion Weight
Length Length Depth
L D Ds (1) (2)
mm inch mm mm mm kg
50 2 5 55 50 1.5
80 3 5 55 50 2.2
100 4 5 55 50 2.9
150 6 5 55 50 3.7
200 8 6 56 50 5.5
250 10 6 86 80 10.6
300 12 6 86 80 15.3
350 14 6 86 80 18.7
400 16 6 116 110 30.0
450 18 6 116 110 32.0
500 20 6 116 110 38.0
600 24 6 146 140 61.0
700 28 6 176 170 81.0
Notes:
(1) Underlined insertion depth for subsequent flanges deviates from other fittings.
(2) The weights shown are for ANSI B16.5 Class 150 drilled flanges. Weights for other
drilling classes may be different. For more detailed information reference is made to
the appropriate product data.
* Heavy Duty Flanges are standard available in drillings according to ANSI and ISO (DIN).
** Full-face elastomeric gaskets may be used, suitable for the service pressure, service
temperature and fluid. Shore A durometer hardness of 60 5 is recommended and a
thickness of 3 mm.
Compressed fibre gaskets, 3 mm thick, compatible with the pressure, temperature
and medium, may also be used. The mechanical properties should be in accordance
with DIN 3754 (IT 400) or equal.
*** For maximum bolt torque refer to the appropriate Bondstrand literature. Please be
aware that excessive torque may result in flange failure and therefore a torque-
wrench is required.
Heavy-Duty Flanges
FP657-12 Fittings & Flanges for 2412/3412. Page 11 of 12.
Filament-wound Stub-end flanges with Taper-Taper adhesive bonded socket ends
and steel backing rings
Nominal Pipe Size Laying Overall Insertion Ring Weigth Weight
Length Length Depth to GRE steel
Face stub- ring
L OL Ds H end (1)
mm inch mm mm mm mm kg kg
50 2 15 65 50 10 0.2 1.8
80 3 15 65 50 10 0.5 3.2
100 4 15 65 50 12 0.8 4.2
150 6 15 65 50 13 1.3 5.2
200 8 15 95 80 20 2.6 8.5
250 10 15 95 80 16 3.1 13.5
300 12 15 95 80 18 3.9 23.0
350 14 15 95 80 19 3.8 32.0
400 16 20 130 110 21 6.9 42.0
450 18 20 130 110 24 11.4 40.0
500 20 20 160 140 29 15 51.0
600 24 20 190 170 35 18 86.0
700 28 20 190 170 33 21 100.0
750 30 20 220 200 36 26 117.0
800 32 20 250 230 38 30 154.0
900 36 20 280 260 42 37 197.0
1000* 40 20 310 290 46 41 303.0
1000** 40 20 220 200 46 35 303.0
* For Bondstrand 2412 only
** For Bondstrand 3412 only
Notes:
(1) The weight shown is for ANSI B16.5 Class 150 drilled flanges. Weights for other
drilling classes may be different. For more detailed information reference is made to
the appropriate product data.
* Stub-End Flange Rings are standard available in drillings according to ANSI and ISO
(DIN).
** Stub-End Flanges are available with and without O-ring groove in the face.
Up to 10 bar stub-ends without grooves can be used with flat elastomeric or
compressed fibre gaskets.
For pressures 12 bar and above suitable O-ring seals should be used, available on
request.
*** Make sure that the O-ring grooved stub-end is compatible with its counter flange,
e.g. use a stub-end without groove or another flat surface flange as counter flange.
**** Maximum bolt-torque for use with O-rings seals may be calculated based on
pressure, size and number of bolts. If using flat face gaskets (maximum pressure 10
bar) refer to the appropriate Bondstrand literature for hubbed flanges.
Stub-end Flanges
Filament around adapters and couplings with Key-lock ends.
Nominal Pipe Qty Laying Overall Insertion Weigth Laying Overall Weigth
Size of Length Length Depth Length Length
Keys L OL Ds L OL
mm inch mm mm mm kg mm mm kg
adapter KLM x TBF coupling KLF x KLF
50 2 1 5 100 50 0.3 100 140 0.8
80 3 1 5 100 50 0.5 100 140 1.0
100 4 1 5 100 50 0.7 100 140 2.2
150 6 1 4 110 50 1.0 127 181 4.3
200 8 1 2 150 80 1.9 152 225 6.3
250 10 1 3 155 80 2.7 163 242 9.6
300 12 1 5 170 80 4.0 186 278 1.6
350 14 1 13 180 80 6.4 191 289 15.8
400 16 1 15 215 110 8.2 197 302 21.0
450 18 1 16 220 110 11.5 204 296 17.8
500 20 1 33 270 140 15.3 210 308 22.0
600 24 2 76 340 170 22.0 200 375 29.0
750 30 2 118 445 200 47.0 279 558 75.0
900 36 2 147 575 260 73.0 356 737 155.0
Key-lock Adapters
& Couplings
Pipe system is designed for field testing with water at 150% of rated pressure.
Maximum allowable surge pressure is 150% of rated pressure.
Field Testing
Surge Pressure
1 psi = 6895 Pa = 0.07031 kg/cm
2
1 bar = 105Pa = 14.5 psi = 1.02 kg/cm
2
1 MPa = 1 N/mm
2
= 145 psi = 10.2 kg/cm
2
1 inch = 25.4 mm
1 Btu.in/ft2hF = 0.1442 W/mK
C = 5/9 (F-32)
This product literature and the recommendations for usage it contains are based on test data
reasonably believed to be reliable. It is intended that this literature be used by personnel
having specialised training in accordance with currently accepted industry practice and
normal operating conditions. Variation in environment, changes in operating procedures, or
extrapolation of data may cause unsatisfactory results. We recommend that your engineers
verify the suitability of this product for your intended application. Since we have no control
over the conditions of service, we expressly disclaim responsibility for the results obtained
or for any consequential or incidental damages of any kind incurred.
Conversions
Important Notice
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.n
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet:www.ameron.com
email:marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Fittings & Flanges for
pipe series 2414 and 3414
using the Taper/Taper adhesive-bonded joint
Bondstrand

Product Data
Bondstrand Taper-Taper fittings & flanges are glassfiber reinforced filament-wound epoxy
pipe fittings in diameters 50 through 1000 mm (2-40 inch) designed to be used with
Bondstrand pipes. Pipe is standard with integral Taper-Taper spigot and socket ends for
adhesive bonding or with integral Key-Lock male and female ends for mechanical joining.
Fittings are filament-wound with integral taper socket ends. Pipes and fittings are
available in several pressure classes from 10 bar upwards.
For intended services and performance capabilities refer to product data sheet FP 452 and
FP 158 pertaining to Bondstrand Series 2400 and 3400 pipe data.
For recommendations pertaining to design, installation and use of Bondstrand Pipe,
Fittings and Flanges reference is made to the following literature:
FP 564 Assembly Instructions for Taper-Taper adhesive bonded joints.
FP 161 Installation Instructions using the Key-Lock mechanical joint.
FP 453 M86 Pipe Shaver operating instructions for Taper-Taper joints in sizes
50 to 150 mm (2-6 inch).
FP 454 M87 Pipe Shaver operating instructions for Taper-Taper joints in sizes
150 to 400 mm (6-16 inch).
FP 455 M87XL Pipe Shaver operating instructions for Taper-Taper joints in
sizes 400 to 600 mm (16-24 inch).
FP 643 M95 Pipe Shaver operating instructions for Taper-Taper joints in sizes
600 to 1000 mm (24-40 inch).
FP 196 Flange Assembly Instructions.
FP 132 Corrosion Guide.
General Bondstrand engineering and installation guides.
Dimensional data for Taper-Taper adhesive bonded fittings are contained in individual
dimensional sheets per pressure class:
FP No. Fitting Pipe System Pressure
549-10 T-10 2410 and 3410 10 bar
549-12 T-12 2412 and 3412 12 bar
549-14 T-14 2414 and 3414 14 bar
549-16 T-16 2416 and 3416 16 bar
549-20 T-20 2420 and 3420 20 bar
549-25 T-25 2425 and 3425 25 bar
549-32 T-32 2432 and 3432 32 bar
549-40 T-40 2440 and 3440 40 bar
549-50 T-50 2450 and 3450 50 bar
Ameron 1998 FP657-14 (5/98). Printed in The Netherlands. Page 1 of 12.
Description
Uses and Application
Design and Installation
How to use this product
data sheet
FP657-14 Fittings & Flanges for 2414/3414. Page 2 of 12.
Nominal Pipe Size Taper Insertion Spigot Spigot
Angle Depth Nose Diameter
Thickness at Nose
Ds t
mm inch degrees mm mm mm
50 2 1.75 50 1.0 55.2
80 3 1.75 50 1.0 83.8
100 4 1.75 50 1.0 107.2
150 6 2.50 50 1.0 161.0
200 8 2.50 80 1.0 210.8
250 10 2.50 110 1.0 264.9
300 12 2.50 140 1.0 315.7
350 14 2.50 140 1.5 347.4
400 16 2.50 170 1.5 396.7
450 18 2.50 170 1.5 436.8
500 20 2.50 140 2.0 486.1
600 24 2.50 170 2.0 582.6
700 28 1.75 230 4.0 708.0
750 30 1.75 260 4.0 758.0
800 32 1.75 230 5.5 811.0
900 36 1.75 260 6.0 912.0
Dimensions of the
taper-taper joint
Nominal Adhesive Minimum number of
Pipe Size Kit Size adhesive kits per joint
fluid
mm inch cm
3
ounce nr.
50 2 89 3 0.2
80 3 89 3 0.2
100 4 89 3 0.4
150 6 89 3 0.4
200 8 89 3 1.0
250 10 177 6 1.0
300 12 177 6 2.0
350 14 177 6 2.0
400 16 177 6 3.0
450 18 177 6 3.0
500 20 177 6 3.0
600 24 177 6 3.0
700 28 177 6 6.0
750 30 177 6 7.0
800* 32 177 6 6.0
900** 36 177 6 8.0
Note:
Adhesive kits should never be split. If remainder is not used for other joints made at the
same time, the surplus must be discarded.
Quantity of Adhesive
FP657-14 Fittings & Flanges for 2414/3414 . Page 3 of 12.
Filament-wound 90 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 87 137 50 0.6
80 3 126 176 50 1.1
100 4 155 205 50 2.1
150 6 240 290 50 4.2
200 8 315 395 80 12.0
250 10 391 501 110 16.1
300 12 463 603 140 26.0
350 14 364 504 140 37.0
400 16 402 572 170 53.0
450 18 472 642 170 76.0
500 20 523 663 140 101.0
600 24 625 795 170 155.0
700 28 726 956 230 238.0
750 30 777 1037 260 290.0
800 32 828 1058 230 290.0
900 36 929 1189 260 402.0
Elbows 90
Filament-wound 45 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 45 95 50 0.5
80 3 61 111 50 0.9
100 4 73 123 50 1.3
150 6 106 156 50 2.5
200 8 137 217 80 7.4
250 10 169 279 110 12.4
300 12 196 336 140 22.0
350 14 125 265 140 29.0
400 16 142 312 170 41.0
450 18 204 374 170 54.0
500 20 225 365 140 67.0
600 24 268 438 170 91.0
700 28 310 540 230 177.0
750 30 331 591 260 226.0
800 32 352 582 230 200.0
900 36 394 654 260 275.0
Elbows 45
FP657-14 Fittings & Flanges for 2414/3414. Page 4 of 12.
Filament-wound 22
1
/2 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 29 79 50 0.4
80 3 37 87 50 0.6
100 4 43 93 50 0.9
150 6 60 110 50 1.4
200 8 76 156 80 5.1
250 10 68 178 110 9.7
300 12 77 217 140 15.5
350 14 71 211 140 21.0
400 16 85 255 170 24.0
450 18 106 276 170 39.0
500 20 116 256 140 32.0
600 24 136 306 170 73.0
700 28 157 387 230 123.0
750 30 167 427 260 158.0
800 32 177 407 230 138.0
900 36 197 457 260 195.0
Elbows 22
1
/2
Filament-wound tees with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Laying Overall Insertion Weight
Length Length Length Length Depth
total total branch branch
run run
L1 OL1 L2 OL2 Ds
mm inch mm mm mm mm mm kg
50 2 148 248 74 124 50 1.3
80 3 192 292 96 146 50 2.9
100 4 230 330 115 165 50 4.0
150 6 306 406 153 203 50 8.7
200 8 376 536 188 268 80 21.0
250 10 452 672 226 336 110 31.0
300 12 528 808 264 404 140 50.0
350 14 544 824 272 412 140 55.0
400 16 590 930 295 465 170 87.0
450 18 678 1018 339 509 170 103.0
500 20 740 1020 370 510 140 127.0
600 24 868 1208 434 604 170 138.0
700 28 994 1454 497 727 230 476.0
750 30 1046 1566 523 783 260 591.0
800 32 1118 1578 559 789 230 567.0
900 36 1248 1768 624 884 260 799.0
Tees
FP657-14 Fittings & Flanges for 2414/3414 . Page 5 of 12.
Filament-wound reducing tees with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Laying Overall Insertion Weight
Length Length Depth Length Length Depth
half half run branch branch branch
run x run x branch run run
L1 OL1 Ds1 L2 OL2 Ds2
mm inch mm mm mm mm mm mm kg
80x80x50 3x3x2 96 146 50 86 136 50 2.7
100x100x50 4x4x2 115 165 50 99 149 50 3.8
100x100x80 4x4x3 115 165 50 108 158 50 4.0
150x150x50 6x6x2 153 203 50 124 174 50 8.0
150x150x80 6x6x3 153 203 50 134 184 50 9.6
150x150x100 6x6x4 153 203 50 140 190 50 9.6
200x200x80 8x8x3 188 268 80 159 209 50 16.0
200x200x100 8x8x4 188 268 80 172 222 50 16.7
200x200x150 8x8x6 188 268 80 178 228 50 13.2
250x250x100 10x10x4 226 366 110 194 244 50 29.0
250x250x150 10x10x6 226 336 110 204 254 50 28.0
250x250x200 10x10x8 226 336 110 213 293 80 34.0
300x300x100 12x12x4 264 404 140 216 266 50 43.0
300x300x150 12x12x6 264 404 140 229 279 50 42.0
300x300x200 12x12x8 264 404 140 239 319 80 45.0
300x300x250 12x12x10 264 404 140 251 361 110 51.0
350x350x150 14x14x6 272 412 140 254 304 50 41.0
350x350x200 14x14x8 272 412 140 264 344 80 54.0
350x350x250 14x14x10 272 412 140 277 387 110 62.0
350x350x300 14x14x12 272 412 140 289 429 140 66.0
400x400x150 16x16x6 295 465 170 274 324 50 51.0
400x400x200 16x16x8 295 465 170 283 363 80 56.0
400x400x250 16x16x10 295 465 170 293 403 110 63.0
400x400x300 16x16x12 295 465 170 305 445 140 67.0
400x400x350 16x16x14 295 465 170 315 455 140 71.0
450x450x200 18x18x8 339 509 170 316 396 80 100.0
450x450x250 18x18x10 339 509 170 329 439 110 104.0
450x450x300 18x18x12 339 509 170 329 469 140 107.0
450x450x350 18x18x14 339 509 170 330 470 140 137.0
450x450x400 18x18x16 339 509 170 330 500 170 143.0
500x500x250 20x20x10 370 510 140 355 465 110 100.0
500x500x300 20x20x12 370 510 140 355 495 140 102.0
500x500x350 20x20x14 370 510 140 356 496 140 120.0
500x500x400 20x20x16 370 510 140 356 526 170 127.0
500x500x450 20x20x18 370 510 140 365 535 170 128.0
600x600x300 24x24x12 434 604 170 405 545 140 160.0
600x600x350 24x24x14 434 604 170 406 546 140 180.0
600x600x400 24x24x16 434 604 170 406 576 170 181.0
600x600x450 24x24x18 434 604 170 428 598 170 190.0
600x600x500 24x24x20 434 604 170 428 568 140 224.0
Reducing Tees
FP657-14 Fittings & Flanges for 2414/3414. Page 6 of 12.
Nominal Pipe Size Laying Overall Insertion Laying Overall Insertion Weight
Length Length Depth Length Length Depth
half half run branch branch branch
run x run x branch run run
L1 OL1 Ds1 L2 OL2 Ds2
mm inch mm mm mm mm mm mm kg
700x700x400 28x28x16 497 727 230 483 653 170 423
700x700x450 28x28x18 497 727 230 483 653 170 428
700x700x500 28x28x20 497 727 230 491 631 140 364
700x700x600 28x28x24 497 727 230 491 661 170 377
750x750x400 30x30x16 523 783 260 501 671 170 516
750x750x450 30x30x18 523 783 260 509 679 170 522
750x750x500 30x30x20 523 783 260 509 649 140 444
750x750x600 30x30x24 523 783 260 517 687 170 460
750x750x700 30x30x28 523 783 260 517 747 230 573
800x800x400 32x32x16 559 789 230 537 707 170 500
800x800x450 32x32x18 559 789 230 537 707 170 504
800x800x500 32x32x20 559 789 230 545 685 140 505
800x800x600 32x32x24 559 789 230 545 715 170 521
800x800x700 32x32x28 559 789 230 553 783 230 552
800x800x750 32x32x30 559 789 230 553 813 260 567
900x900x450 36x36x18 624 884 260 603 773 170 699
900x900x500 36x36x20 624 884 260 603 743 140 699
900x900x600 36x36x24 624 884 260 611 781 170 719
900x900x700 36x36x28 624 884 260 611 841 230 753
900x900x750 36x36x30 624 884 260 618 878 260 771
900x900x800 36x36x32 624 884 260 618 848 230 770
Reducing Tees (cont.)
FP657-14 Fittings & Flanges for 2414/3414 . Page 7 of 12.
Filament-wound concentric reducers with integral Taper-Taper adhesive bonded
socket ends
Nominal Pipe Size Laying Overall Overall Insertion Weight
Length Length Length Depth
L OL Ds1 Ds2
mm inch mm mm mm mm kg
80x50 3x2 74 174 50 50 0.8
100x50 4x2 96 196 50 50 1.1
100x80 4x3 94 194 50 50 1.3
150x80 6x3 117 217 50 50 1.8
150x100 6x4 124 224 50 50 1.8
200x100 8x4 163 293 80 50 4.3
200x150 8x6 129 259 80 50 4.3
250x150 10x6 148 308 110 50 6.2
250x200 10x8 135 325 110 80 6.9
300x200 12x8 180 400 140 80 9.9
300x250 12x10 167 417 140 110 10.8
350x250 14x10 214 464 140 110 17.0
350x300 14x12 208 488 140 140 16.8
400x300 16x12 195 505 170 140 22.0
400x350 16x14 183 493 170 140 23.0
450x400 18x16 128 468 170 170 27.0
500x400 20x16 249 559 140 170 34.0
500x450 20x18 151 461 140 170 33.0
600x400 24x16 486 826 170 170 52.0
600x450 24x18 388 728 170 170 50.0
600x500 24x20 267 577 170 140 43.0
700x400 28x16 796 1196 230 170 142.0
700x450 28x18 698 1098 230 170 140.0
700x500 28x20 577 947 230 140 111.0
700x600 28x24 340 740 230 170 109.0
750x400 30x16 915 1345 260 170 177.0
750x450 30x18 817 1247 260 170 175.0
750x500 30x20 696 1096 260 140 141.0
750x600 30x24 459 889 260 170 139.0
750x700 30x28 149 639 260 230 165.0
800x400 32x16 1038 1438 230 170 167.0
800x450 32x18 940 1340 230 170 165.0
800x500 32x20 819 1189 230 140 157.0
800x600 32x24 582 982 230 170 155.0
800x700 32x28 272 732 230 230 156.0
800x750 32x30 153 643 230 260 159.0
900x450 36x18 1186 1616 260 170 232.0
900x500 36x20 1065 1465 260 170 223.0
900x600 36x24 828 1258 260 170 220.0
900x700 36x28 518 1008 260 230 222.0
900x750 36x30 399 919 260 260 225.0
900x800 36x32 276 766 260 230 209.0
Note: Eccentric Reducers are available on request
Concentric Reducers
FP657-14 Fittings & Flanges for 2414/3414. Page 8 of 12.
Filament-wound couplings with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Outside Weight
Length Length Depth Diameter
L OL Ds OD
mm inch mm mm mm mm kg
50 2 70 170 50 70 0.4
80 3 70 170 50 100 0.7
100 4 70 170 50 124 0.9
150 6 70 170 50 180 1.5
200 8 70 230 80 230 2.5
250 10 70 290 110 286 4.0
300 12 70 350 140 339 9.8
350 14 70 350 140 370 10.5
400 16 70 410 170 419 13.2
450 18 70 410 170 460 9.0
500 20 70 350 140 524 16.7
600 24 70 410 170 619 21.0
700 28 70 530 230 745 34.0
750 30 70 590 260 795 39.0
800 32 70 530 230 840 29.0
900 36 70 590 260 945 41.0
Couplings
Filament-wound pipe nipples with integral Taper-Taper adhesive bonded spigot ends
Nominal Pipe Size Laying gap Insertion Weight
Length Depth
L Ds
mm inch mm mm mm kg
50 2 125 25 50 0.1
80 3 125 25 50 0.1
100 4 125 25 50 0.1
150 6 125 25 50 0.3
200 8 190 30 80 0.6
250 10 250 30 110 1.3
300 12 320 40 140 2.3
350 14 320 40 140 2.8
400 16 380 40 170 4.3
450 18 400 60 170 5.2
500 20 340 60 140 5.2
600 24 400 60 170 8.3
700 28 520 60 230 16.5
750 30 580 60 260 21.0
800 32 520 60 230 22.0
900 36 580 60 260 31.0
Nipples
FP657-14 Fittings & Flanges for 2414/3414 . Page 9 of 12.
Heavy-Duty filament-wound flanges with Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overal Insertion Weight
Length Length Depth
L D Ds (1) (2)
mm inch mm mm mm kg
50 2 5 55 50 1.5
80 3 5 55 50 2.2
100 4 5 55 50 2.9
150 6 5 55 50 3.7
200 8 6 86 80 8.4
250 10 6 86 80 10.6
300 12 6 116 110 21.0
350 14 6 116 110 25.0
400 16 6 116 110 30.0
450 18 6 146 140 41.0
500 20 6 146 140 48.0
600 24 6 176 170 74.0
Notes:
(1) Underlined insertion depth for subsequent flanges deviates from other fittings.
(2) The weights shown are for ANSI B16.5 Class 150 drilled flanges. Weights for other
drilling classes may be different. For more detailed information reference is made to
the appropriate product data.
* Heavy Duty Flanges are standard available in drillings according to ANSI and ISO (DIN).
** Full-face elastomeric gaskets may be used, suitable for the service pressure, service
temperature and fluid. Shore A durometer hardness of 60 5 is recommended and a
thickness of 3 mm.
Compressed fibre gaskets, 3 mm thick, compatible with the pressure, temperature
and medium, may also be used. The mechanical properties should be in accordance
with DIN 3754 (IT 400) or equal.
*** For maximum bolt torque refer to the appropriate Bondstrand literature. Please be
aware that excessive torque may result in flange failure and, therefore a torque-
wrench is required.
Heavy-Duty Flanges
FP657-14 Fittings & Flanges for 2414/3414. Page 10 of 12.
Filament-wound Stub-end flanges with Taper-Taper adhesive bonded socket ends
and steel backing rings
Nominal Pipe Size Laying Overall Insertion Ring Weigth Weight
Length Length Depth to GRE steel
Face stub- ring
L OL Ds H end (1)
mm inch mm mm mm mm kg kg
50 2 15 65 50 10 0.2 1.8
80 3 15 65 50 10 0.5 3.2
100 4 15 65 50 12 0.8 4.2
150 6 15 65 50 13 1.3 5.2
200 8 15 95 80 20 2.6 8.5
250 10 15 125 110 23 4 13.5
300 12 15 155 140 26 5.9 23.0
350 14 15 155 140 27 5.8 32.0
400 16 20 190 170 32 9.6 42.0
450 18 20 190 170 35 16.1 40.0
500 20 20 160 140 29 15 51.0
600 24 20 190 170 35 18 86.0
700 28 20 250 230 38 26 100.0
750 30 20 280 260 41 31 117.0
800 32 20 250 230 48 29 154.0
900 36 20 280 260 53 36 197.0
Notes:
(1) The weight shown is for ANSI B16.5 Class 150 drilled flanges. Weights for other
drilling classes may be different. For more detailed information reference is made to
the appropriate product data.
* Stub-End Flange Rings are standard available in drillings according to ANSI and ISO
(DIN).
** Stub-End Flanges are available with and without O-ring groove in the face.
Up to 10 bar stub-ends without grooves can be used with flat elastomeric or
compressed fibre gaskets.
For pressures 12 bar and above suitable O-ring seals should be used, available on
request.
*** Make sure that the O-ring grooved stub-end is compatible with its counter flange,
e.g. use a stub-end without groove or another flat surface flange as counter flange.
**** Maximum bolt-torque for use with O-rings seals may be calculated based on
pressure, size and number of bolts. If using flat face gaskets (maximum pressure 10
bar) refer to the appropriate Bondstrand literature for hubbed flanges.
Stub-end Flanges
FP657-14 Fittings & Flanges for 2414/3414 . Page 11 of 12.
Filament around adapters and couplings with Key-lock ends.
Nominal Pipe Qty Laying Overall Insertion Weigth Laying Overall Weigth
Size of Length Length Depth Length Length
Keys L OL Ds L OL
mm inch mm mm mm kg mm mm kg
adapter KLM x TBF coupling KLF x KLF
50 2 1 5 100 50 0.3 100 140 0.8
80 3 1 5 100 50 0.5 100 140 1.0
100 4 1 5 100 50 0.7 100 140 2.2
150 6 1 4 110 50 1.0 127 181 4.3
200 8 1 2 150 80 1.9 152 225 6.3
250 10 1 3 185 110 3.1 163 242 9.6
300 12 1 5 230 140 5.2 186 278 11.4
350 14 1 18 245 140 8.4 191 289 15.8
400 16 1 15 275 170 10.0 197 302 20.0
450 18 2 61 325 170 16.5 204 392 27.0
500 20 2 83 320 140 18.3 210 409 32.0
600 24 2 76 340 170 22.0 200 375 29.0
750 30 2 118 505 260 52.0 279 558 75.0
Key-lock Adapters
& Couplings
Pipe system is designed for field testing with water at 150% of rated pressure.
Maximum allowable surge pressure is 150% of rated pressure.
Field Testing
Surge Pressure
1 psi = 6895 Pa = 0.07031 kg/cm
2
1 bar = 105Pa = 14.5 psi = 1.02 kg/cm
2
1 MPa = 1 N/mm
2
= 145 psi = 10.2 kg/cm
2
1 inch = 25.4 mm
1 Btu.in/ft2hF = 0.1442 W/mK
C = 5/9 (F-32)
This product literature and the recommendations for usage it contains are based on test data
reasonably believed to be reliable. It is intended that this literature be used by personnel
having specialised training in accordance with currently accepted industry practice and
normal operating conditions. Variation in environment, changes in operating procedures, or
extrapolation of data may cause unsatisfactory results. We recommend that your engineers
verify the suitability of this product for your intended application. Since we have no control
over the conditions of service, we expressly disclaim responsibility for the results obtained
or for any consequential or incidental damages of any kind incurred.
Conversions
Important Notice
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.n
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet:www.ameron.com
email:marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Fittings & Flanges for
pipe series 2416 and 3416
using the Taper/Taper adhesive-bonded joint
Bondstrand

Product Data
Bondstrand Taper-Taper fittings & flanges are glassfiber reinforced filament-wound epoxy
pipe fittings in diameters 50 through 1000 mm (2-40 inch) designed to be used with
Bondstrand pipes. Pipe is standard with integral Taper-Taper spigot and socket ends for
adhesive bonding or with integral Key-Lock male and female ends for mechanical joining.
Fittings are filament-wound with integral taper socket ends. Pipes and fittings are
available in several pressure classes from 10 bar upwards.
For intended services and performance capabilities refer to product data sheet FP 452 and
FP 158 pertaining to Bondstrand Series 2400 and 3400 pipe data.
For recommendations pertaining to design, installation and use of Bondstrand Pipe,
Fittings and Flanges reference is made to the following literature:
FP 564 Assembly Instructions for Taper-Taper adhesive bonded joints.
FP 161 Installation Instructions using the Key-Lock mechanical joint.
FP 453 M86 Pipe Shaver operating instructions for Taper-Taper joints in sizes
50 to 150 mm (2-6 inch).
FP 454 M87 Pipe Shaver operating instructions for Taper-Taper joints in sizes
150 to 400 mm (6-16 inch).
FP 455 M87XL Pipe Shaver operating instructions for Taper-Taper joints in
sizes 400 to 600 mm (16-24 inch).
FP 204 M95 Pipe Shaver operating instructions for Taper-Taper joints in sizes
600 to 1000 mm (24-40 inch).
FP 196 Flange Assembly Instructions.
FP 132 Corrosion Guide.
General Bondstrand engineering and installation guides.
Dimensional data for Taper-Taper adhesive bonded fittings are contained in individual
dimensional sheets per pressure class:
FP No. Fitting Pipe System Pressure
549-10 T-10 2410 and 3410 10 bar
549-12 T-12 2412 and 3412 12 bar
549-14 T-14 2414 and 3414 14 bar
549-16 T-16 2416 and 3416 16 bar
549-20 T-20 2420 and 3420 20 bar
549-25 T-25 2425 and 3425 25 bar
549-32 T-32 2432 and 3432 32 bar
549-40 T-40 2440 and 3440 40 bar
549-50 T-50 2450 and 3450 50 bar
Ameron 1998 FP657-16 (8/98). Printed in The Netherlands. Page 1 of 12.
Description
Uses and Application
Design and Installation
How to use this product
data sheet
FP657-16 (8/98). Fittings & Flanges for 2416/3416. Page 2 of 12.
Nominal Pipe Size Taper Insertion Spigot Spigot
Angle Depth Nose Diameter
Thickness at Nose
Ds t
mm inch degrees mm mm mm
50 2 1.75 50 1.0 55.2
80 3 1.75 50 1.0 83.8
100 4 1.75 50 1.0 107.2
150 6 2.50 50 1.0 161.0
200 8 2.50 80 1.0 210.8
250 10 2.50 110 1.0 264.9
300 12 2.50 140 1.0 315.7
350 14 2.50 140 1.5 347.4
400 16 2.50 170 1.5 396.7
450 18 2.50 170 1.5 436.8
500 20 2.50 200 2.0 486.1
600 24 2.50 230 2.5 583.6
700 28 1.75 230 5.5 711.0
750 30 1.75 260 6.0 762.0
800 32 1.75 290 5.5 811.0
900* 36 1.75 350 6.0 912.0
900** 36 1.75 260 6.0 912.0
* For Bondstrand 2416 only
** For Bondstrand 3416 only
Dimensions of the
taper-taper joint
Nominal Adhesive Minimum number of
Pipe Size Kit Size adhesive kits per joint
fluid
mm inch cm
3
ounce nr.
50 2 89 3 0.2
80 3 89 3 0.2
100 4 89 3 0.4
150 6 89 3 0.4
200 8 89 3 1.0
250 10 177 6 1.0
300 12 177 6 2.0
350 14 177 6 2.0
400 16 177 6 3.0
450 18 177 6 3.0
500 20 177 6 3.0
600 24 177 6 4.0
700 28 177 6 6.0
750 30 177 6 7.0
800 32 177 6 8.0
900* 36 177 6 10.0
900** 36 177 6 8.0
* For Bondstrand 2416 only
** For Bondstrand 3416 only
Note:
Adhesive kits should never be split. If remainder is not used for other joints made at the
same time, the surplus must be discarded.
Quantity of Adhesive
FP657-16 (8/98). Fittings & Flanges for 2416/3416. Page 3 of 12.
Filament-wound 90 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 87 137 50 0.6
80 3 126 176 50 1.1
100 4 155 205 50 2.1
150 6 240 290 50 4.2
200 8 315 395 80 12.0
250 10 391 501 110 16.1
300 12 463 603 140 26.0
350 14 364 504 140 37.0
400 16 402 572 170 53.0
450 18 472 642 170 76.0
500 20 523 723 200 125.0
600 24 625 855 230 228.0
700 28 726 956 230 238.0
750 30 777 1037 260 290.0
800 32 828 1118 290 364.0
900* 36 929 1279 350 595.0
900** 36 929 1189 260 544.0
* For Bondstrand 2416 only
** For Bondstrand 3416 only
Elbows 90
Filament-wound 45 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 45 95 50 0.5
80 3 61 111 50 0.9
100 4 73 123 50 1.3
150 6 106 156 50 2.5
200 8 137 217 80 7.4
250 10 169 279 110 12.4
300 12 196 336 140 22.0
350 14 125 265 140 29.0
400 16 142 312 170 41.0
450 18 204 374 170 54.0
500 20 225 425 200 75.0
600 24 268 498 230 130.0
700 28 310 540 230 177.0
750 30 331 591 260 226.0
800 32 352 642 290 272.0
900* 36 394 744 350 463.0
900** 36 394 654 260 382.0
* For Bondstrand 2416 only
** For Bondstrand 3416 only
Elbows 45
FP657-16 (8/98). Fittings & Flanges for 2416/3416. Page 4 of 12.
Filament-wound 22
1
/2 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 29 79 50 0.4
80 3 37 87 50 0.6
100 4 43 93 50 0.9
150 6 60 110 50 1.4
200 8 76 156 80 5.1
250 10 68 178 110 9.7
300 12 77 217 140 15.5
350 14 71 211 140 21.0
400 16 85 255 170 24.0
450 18 106 276 170 39.0
500 20 116 316 200 56.0
600 24 136 366 230 93.0
700 28 157 387 230 123.0
750 30 167 427 260 158.0
800 32 177 467 290 198.0
900* 36 197 547 350 343.0
900** 36 197 457 260 266.0
* For Bondstrand 2416 only
** For Bondstrand 3416 only
Elbows 22
1
/2
Filament-wound tees with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Laying Overall Insertion Weight
Length Length Length Length Depth
total total branch branch
run run
L1 OL1 L2 OL2 Ds
mm inch mm mm mm mm mm kg
50 2 148 248 74 124 50 1.3
80 3 192 292 96 146 50 2.9
100 4 230 330 115 165 50 4.0
150 6 306 406 153 203 50 8.7
200 8 376 536 188 268 80 21.0
250 10 452 672 226 336 110 31.0
300 12 528 808 264 404 140 50.0
350 14 544 824 272 412 140 55.0
400 16 590 930 295 465 170 87.0
450 18 678 1018 339 509 170 103.0
500 20 740 1140 370 570 200 209.0
600 24 868 1328 434 664 230 351.0
700 28 994 1454 497 727 230 476.0
750 30 1046 1566 523 783 260 591.0
800 32 1118 1698 559 849 290 727.0
900* 36 1248 1948 624 974 350 1213.0
900** 36 1248 1768 624 884 260 1080.0
* For Bondstrand 2416 only
** For Bondstrand 3416 only
Tees
FP657-16 (8/98). Fittings & Flanges for 2416/3416. Page 5 of 12.
Filament-wound reducing tees with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Laying Overall Insertion Weight
Length Length Depth Length Length Depth
half half run branch branch branch
run x run x branch run run
L1 OL1 Ds1 L2 OL2 Ds2
mm inch mm mm mm mm mm mm kg
80x80x50 3x3x2 96 146 50 86 136 50 2.7
100x100x50 4x4x2 115 165 50 99 149 50 3.8
100x100x80 4x4x3 115 165 50 108 158 50 4.0
150x150x50 6x6x2 153 203 50 124 174 50 8.0
150x150x80 6x6x3 153 203 50 134 184 50 9.6
150x150x100 6x6x4 153 203 50 140 190 50 9.6
200x200x80 8x8x3 188 268 80 159 209 50 16.0
200x200x100 8x8x4 188 268 80 172 222 50 16.7
200x200x150 8x8x6 188 268 80 178 228 50 13.2
250x250x100 10x10x4 226 336 110 194 244 50 29.0
250x250x150 10x10x6 226 336 110 204 254 50 28.0
250x250x200 10x10x8 226 336 110 213 293 80 34.0
300x300x100 12x12x4 264 404 140 216 266 50 43.0
300x300x150 12x12x6 264 404 140 229 279 50 42.0
300x300x200 12x12x8 264 404 140 239 319 80 45.0
300x300x250 12x12x10 264 404 140 251 361 110 51.0
350x350x150 14x14x6 272 412 140 254 304 50 41.0
350x350x200 14x14x8 272 412 140 264 344 80 54.0
350x350x250 14x14x10 272 412 140 277 387 110 62.0
350x350x300 14x14x12 272 412 140 289 429 140 66.0
400x400x150 16x16x6 295 465 170 274 324 50 51.0
400x400x200 16x16x8 295 465 170 283 363 80 56.0
400x400x250 16x16x10 295 465 170 293 403 110 63.0
400x400x300 16x16x12 295 465 170 305 445 140 67.0
400x400x350 16x16x14 295 465 170 315 455 140 710.0
450x450x200 18x18x8 339 509 170 316 396 80 100.0
450x450x250 18x18x10 339 509 170 329 439 110 104.0
450x450x300 18x18x12 339 509 170 329 469 140 107.0
450x450x350 18x18x14 339 509 170 330 470 140 137.0
450x450x400 18x18x16 339 509 170 330 500 170 143.0
500x500x250 20x20x10 370 570 200 355 465 110 180.0
500x500x300 20x20x12 370 570 200 355 495 140 186.0
500x500x350 20x20x14 370 570 200 356 496 140 188.0
500x500x400 20x20x16 370 570 200 356 526 170 195.0
500x500x450 20x20x18 370 570 200 365 535 170 200.0
600x600x300 24x24x12 434 664 230 405 545 140 211.0
600x600x350 24x24x14 434 664 230 406 546 140 281.0
600x600x400 24x24x16 434 664 230 406 576 170 220.0
600x600x450 24x24x18 434 664 230 428 598 170 239.0
600x600x500 24x24x20 434 664 230 428 628 200 279.0
Reducing Tees
FP657-16 (8/98). Fittings & Flanges for 2416/3416. Page 6 of 12.
Nominal Pipe Size Laying Overall Insertion Laying Overall Insertion Weight
Length Length Depth Length Length Depth
half half run branch branch branch
run x run x branch run run
L1 OL1 Ds1 L2 OL2 Ds2
mm inch mm mm mm mm mm mm kg
700x700x400 28x28x16 497 727 230 485 655 170 423
700x700x450 28x28x18 497 727 230 483 653 170 428
700x700x500 28x28x20 497 727 230 491 691 200 440
700x700x600 28x28x24 497 727 230 491 721 230 458
750x750x400 30x30x16 523 783 260 501 671 170 516
750x750x450 30x30x18 523 783 260 509 679 170 522
750x750x500 30x30x20 523 783 260 509 709 200 534
750x750x600 30x30x24 523 783 260 517 747 230 555
750x750x700 30x30x28 523 783 260 517 747 230 573
800x800x400 32x32x16 559 849 290 537 707 170 628
800x800x450 32x32x18 559 849 290 537 707 170 633
800x800x500 32x32x20 559 849 290 545 745 200 647
800x800x600 32x32x24 559 849 290 545 775 230 667
800x800x700 32x32x28 559 849 290 553 783 230 689
800x800x750 32x32x30 559 849 290 553 813 260 706
900x900x450* 36x36x18 624 974 350 603 773 170 1035
900x900x500* 36x36x20 624 974 350 603 803 200 1052
900x900x600* 36x36x24 624 974 350 611 841 230 1082
900x900x700* 36x36x28 624 974 350 611 841 230 964
900x900x750* 36x36x30 624 974 350 618 878 260 986
900x900x800* 36x36x32 624 974 350 618 908 290 1008
900x900x450** 36x36x18 624 884 260 603 773 170 947
900x900x500** 36x36x20 624 884 260 603 803 200 975
900x900x600** 36x36x24 624 884 260 611 841 230 878
900x900x700** 36x36x28 624 884 260 611 841 230 887
900x900x750** 36x36x30 624 884 260 618 878 260 909
900x900x800** 36x36x32 624 884 260 618 908 290 931
* For Bondstrand 2416 only
** For Bondstrand 3416 only
Reducing Tees (cont.)
Filament-wound concentric reducers with integral Taper-Taper adhesive bonded
socket ends
Nominal Pipe Size Laying Overall Overall Insertion Weight
Length Length Length Depth
L OL Ds1 Ds2
mm inch mm mm mm mm kg
80x50 3x2 74 174 50 50 0.8
100x50 4x2 96 196 50 50 1.1
100x80 4x3 94 194 50 50 1.3
150x80 6x3 117 217 50 50 1.5
150x100 6x4 124 224 50 50 1.8
200x100 8x4 163 293 80 50 4.3
200x150 8x6 129 259 80 50 4.3
250x150 10x6 148 308 110 50 6.2
250x200 10x8 135 325 110 80 6.9
300x200 12x8 180 400 140 80 9.9
300x250 12x10 167 417 140 110 10.8
350x250 14x10 214 464 140 110 17.0
350x300 14x12 208 488 140 140 16.8
400x300 16x12 195 505 170 140 22.0
400x350 16x14 183 493 170 140 23.0
450x400 18x16 128 468 170 170 27.0
500x400 20x16 249 619 200 170 36.0
500x450 20x18 151 521 200 170 35.0
600x400 24x16 486 886 230 170 70.0
600x450 24x18 388 788 230 170 70.0
600x500 24x20 267 697 230 200 70.0
700x400 28x16 796 1196 230 170 141.0
700x450 28x18 698 1098 230 170 140.0
700x500 28x20 577 1007 230 200 142.0
700x600 28x24 340 800 230 230 142.0
750x400 30x16 915 1345 260 170 177.0
750x450 30x18 817 1247 260 170 175.0
750x500 30x20 696 1156 260 200 177.0
750x600 30x24 459 949 260 230 177.0
750x700 30x28 149 639 260 230 165.0
800x400 32x16 1038 1498 290 170 216.0
800x450 32x18 940 1400 290 170 214.0
800x500 32x20 819 1309 290 200 217.0
800x600 32x24 582 1102 290 230 217.0
800x700 32x28 272 792 290 230 203.0
800x750 32x30 153 703 290 260 207.0
900x450* 36x18 1186 1706 350 170 358.0
900x500* 36x20 1065 1615 350 200 362.0
900x600* 36x24 828 1408 350 230 361.0
900x700* 36x28 518 1098 350 230 300.0
900x750* 36x30 399 1009 350 260 304.0
900x800* 36x32 276 916 350 290 307.0
900x450** 36x18 1186 1616 260 170 314.0
900x500** 36x20 1065 1525 260 200 314.0
900x600** 36x24 828 1318 260 230 268.0
900x700** 36x28 518 1008 260 230 261.0
900x750** 36x30 399 919 260 260 265.0
900x800** 36x32 276 826 260 290 269.0
* For Bondstrand 2416 only
** For Bondstrand 3416 only
Note: Eccentric Reducers are available on request.
Concentric Reducers
FP657-16 (8/98). Fittings & Flanges for 2416/3416. Page 7 of 12.
FP657-16 (8/98). Fittings & Flanges for 2416/3416. Page 8 of 12.
Filament-wound couplings with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Outside Weight
Length Length Depth Diameter
L OL Ds OD
mm inch mm mm mm mm kg
50 2 70 170 50 70 0.4
80 3 70 170 50 100 0.7
100 4 70 170 50 124 0.9
150 6 70 170 50 180 1.5
200 8 70 230 80 230 2.5
250 10 70 290 110 286 4.0
300 12 70 350 140 350 9.8
350 14 70 350 140 381 10.5
400 16 70 410 170 430 13.2
450 18 70 410 170 460 9.0
500 20 70 470 200 524 21.0
600 24 70 530 230 619 24.0
700 28 70 530 230 745 31.0
750 30 70 590 260 795 34.0
800 32 70 650 290 840 32.0
900* 36 70 770 350 951 50.0
900** 36 70 590 260 945 41.0
* For Bondstrand 2416 only
** For Bondstrand 3416 only
Couplings
Filament-wound pipe nipples with integral Taper-Taper adhesive bonded spigot ends
Nominal Pipe Size Laying gap Insertion Weight
Length Depth
L Ds
mm inch mm mm mm kg
50 2 125 25 50 0.1
80 3 125 25 50 0.1
100 4 125 25 50 0.1
150 6 125 25 50 0.3
200 8 190 30 80 0.7
250 10 250 30 110 1.3
300 12 320 40 140 2.4
350 14 320 40 140 3.0
400 16 380 40 170 4.6
450 18 400 60 170 5.6
500 20 460 60 200 8.3
600 24 520 60 230 13.3
700 28 520 60 230 19.7
750 30 580 60 260 26.0
800 32 640 60 290 30.0
900* 36 760 60 350 39.0
900** 36 580 60 260 31.0
* For Bondstrand 2416 only
** For Bondstrand 3416 only
Nipples
FP657-16 (8/98). Fittings & Flanges for 2416/3416. Page 9 of 12.
Heavy-Duty filament-wound flanges with Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overal Insertion Weight
Length Length Depth
L D Ds
1) 2)
mm inch mm mm mm kg
50 2 5 55 50 1.5
80 3 5 55 50 2.2
100 4 5 55 50 2.9
150 6 5 55 50 3.7
200 8 6 86 80 8.4
250 10 6 116 110 14.3
300 12 6 116 110 21.0
350 14 6 116 110 25.0
400 16 6 146 140 38.0
450 18 6 146 140 41.0
500 20 6 176 170 58.0
Notes:
1) Underlined insertion depth for subsequent flanges deviates from other fittings.
2) The weights shown are for ANSI B16.5 Class 150 drilled flanges. Weights for other
drilling classes may be different. For more detailed information reference is made to
the appropriate product data.
* Heavy Duty Flanges are standard available in drillings according to ANSI and ISO
(DIN).
** Full-face elastomeric gaskets may be used, suitable for the service pressure, service
temperature and fluid. Shore A durometer hardness of 60 5 is recommended and a
thickness of 3 mm.
Compressed fibre gaskets, 3 mm thick, compatible with the pressure, temperature
and medium, may also be used. The mechanical properties should be in accordance
with DIN 3754 (IT 400) or equal.
*** For maximum bolt torque refer to the appropriate Bondstrand literature. Please be
aware that excessive torque may result in flange failure and, therefore a torque-
wrench is required.
Heavy-Duty Flanges
FP657-16 (8/98). Fittings & Flanges for 2416/3416. Page 10 of 12.
Filament-wound Stub-end flanges with Taper-Taper adhesive bonded socket ends
and steel backing rings
Nominal Pipe Size Laying Overall Insertion Ring Weigth Weight
Length Length Depth to GRE steel
Face stub- ring
L OL Ds H end (1)
mm inch mm mm mm mm kg kg
50 2 15 65 50 10 0.2 1.8
80 3 15 65 50 10 0.5 3.2
100 4 15 65 50 12 0.8 4.2
150 6 15 65 50 13 1.3 5.2
200 8 15 95 80 20 2.6 8.5
250 10 15 125 110 23 4.0 13.5
300 12 15 155 140 26 5.9 23.0
350 14 15 155 140 27 5.8 32.0
400 16 20 190 170 32 9.6 42.0
450 18 20 190 170 35 16.1 40.0
500 20 20 220 200 39 19.8 51.0
600 24 20 250 230 47 22 86.0
700 28 20 250 230 51 26 100.0
750 30 20 280 260 46 29 117.0
800 32 20 310 290 48 34 154.0
900* 36 20 370 350 53 41 197.0
900** 36 20 280 260 53 36 197.0
* For Bondstrand 2416 only
** For Bondstrand 3416 only
Notes:
(1) The weight shown is for ANSI B16.5 Class 150 drilled flanges. Weights for other
drilling classes may be different. For more detailed information reference is made to
the appropriate product data.
* Stub-End Flange Rings are standard available in drillings according to ANSI and ISO
(DIN).
** Stub-End Flanges are available with and without O-ring groove in the face.
Up to 10 bar stub-ends without grooves can be used with flat elastomeric or
compressed fibre gaskets.
For pressures 12 bar and above suitable O-ring seals should be used, available on
request.
*** Make sure that the O-ring grooved stub-end is compatible with its counter flange,
e.g. use a stub-end without groove or another flat surface flange as counter flange.
**** Maximum bolt-torque for use with O-rings seals may be calculated based on
pressure, size and number of bolts. If using flat face gaskets (maximum pressure 10
bar) refer to the appropriate Bondstrand literature for hubbed flanges.
Stub-end Flanges
Van Stone
FP657-16 (8/98). Fittings & Flanges for 2416/3416. Page 11 of 12.
Filament around adapters and couplings with Key-lock ends.
Nominal Pipe Qty Laying Overall Insertion Weigth Laying Overall Weigth
Size of Length Length Depth Length Length
Keys L OL Ds L OL
mm inch mm mm mm kg mm mm kg
adapter KLM x TBF coupling KLF x KLF
50 2 1 5 100 50 0.3 100 140 0.8
80 3 1 5 100 50 0.5 100 140 1.0
100 4 1 5 100 50 0.7 100 140 2.2
150 6 1 4 110 50 1.0 127 181 4.3
200 8 1 2 150 80 1.9 152 225 6.3
250 10 1 3 185 110 3.1 163 242 9.6
300 12 1 5 230 140 5.2 186 278 11.6
350 14 1 18 245 140 8.4 191 289 15.6
400 16 2 15 275 170 12.7 197 426 38.0
450 18 2 61 325 170 16.5 204 392 27.0
500 20 2 83 380 200 21.0 210 409 32.0
600 24 2 76 400 230 25.0 200 375 29.0
750 30 2 118 505 260 51.0 279 558 75.0
Key-lock Adapters
& Couplings
Pipe system is designed for field testing with water at 150% of rated pressure.
Maximum allowable surge pressure is 150% of rated pressure.
Field Testing
Surge Pressure
1 psi = 6895 Pa = 0.07031 kg/cm
2
1 bar = 105Pa = 14.5 psi = 1.02 kg/cm
2
1 MPa = 1 N/mm
2
= 145 psi = 10.2 kg/cm
2
1 inch = 25.4 mm
1 Btu.in/ft2hF = 0.1442 W/mK
C = 5/9 (F-32)
This product literature and the recommendations for usage it contains are based on test data
reasonably believed to be reliable. It is intended that this literature be used by personnel
having specialised training in accordance with currently accepted industry practice and
normal operating conditions. Variation in environment, changes in operating procedures, or
extrapolation of data may cause unsatisfactory results. We recommend that your engineers
verify the suitability of this product for your intended application. Since we have no control
over the conditions of service, we expressly disclaim responsibility for the results obtained
or for any consequential or incidental damages of any kind incurred.
Conversions
Important Notice
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.n
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet:www.ameron.com
email:marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Fittings & Flanges for
pipe series 2420 and 3420
using the Taper/Taper adhesive-bonded joint
Bondstrand Taper-Taper fittings & flanges are glassfiber reinforced filament-wound epoxy
pipe fittings in diameters 50 through 1000 mm (2-40 inch) designed to be used with
Bondstrand pipes. Pipe is standard with integral Taper-Taper spigot and socket ends for
adhesive bonding or with integral Key-Lock male and female ends for mechanical joining.
Fittings are filament-wound with integral taper socket ends. Pipes and fittings are
available in several pressure classes from 10 bar upwards.
For intended services and performance capabilities refer to product data sheet FP 452 and
FP 158 pertaining to Bondstrand Series 2400 and 3400 pipe data.
For recommendations pertaining to design, installation and use of Bondstrand Pipe,
Fittings and Flanges reference is made to the following literature:
FP 564 Assembly Instructions for Taper-Taper adhesive bonded joints.
FP 161 Installation Instructions using the Key-Lock mechanical joint.
FP 453 M86 Pipe Shaver operating instructions for Taper-Taper joints in sizes
50 to 150 mm (2-6 inch).
FP 454 M87 Pipe Shaver operating instructions for Taper-Taper joints in sizes
150 to 400 mm (6-16 inch).
FP 455 M87XL Pipe Shaver operating instructions for Taper-Taper joints in
sizes 400 to 600 mm (16-24 inch).
FP 643 M95 Pipe Shaver operating instructions for Taper-Taper joints in sizes
600 to 1000 mm (24-40 inch).
FP 196 Flange Assembly Instructions.
FP 132 Corrosion Guide.
General Bondstrand engineering and installation guides.
Dimensional data for Taper-Taper adhesive bonded fittings are contained in individual
dimensional sheets per pressure class:
FP No. Fitting Pipe System Pressure
549-10 T-10 2410 and 3410 10 bar
549-12 T-12 2412 and 3412 12 bar
549-14 T-14 2414 and 3414 14 bar
549-16 T-16 2416 and 3416 16 bar
549-20 T-20 2420 and 3420 20 bar
549-25 T-25 2425 and 3425 25 bar
549-32 T-32 2432 and 3432 32 bar
549-40 T-40 2440 and 3440 40 bar
549-50 T-50 2450 and 3450 50 bar
Ameron 1998 FP657-20 (8/98). Printed in The Netherlands. Page 1 of 12.
Description
Uses and Application
Design and Installation
How to use this product
data sheet
FP657-20 Fittings & Flanges for 2420/3420.Page 2 of 12.
Nominal Pipe Size Taper Insertion Spigot Spigot
Angle Depth Nose Diameter
Thickness at Nose
Ds t
mm inch degrees mm mm mm
50 2 1.75 50 1.0 55.2
80 3 1.75 50 1.0 83.8
100 4 1.75 50 1.0 107.2
150 6 2.50 80 1.0 161.0
200 8 2.50 80 1.0 210.8
250 10 2.50 110 1.0 264.9
300 12 2.50 140 1.0 315.7
350 14 2.50 140 1.5 347.4
400 16 2.50 170 1.5 396.7
450 18 2.50 170 1.5 436.8
500 20 2.50 200 2.0 486.1
600 24 2.50 230 2.5 583.6
700 28 1.75 290 5.5 711.0
Dimensions of the
taper-taper joint
Nominal Adhesive Minimum number of
Pipe Size Kit Size adhesive kits per joint
fluid
mm inch cm
3
ounce nr.
50 2 89 3 0.2
80 3 89 3 0.2
100 4 89 3 0.4
150 6 89 3 0.8
200 8 177 6 1.0
250 10 177 6 1.0
300 12 177 6 2.0
350 14 177 6 2.0
400 16 177 6 3.0
450 18 177 6 3.0
500 20 177 6 3.0
600 24 177 6 5.0
700 28 177 6 7.0
Note:
Adhesive kits should never be split. If remainder is not used for other joints made at the
same time, the surplus must be discarded.
Quantity of Adhesive
FP657-20 Fittings & Flanges for 2420/3420. Page 3 of 12.
Filament-wound 90 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 87 137 50 0.6
80 3 126 176 50 1.1
100 4 155 205 50 2.1
150 6 240 320 80 5.8
200 8 315 395 80 12.0
250 10 391 501 110 16.1
300 12 463 603 140 26.0
350 14 364 504 140 37.0
400 16 402 572 170 53.0
450 18 472 642 170 76.0
500 20 523 723 200 125.0
600 24 625 855 230 228.0
700 28 726 1016 290 293.0
Elbows 90
Filament-wound 45 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 45 95 50 0.5
80 3 61 111 50 0.9
100 4 73 123 50 1.3
150 6 106 186 80 3.9
200 8 137 217 80 7.4
250 10 169 279 110 12.4
300 12 196 336 140 22.0
350 14 125 265 140 29.0
400 16 142 312 170 41.0
450 18 204 374 170 54.0
500 20 225 425 200 75.0
600 24 268 498 230 130.0
700 28 310 600 290 229.0
Elbows 45
FP657-20 Fittings & Flanges for 2420/3420.Page 4 of 12.
Filament-wound 22
1
/2 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 29 79 50 0.4
80 3 37 87 50 0.6
100 4 43 93 50 0.9
150 6 60 140 80 2.8
200 8 76 156 80 5.1
250 10 68 178 110 9.7
300 12 77 217 140 15.5
350 14 71 211 140 21.0
400 16 85 255 170 24.0
450 18 106 276 170 39.0
500 20 116 316 200 56.0
600 24 136 366 230 93.0
700 28 157 447 290 173.0
Elbows 22
1
/2
Filament-wound tees with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Laying Overall Insertion Weight
Length Length Length Length Depth
total total branch branch
run run
L1 OL1 L2 OL2 Ds
mm inch mm mm mm mm mm kg
50 2 148 248 74 124 50 1.3
80 3 192 292 96 146 50 2.9
100 4 230 330 115 165 50 4.0
150 6 306 466 153 233 80 11.9
200 8 376 536 188 268 80 21.0
250 10 452 672 226 336 110 21.0
300 12 528 808 264 404 140 50.0
350 14 544 824 272 412 140 55.0
400 16 590 930 295 465 170 87.0
450 18 678 1018 339 509 170 103.0
500 20 740 1140 370 570 200 209.0
600 24 868 1328 434 664 230 351.0
700 28 994 1574 497 787 290 599.0
Tees
FP657-20 Fittings & Flanges for 2420/3420. Page 5 of 12.
Filament-wound reducing tees with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Laying Overall Insertion Weight
Length Length Depth Length Length Depth
half half run branch branch branch
run x run x branch run run
L1 OL1 Ds1 L2 OL2 Ds2
mm inch mm mm mm mm mm mm kg
80x80x50 3x3x2 96 146 50 86 136 50 2.7
100x100x50 4x4x2 115 165 50 99 149 50 3.8
100x100x80 4x4x3 115 165 50 108 158 50 4.0
150x150x50 6x6x2 153 233 80 124 174 50 10.9
150x150x80 6x6x3 153 233 80 134 184 50 12.0
150x150x100 6x6x4 153 233 80 140 190 50 12.2
200x200x80 8x8x3 188 268 80 159 209 50 16.0
200x200x100 8x8x4 188 268 80 172 222 50 16.7
200x200x150 8x8x6 188 268 80 178 258 80 17.9
250x250x100 10x10x4 226 336 110 194 244 50 29.0
250x250x150 10x10x6 226 336 110 204 284 80 32.0
250x250x200 10x10x8 226 336 110 213 293 80 34.0
300x300x100 12x12x4 264 404 140 216 266 50 43.0
300x300x150 12x12x6 264 404 140 229 309 80 44.0
300x300x200 12x12x8 264 404 140 239 319 80 45.0
300x300x250 12x12x10 264 404 140 251 361 110 51.0
350x350x150 14x14x6 272 412 140 254 334 80 42.0
350x350x200 14x14x8 272 412 140 264 344 80 54.0
350x350x250 14x14x10 272 412 140 277 387 110 62.0
350x350x300 14x14x12 272 412 140 289 429 140 66.0
400x400x150 16x16x6 295 465 170 274 354 80 55.0
400x400x200 16x16x8 295 465 170 283 363 80 56.0
400x400x250 16x16x10 295 465 170 293 403 110 63.0
400x400x300 16x16x12 295 465 170 305 445 140 67.0
400x400x350 16x16x14 295 465 170 315 455 140 71.0
450x450x200 18x18x8 339 509 170 316 396 80 100.0
450x450x250 18x18x10 339 509 170 329 439 110 104.0
450x450x300 18x18x12 339 509 170 329 469 140 107.0
450x450x350 18x18x14 339 509 170 330 470 140 137.0
450x450x400 18x18x16 339 509 170 330 500 170 143.0
500x500x250 20x20x10 370 570 200 355 465 110 180.0
500x500x300 20x20x12 370 570 200 355 495 140 186.0
500x500x350 20x20x14 370 570 200 356 496 140 188.0
500x500x400 20x20x16 370 570 200 356 526 170 195.0
500x500x450 20x20x18 370 570 200 365 535 170 200.0
600x600x300 24x24x12 434 664 230 405 545 140 211.0
600x600x350 24x24x14 434 664 230 406 546 140 281.0
600x600x400 24x24x16 434 664 230 406 576 170 220.0
600x600x450 24x24x18 434 664 230 428 598 170 239.0
600x600x500 24x24x20 434 664 230 428 628 200 279.0
700x700x400 28x28x16 497 787 290 483 653 170 520.0
700x700x450 28x28x18 497 787 290 483 653 170 525.0
700x700x500 28x28x20 497 787 290 491 691 200 539.0
700x700x600 28x28x24 497 787 290 491 721 230 560.0
Reducing Tees
FP657-20 Fittings & Flanges for 2420/3420.Page 6 of 12.
Filament-wound concentric reducers with integral Taper-Taper adhesive bonded
socket ends
Nominal Pipe Size Laying Overall Overall Insertion Weight
Length Length Length Depth
L OL Ds1 Ds2
mm inch mm mm mm mm kg
80x50 3x2 74 174 50 50 0.8
100x50 4x2 96 196 50 50 1.1
100x80 4x3 94 194 50 50 1.3
150x80 6x3 117 247 80 50 2.2
150x100 6x4 124 254 80 50 2.4
200x100 8x4 163 293 80 50 4.3
200x150 8x6 129 289 80 80 5.1
250x150 10x6 148 338 110 80 6.8
250x200 10x8 135 325 110 80 6.9
300x200 12x8 180 400 140 80 9.9
300x250 12x10 167 417 140 110 10.8
350x250 14x10 214 464 140 110 17.0
350x300 14x12 208 488 140 140 16.8
400x300 16x12 195 505 170 140 22.0
400x350 16x14 183 493 170 140 23.0
450x400 18x16 128 468 170 170 27.0
500x400 20x16 249 619 200 170 36.0
500x450 20x18 151 521 200 170 35.0
600x400 24x16 486 886 230 170 70.0
600x450 24x18 388 788 230 170 70.0
600x500 24x20 267 697 230 200 70.0
700x400 28x16 796 1256 290 170 180.0
700x450 28x18 698 1158 290 170 156.0
700x500 28x20 577 1067 290 200 181.0
700x600 28x24 340 860 290 230 132.0
Note: Eccentric Reducers are available on request
Concentric Reducers
FP657-20 Fittings & Flanges for 2420/3420. Page 7 of 12.
Filament-wound couplings with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Outside Weight
Length Length Depth Diameter
L OL Ds OD
mm inch mm mm mm mm kg
50 2 70 170 50 70 0.4
80 3 70 170 50 100 0.7
100 4 70 170 50 124 0.9
150 6 70 230 80 180 1.9
200 8 70 230 80 230 2.5
250 10 70 290 110 286 4.0
300 12 70 350 140 350 9.8
350 14 70 350 140 381 10.5
400 16 70 410 170 430 13.2
450 18 70 410 170 460 9.0
500 20 70 470 200 524 21.0
600 24 70 530 230 619 24.0
700 28 70 650 290 745 35.0
Couplings
Filament-wound pipe nipples with integral Taper-Taper adhesive bonded spigot ends
Nominal Pipe Size Laying gap Insertion Weight
Lenght Depth
L Ds
mm inch mm mm mm kg
50 2 125 25 50 0.1
80 3 125 25 50 0.1
100 4 125 25 50 0.1
150 6 185 25 80 0.5
200 8 190 30 80 0.7
250 10 250 30 110 1.4
300 12 320 40 140 2.5
350 14 320 40 140 3.1
400 16 380 40 170 4.8
450 18 400 60 170 5.8
500 20 460 60 200 8.7
600 24 520 60 230 13.9
700 28 640 60 290 27.0
Nipples
FP657-20 Fittings & Flanges for 2420/3420.Page 8 of 12.
Heavy-Duty filament-wound flanges with Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overal Insertion Weight
Length Length Depth
L D Ds (1)
mm inch mm mm mm kg
50 2 5 55 50 1.5
80 3 5 55 50 2.2
100 4 5 55 50 2.9
150 6 5 85 80 5.8
200 8 6 86 80 8.4
250 10 6 116 110 14.3
300 12 6 146 140 26.0
350 14 6 146 140 33.0
400 16 6 176 170 46.0
450 18 6 176 170 49.0
Notes:
(1) The weights shown are for ANSI B16.5 Class 150 drilled flanges. Weights for other
drilling classes may be different. For more detailed information reference is made to
the appropriate product data.
* Heavy Duty Flanges are standard available in drillings according to ANSI and ISO
(DIN).
** Full-face elastomeric gaskets may be used, suitable for the service pressure, service
temperature and fluid. Shore A durometer hardness of 60 5 is recommended and a
thickness of 3 mm.
Compressed fibre gaskets, 3 mm thick, compatible with the pressure, temperature
and medium, may also be used. The mechanical properties should be in accordance
with DIN 3754 (IT 400) or equal.
*** For maximum bolt torque refer to the appropriate Bondstrand literature. Please be
aware that excessive torque may result in flange failure and, therefore a torque-
wrench is required.
Heavy-Duty Flanges
FP657-20 Fittings & Flanges for 2420/3420. Page 9 of 12.
Filament-wound Stub-end flanges with Taper-Taper adhesive bonded socket ends
and steel backing rings
Nominal Pipe Size Laying Overall Insertion Ring Weigth Weight
Length Length Depth to GRE steel
Face stub- ring
L OL Ds H end (1)
mm inch mm mm mm mm kg kg
50 2 15 65 50 10 0.2 1.8
80 3 15 65 50 10 0.5 3.2
100 4 15 65 50 12 0.8 4.2
150 6 15 95 80 16 1.8 5.2
200 8 15 95 80 20 2.6 8.5
250 10 15 125 110 23 4.0 13.5
300 12 15 155 140 26 5.9 23.0
350 14 15 155 140 27 5.8 32.0
400 16 20 190 170 32 9.6 42.0
450 18 20 190 170 35 16.1 40.0
500 20 20 220 200 39 19.8 51.0
600 24 20 250 230 47 22 86.0
700 28 20 310 290 51 29 100.0
Notes:
(1) The weight shown is for ANSI B16.5 Class 150 drilled flanges. Weights for other
drilling classes may be different. For more detailed information reference is made to
the appropriate product data.
* Stub-End Flange Rings are standard available in drillings according to ANSI and ISO
(DIN).
** Stub-End Flanges are available with and without O-ring groove in the face.
Up to 10 bar stub-ends without grooves can be used with flat elastomeric or
compressed fibre gaskets.
For pressures 12 bar and above suitable O-ring seals should be used, available on
request.
*** Make sure that the O-ring grooved stub-end is compatible with its counter flange,
e.g. use a stub-end without groove or another flat surface flange as counter flange.
**** Maximum bolt-torque for use with O-rings seals may be calculated based on
pressure, size and number of bolts. If using flat face gaskets (maximum pressure 10
bar) refer to the appropriate Bondstrand literature for hubbed flanges.
Stub-end Flanges
FP657-20 Fittings & Flanges for 2420/3420.Page 10 of 12.
Filament around adapters and couplings with Key-lock ends.
Nominal Pipe Qty Laying Overall Insertion Weigth Laying Overall Weigth
Size of Length Length Depth Length Length
Keys L OL Ds L OL
mm inch mm mm mm kg mm mm kg
adapter KLM x TBF coupling KLF x KLF
50 2 1 5 100 50 0.3 100 140 0.8
80 3 1 5 100 50 0.5 100 140 1.0
100 4 1 5 100 50 0.7 100 140 2.2
150 6 1 4 140 80 1.3 127 181 4.3
200 8 1 2 150 80 1.9 152 225 6.3
250 10 1 3 185 110 3.1 163 242 9.6
300 12 2 60 285 140 6.7 186 386 25.0
350 14 2 73 300 140 10.7 191 403 29.0
400 16 2 80 340 170 10.2 197 426 38.0
450 18 2 61 325 170 16.5 204 392 27.0
500 20 2 83 380 200 21.0 210 409 32.0
600 24 2 98 450 230 33.0 261 519 71.0
Key-lock Adapters
& Couplings
Pipe system is designed for field testing with water at 150% of rated pressure.
Maximum allowable surge pressure is 150% of rated pressure.
Field Testing
Surge Pressure
1 psi = 6895 Pa = 0.07031 kg/cm
2
1 bar = 105Pa = 14.5 psi = 1.02 kg/cm
2
1 MPa = 1 N/mm
2
= 145 psi = 10.2 kg/cm
2
1 inch = 25.4 mm
1 Btu.in/ft2hF = 0.1442 W/mK
C = 5/9 (F-32)
This product literature and the recommendations for usage it contains are based on test data
reasonably believed to be reliable. It is intended that this literature be used by personnel
having specialised training in accordance with currently accepted industry practice and
normal operating conditions. Variation in environment, changes in operating procedures, or
extrapolation of data may cause unsatisfactory results. We recommend that your engineers
verify the suitability of this product for your intended application. Since we have no control
over the conditions of service, we expressly disclaim responsibility for the results obtained
or for any consequential or incidental damages of any kind incurred.
Conversions
Important Notice
FP657-20 Fittings & Flanges for 2420/3420. Page 11 of 12.
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.n
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet:www.ameron.com
email:marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Fittings & Flanges for
pipe series 2425 and 3425
using the Taper/Taper adhesive-bonded joint
Bondstrand

Product Data
Bondstrand Taper-Taper fittings & flanges are glassfiber reinforced filament-wound epoxy
pipe fittings in diameters 50 through 1000 mm (2-40 inch) designed to be used with
Bondstrand pipes. Pipe is standard with integral Taper-Taper spigot and socket ends for
adhesive bonding or with integral Key-Lock male and female ends for mechanical joining.
Fittings are filament-wound with integral taper socket ends. Pipes and fittings are
available in several pressure classes from 10 bar upwards.
For intended services and performance capabilities refer to product data sheet FP 452 and
FP 158 pertaining to Bondstrand Series 2400 and 3400 pipe data.
For recommendations pertaining to design, installation and use of Bondstrand Pipe,
Fittings and Flanges reference is made to the following literature:
FP 564 Assembly Instructions for Taper-Taper adhesive bonded joints.
FP 161 Installation Instructions using the Key-Lock mechanical joint.
FP 453 M86 Pipe Shaver operating instructions for Taper-Taper joints in sizes
50 to 150 mm (2-6 inch).
FP 454 M87 Pipe Shaver operating instructions for Taper-Taper joints in sizes
150 to 400 mm (6-16 inch).
FP 455 M87XL Pipe Shaver operating instructions for Taper-Taper joints in
sizes 400 to 600 mm (16-24 inch).
FP 643 M95 Pipe Shaver operating instructions for Taper-Taper joints in sizes
600 to 1000 mm (24-40 inch).
FP 196 Flange Assembly Instructions.
FP 132 Corrosion Guide.
General Bondstrand engineering and installation guides.
Dimensional data for Taper-Taper adhesive bonded fittings are contained in individual
dimensional sheets per pressure class:
FP No. Fitting Pipe System Pressure
549-10 T-10 2410 and 3410 10 bar
549-12 T-12 2412 and 3412 12 bar
549-14 T-14 2414 and 3414 14 bar
549-16 T-16 2416 and 3416 16 bar
549-20 T-20 2420 and 3420 20 bar
549-25 T-25 2425 and 3425 25 bar
549-32 T-32 2432 and 3432 32 bar
549-40 T-40 2440 and 3440 40 bar
549-50 T-50 2450 and 3450 50 bar
Ameron 1998 FP657-25 (8/98). Printed in The Netherlands. Page 1 of 12.
Description
Uses and Application
Design and Installation
How to use this product
data sheet
FP657-25 Fittings & Flanges for 2425/3425. Page 2 of 12.
Nominal Pipe Size Taper Insertion Spigot Spigot
Angle Depth Nose Diameter
Thickness at Nose
Ds t
mm inch degrees mm mm mm
50 2 1.75 50 1.0 55.2
80 3 1.75 80 1.0 83.8
100 4 1.75 80 1.0 107.2
150 6 2.50 110 1.0 161.0
200 8 2.50 140 1.0 210.8
250 10 2.50 170 1.5 265.9
300 12 2.50 200 1.5 316.7
350 14 2.50 170 2.0 348.4
400 16 2.50 230 2.5 398.7
450 18 2.50 200 2.5 438.8
500 20 2.50 230 3.0 488.1
600 24 2.50 260 3.5 585.6
700* 28 1.75 350 7.0 714.0
700** 28 1.75 260 7.0 714.0
Dimensions of the
taper-taper joint
Nominal Adhesive Minimum number of
Pipe Size Kit Size adhesive kits per joint
fluid
mm inch cm
3
ounce nr.
50 2 89 3 0.2
80 3 89 3 0.4
100 4 89 3 0.6
150 6 89 3 1.0
200 8 177 6 1.0
250 10 177 6 2.0
300 12 177 6 2.0
350 14 177 6 2.0
400 16 177 6 3.0
450 18 177 6 3.0
500 20 177 6 4.0
600 24 177 6 5.0
700 28 177 6 8.0
700 28 177 6 6.0
* For Bondstrand 2425 only
** For Bondstrand 3425 only
Note:
Adhesive kits should never be split. If remainder is not used for other joints made at the
same time, the surplus must be discarded.
Quantity of Adhesive
* For Bondstrand 2425 only
** For Bondstrand 3425 only
FP657-25 Fittings & Flanges for 2425/3425. Page 3 of 12.
Filament-wound 90 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 87 137 50 0.6
80 3 110 190 80 2.1
100 4 155 235 80 3.8
150 6 240 350 110 8.7
200 8 315 455 140 24.0
250 10 391 561 170 39.0
300 12 463 663 200 61.0
350 14 374 544 170 51.0
400 16 402 632 230 84.0
450 18 497 679 200 87.0
500 20 548 778 230 173.0
600 24 650 910 260 266.0
700* 28 726 1076 350 365.0
700** 28 726 986 260 358.0
Elbows 90
Filament-wound 45 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 45 95 50 0.5
80 3 61 141 80 1.7
100 4 73 153 80 2.4
150 6 106 216 110 7.0
200 8 137 277 140 15.5
250 10 169 339 170 32.0
300 12 196 396 200 47.0
350 14 135 305 170 38.0
400 16 142 372 230 80.0
450 18 229 429 200 78.0
500 20 250 480 230 109.0
600 24 293 553 260 184.0
700* 28 310 660 350 333.0
700** 28 310 570 260 271.0
Elbows 45
* For Bondstrand 2425 only
** For Bondstrand 3425 only
* For Bondstrand 2425 only
** For Bondstrand 3425 only
FP657-25 Fittings & Flanges for 2425/3425. Page 4 of 12.
Filament-wound 22
1
/2 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 29 79 50 0.4
80 3 37 117 80 1.5
100 4 43 123 80 2.0
150 6 60 170 110 5.9
200 8 76 216 140 10.5
250 10 68 238 170 19.1
300 12 77 277 200 32.0
350 14 81 251 170 26.0
400 16 85 315 230 57.0
450 18 131 331 200 51.0
500 20 141 371 230 71.0
600 24 161 421 260 114.0
700* 28 157 507 350 221.0
700** 28 157 417 260 170.0
Elbows 22
1
/2
Filament-wound tees with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Laying Overall Insertion Weight
Length Length Length Length Depth
total total branch branch
run run
L1 OL1 L2 OL2 Ds
mm inch mm mm mm mm mm kg
50 2 148 248 74 124 50 1.6
80 3 192 352 96 176 80 3.6
100 4 230 390 115 195 80 6.4
150 6 306 526 153 263 110 18.0
200 8 376 656 188 328 140 37.0
250 10 452 792 226 396 170 55.0
300 12 528 928 264 464 200 92.0
350 14 564 904 282 452 170 80.0
400 16 590 1050 295 525 230 126.0
450 18 728 1128 364 564 200 218.0
500 20 790 1250 395 625 230 297.0
600 24 918 1438 459 719 260 483.0
700* 28 994 1694 497 847 350 828.0
700** 28 994 1514 497 757 260 726.0
Tees
* For Bondstrand 2425 only
** For Bondstrand 3425 only
* For Bondstrand 2425 only
** For Bondstrand 3425 only
FP657-25 Fittings & Flanges for 2425/3425. Page 5 of 12.
Filament-wound reducing tees with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Laying Overall Insertion Weight
Length Length Depth Length Length Depth
half half run branch branch branch
run x run x branch run run
L1 OL1 Ds1 L2 OL2 Ds2
mm inch mm mm mm mm mm mm kg
80x80x50 3x3x2 96 176 80 86 136 50 3.0
100x100x50 4x4x2 115 195 80 99 149 50 5.4
100x100x80 4x4x3 115 195 80 108 188 80 5.5
150x150x50 6x6x2 153 263 110 124 174 50 12.2
150x150x80 6x6x3 153 263 110 134 214 80 12.6
150x150x100 6x6x4 153 263 110 140 220 80 13.7
200x200x80 8x8x3 188 328 140 159 239 80 19.3
200x200x100 8x8x4 188 328 140 172 252 80 26.0
200x200x150 8x8x6 188 328 140 178 288 110 33.0
250x250x100 10x10x4 226 396 170 194 274 80 42.0
250x250x150 10x10x6 226 396 170 204 314 110 42.0
250x250x200 10x10x8 226 396 170 213 353 140 53.0
300x300x100 12x12x4 264 464 200 216 296 80 60.0
300x300x150 12x12x6 264 464 200 229 339 110 86.0
300x300x200 12x12x8 264 464 200 239 379 140 90.0
300x300x250 12x12x10 264 464 200 251 421 170 92.0
350x350x150 14x14x6 282 452 170 254 364 110 66.0
350x350x200 14x14x8 282 452 170 264 404 80 69.0
350x350x250 14x14x10 282 452 170 277 447 170 74.0
350x350x300 14x14x12 282 452 170 289 489 200 79.0
400x400x150 16x16x6 295 525 230 274 384 110 97.0
400x400x200 16x16x8 295 525 230 283 423 140 102.0
400x400x250 16x16x10 295 525 230 293 463 170 107.0
400x400x300 16x16x12 295 525 230 305 505 200 117.0
400x400x350 16x16x14 295 525 230 325 495 170 100.0
450x450x200 18x18x8 364 564 200 316 456 140 158.0
450x450x250 18x18x10 364 564 200 329 499 170 165.0
450x450x300 18x18x12 364 564 200 329 529 200 172.0
450x450x350 18x18x14 364 564 200 340 510 170 172.0
450x450x400 18x18x16 364 564 200 330 560 230 182.0
500x500x250 20x20x10 395 625 230 355 525 170 257.0
500x500x300 20x20x12 395 625 230 355 555 200 265.0
500x500x350 20x20x14 395 625 230 366 536 170 267.0
500x500x400 20x20x16 395 625 230 356 586 230 279.0
500x500x450 20x20x18 395 625 230 390 590 200 285.0
600x600x300 24x24x12 459 719 260 405 605 200 422.0
600x600x350 24x24x14 459 719 260 416 586 170 423.0
600x600x400 24x24x16 459 719 260 406 636 230 438.0
600x600x450 24x24x18 459 719 260 453 653 200 448.0
600x600x500 24x24x20 459 719 260 453 683 230 462.0
700x700x350* 28x28x14 497 847 350 485 655 170 700.0
700x700x400* 28x28x16 497 847 350 483 713 230 720.0
700x700x450* 28x28x18 497 847 350 508 708 200 726.0
700x700x500* 28x28x20 497 847 350 516 746 230 745.0
700x700x600** 28x28x24 497 847 350 516 776 260 774.0
700x700x350** 28x28x14 497 757 260 485 655 170 631.0
700x700x400** 28x28x16 497 757 260 483 713 230 625.0
700x700x450** 28x28x18 497 757 260 508 708 200 658.0
700x700x500** 28x28x20 497 757 260 516 746 230 677.0
700x700x600** 28x28x24 497 757 260 516 776 260 706.0
Reducing Tees
* For Bondstrand 2425 only
** For Bondstrand 3425 only
FP657-25 Fittings & Flanges for 2425/3425. Page 6 of 12.
Filament-wound concentric reducers with integral Taper-Taper adhesive bonded
socket ends
Nominal Pipe Size Laying Overall Overall Insertion Weight
Length Length Length Depth
L OL Ds1 Ds2
mm inch mm mm mm mm kg
80x50 3x2 74 204 80 50 0.9
100x50 4x2 96 226 80 50 2.7
100x80 4x3 94 254 80 80 2.0
150x80 6x3 117 307 110 80 3.9
150x100 6x4 124 314 110 80 4.2
200x100 8x4 163 383 140 80 9.5
200x150 8x6 129 379 140 110 9.5
250x150 10x6 148 428 170 110 14.5
250x200 10x8 135 445 170 140 16.0
300x200 12x8 180 520 200 140 33.0
300x250 12x10 167 537 200 170 35.0
350x250 14x10 224 564 170 170 31.0
350x300 14x12 218 588 170 200 34.0
400x300 16x12 195 625 230 200 42.0
400x350 16x14 193 593 230 170 45.0
450x400 18x16 153 583 200 230 51.0
500x400 20x16 274 734 230 230 81.0
500x450 20x18 201 631 230 200 78.0
600x400 24x16 511 1001 260 230 108.0
600x450 24x18 438 898 260 200 100.0
600x500 24x20 317 807 260 230 106.0
700x400 28x16 796 1376 350 230 264.0
700x450 28x18* 723 1273 350 200 257.0
700x500 28x20* 602 1182 350 230 262.0
700x600 28x24* 365 975 350 260 263.0
700x400 28x16** 796 1286 260 230 230.0
700x450 28x18** 723 1183 260 200 223.0
700x500 28x20** 602 1092 260 230 228.0
700x600 28x24** 365 885 260 260 229.0
* For Bondstrand 2425 only
** For Bondstrand 3425 only
Note: Eccentric Reducers are available on request
Concentric Reducers
FP657-25 Fittings & Flanges for 2425/3425. Page 7 of 12.
Filament-wound couplings with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Outside Weight
Length Length Depth Diameter
L OL Ds OD
mm inch mm mm mm mm kg
50 2 70 170 50 70 0.4
80 3 70 230 80 100 0.9
100 4 70 230 80 124 1.2
150 6 70 290 110 180 2.2
200 8 70 350 140 238 5.0
250 10 70 410 170 296 7.9
300 12 70 470 200 350 11.6
350 14 70 410 170 381 11.3
400 16 70 530 230 435 17.4
450 18 70 470 200 472 15.8
500 20 70 530 230 524 21.0
600 24 70 590 260 634 39.0
700* 28 70 770 350 752 39.0
700** 28 70 590 260 745 29.0
Couplings
Filament-wound pipe nipples with integral Taper-Taper adhesive bonded spigot ends
Nominal Pipe Size Laying gap Insertion Weight
Length Depth
L Ds
mm inch mm mm mm kg
50 2 125 25 50 0.1
80 3 185 25 80 0.2
100 4 185 25 80 0.3
150 6 245 25 110 0.8
200 8 310 30 140 1.5
250 10 370 30 170 2.9
300 12 440 40 200 4.7
350 14 380 40 170 4.6
400 16 500 40 230 8.6
450 18 460 60 200 8.6
500 20 520 60 230 12.4
600 24 580 60 260 19.0
700* 28 760 60 350 35.0
700** 28 580 60 260 26.0
Nipples
* For Bondstrand 2425 only
** For Bondstrand 3425 only
* For Bondstrand 2425 only
** For Bondstrand 3425 only
FP657-25 Fittings & Flanges for 2425/3425. Page 8 of 12.
Heavy-Duty filament-wound flanges with Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overal Insertion Weight
Length Length Depth
L D Ds (1) (2)
mm inch mm mm mm kg
50 2 5 55 50 1.7
80 3 5 55 50 2.6
100 4 5 85 80 5.9
150 6 5 85 80 8.3
200 8 6 116 110 15.2
250 10 6 146 140 24.0
300 12 6 176 170 39.0
350 14 6 176 170 50.0
Notes:
(1) Underlined insertion depth for subsequent flanges deviates from other fittings.
(2) The weights shown are for ANSI B16.5 Class 150 drilled flanges. Weights for other
drilling classes may be different. For more detailed information reference is made to
the appropriate product data.
* Heavy Duty Flanges are standard available in drillings according to ANSI and ISO (DIN).
** Full-face elastomeric gaskets may be used, suitable for the service pressure, service
temperature and fluid. Shore A durometer hardness of 60 5 is recommended and a
thickness of 3 mm.
Compressed fibre gaskets, 3 mm thick, compatible with the pressure, temperature
and medium, may also be used. The mechanical properties should be in accordance
with DIN 3754 (IT 400) or equal.
*** For maximum bolt torque refer to the appropriate Bondstrand literature. Please be
aware that excessive torque may result in flange failure and, therefore a torque-
wrench is required.
* For Bondstrand 2425 only
** For Bondstrand 3425 only
Heavy-Duty Flanges
FP657-25 Fittings & Flanges for 2425/3425. Page 9 of 12.
Filament-wound Stub-end flanges with Taper-Taper adhesive bonded socket ends
and steel backing rings
Nominal Pipe Size Laying Overall Insertion Ring Weigth Weight
Length Length Depth to GRE steel
Face stub- ring
L OL Ds H end (1)
mm inch mm mm mm mm kg kg
50 2 15 65 50 10 0.2 2.5
80 3 15 95 80 16 0.7 4.8
100 4 15 95 80 16 1.1 7.0
150 6 15 125 110 23 2.3 12.2
200 8 15 155 140 29 4.0 18.3
250 10 15 185 170 33 5.5 26.0
300 12 15 215 200 38 7.6 39.0
350 14 15 185 170 33 6.5 56.0
400 16 20 250 230 47 11.6 70.0
450 18 20 220 200 42 17.9 85.0
500 20 20 250 230 47 22 107.0
600 24 20 280 260 57 23 182.0
700* 28 20 370 350 63 26 252.0
700** 28 20 280 260 63 21 252.0
* For Bondstrand 2425 only
** For Bondstrand 3425 only
Notes:
(1) The weight shown is for ANSI B16.5 Class 150 drilled flanges. Weights for other
drilling classes may be different. For more detailed information reference is made to
the appropriate product data.
* Stub-End Flange Rings are standard available in drillings according to ANSI and ISO
(DIN).
** Stub-End Flanges are available with and without O-ring groove in the face.
Up to 10 bar stub-ends without grooves can be used with flat elastomeric or
compressed fibre gaskets.
For pressures 12 bar and above suitable O-ring seals should be used, available on
request.
*** Make sure that the O-ring grooved stub-end is compatible with its counter flange,
e.g. use a stub-end without groove or another flat surface flange as counter flange.
**** Maximum bolt-torque for use with O-rings seals may be calculated based on
pressure, size and number of bolts. If using flat face gaskets (maximum pressure 10
bar) refer to the appropriate Bondstrand literature for hubbed flanges.
Stub-end Flanges
FP657-25 Fittings & Flanges for 2425/3425. Page 10 of 12.
Filament around adapters and couplings with Key-lock ends.
Nominal Pipe Qty Laying Overall Insertion Weigth Laying Overall Weigth
Size of Length Length Depth Length Length
Keys L OL Ds L OL
mm inch mm mm mm kg mm mm kg
adapter KLM x TBF coupling KLF x KLF
50 2 1 5 100 50 0.3 100 140 0.8
80 3 1 5 130 80 0.6 100 140 1.0
100 4 2 30 155 80 1.0 100 191 2.9
150 6 2 59 225 110 2.1 127 245 5.7
200 8 2 77 285 140 3.6 152 312 10.9
250 10 2 83 325 170 5.2 163 335 15.6
300 12 2 95 380 200 8.3 186 386 25.0
350 14 2 83 340 170 11.7 191 403 29.0
400 16 2 85 405 230 13.8 197 426 38.0
450 18 2 87.5 382 200 18.2 204 392 27.0
500 20 2 108 435 230 23.0 210 409 32.0
600 24 2 124 506 260 35.0 261 519 71.0
Key-lock Adapters
& Couplings
Pipe system is designed for field testing with water at 150% of rated pressure.
Maximum allowable surge pressure is 150% of rated pressure.
Field Testing
Surge Pressure
1 psi = 6895 Pa = 0.07031 kg/cm
2
1 bar = 105Pa = 14.5 psi = 1.02 kg/cm
2
1 MPa = 1 N/mm
2
= 145 psi = 10.2 kg/cm
2
1 inch = 25.4 mm
1 Btu.in/ft2hF = 0.1442 W/mK
C = 5/9 (F-32)
This product literature and the recommendations for usage it contains are based on test data
reasonably believed to be reliable. It is intended that this literature be used by personnel
having specialised training in accordance with currently accepted industry practice and
normal operating conditions. Variation in environment, changes in operating procedures, or
extrapolation of data may cause unsatisfactory results. We recommend that your engineers
verify the suitability of this product for your intended application. Since we have no control
over the conditions of service, we expressly disclaim responsibility for the results obtained
or for any consequential or incidental damages of any kind incurred.
Conversions
Important Notice
FP657-25 Fittings & Flanges for 2425/3425. Page 11 of 12.
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.n
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet:www.ameron.com
email:marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Fittings & Flanges for
pipe series 2432 and 3432
using the Taper/Taper adhesive-bonded joint
Bondstrand

Product Data
Bondstrand Taper-Taper fittings & flanges are glassfiber reinforced filament-wound epoxy
pipe fittings in diameters 50 through 1000 mm (2-40 inch) designed to be used with
Bondstrand pipes. Pipe is standard with integral Taper-Taper spigot and socket ends for
adhesive bonding or with integral Key-Lock male and female ends for mechanical joining.
Fittings are filament-wound with integral taper socket ends. Pipes and fittings are
available in several pressure classes from 10 bar upwards.
For intended services and performance capabilities refer to product data sheet FP 452 and
FP 158 pertaining to Bondstrand Series 2400 and 3400 pipe data.
For recommendations pertaining to design, installation and use of Bondstrand Pipe,
Fittings and Flanges reference is made to the following literature:
FP 564 Assembly Instructions for Taper-Taper adhesive bonded joints.
FP 161 Installation Instructions using the Key-Lock mechanical joint.
FP 453 M86 Pipe Shaver operating instructions for Taper-Taper joints in sizes
50 to 150 mm (2-6 inch).
FP 454 M87 Pipe Shaver operating instructions for Taper-Taper joints in sizes
150 to 400 mm (6-16 inch).
FP 455 M87XL Pipe Shaver operating instructions for Taper-Taper joints in
sizes 400 to 600 mm (16-24 inch).
FP 643 M95 Pipe Shaver operating instructions for Taper-Taper joints in sizes
600 to 1000 mm (24-40 inch).
FP 196 Flange Assembly Instructions.
FP 132 Corrosion Guide.
General Bondstrand engineering and installation guides.
Dimensional data for Taper-Taper adhesive bonded fittings are contained in individual
dimensional sheets per pressure class:
FP No. Fitting Pipe System Pressure
549-10 T-10 2410 and 3410 10 bar
549-12 T-12 2412 and 3412 12 bar
549-14 T-14 2414 and 3414 14 bar
549-16 T-16 2416 and 3416 16 bar
549-20 T-20 2420 and 3420 20 bar
549-25 T-25 2425 and 3425 25 bar
549-32 T-32 2432 and 3432 32 bar
549-40 T-40 2440 and 3440 40 bar
549-50 T-50 2450 and 3450 50 bar
Ameron 1998 FP657-32 (8/98). Printed in The Netherlands. Page 1 of 12.
Description
Uses and Application
Design and Installation
How to use this product
data sheet
FP657-32 Fittings & Flanges for 2432/3432. Page 2 of 12.
Nominal Pipe Size Taper Insertion Spigot Spigot
Angle Depth Nose Diameter
Thickness at Nose
Ds t
mm inch degrees mm mm mm
50 2 1.75 50 1.0 55.2
80 3 1.75 80 1.0 83.8
100 4 1.75 80 1.0 107.2
150 6 2.50 110 1.0 161.0
200 8 2.50 140 1.0 210.8
250 10 2.50 170 1.5 265.9
300 12 2.50 200 1.5 316.7
350 14 2.50 230 2.0 348.4
400 16 2.50 230 2.5 398.7
450 18 2.50 260 2.5 438.8
500 20 2.50 290 3.0 488.1
600 24 2.50 350 3.5 585.6
Dimensions of the
taper-taper joint
Nominal Adhesive Minimum number of
Pipe Size Kit Size adhesive kits per joint
fluid
mm inch cm
3
ounce nr.
50 2 89 3 0.2
80 3 89 3 0.4
100 4 89 3 0.6
150 6 89 3 1.0
200 8 177 6 1.0
250 10 177 6 2.0
300 12 177 6 2.0
350 14 177 6 3.0
400 16 177 6 3.0
450 18 177 6 4.0
500 20 177 6 5.0
600 24 177 6 7.0
Note:
Adhesive kits should never be split. If remainder is not used for other joints made at the
same time, the surplus must be discarded.
Quantity of Adhesive
FP657-32 Fittings & Flanges for 2432/3432. Page 3 of 12.
Filament-wound 90 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 87 137 50 0.6
80 3 110 190 80 2.1
100 4 155 235 80 3.8
150 6 240 350 110 8.7
200 8 315 455 140 24.0
250 10 391 561 170 39.0
300 12 463 663 200 61.0
350 14 364 594 230 66.0
400 16 402 632 230 84.0
450 18 472 732 260 168.0
500 20 523 813 290 230.0
600 24 625 975 350 367.0
Elbows 90
Filament-wound 45 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 45 95 50 0.5
80 3 61 141 80 1.7
100 4 73 153 80 2.4
150 6 106 216 110 7.0
200 8 137 277 140 15.5
250 10 169 339 170 32.0
300 12 196 396 200 45.0
350 14 125 355 230 58.0
400 16 142 372 230 80.0
450 18 204 464 260 115.0
500 20 225 515 290 157.0
600 24 268 618 350 281.0
Elbows 45
FP657-32 Fittings & Flanges for 2432/3432. Page 4 of 12.
Filament-wound 22
1
/2 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 29 79 50 0.4
80 3 37 117 80 1.5
100 4 43 123 80 2.0
150 6 60 170 110 5.9
200 8 76 216 140 10.5
250 10 68 238 170 19.1
300 12 77 277 200 32.0
350 14 71 301 230 43.0
400 16 85 315 230 57.0
450 18 106 366 260 78.0
500 20 116 406 290 107.0
600 24 136 486 350 185.0
Elbows 22
1
/2
Filament-wound tees with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Laying Overall Insertion Weight
Length Length Length Length Depth
total total branch branch
run run
L1 OL1 L2 OL2 Ds
mm inch mm mm mm mm mm kg
50 2 148 248 74 124 50 1.6
80 3 192 352 96 176 80 3.6
100 4 230 390 115 195 80 6.4
150 6 306 526 153 263 110 18.0
200 8 376 656 188 328 140 37.0
250 10 452 792 226 396 170 55.0
300 12 528 928 264 464 200 92.0
350 14 544 1004 272 502 230 106.0
400 16 590 1050 295 525 230 126.0
450 18 678 1198 339 599 260 293.0
500 20 740 1320 370 660 290 398.0
600 24 868 1568 434 784 350 682.0
Tees
FP657-32 Fittings & Flanges for 2432/3432. Page 5 of 12.
Filament-wound reducing tees with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Laying Overall Insertion Weight
Length Length Depth Length Length Depth
half half run branch branch branch
run x run x branch run run
L1 OL1 Ds1 L2 OL2 Ds2
mm inch mm mm mm mm mm mm kg
80x80x50 3x3x2 96 176 80 86 136 50 3.0
100x100x50 4x4x2 115 195 80 99 149 50 5.4
100x100x80 4x4x3 115 195 80 108 188 80 5.5
150x150x50 6x6x2 153 263 110 124 174 50 12.2
150x150x80 6x6x3 153 263 110 134 214 80 12.6
150x150x100 6x6x4 153 263 110 140 220 80 13.7
200x200x80 8x8x3 188 328 140 159 239 80 19.3
200x200x100 8x8x4 188 328 140 172 252 80 26.0
200x200x150 8x8x6 188 328 140 178 288 110 33.0
250x250x100 10x10x4 226 396 170 194 274 80 42.0
250x250x150 10x10x6 226 396 170 204 314 110 42.0
250x250x200 10x10x8 226 396 170 213 353 140 53.0
300x300x100 12x12x4 264 464 200 216 296 80 60.0
300x300x150 12x12x6 264 464 200 229 339 110 86.0
300x300x200 12x12x8 264 464 200 239 379 140 90.0
300x300x250 12x12x10 264 464 200 251 421 170 92.0
350x350x150 14x14x6 272 502 230 254 364 110 92.0
350x350x200 14x14x8 272 502 230 264 404 140 96.0
350x350x250 14x14x10 272 502 230 277 447 170 102.0
350x350x300 14x14x12 272 502 230 289 489 200 106.0
400x400x150 16x16x6 295 525 230 274 384 110 97.0
400x400x200 16x16x8 295 525 230 283 423 140 102.0
400x400x250 16x16x10 295 525 230 293 463 170 107.0
400x400x300 16x16x12 295 525 230 305 505 200 117.0
400x400x350 16x16x14 295 525 230 315 545 230 104.0
450x450x200 18x18x8 339 599 260 316 456 140 210.0
450x450x250 18x18x10 339 599 260 329 499 170 218.0
450x450x300 18x18x12 339 599 260 329 529 200 227.0
450x450x350 18x18x14 339 599 260 330 560 230 234.0
450x450x400 18x18x16 339 599 260 330 560 230 240.0
500x500x250 20x20x10 370 660 290 355 525 170 339.0
500x500x300 20x20x12 370 660 290 355 555 200 250.0
500x500x350 20x20x14 370 660 290 356 586 230 360.0
500x500x400 20x20x16 370 660 290 356 586 230 367.0
500x500x450 20x20x18 370 660 290 365 525 260 381.0
600x600x300 24x24x12 434 784 350 405 605 200 577.0
600x600x350 24x24x14 434 784 350 406 636 230 589.0
600x600x400 24x24x16 434 784 350 406 636 230 598.0
600x600x450 24x24x18 434 784 350 428 688 260 619.0
600x600x500 24x24x20 434 784 350 428 716 290 638.0
Reducing Tees
FP657-32 Fittings & Flanges for 2432/3432. Page 6 of 12.
Filament-wound concentric reducers with integral Taper-Taper adhesive bonded
socket ends
Nominal Pipe Size Laying Overall Overall Insertion Weight
Length Length Length Depth
L OL Ds1 Ds2
mm inch mm mm mm mm kg
80x50 3x2 74 204 80 50 0.9
100x50 4x2 96 226 80 50 2.7
100x80 4x3 94 254 80 80 2.8
150x80 6x3 117 307 110 80 3.9
150x100 6x4 124 314 110 80 4.2
200x100 8x4 163 383 140 80 9.5
200x150 8x6 129 379 140 110 9.5
250x150 10x6 148 428 170 110 14.5
250x200 10x8 135 445 170 140 16.0
300x200 12x8 180 520 200 140 33.0
300x250 12x10 167 537 200 170 35.0
350x250 14x10 214 614 230 170 45.0
350x300 14x12 208 638 230 200 50.0
400x300 16x12 195 625 230 200 42.0
400x350 16x14 183 643 230 230 48.0
450x400 18x16 128 618 260 230 71.0
500x400 20x16 249 769 290 230 113.0
500x450 20x18 151 701 290 260 117.0
600x400 24x16 486 1066 350 230 156.0
600x450 24x18 388 998 350 260 155.0
600x500 24x20 267 907 350 290 164.0
Note: Eccentric Reducers are available on request
Concentric Reducers
FP657-32 Fittings & Flanges for 2432/3432. Page 7 of 12.
Filament-wound couplings with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Outside Weight
Length Length Depth Diameter
L OL Ds OD
mm inch mm mm mm mm kg
50 2 70 170 50 70 0.4
80 3 70 230 80 100 0.9
100 4 70 230 80 124 1.2
150 6 70 290 110 180 2.2
200 8 70 350 140 238 5.0
250 10 70 410 170 296 7.9
300 12 70 470 200 350 11.6
350 14 70 530 230 381 13.2
400 16 70 530 230 435 17.4
450 18 70 590 260 472 17.8
500 20 70 650 290 524 23.0
600 24 70 770 350 630 41.0
Couplings
Filament-wound pipe nipples with integral Taper-Taper adhesive bonded spigot ends
Nominal Pipe Size Laying gap Insertion Weight
Length Depth
L Ds
mm inch mm mm mm kg
50 2 125 25 50 0.1
80 3 185 25 80 0.2
100 4 185 25 80 0.3
150 6 245 25 110 0.8
200 8 310 30 140 1.6
250 10 370 30 170 3.1
300 12 440 40 200 5.0
350 14 500 40 230 7.4
400 16 500 40 230 9.1
450 18 580 60 260 12.9
500 20 640 60 290 17.8
600 24 760 60 350 30.0
Nipples
FP657-32 Fittings & Flanges for 2432/3432. Page 8 of 12.
Heavy-Duty filament-wound flanges with Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overal Insertion Weight
Length Length Depth
L D Ds (1)
mm inch mm mm mm kg
50 2 5 55 50 1.7
80 3 5 85 80 4.0
100 4 5 85 80 5.9
150 6 5 115 110 11.2
200 8 6 146 140 19.2
250 10 6 176 170 28.0
Notes:
(1) The weights shown are for ANSI B16.5 Class 300 drilled flanges. Weights for other
drilling classes may be different. For more detailed information reference is made to
the appropriate product data.
* Heavy Duty Flanges are standard available in drillings according to ANSI and ISO (DIN).
** Full-face elastomeric gaskets may be used, suitable for the service pressure, service
temperature and fluid. Shore A durometer hardness of 60 5 is recommended and a
thickness of 3 mm.
Compressed fibre gaskets, 3 mm thick, compatible with the pressure, temperature
and medium, may also be used. The mechanical properties should be in accordance
with DIN 3754 (IT 400) or equal.
*** For maximum bolt torque refer to the appropriate Bondstrand literature. Please be
aware that excessive torque may result in flange failure and, therefore a torque-
wrench is required.
Heavy-Duty Flanges
FP657-32 Fittings & Flanges for 2432/3432. Page 9 of 12.
Filament-wound Stub-end flanges with Taper-Taper adhesive bonded socket ends
and steel backing rings
Nominal Pipe Size Laying Overall Insertion Ring Weigth Weight
Length Length Depth to GRE steel
Face stub- ring
L OL Ds H end (1)
mm inch mm mm mm mm kg kg
50 2 15 65 50 10 0.2 2.5
80 3 15 95 80 16 0.7 4.8
100 4 15 95 80 16 1.1 7.0
150 6 15 125 110 23 2.3 12.2
200 8 15 155 140 29 4.0 18.3
250 10 15 185 170 33 5.5 26.0
300 12 15 215 200 38 7.6 39.0
350 14 15 245 230 40 7.9 56.0
400 16 20 250 230 47 11.6 70.0
450 18 20 280 260 51 22.0 85.0
500 20 20 310 290 58 26.0 107.0
600 24 20 370 350 71 29.0 182.0
Notes:
(1) The weight shown is for ANSI B16.5 Class 300 drilled flanges. Weights for other
drilling classes may be different. For more detailed information reference is made to
the appropriate product data.
* Stub-End Flange Rings are standard available in drillings according to ANSI and ISO
(DIN).
** Stub-End Flanges are available with and without O-ring groove in the face.
Suitable O-ring seals should be used, available on request.
*** Make sure that the O-ring grooved stub-end is compatible with its counter flange,
e.g. use a stub-end without groove or another flat surface flange as counter flange.
**** Maximum bolt-torque for use with O-rings seals may be calculated based on
pressure, size and number of bolts.
Stub-end Flanges
FP657-32 Fittings & Flanges for 2432/3432. Page 10 of 12.
Filament around adapters and couplings with Key-lock ends.
Nominal Pipe Qty Laying Overall Insertion Weigth Laying Overall Weigth
Size of Length Length Depth Length Length
Keys L OL Ds L OL
mm inch mm mm mm kg mm mm kg
adapter KLM x TBF coupling KLF x KLF
50 2 1 5 100 50 0.3 100 140 0.8
80 3 2 60 185 80 0.9 100 191 2.4
100 4 2 30 155 80 1.0 100 191 2.9
150 6 2 59 225 110 2.1 127 245 5.7
200 8 2 77 285 140 3.6 152 312 10.9
250 10 2 83 325 170 5.2 163 335 15.8
300 12 2 100 390 200 20.0 196 470 45.0
350 14 2 111 437 230 36.0 208 498 59.0
400 16 2 116 462 230 45.0 247 553 76.0
Key-lock Adapters
& Couplings
Pipe system is designed for field testing with water at 150% of rated pressure.
Maximum allowable surge pressure is 150% of rated pressure.
Field Testing
Surge Pressure
1 psi = 6895 Pa = 0.07031 kg/cm
2
1 bar = 105Pa = 14.5 psi = 1.02 kg/cm
2
1 MPa = 1 N/mm
2
= 145 psi = 10.2 kg/cm
2
1 inch = 25.4 mm
1 Btu.in/ft2hF = 0.1442 W/mK
C = 5/9 (F-32)
This product literature and the recommendations for usage it contains are based on test data
reasonably believed to be reliable. It is intended that this literature be used by personnel
having specialised training in accordance with currently accepted industry practice and
normal operating conditions. Variation in environment, changes in operating procedures, or
extrapolation of data may cause unsatisfactory results. We recommend that your engineers
verify the suitability of this product for your intended application. Since we have no control
over the conditions of service, we expressly disclaim responsibility for the results obtained
or for any consequential or incidental damages of any kind incurred.
Conversions
Important Notice
FP657-32 Fittings & Flanges for 2432/3432. Page 11 of 12.
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.n
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet:www.ameron.com
email:marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Fittings & Flanges for
pipe series 2440 and 3440
using the Taper-Taper adhesive-bonded joint
Bondstrand

Product Data
Bondstrand Taper-Taper fittings & flanges are glassfiber reinforced filament-wound epoxy
pipe fittings in diameters 50 through 1000 mm (2-40 inch) designed to be used with
Bondstrand pipes. Pipe is standard with integral Taper-Taper spigot and socket ends for
adhesive bonding or with integral Key-Lock male and female ends for mechanical joining.
Fittings are filament-wound with integral taper socket ends. Pipes and fittings are
available in several pressure classes from 10 bar upwards.
For intended services and performance capabilities refer to product data sheet FP 452 and
FP 158 pertaining to Bondstrand Series 2400 and 3400 pipe data.
For recommendations pertaining to design, installation and use of Bondstrand Pipe,
Fittings and Flanges reference is made to the following literature:
FP 564 Assembly Instructions for Taper-Taper adhesive bonded joints.
FP 161 Installation Instructions using the Key-Lock mechanical joint.
FP 453 M86 Pipe Shaver operating instructions for Taper-Taper joints in sizes
50 to 150 mm (2-6 inch).
FP 454 M87 Pipe Shaver operating instructions for Taper-Taper joints in sizes
150 to 400 mm (6-16 inch).
FP 455 M87XL Pipe Shaver operating instructions for Taper-Taper joints in
sizes 400 to 600 mm (16-24 inch).
FP 643 M95 Pipe Shaver operating instructions for Taper-Taper joints in sizes
600 to 1000 mm (24-40 inch).
FP 196 Flange Assembly Instructions.
FP 132 Corrosion Guide.
General Bondstrand engineering and installation guides.
Dimensional data for Taper-Taper adhesive bonded fittings are contained in individual
dimensional sheets per pressure class:
FP No. Fitting Pipe System Pressure
549-10 T-10 2410 and 3410 10 bar
549-12 T-12 2412 and 3412 12 bar
549-14 T-14 2414 and 3414 14 bar
549-16 T-16 2416 and 3416 16 bar
549-20 T-20 2420 and 3420 20 bar
549-25 T-25 2425 and 3425 25 bar
549-32 T-32 2432 and 3432 32 bar
549-40 T-40 2440 and 3440 40 bar
549-50 T-50 2450 and 3450 50 bar
Ameron 1998 FP657-40 (8/98). Printed in The Netherlands. Page 1 of 12.
Description
Uses and Application
Design and Installation
How to use this product
data sheet
FP657-40 Fittings & Flanges for 2440/3440. Page 2 of 12.
Nominal Pipe Size Taper Insertion Spigot Spigot
Angle Depth Nose Diameter
Thickness at Nose
Ds t
mm inch degrees mm mm mm
50 2 1.75 80 1.0 55.2
80 3 1.75 80 1.0 83.8
100 4 1.75 110 1.5 108.2
150 6 2.50 140 1.5 162.0
200 8 2.50 170 1.5 211.8
250 10 2.50 200 2.5 267.9
300 12 2.50 260 2.5 318.7
350 14 2.50 260 3.0 350.4
400 16 2.50 290 3.5 400.7
450 18 2.50 320 4.0 441.8
500* 20 2.50 380 4.0 490.1
500** 20 2.50 290 4.0 490.1
Dimensions of the
taper-taper joint
Nominal Adhesive Minimum number of
Pipe Size Kit Size adhesive kits per joint
fluid
mm inch cm
3
ounce nr.
50 2 89 3 0.2
80 3 89 3 0.4
100 4 89 3 0.8
150 6 177 6 1.0
200 8 177 6 2.0
250 10 177 6 2.0
300 12 177 6 3.0
350 14 177 6 3.0
400 16 177 6 4.0
450 18 177 6 5.0
500* 20 177 6 7.0
500** 20 177 6 6.0
* For Bondstrand 2440 only
** For Bondstrand 3440 only
Note:
Adhesive kits should never be split. If remainder is not used for other joints made at the
same time, the surplus must be discarded.
Quantity of Adhesive
* For Bondstrand 2440 only
** For Bondstrand 3440 only
FP657-40 Fittings & Flanges for 2440/3440. Page 3 of 12.
Filament-wound 90 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 87 167 80 0.9
80 3 110 190 80 2.1
100 4 170 280 110 5.2
150 6 240 380 140 13.0
200 8 315 485 170 34.0
250 10 416 616 200 54.0
300 12 488 748 260 94.0
350 14 389 649 260 100.0
400 16 427 717 290 135.0
450 18 507 827 320 200.0
500* 20 548 928 380 278.0
500** 20 548 838 290 247.0
Elbows 90
Filament-wound 45 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 45 125 80 0.8
80 3 61 141 80 1.7
100 4 88 198 110 4.0
150 6 106 246 140 10.8
200 8 137 307 170 23.0
250 10 194 394 200 45.0
300 12 221 481 260 73.0
350 14 150 410 260 86.0
400 16 167 457 290 121.0
450 18 239 559 320 182.0
500* 20 250 630 380 258.0
500** 20 250 540 290 211.0
Elbows 45
* For Bondstrand 2440 only
** For Bondstrand 3440 only
* For Bondstrand 2440 only
** For Bondstrand 3440 only
FP657-40 Fittings & Flanges for 2440/3440. Page 4 of 12.
Filament-wound 22
1
/2 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 29 109 80 0.7
80 3 37 117 80 1.5
100 4 58 168 110 3.5
150 6 60 200 140 9.2
200 8 76 246 170 16.1
250 10 93 293 200 30.0
300 12 102 362 260 54.0
350 14 96 356 260 64.0
400 16 110 400 290 87.0
450 18 141 461 320 126.0
500* 20 141 521 380 181.0
500** 20 141 431 290 142.0
Elbows 22
1
/2
Filament-wound tees with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Laying Overall Insertion Weight
Length Length Length Length Depth
total total branch branch
run run
L1 OL1 L2 OL2 Ds
mm inch mm mm mm mm mm kg
50 2 148 308 74 154 80 2.0
80 3 192 352 96 176 80 3.6
100 4 260 480 130 240 110 9.8
150 6 306 586 153 293 140 21.0
200 8 376 716 188 358 170 49.0
250 10 502 902 251 451 200 78.0
300 12 578 1098 289 549 260 136.0
350 14 594 1114 297 557 260 164.0
400 16 640 1220 320 610 290 219.0
450 18 748 1388 374 694 320 388.0
500* 20 790 1550 395 775 380 623.0
500** 20 790 1370 395 685 290 542.0
Tees
* For Bondstrand 2440 only
** For Bondstrand 3440 only
* For Bondstrand 2440 only
** For Bondstrand 3440 only
FP657-40 Fittings & Flanges for 2440/3440. Page 5 of 12.
Filament-wound reducing tees with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Laying Overall Insertion Weight
Length Length Depth Length Length Depth
half half run branch branch branch
run x run x branch run run
L1 OL1 Ds1 L2 OL2 Ds2
mm inch mm mm mm mm mm mm kg
80x80x50 3x3x2 96 176 80 86 166 80 3.5
100x100x50 4x4x2 130 240 110 99 179 80 8.5
100x100x80 4x4x3 130 240 110 108 188 80 8.7
150x150x50 6x6x2 153 293 140 124 204 80 18.3
150x150x80 6x6x3 153 293 140 134 214 80 19.1
150x150x100 6x6x4 153 293 140 155 265 110 21.0
200x200x80 8x8x3 188 358 170 159 239 80 39.0
200x200x100 8x8x4 188 358 170 187 297 110 41.0
200x200x150 8x8x6 188 358 170 178 318 140 44.0
250x250x100 10x10x4 251 451 200 209 319 110 62.0
250x250x150 10x10x6 251 451 200 204 344 140 66.0
250x250x200 10x10x8 251 451 200 213 383 170 70.0
300x300x100 12x12x4 289 549 260 231 341 110 107.0
300x300x150 12x12x6 289 549 260 229 369 140 111.0
300x300x200 12x12x8 289 549 260 239 409 170 116.0
300x300x250 12x12x10 289 549 260 276 476 200 125.0
350x350x150 14x14x6 297 557 260 254 394 140 134.0
350x350x200 14x14x8 297 557 260 264 434 170 140.0
350x350x250 14x14x10 297 557 260 302 502 200 150.0
350x350x300 14x14x12 297 557 260 314 574 260 163.0
400x400x150 16x16x6 320 610 290 274 414 140 176.0
400x400x200 16x16x8 320 610 290 283 453 170 182.0
400x400x250 16x16x10 320 610 290 318 518 200 193.0
400x400x300 16x16x12 320 610 290 330 590 260 206.0
400x400x350 16x16x14 320 610 290 340 600 260 137.0
450x450x200 18x18x8 374 694 320 316 486 170 317.0
450x450x250 18x18x10 374 694 320 354 554 200 3330.0
450x450x300 18x18x12 374 694 320 354 614 260 350.0
450x450x350 18x18x14 374 694 320 355 615 260 356.0
450x450x400 18x18x16 374 694 320 355 645 290 370.0
500x500x250* 20x20x10 395 775 380 380 580 200 521.0
500x500x300* 20x20x12 395 775 380 380 640 260 543.0
500x500x350* 20x20x14 395 775 380 381 641 260 551.0
500x500x400* 20x20x16 395 775 380 381 671 290 570.0
500x500x450* 20x20x18 395 775 380 400 720 320 593.0
500x500x250** 20x20x10 395 685 290 380 580 200 467.0
500x500x300** 20x20x12 395 685 290 380 640 260 489.0
500x500x350** 20x20x14 395 685 290 381 641 260 497.0
500x500x400** 20x20x16 395 685 290 381 671 290 516.0
500x500x450** 20x20x18 395 685 290 400 720 320 539.0
Reducing Tees
* For Bondstrand 2440 only
** For Bondstrand 3440 only
FP657-40 Fittings & Flanges for 2440/3440. Page 6 of 12.
Filament-wound concentric reducers with integral Taper-Taper adhesive bonded
socket ends
Nominal Pipe Size Laying Overall Overall Insertion Weight
Length Length Length Depth
L OL Ds1 Ds2
mm inch mm mm mm mm kg
80x50 3x2 74 234 80 80 1.4
100x50 4x2 111 301 110 80 4.2
100x80 4x3 109 299 110 80 4.3
150x80 6x3 117 337 140 80 4.4
150x100 6x4 139 389 140 110 5.0
200x100 8x4 178 458 170 110 14.2
200x150 8x6 129 439 170 140 16.5
250x150 10x6 173 513 200 140 23.0
250x200 10x8 160 530 200 170 26.0
300x200 12x8 205 635 260 170 50.0
300x250 12x10 217 677 260 200 57.0
350x250 14x10 264 724 260 200 67.0
350x300 14x12 258 778 260 260 79.0
400x300 16x12 245 795 290 260 95.0
400x350 16x14 233 783 290 260 64.0
450x400 18x16 188 798 320 290 116.0
500x400 20x16 299 969 380 290 187.0
500x450 20x18 211 911 380 320 194.0
500x400 20x16 299 879 290 290 164.0
500x450 20x18 211 821 290 320 171.0
* For Bondstrand 2440 only
** For Bondstrand 3440 only
Note: Eccentric Reducers are available on request
Concentric Reducers
FP657-40 Fittings & Flanges for 2440/3440. Page 7 of 12.
Filament-wound couplings with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Outside Weight
Length Length Depth Diameter
L OL Ds OD
mm inch mm mm mm mm kg
50 2 70 230 80 70 0.5
80 3 70 230 80 100 0.9
100 4 70 290 110 124 1.3
150 6 70 350 140 188 3.7
200 8 70 410 170 238 5.3
250 10 70 470 200 296 7.9
300 12 70 590 260 350 12.0
350 14 70 590 260 390 18.5
400 16 70 650 290 445 26.0
450 18 70 710 320 480 24.0
500* 20 70 830 380 544 40.0
500** 20 70 650 290 535 32.0
Couplings
Filament-wound pipe nipples with integral Taper-Taper adhesive bonded spigot ends
Nominal Pipe Size Laying gap Insertion Weight
Length Depth
L Ds
mm inch mm mm mm kg
50 2 185 25 80 0.1
80 3 185 25 80 0.2
100 4 245 25 110 0.5
150 6 305 25 140 1.3
200 8 370 30 170 2.5
250 10 430 30 200 4.8
300 12 560 40 260 8.8
350 14 560 40 260 10.3
400 16 620 40 290 14.6
450 18 700 60 320 21.0
500* 20 820 60 380 26.0
500** 20 640 60 290 20.0
Nipples
* For Bondstrand 2440 only
** For Bondstrand 3440 only
* For Bondstrand 2440 only
** For Bondstrand 3440 only
FP657-40 Fittings & Flanges for 2440/3440. Page 8 of 12.
Heavy-Duty filament-wound flanges with Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overal Insertion Weight
Length Length Depth
L D Ds (1) (2)
mm inch mm mm mm kg
50 2 5 55 50 1.7
80 3 5 85 80 4.0
100 4 5 115 110 7.9
150* 6 5 145 140 14.1
200** 8 6 176 170 23.0
* For Bondstrand 2440 only
** For Bondstrand 3440 only
Notes:
(1) Underlined insertion depth for subsequent flanges deviates from other fittings.
(2) The weights shown are for ANSI B16.5 Class 300 drilled flanges. Weights for other
drilling classes may be different. For more detailed information reference is made to
the appropriate product data.
* Heavy Duty Flanges are standard available in drillings according to ANSI and ISO (DIN).
** Compressed fibre gaskets, 3 mm thick, compatible with the pressure, temperature
and medium, may be used. The mechanical properties should be in accordance with
DIN 3754 (IT 400) or equal.
Heavy-Duty Flanges
FP657-40 Fittings & Flanges for 2440/3440. Page 9 of 12.
Filament-wound Stub-end flanges with Taper-Taper adhesive bonded socket ends
and steel backing rings
Nominal Pipe Size Laying Overall Insertion Ring Weigth Weight
Length Length Depth to GRE steel
Face stub- ring
L OL Ds H end (1)
mm inch mm mm mm mm kg kg
50 2 15 95 80 14 0.3 2.5
80 3 15 95 80 16 0.7 4.8
100 4 15 125 110 19 1.3 7.0
150 6 15 155 140 27 2.7 12.2
200 8 15 185 170 35 4.5 18.3
250 10 15 215 200 40 5.9 26.0
300 12 15 275 260 46 8.5 39.0
350 14 15 275 260 49 8.1 56.0
400 16 20 310 290 58 12.7 70.0
450 18 20 340 320 62 24 85.0
500* 20 20 400 380 70 28 107.0
500** 20 20 310 290 70 25 107.0
* For Bondstrand 2440 only
** For Bondstrand 3440 only
Notes:
(1) The weight shown is for ANSI B16.5 Class 300 drilled flanges. Weights for other
drilling classes may be different. For more detailed information reference is made to
the appropriate product data.
* Stub-End Flange Rings are standard available in drillings according to ANSI and ISO
(DIN).
** Stub-End Flanges are available with and without O-ring groove in the face.
Suitable O-ring seals should be used, available on request.
*** Make sure that the O-ring grooved stub-end is compatible with its counter flange,
e.g. use a stub-end without groove or another flat surface flange as counter flange.
**** Maximum bolt-torque for use with O-rings seals may be calculated based on
pressure, size and number of bolts.
Stub-end Flanges
FP657-40 Fittings & Flanges for 2440/3440. Page 10 of 12.
Filament around adapters and couplings with Key-lock ends.
Nominal Pipe Qty Laying Overall Insertion Weigth Laying Overall Weigth
Size of Length Length Depth Length Length
Keys L OL Ds L OL
mm inch mm mm mm kg mm mm kg
adapter KLM x TBF coupling KLF x KLF
50 2 35 160 80 0.5 100 140 0.8
80 3 2 60 185 80 0.9 100 191 2.4
100 4 2 45 200 110 1.2 100 191 2.9
150 6 2 69 265 140 2.3 127 245 5.8
200 8 2 101 370 170 8.4 228 501 23.0
250 10 2 100 395 200 19.4 210 484 25.0
300 12 2 100 450 260 22.0 196 470 45.0
350* 14 2 111 467 260 39.0 208 498 59.0
400** 16 2 116 522 290 42.0 247 553 76.0
Key-lock Adapters
& Couplings
Pipe system is designed for field testing with water at 150% of rated pressure.
Maximum allowable surge pressure is 150% of rated pressure.
Field Testing
Surge Pressure
1 psi = 6895 Pa = 0.07031 kg/cm
2
1 bar = 105Pa = 14.5 psi = 1.02 kg/cm
2
1 MPa = 1 N/mm
2
= 145 psi = 10.2 kg/cm
2
1 inch = 25.4 mm
1 Btu.in/ft2hF = 0.1442 W/mK
C = 5/9 (F-32)
This product literature and the recommendations for usage it contains are based on test data
reasonably believed to be reliable. It is intended that this literature be used by personnel
having specialised training in accordance with currently accepted industry practice and
normal operating conditions. Variation in environment, changes in operating procedures, or
extrapolation of data may cause unsatisfactory results. We recommend that your engineers
verify the suitability of this product for your intended application. Since we have no control
over the conditions of service, we expressly disclaim responsibility for the results obtained
or for any consequential or incidental damages of any kind incurred.
Conversions
Important Notice
* For Bondstrand 2440 only
** For Bondstrand 3440 only
FP657-40 Fittings & Flanges for 2440/3440. Page 11 of 12.
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.n
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet:www.ameron.com
email:marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Fittings & Flanges for
pipe series 2450 and 3450
using the Taper/Taper adhesive-bonded joint
Bondstrand

Product Data
Bondstrand Taper-Taper fittings & flanges are glassfiber reinforced filament-wound epoxy
pipe fittings in diameters 50 through 1000 mm (2-40 inch) designed to be used with
Bondstrand pipes. Pipe is standard with integral Taper-Taper spigot and socket ends for
adhesive bonding or with integral Key-Lock male and female ends for mechanical joining.
Fittings are filament-wound with integral taper socket ends. Pipes and fittings are
available in several pressure classes from 10 bar upwards.
For intended services and performance capabilities refer to product data sheet FP 452 and
FP 158 pertaining to Bondstrand Series 2400 and 3400 pipe data.
For recommendations pertaining to design, installation and use of Bondstrand Pipe,
Fittings and Flanges reference is made to the following literature:
FP 564 Assembly Instructions for Taper-Taper adhesive bonded joints.
FP 161 Installation Instructions using the Key-Lock mechanical joint.
FP 453 M86 Pipe Shaver operating instructions for Taper-Taper joints in sizes
50 to 150 mm (2-6 inch).
FP 454 M87 Pipe Shaver operating instructions for Taper-Taper joints in sizes
150 to 400 mm (6-16 inch).
FP 455 M87XL Pipe Shaver operating instructions for Taper-Taper joints in
sizes 400 to 600 mm (16-24 inch).
FP 643 M95 Pipe Shaver operating instructions for Taper-Taper joints in sizes
600 to 1000 mm (24-40 inch).
FP 196 Flange Assembly Instructions.
FP 132 Corrosion Guide.
General Bondstrand engineering and installation guides.
Dimensional data for Taper-Taper adhesive bonded fittings are contained in individual
dimensional sheets per pressure class:
FP No. Fitting Pipe System Pressure
549-10 T-10 2410 and 3410 10 bar
549-12 T-12 2412 and 3412 12 bar
549-14 T-14 2414 and 3414 14 bar
549-16 T-16 2416 and 3416 16 bar
549-20 T-20 2420 and 3420 20 bar
549-25 T-25 2425 and 3425 25 bar
549-32 T-32 2432 and 3432 32 bar
549-40 T-40 2440 and 3440 40 bar
549-50 T-50 2450 and 3450 50 bar
Ameron 1998 FP657-50 (8/98). Printed in The Netherlands. Page 1 of 12.
Description
Uses and Application
Design and Installation
How to use this product
data sheet
FP657-50 Fittings & Flanges for 2450/3450. Page 2 of 12.
Nominal Pipe Size Taper Insertion Spigot Spigot
Angle Depth Nose Diameter
Thickness at Nose
Ds t
mm inch degrees mm mm mm
50 2 1.75 80 1.0 55.2
80 3 1.75 110 1.5 84.8
100 4 1.75 140 2.0 109.2
150 6 2.50 170 2.0 163.0
200 8 2.50 200 2.5 213.8
250 10 2.50 260 3.0 268.9
300 12 2.50 290 3.5 320.7
Dimensions of the
taper-taper joint
Nominal Adhesive Minimum number of
Pipe Size Kit Size adhesive kits per joint
fluid
mm inch cm
3
ounce nr.
50 2 89 3 0.2
80 3 89 3 0.6
100 4 89 3 1.0
150 6 177 6 1.0
200 8 177 6 2.0
250 10 177 6 3.0
300 12 177 6 3.0
Note:
Adhesive kits should never be split. If remainder is not used for other joints made at the
same time, the surplus must be discarded.
Quantity of Adhesive
FP657-50 Fittings & Flanges for 2450/3450. Page 3 of 12.
Filament-wound 90 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 87 167 80 1.1
80 3 125 235 110 3.4
100 4 190 330 140 7.0
150 6 250 420 170 22.0
200 8 340 540 200 48.0
250 10 416 676 260 77.0
300 12 463 753 290 122.0
Elbows 90
Filament-wound 45 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 45 125 80 1.0
80 3 76 186 110 2.9
100 4 108 248 140 6.3
150 6 116 286 170 16.7
200 8 162 362 200 35.0
250 10 194 454 260 70.0
300 12 196 486 290 97.0
Elbows 45
FP657-50 Fittings & Flanges for 2450/3450. Page 4 of 12.
Filament-wound 22
1
/2 elbows with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Weight
Length Length Depth
L OL Ds
mm inch mm mm mm kg
50 2 29 109 80 0.8
80 3 52 162 110 2.5
100 4 78 218 140 5.5
150 6 70 240 170 14.1
200 8 101 301 200 24.0
250 10 93 353 260 48.0
300 12 77 367 290 74.0
Elbows 22
1
/2
Filament-wound tees with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Laying Overall Insertion Weight
Length Length Length Length Depth
total total branch branch
run run
L1 OL1 L2 OL2 Ds
mm inch mm mm mm mm mm kg
50 2 148 308 74 154 80 2.3
80 3 222 442 111 221 110 7.3
100 4 300 580 150 290 140 16.4
150 6 326 666 163 333 170 28.0
200 8 426 826 213 413 200 58.0
250 10 502 1022 251 511 260 114.0
300 12 528 1108 264 554 290 174.0
Tees
FP657-50 Fittings & Flanges for 2450/3450. Page 5 of 12.
Filament-wound reducing tees with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Laying Overall Insertion Weight
Length Length Depth Length Length Depth
half half run branch branch branch
run x run x branch run run
L1 OL1 Ds1 L2 OL2 Ds2
mm inch mm mm mm mm mm mm kg
80x80x50 3x3x2 111 221 110 86 166 80 6.2
100x100x50 4x4x2 150 290 140 99 179 80 12.6
100x100x80 4x4x3 150 290 140 123 233 110 13.3
150x150x50 6x6x2 163 333 170 124 204 80 21.0
150x150x80 6x6x3 163 333 170 149 259 110 23.0
150x150x100 6x6x4 163 333 170 175 315 140 25.0
200x200x80 8x8x3 213 413 200 174 284 110 46.0
200x200x100 8x8x4 213 413 200 207 347 140 49.0
200x200x150 8x8x6 213 413 200 188 358 170 52.0
250x250x100 10x10x4 251 511 260 229 369 140 92.0
250x250x150 10x10x6 251 511 260 214 384 170 96.0
250x250x200 10x10x8 251 511 260 238 438 200 103.0
300x300x100 12x12x4 264 554 290 251 391 140 138.0
300x300x150 12x12x6 264 554 290 239 409 170 144.0
300x300x200 12x12x8 264 554 290 264 464 200 153.0
300x300x250 12x12x10 264 554 290 276 536 260 165.0
Reducing Tees
FP657-50 Fittings & Flanges for 2450/3450. Page 6 of 12.
Filament-wound concentric reducers with integral Taper-Taper adhesive bonded
socket ends
Nominal Pipe Size Laying Overall Overall Insertion Weight
Length Length Length Depth
L OL Ds1 Ds2
mm inch mm mm mm mm kg
80x50 3x2 89 279 110 80 2.0
100x50 4x2 131 351 140 80 6.2
100x80 4x3 144 394 140 110 6.9
150x80 6x3 142 422 170 110 6.8
150x100 6x4 169 479 170 140 8.0
200x100 8x4 223 563 200 140 21.0
200x150 8x6 164 534 200 170 25.0
250x150 10x6 183 613 260 170 35.0
250x200 10x8 185 645 260 200 41.0
300x200 12x8 205 695 290 200 70.0
300x250 12x10 192 742 290 260 82.0
Note: Eccentric Reducers are available on request
Concentric Reducers
FP657-50 Fittings & Flanges for 2450/3450. Page 7 of 12.
Filament-wound couplings with integral Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overall Insertion Outside Weight
Length Length Depth Diameter
L OL Ds OD
mm inch mm mm mm mm kg
50 2 70 230 80 70 0.5
80 3 70 290 110 100 1.0
100 4 70 350 140 128 1.8
150 6 70 410 170 188 3.9
200 8 70 470 200 242 6.4
250 10 70 590 260 302 11.1
300 12 70 650 290 380 31.0
Couplings
Filament-wound pipe nipples with integral Taper-Taper adhesive bonded spigot ends
Nominal Pipe Size Laying gap Insertion Weight
Length Depth
L Ds
mm inch mm mm mm kg
50 2 185 25 80 0.1
80 3 245 25 110 0.4
100 4 305 25 140 0.8
150 6 365 25 170 2.0
200 8 430 30 200 3.8
250 10 550 30 260 7.7
300 12 620 40 290 11.8
Nipples
FP657-50 Fittings & Flanges for 2450/3450. Page 8 of 12.
Heavy-Duty filament-wound flanges with Taper-Taper adhesive bonded socket ends
Nominal Pipe Size Laying Overal Insertion Weight
Length Length Depth
L D Ds (1)
mm inch mm mm mm kg
50 2 5 85 80 2.6
80 3 5 115 110 5.4
100 4 5 145 140 9.8
150 6 5 175 170 16.5
Notes:
(1) The weights shown are for ANSI B16.5 Class 400 drilled flanges. Weights for other
drilling classes may be different. For more detailed information reference is made to
the appropriate product data.
* Heavy Duty Flanges are standard available in drillings according to ANSI and ISO (DIN).
** Compressed fibre gaskets, 3 mm thick, compatible with the pressure, temperature
and medium, may be used. The mechanical properties should be in accordance with
DIN 3754 (IT 400) or equal.
*** For maximum bolt torque refer to the appropriate Bondstrand literature. Please be
aware that excessive torque may result in flange failure and, therefore a torque-
wrench is required.
Heavy-Duty Flanges
FP657-50 Fittings & Flanges for 2450/3450. Page 9 of 12.
Filament-wound Stub-end flanges with Taper-Taper adhesive bonded socket ends
and steel backing rings
Nominal Pipe Size Laying Overall Insertion Ring Weigth Weight
Length Length Depth to GRE steel
Face stub- ring
L OL Ds H end (1)
mm inch mm mm mm mm kg kg
50 2 15 95 80 14 0.3 2.8
80 3 15 125 110 19 0.8 5.3
100 4 15 155 140 22 1.6 8.4
150 6 15 185 170 34 3.0 13.3
200 8 15 215 200 43 4.8 21.0
250 10 15 275 260 48 6.7 29.0
300 12 15 305 290 56 8.6 42.0
Notes:
(1) The weight shown is for ANSI B16.5 Class 400 drilled flanges. Weights for other
drilling classes may be different. For more detailed information reference is made to
the appropriate product data.
* Stub-End Flange Rings are standard available in drillings according to ANSI and ISO
(DIN).
** Stub-End Flanges are available with and without O-ring groove in the face.
Suitable O-ring seals should be used, available on request.
*** Make sure that the O-ring grooved stub-end is compatible with its counter flange,
e.g. use a stub-end without groove or another flat surface flange as counter flange.
**** Maximum bolt-torque for use with O-rings seals may be calculated based on
pressure, size and number of bolts.
Stub-end Flanges
FP657-50 Fittings & Flanges for 2450/3450. Page 10 of 12.
Filament around adapters and couplings with Key-lock ends.
Nominal Pipe Qty Laying Overall Insertion Weigth Laying Overall Weigth
Size of Length Length Depth Length Length
Keys L OL Ds L OL
mm inch mm mm mm kg mm mm kg
adapter KLM x TBF coupling KLF x KLF
50 2 2 60 185 80 0.5 100 191 1.7
80 3 2 75 230 110 1.0 100 191 2.4
100 4 2 85 270 140 1.6 100 191 2.9
150 6 2 81.5 320 170 4.6 152 305 11.4
200 8 2 101 400 200 8.6 228 501 23.0
250 10 2 125 480 260 23.0 210 484 25.0
300 12 2 100 480 290 23.0 196 470 45.0
Key-lock Adapters
& Couplings
Pipe system is designed for field testing with water at 150% of rated pressure.
Maximum allowable surge pressure is 150% of rated pressure.
Field Testing
Surge Pressure
1 psi = 6895 Pa = 0.07031 kg/cm
2
1 bar = 105Pa = 14.5 psi = 1.02 kg/cm
2
1 MPa = 1 N/mm
2
= 145 psi = 10.2 kg/cm
2
1 inch = 25.4 mm
1 Btu.in/ft2hF = 0.1442 W/mK
C = 5/9 (F-32)
This product literature and the recommendations for usage it contains are based on test data
reasonably believed to be reliable. It is intended that this literature be used by personnel
having specialised training in accordance with currently accepted industry practice and
normal operating conditions. Variation in environment, changes in operating procedures, or
extrapolation of data may cause unsatisfactory results. We recommend that your engineers
verify the suitability of this product for your intended application. Since we have no control
over the conditions of service, we expressly disclaim responsibility for the results obtained
or for any consequential or incidental damages of any kind incurred.
Conversions
Important Notice
FP657-50 Fittings & Flanges for 2450/3450. Page 11 of 12.
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.n
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet:www.ameron.com
email:marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Ameron 2002 - FP 603 B 02/03 supersedes FP 603 A - 04/02. Page 1 of 12. Printed in the Netherlands
Bondstrand

2020
Glassfiber Reinforced Epoxy
pipe systems for general
offshore service
Uses and applications
The pipe system is designed and rated to meet the following requirements:
- U.K.O.O.A. specification.
- Shell DEP 31.40.10.31-Gen. 1998.
- ISO 14692;
- Lloyd's Register Type Approval;
- Fire Endurance according to IMO A753 (18) level 3.
Maximum operating temperature: 93C.
Pipe system design for pressure ratings of 20 bar, using 148 N/mm
2
Hydrostatic Design
Basis in accordance with ASTM D-2992 Procedure B and a service factor of 0.5.
ASTM D-2310 Classification: RTRP-11 FE for cyclic hydrostatic design basis.
ASTM D-2310 Classification: RTRP-11 FX for static hydrostatic design basis.
A minimum safety factor of 4:1 is provided in accordance with ASTM D-1599 for a system
operating pressure of 20 bar.
Pipe
Filament-wound Glassfiber Reinforced Epoxy (GRE) pipe with integral 0.5 mm nominal
thickness resin-rich reinforced liner for adhesive-bonding systems. On request, pipes can
be supplied without an internal liner.
Fittings
A wide range of lined filament-wound Glassfiber Reinforced Epoxy (GRE) fittings for
adhesive-bonding systems. For special fittings, not listed in this product guide,
please contact your Ameron representative.
Flanges
Filament-wound Glassfiber Reinforced Epoxy (GRE) heavy-duty flanges and
stub-end flanges for adhesive bonding systems. Standard flange drilling patterns as per
ANSI B16.5. Other flange drilling patterns, such as DIN, ISO, JIS, ANSI B16.5 300 Lb are
Optional: This system can be supplied conductive, with or without a (conductive)
availabe.
Characteristics

Cooling water

Ballast

Caissons

Chlorination

Drilling mud injection

Drainage

Fire water system

Fresh water service

Produced water

Saltwater service

Sanitary service/sewage

Submersible pump column piping


internal liner.
Ameron 2002 - FP 603 B 02/03 supersedes FP 603 A - 04/02. Page 2 of 12. Printed in the Netherlands
Typical mechanical
properties
Joining systems &
configurations
Typical physical
properties
Pipe sizes
Pipe
25-40 mm (1-1
1
/2 inch): Quick-Lock straight taper adhesive joint with integral pipe
stop in bell end.
End configuration: Integral Quick-Lock bell x shaved
straight spigot.
50-600 mm (2-24 inch): Taper/Taper adhesive joint.
End configuration: Integral Taper bell x shaved taper spigot.
Fittings & Flanges
25-40 mm (1-1
1
/2 inch) Quick-Lock straight taper adhesive joint with integral pipe
stop in bell end.
End configuration: Integral Quick-Lock bell ends.
50-600 mm (2-24 inch) Taper/Taper adhesive joint.
End configuration: Integral Taper bell ends.
Note:
* Pipe nipples, saddles and flanged fittings have different end configurations.
Nominal Joining Approximate
Pipe size System Overall Length*
[mm] [inch] [m]
25-40 1-1
1
/2 Quick-Lock 5.50
50-150 2-6 Taper/Taper 5.95
200-600 8-24 Taper/Taper 5.95 and 11.70
* Tolerance +/- 50 mm.
Please note that all weights mentioned in this product literature are average weights.
Pipe property Units Value Method
Thermal conductivity pipe wall W(m.K) .33 Ameron
Thermal expansivity (lineair) 10
-6
mm/mm/C 18.0 Ameron
Flow coefficient Hazen-Williams 150
Absolute roughness 10
-6
m 5.3
Density kg/m
3
1800
Specific gravity - 1.8 ASTM D-792
Pipe property Units 21C 93C Method
Bi-axial
Ultimate hoop stress at weeping N/mm
2
300 ASTM D-1599
Circumferential
Hoop tensile strength N/mm
2
380 ASTM D-2290
Hoop tensile modulus N/mm
2
23250 18100 ASTM D-2290
Poisson's ratio axial/hoop 0.93 1.04 Ameron
Longitudinal
Axial tensile strength N/mm
2
65 50 ASTM D-2105
Axial tensile modulus N/mm
2
10000 7800 ASTM D-2105
Poisson's ratio hoop/axial 0.40 0.45 ASTM D-2105
Axial bending strength 80 Ameron
Beam
Apparent elastic modulus N/mm
2
9200 7000 ASTM D-2925
Hydrostatic Design Basis
Static N/mm
2
148* ASTM D-2992
(Proc. B.)
* At 65C.
Ameron 2002 - FP 603 B 02/03 supersedes FP 603 A - 04/02. Page 3 of 12. Printed in the Netherlands
Span length
Nominal Pipe Minimum Insertion Pipe Designation per
Pipe size Inside Wall Depth Weight ASTM
Diameter Thickness* (DS)** D-2996
[mm] [inch] [mm] [mm] [mm] [kg/m]
25 1 27.1 3.5 27 0.81 RTRP-11FX1-3112
40 1
1
/2 42.1 3.5 32 1.42 RTRP-11FX1-3112
50 2 53.2 2.3 50 1.33 RTRP-11FX1-3111
80 3 81.8 2.4 50 1.78 RTRP-11FX1-3111
100 4 105.2 2.9 50 2.49 RTRP-11FX1-3112
150 6 159.0 3.9 80 4.87 RTRP-11FX1-3112
200 8 208.8 5.0 80 7.83 RTRP-11FX1-3114
250 10 262.9 6.0 110 10.33 RTRP-11FX1-3116
300 12 313.7 7.1 140 14.62 RTRP-11FX1-3116
350 14 344.4 7.9 140 16.43 RTRP-11FX1-3116
4.00 16 393.7 8.9 170 25.04 RTRP-11FX1-3116
450 18 433.8 9.7 170 29.98 RTRP-11FX1-3116
500 20 482.1 10.7 200 30.79 RTRP-11FX1-3116
600 24 578.6 12.8 230 43.97 RTRP-11FX1-3116
* Minimum wall thickness includes 0.5 mm internal liner.
** Insertion Depths stated are for pipe and fittings.
Nominal Internal External STIS Stifness Pipe
Pipe size Pressure Pressure Factor Stiffness
Rating** Rating* *** *** ***
[mm] [inch] [bar] [bar] [kN/m
2
] [lb.in] [psi]
25 1 20 244.4 1918.3 463 14934
40 1
1
/2 20 72.7 570.3 463 4440
50 2 20 8.7 67.9 100 529
80 3 20 2.9 22.7 118 176
100 4 20 2.7 21.5 237 167
150 6 320 2.3 17.8 674 138
200 8 20 2.3 18.2 1563 142
250 10 20 2.1 16.7 2853 130
300 12 20 2.2 17.0 4930 132
350 14 20 2.3 18.0 6948 140
400 16 20 2.3 17.7 10163 138
450 18 20 2.2 17.4 13352 135
500 20 20 2.2 17.2 18196 134
600 24 20 2.2 17.6 31908 136
* The safety factor used for rated external pressure is 3:1.
** At 93C, using Bondstrand approved adhesive.
*** At 21C.
Nominal Single Continuous
Pipe size Span * Span *
[mm] [inch] [m] [m]
25 1 2.4 3.0
40 1
1
/2 2.7 3.4
50 2 2.6 3.4
80 3 3.0 3.8
100 4 3.4 4.3
150 6 4.0 5.1
200 8 4.6 5.8
250 10 5.1 6.4
300 12 5.5 7.0
350 14 5.8 7.4
400 16 6.2 7.9
450 18 6.5 8.2
500 20 6.8 8.7
600 24 7.5 9.5
Note: Span recommendations are based on pipes filled with water having a density of
1000 kg/m
3
and include no provisions for weights caused by valves, flanges
or other heavy objects.
* At 21C.
Typical pipe performance
Typical pipe dimensions
and weights
Ameron 2002 - FP 603 B 02/03 supersedes FP 603 A - 04/02. Page 4 of 12. Printed in the Netherlands
Elbows 90
Nominal Laying Overall Weight
Pipe size Length Length
(LL) (OL)
[mm] [inch] [mm] [mm] [kg]
25 1 65 92 0.3
40 1
1
/2 81 113 0.4
50 2 87 137 0.6
80 3 126 176 1.1
100 4 155 205 2.1
150 6 240 320 5.8
200 8 315 395 12
250 10 391 501 16
300 12 463 604 26
350 14 364 504 37
400 16 402 572 53
450 18 472 642 76
500 20 523 723 125
600 24 625 855 228
Nominal Laying Overall Weight
Pipe size Length Length
(LL) (OL)
[mm] [inch] [mm] [mm] [kg]
25 1 22 49 0.2
40 1
1
/2 29 61 0.3
50 2 45 95 0.5
80 3 61 111 0.9
100 4 73 123 1.3
150 6 106 186 3.9
200 8 137 217 7.4
250 10 169 279 12.4
300 12 196 336 22
350 14 125 265 29
400 16 142 312 41
450 18 204 374 54
500 20 225 425 75
600 24 268 498 130
Nominal Laying Overall Weight
Pipe size Length Length
(LL) (OL)
[mm] [inch] [mm] [mm] [kg]
25 1 9 36 0.1
40 1
1
/2 9 41 0.2
50 2 29 79 0.4
80 3 37 87 0.6
100 4 43 93 0.9
150 6 60 140 1.4
200 8 76 156 5.1
250 10 68 178 9.7
300 12 77 217 15.5
350 14 71 211 21
400 16 85 255 24
450 18 106 276 39
500 20 116 316 56
600 24 136 366 93
Elbows 45
Elbows 22
1
/2
Ameron 2002 - FP 603 B - 02/03 supersedes FP 603 A - 04/02. Page 5 of 12. Printed in the Netherlands
Reducing Tees
Nominal Laying Overall Laying Overall Weight
Pipe size Length Length Length Length
total run total run branch branch
(LL1) (OL1) (LL2) (OL2)
[mm] [inch] [mm] [mm] [mm] [mm] [kg]
25 1 54 108 27 54 0.2
40 1
1
/2 60 124 30 62 0.4
50 2 148 248 74 124 1.3
80 3 192 292 96 146 2.9
100 4 230 330 115 165 4.0
150 6 306 466 153 233 11.9
200 8 376 536 188 268 21
250 10 452 672 226 336 21
300 12 528 808 264 404 50
350 14 544 824 272 412 55
400 16 590 930 295 465 87
450 18 678 1018 339 509 103
500 20 740 1140 370 570 209
600 24 868 1328 434 664 351
Nominal Laying Overall Laying Overall Weight
Pipe size Length Length Length Length
(runxrunxbranch) (LL1) half run (OL1) half run (LL2) branch (OL2) branch branch
[mm] [inch] [mm] [mm] [mm] [mm] [kg]
80x80x50 3x3x2 96 146 86 136 2.7
100x100x50 4x4x2 115 165 99 149 3.8
100x100x80 4x4x3 115 165 108 158 4.0
150x150x50 6x6x2 153 233 124 174 10.9
150x150x80 6x6x3 153 233 134 184 12.0
150x150x100 6x6x4 153 233 140 190 12.2
200x200x50 8x8x2 88 168 179 229 14.6
200x200x80 8x8x3 188 268 159 209 16.0
200x200x100 8x8x4 188 268 172 222 16.7
200x200x150 8x8x6 188 268 178 258 17.9
250x250x50 10x10x2 88 198 206 256 18.7
250x250x80 10x10x3 100 210 206 256 20.5
250x250x100 10x10x4 226 336 194 244 29
250x250x150 10x10x6 226 336 204 284 32
250x250x200 10x10x8 226 336 213 293 34
300x300x100 12x12x4 264 404 216 266 43
300x300x150 12x12x6 264 404 229 309 44
300x300x200 12x12x8 264 404 239 319 45
300x300x250 12x12x10 264 404 251 361 51
350x350x150 14x14x6 272 412 254 334 41
350x350x200 14x14x8 272 412 264 344 54
350x350x250 14x14x10 272 412 277 387 62
350x350x300 14x14x12 272 412 289 429 66
400x400x150 16x16x6 295 465 274 354 51
400x400x200 16x16x8 295 465 283 363 56
400x400x250 16x16x10 295 465 293 403 63
400x400x300 16x16x12 295 465 305 445 67
400x400x350 16x16x14 295 465 315 455 71
450x450x200 18x18x8 339 509 316 396 100
450x450x250 18x18x10 339 509 329 439 104
450x450x300 18x18x12 339 509 329 469 107
450x450x350 18x18x14 339 509 330 470 137
450x450x400 18x18x16 339 509 330 500 143
500x500x250 20x20x10 370 570 355 465 180
500x500x300 20x20x12 370 570 355 495 188
500x500x350 20x20x14 370 570 356 496 188
500x500x400 20x20x16 370 570 356 526 195
500x500x450 20x20x18 370 570 365 535 200
600x600x300 24x24x12 434 664 405 545 211
600x600x350 24x24x14 434 664 406 546 215
600x600x400 24x24x16 434 664 406 576 220
600x600x450 24x24x18 434 664 428 598 239
600x600x500 24x24x20 434 664 428 628 279
Note: Regular numbers are filament wound tees; Italic numbers are fabricated tees.
Equal Tees
Filament wound
Fabricated
Ameron 2002 - FP 603 B 02/03 supersedes FP 603 A - 04/02. Page 6 of 12. Printed in the Netherlands
Nominal Laying Overall Outside Weight
Pipe size Length Length Diameter
(LL) (OL) (OD)
[mm] [inch] [mm] [mm] [mm] [kg]
25 1 10 64 47 0.1
40 1
1
/2 10 74 61 0.2
50 2 70 170 70 0.4
80 3 70 170 100 0.9
100 4 70 170 124 1.0
150 6 70 230 180 2.6
200 8 70 230 230 3.0
250 10 70 290 286 4.0
300 12 70 350 350 9.8
350 14 70 350 381 10.5
400 16 70 410 430 13.2
450 18 70 410 460 15.0
500 20 70 470 524 21.0
600 24 70 530 619 24.0
Nominal Laying Gap Weight
Pipe size Length
(LL)
[mm] [inch] [mm] [mm] [kg]
25 1 57 3 0.05
40 1
1
/2 67 3 0.08
50 2 125 25 0.13
80 3 125 25 0.20
100 4 125 25 0.25
150 6 185 25 0.50
200 8 190 30 0.90
250 10 250 30 1.75
300 12 320 40 3.00
350 14 320 40 4.00
400 16 380 40 5.20
450 18 400 60 5.80
500 20 460 60 8.70
600 24 520 60 11.0
Filament-wound Glassfiber Reinforced Epoxy (GRE) pipe saddles for wear,
supporting and anchoring
Nominal Saddle Saddle Saddle Required Saddle Required
Pipe size Angle Thickn. Weight Adhesive Weight Adhesive
t
s
100mm # Kits/ea 150mm # Kits/ea
[mm] [inch] [degree] [mm] [kg] [3Oz] [6Oz] [kg] [3Oz-6Oz]
25 1 180 14 0.2 1 - 0.3 1 -
40 1
1
/2 180 14 0.2 1 - 0.4 1 -
50 2 180 14 0.3 1 - 0.4 1 -
80 3 180 14 0.4 1 - 0.6 - 1
100 4 180 14 0.5 - 1 0.7 - 1
150 6 180 14 0.7 - 1 1.1 1 1
200 8 180 14 0.9 - 1 1.4 1 1
250 10 180 14 1.1 1 1 1.7 - 2
300 12 180 14 1.4 1 1 2.0 1 2
350 14 180 14 1.5 - 2 2.2 1 2
400 16 180 14 1.7 - 2 2.5 - 3
450 18 180 16 1.8 - 2 2.8 - 3
500 20 180 16 2.0 1 2 3.1 1 3
600 24 180 16 2.4 - 3 3.7 - 4
Notes:
* Filament-wound support saddles are intended for protection of pipe at supports and clamps,
as well as for anchoring purposes. Support and anchoring saddles are standard 180.
Saddles are supplied in standard lengths of 100 mm and 150 mm (D).
** For special saddle -lengths, -thickness and/or angles contact your Ameron representative.
# Wear saddles are standard 90 and weigh 50% of values shown.
Couplings
Nipples
Support Saddles
Ameron 2002 - FP 603 B - 02/03 supersedes FP 603 A - 04/02. Page 7 of 12. Printed in the Netherlands
Grounding Saddles
Nominal Saddle Saddle Saddle Saddle Required
Pipe size Angle Length Thickness Weight Adhesive
B t
s
Kits/ea
[mm] [inch] [degree] [mm] [mm] [kg] [3Oz]
25 1 90 76 14 0.1 1
40 1
1
/2 90 76 14 0.1 1
50 2 90 76 14 0.1 1
80 3 90 76 14 0.2 1
100 4 90 76 14 0.2 1
150 6 90 76 14 0.3 1
200 8 45 76 14 0.2 1
250 10 45 76 14 0.2 1
300 12 45 76 14 0.3 1
350 14 45 76 14 0.3 1
400 16 45 76 14 0.3 1
450 18 22
1
/2 76 14 0.2 1
500 20 22
1
/2 76 14 0.2 1
600 24 22
1
/2 76 14 0.2 1
Notes :
*Grounding saddles are intended for use in conductive piping systems.
**Bondstrand conductive adhesive should be used for mounting.
***Saddles come with cable having a length of 600 mm.
Nominal Laying Overall Insertion Weight
Pipe size Length Length Depth (*)
(LL) (OL) (DS)
[mm] [inch] [mm] [mm] [mm] [kg]
25 1 3 30 27 0.5
40 1
1
/2 3 35 32 1.1
50 2 5 51 46 1.5
80 3 5 51 46 2.2
100 4 5 51 46 2.9
150 6 5 85 80 5.8
200 8 6 86 81 8.4
250 10 6 116 110 14.3
300 12 6 146 140 26.0
350 14 6 146 140 33.0
400 16 6 176 170 46.0
450 18 6 176 170 49.0
* Weights are for ANSI B16.5 Class 150 drilled flanges.
Weights for other drilling classes may be different.
** Heavy Duty Flanges are standard available in ANSI and ISO (DIN) drillings.
*** Full-face elastomeric gaskets (3 mm thick) may be used suitable for the service pressure,
service temperature and fluid. Shore A durometer hardness of 60 5 is recommended.
Compressed fibre gaskets (3 mm thick), compatible with pressure,temperature and medium
may also be used.
Mechanical properties should be in accordance with DIN 3754 (IT 400) or equal.
**** For maximum bolt torque refer to the appropriate Bondstrand literature.
A torque-wrench must be used, since excessive torque may result in flange damage.
Heavy-Duty Flanges
hole diameter
is 12 mm
Ameron 2002 - FP 603 B 02/03 supersedes FP 603 A - 04/02. Page 8 of 12. Printed in the Netherlands
Concentric Reducers
Nominal Laying Overall Ring Weight Weight
Pipe size Length Length to face GRE Steel ring
(LL) (OL) (H) Stub-end *
[mm] [inch] [mm] [mm] [mm] [kg] [kg]
50 2 15 65 10 0.3 1.8
80 3 15 65 10 0.5 3.3
100 4 15 65 16 0.8 4.3
150 6 15 95 16 1.8 5.3
200 8 15 95 20 2.7 8.6
250 10 15 125 23 4.1 13.7
300 12 15 155 26 6.0 23.3
350 14 15 155 27 5.9 31.7
400 16 20 190 32 9.7 42.8
450 18 20 190 35 16.4 46.0
500 20 20 220 39 20.0 51.2
600 24 20 250 47 22.8 87.2
Notes :
* Weights shown are for ANSI B16.5 Class 150 drilled flanges.
Weights for other drilling classes may be different.
** Stub-end Flanges are standard available in ANSI and ISO (DIN) drillings.
*** Stub-end Flanges for Bondstrand 2020 are standard with an O-ring groove in the face.
Suitable O-ring seals should be used (available on request).
*** Ensure the O-ring grooved stub-end is compatible with its counter flange, using a stub-end
without groove, or another flat surface flange as counter flange.
Nominal Laying Overall Weight
Pipe size Length Length
(run x run) (LL) (OL)
[mm] [inch] [mm] [mm] [kg]
80x50 3x2 74 174 0.8
100x50 4x2 96 196 1.1
100x80 4x3 94 194 1.2
150x80 6x3 117 247 2.2
150x100 6x4 124 254 2.4
200x100 8x4 163 293 4.3
200x150 8x6 129 289 5.1
250x150 10x6 148 338 6.8
250x200 10x8 135 325 6.9
300x200 12x8 180 400 9.9
300x250 12x10 167 417 10.8
350x250 14x10 214 464 17.0
350x300 14x12 208 488 16.8
400x300 16x12 195 505 22.0
400x350 16x14 183 493 23.0
450x400 18x16 128 468 27.0
500x400 20x16 249 619 36.0
500x450 20x18 151 521 35.0
600x400 24x16 486 886 70.0
600x450 24x18 388 788 70.0
600x500 24x20 267 697 70.0
Stub-end Flanges
Ameron 2002 - FP 603 B 02/03 supersedes FP 603 A - 04/02. Page 9 of 12. Printed in the Netherlands
Nominal Laying Overall Weight
Pipe size Length Length
(run x run) (LL) (OL)
[mm] [inch] [mm] [mm] [kg]
80x50 3x2 103 203 1.6
100x50 4x2 161 261 1.8
100x80 4x3 90 190 2.2
150x80 6x3 224 354 4.5
150x100 6x4 165 245 5.1
200x100 8x4 290 420 5.6
200x150 8x6 155 315 6.1
250x150 10x6 290 480 6.0
250x200 10x8 166 356 6.5
300x200 12x8 293 513 8.5
300x250 12x10 158 408 10.0
350x250 14x10 235 485 10.5
350x300 14x12 108 388 11.0
400x300 16x12 231 541 12.0
400x350 16x14 155 465 12.0
450x350 18x14 255 565 19.0
450x400 18x16 132 472 22.0
500x400 20x16 253 623 24.0
500x450 20x18 153 523 27.0
600x500 24x20 274 704 40.0
Nominal Laying Overall Outside Weight
Pipe size Length Length Diameter
(LL) (OL) (OD)
[mm] [inch] [mm] [mm] [mm] [kg]
50* *2 160 260 95 1.2
80 3 160 260 126 1.6
100 4 160 260 175 1.8
150 6 160 320 229 5.8
200 8 160 320 279 7.2
Note: Outlets are in NPT or BSP and in various alloys; to be specified with order.
*Other configurations are available on request.
* Not available with 3/4" outlet.
Number of Adhesive Kits per joint
Nominal Adhesive Minimum number
Pipe size Kit size/ea of Adhesive Kits/ea
required per joint
[mm] [inch] [cm
3
] [Oz] nr.
25 1 89 3 1/5
40 1
1
/2 89 3 1/5
50 2 89 3 1/4
80 3 89 3 1/3
100 4 89 3 1/2
150 6 89 3 1
200 8 89 3 1
250 10 177 6 1
300 12 177 6 1
1/2
350 14 177 6 2
400 16 177 6 2
450 18 177 6 3
500 20 177 6 3
600 24 177 6 4
Note:
* Adhesive Kits should never be split. If remainder is not used for other joints made at the same
time, the surplus must be discarded.
** Required adhesive for saddles is shown in the dimension table of the respective saddles.
*** For type of adhesive to be used, please refer to the Bondstrand Corrosion Guide.
Adhesive
Eccentric Reducers
Deluge Couplings with
Reversed Taper Bushing
with 1/2" or 3/4" Outlet
OL
LL DS
O
D
Ameron 2002 - FP 603 B 02/03 supersedes FP 603 A - 04/02. Page 10 of 12. Printed in the Netherlands
Field testing
Surge pressure
Consult de following literature for recommendations pertaining design, installation
and use of Bondstrand pipe, fittings and flanges:
Assembly Instructions for Quick-Lock adhesive-bonded joints FP 170
Assembly Instructions for Taper/Taper adhesive-bonded joints FP 657
Bondstrand Corrosion Guide for fiberglass pipe and tubing FP 132
Assembly Instructions for Bondstrand fiberglass flanges FP 196
Guide for Installing Suspended Pipe FP 679
Bondstrand Engineering Guide for Suspended Pipe FP 288
Bondstrand M86 Pipe Shaver FP 453
Bondstrand M87 Pipe Shaver FP 454
Bondstrand B-1 Pipe preparation tool FP 810
Please consult Ameron for the latest version of the above mentioned literature.
Pipe system is designed for field testing with water at 150% of rated pressure.
Maximum allowable surge pressure is max. 150% of rated pressure.
Engineering design &
installation
Ameron 2002 - FP 603 B - 02/03 supersedes FP 603 A - 04/02. Page 11 of 12. Printed in the Netherlands
1 psi = 6895 Pa = 0.07031 kg/cm
2
1 bar = 10
5
Pa = 14.5 psi = 1.02 kg/cm
2
1 MPa = 1 N/mm
2
= 145 psi = 10.2 kg/cm
2
1 inch = 25.4 mm
1 Btu.in/ft
2
hF = 0.1442 W/mK
C = 5/9 (F-32)
This product literature and the recommendations for usage it contains are based on test
data reasonably believed to be reliable. It is intended that this literature be used by personnel
having specialised training in accordance with currently acceptable industry practice and
normal operating conditions. Variation in environment, changes in operating procedures,
or extrapolation of data may cause unsatisfactory results. We recommend that your
engineers verify the suitability of this product for your intended application. Since we have
no control over the conditions of service, we expressly disclaim responsibility for the results
obtained or for any consequential or incidental damages of any kind incurred.
Important notice
Conversions

Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.nl
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet: www.ameron.com
email: marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
1997 Ameron - FP 170 A 11/97 (formerly BA-20). Page 1 of 8 Printed in Holland.
photo 1
photo 3
photo 2
photo 4
photo 5
T
o make the bell and spigot assembly of
Bondstrand pipe and fittings using Amerons
thermosetting adhesives, you need only follow
these step-by-step instructions. 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
Quick-Lock joint.
1
To cut the pipe to length, measure the desired length
and scribe the pipe using a pipefitters wrap-around
(photo 1). Place the pipe in a vise, using 6 mm (1/4 inch)
thick rubber pad to protect pipe from damage. Cut pipe
with hacksaw, sabre saw, or abrasive wheel (photo 2).
Check the squareness of cut by inserting a pipe shaver
arbor flush in to the cut pipe. Pipe up to 100 mm (4 inches)
should be square to within 1.6 mm (1/16 inch). Larger
pipe should be square to within 3.2 mm (1/8 inch). Use a
disc grinder or file to correct squareness.
Danger: Avoid inhaling dust produced by cutting and grin-
ding operations. Provide adequate ventilation; wear-appro-
ved dust respirators.
2
Shave the cut end of the pipe using the Bondstrand
pipe shaver (photo 4). Shaving can be done manually,
but a portable power drive is advisable for larger sizes and
if shaving several sections. Measure the shaved pipe using
a Pi Taper (photo 5). See table 1 for shaving dimen-
sions.
Note 1: Instructions for adjusting and operating the pipe
shaver to prepare the correct spigot diameter and length are
provided with the shaver or may be obtained from your
local Ameron representative. For 25 and 40 mm (1-1
1
/2)
diameters a compact pipe shaver is available from Ameron.
Note 2: Diameters 350 and 400 mm (14 and 16) of series
2000M and 7000M have a deviating internal diameter that
need different sized arbors.
Table 1. Shaved dimensions
Pipe Dia Max. Dia. Min.Dia. Spigot Length*
(mm) (in) (mm) (in) (mm) (in) (mm) (in)
25 1 32.9 1.296 32.6 1.284 28.6-31 1.13-1.22
40 1.5 47.8 1.882 47.5 1.870 33.4-36 1.32-1.42
50 2 59.6 2.346 59.2 2.331 49-52 1.93-2.05
80 3 88.0 3.465 87.6 3.449 49-52 1.93-2.05
100 4 112.9 4.445 112.5 4.429 49-52 1.93-2.05
125 5 139.5 3.543 139.9 3.553 59-62 2.32-2.44
150 6 166.6 6.559 166.2 6.543 59-62 2.32-2.44
200 8 217.5 8.563 217.1 8.547 65-68 2.60-2.68
250 10 271.7 10.697 271.3 10.681 71-74 2.80-2.91
300 12 322.6 12.701 322.2 12.685 78-81 3.07-3.19
350 14 354.2 13.945 353.8 13.929 89-93 3.50-3.66
400 16 404.5 15.925 404.1 15.910 103-106 4.06-4.17
* When correct spigot lengths are taken adjusted on the shaver, the length of
the shaved pipe end will be automatically within the min. and max. size as
described above.
1997 Ameron - FP 170 A 11/97 (formerly BA-20). Page 2 of 8 Printed in Holland.
photo 10
photo 11 photo 12 photo 6 photo 7
photo 8 photo 9
3
All fittings, sockets, pipe ends (spigots) and pipe soc-
kets must be clean, dry and sanded within two hours of
assembly. Sanding should be accomplished using a 10-12
mm (1/2 inch) drill motor, 1700-2000 rpm (photos 6-8)
and flapper type sander with a 40-60 grit aluminium oxide
abrasive, available from Ameron. After sanding, surfaces
to be bonded should show a dull fresh finish, not a polis-
hed look. Do not forget to lightly sand the edges of the
spigot. Clean and dry sanded surfaces are necessary for
proper bonding.
Sockets with a 25 and 40 mm diameter must be sanded
with sandpaper with a 40-60 grit, since they are too small
for the flapper sander.
Danger: Avoid inhaling dust produced by sanding opera-
tions. Provide adequate ventilation; wear an approved dust
respirator.
Thoroughly wipe the sanded socket and spigot with a
clean, dry cloth, or use a duster brush to remove dust par-
ticles (photo 9). If surfaces are wet, warm with
Bondstrand heating blanket until dry, then resand.
Protect the bonding surfaces from moisture during bad
weather with tenting over the working area. Do not touch
the prepared surfaces with bare hands or any articles that
would leave an oily film.
4a
Use table 2 to measure back from the spigot end of
each pipe to be joined (photo 10) and scribe a line
using a white grease pencil or soapstone. When the spigot
is bottomed in the socket, the scribed line will be 25 mm
(1 inch) from the end of the socket.
b
Match mark the two mating pieces for proper align-
ment. Taking care to avoid contaminating mating sur-
faces, fit together loosely the two pieces to be joined
(photo 11). Using a white grease pencil or soapstone,
mark each piece in a common longitudinal line for subse-
quent realignment (photo 12).
5
Ameron offers several chemically resistant thermoset-
ting adhesives recommended for use in pipelines trans-
porting most fluids (for exceptions see Bondstrand
Chemical Resistance Chart available from Ameron).
Because the acceptability for pipelines transporting food
or potable water depends on local laws and regulations,
contact your Bondstrand supplier for advice or assistance
before using adhesives in these services.
Table 2: Mark location for
checking spigot insertion
Nom. Dia Mark location for
checking spigot
insertion in mm/in
25 1 52 2.05
40 1.5 57 2.24
50 2 71 2.80
80 3 71 2.80
100 4 71 2.80
125 5 82 3.23
150 6 82 3.23
200 8 89 3.50
250 10 95 3.74
300 12 101 3.98
350 14 113 4.45
400 16 127 5.00
1997 Ameron - FP 170 A 11/97 (formerly BA-20). Page 3 of 8 Printed in Holland.
photo 13 photo 14
a
Store adhesives at temperatures below 38C (100F)
and use before the expiration date stamped on the top
flap of the package. Do not use kit if either container
shows evidence of leakage.
b
Select the size of adhesive kit in accordance with
table 3.
Be aware of the working time available to you after the
adhesive is mixed.
Working times at various temperatures are stated on the
adhesive package.
If the adhesive is not within the 21C (70F) and 38C
(100F) range, you will need to warm or cool it before
mixing. The adhesive will not mix and spread well below
21C and will set up too fast above 38C.
Caution: These adhesive resins and hardeners, separately or
combined, will cause skin and eye irritation. Avoid contact
with skin and eyes. Do not take internally. In case of con-
tact, wash skin with soap and water. For eyes, flush with
plenty of water for at least 15 minutes and get medical
attention. For industrial use only. Keep away from children.
c
Observe the following:
(1) Use soap and water to wash skin area with which
adhesive components have come in contact. Do not use
solvents on the skin.
(2) Use water-removable protective creams to avoid aller-
gic reactions. Solvent-removable creams are not recom-
mended. Disposable polyethylene gloves can also be used
to avoid contact of Bondstrand adhesive with the hands.
d
After the joint has been properly prepared (see steps
1 through 4) and it is ready to be bonded, add the con-
tents of the small container (hardener) to the large con-
tainer (resin) and stir thoroughly for at least one minute
and until no streaks are visible in the mixture (photos
13/14).
Immediately after mixing, apply the adhesive to the sur-
faces to be bonded as described below. If your epoxy
adhesive mixture has started to heat in the container, dis-
card and start a new one. Heating indicates that the mix-
ture has started to cure.
6
With the spatula supplied in the adhesive kit, or a reus-
able steel spatula, apply a layer of adhesive approxi-
mately 0.8 mm (1/32 inch) thick to the surface of the
socket (photo 15).
Table 3: Determining adhesive quantities
Pipe Dia Kit Size Joints per Kit
(mm) (cc)
25 1 89 5
40 1.5 89 5
50 2 89 4
80 3 89 3
100 4 89 2
150 6 89 1
200 8 89 1
250 10 177 1
300 12 177 1
350 14 177
3
/4
400 16 177
1
/2
1997 Ameron - FP 170 A 11/97 (formerly BA-20). Page 4 of 8 Printed in Holland.
photo 18 photo 17
photo 19
photo 15 photo 16
Too much adhesive on the socket will result in a flow res-
triction inside the joint.
Apply adhesive liberally to the entire spigot surface and a
thin layer to the cut end of the pipe. Excess adhesive on
the spigot surface will be forced out when the socket and
spigot are joined.
7a
Without delay, insert the pipe slowly and without
rotation into the socket until the spigot end rests
firmly rests against the pipe stop (photo 17). For 150 mm
(6) pipe and larger, use a light strap winch to seat and
clamp the joint. Support the winch on a wooden bridge
across the joint so the winch can be left snug while the
heating blanket cures the adhesive. Smaller pipe (25, 40,
50, 80 and 100 mm (1, 1
1
/2, 2, 3 and 4) is joined by tapping
on a 50x100 mm (2 x 4) wooden block placed over the
pipe end to seat the spigot in to the socket.
b
Fittings may be joined to pipe spigots by using one of
the two methods of Step 7a or a 1 kg rubber hammer
(Shore A Durometer 70-80) 60 to 75 mm (2
1
/2-3) in dia-
meter may be used to tap directly on Bondstrand fittings
for proper seating. It may be helpful or even necessary to
back up the outside radius of an elbow, tee, lateral, etc.
with a sandbag or similar shock absorber while tapping
pipe spigots into fittings.
c
Align flanges, tees and other fittings to the matchmarks
as you assemble the spigot and socket. Avoid having to
rotate the part while assembling. Then, for flanges, check
rotational alignment of bolt holes and squareness of flan-
ge faces. Flanges with bolt holes more than 1.6 mm (1/16
inch) out of rotational alignment, flanges more than 1.6
mm out of square across the flange face, or any angular
errors of more than 1/2 degree in the axial or rotational
alignment of spigot and socket joints are likely to intro-
duce subsequent assembly problems. If misaligned, pull
joint apart, remove adhesive from the pipe stop area,
reapply adhesive as in step 6 and rejoin before adhesive
starts to set up.
d
Check for proper seating. The scribed mark on the spi-
got (see step 4a) should now be 25 mm (1 inch) from
the end of the socket (photo 19).
e
Clean up and remove excess adhesive from outside of
joint and from front, back and inside of flange. Flange
face must be clean and free of adhesive.
Correct
Incorrect !
1997 Ameron - FP 170 A 11/97 (formerly BA-20). Page 5 of 8 Printed in Holland.
Blanket
Thermostat
Pipe
Pipe
Heating Blanket
8a
Cure adhesive joints as follows: Place the thermo-
stat end of your Bondstrand heating blanket
against the assembled joint with the thermostat side
facing out from the joint. Wrap the remainder of the blan-
ket around the joint so that any overlap will cover the
thermostat. Tie the blanket in place with any nonconduc-
ting tie.
b
It is always a good idea to insulate around the heating
blanket and to close the pipe ends. This is essential
when it is windy or when the air temperature is below
15C (59F). Fiberglass insulation backed with aluminium
foil generally works well. Insulation should overlap the
blanket sides about 100 mm (4 inch) each way and be tied
down near the edges to trap the heat.
Caution: Joint must not be moved, vibrated, or otherwise
disturbed during cure of adhesive.
c
Flange mounting requires a special wrap. Lay the blan-
ket flat with the thermostat down and, starting at the
thermostat end, roll up the blanket. Insert the rolled blan-
ket into the pipe end the depth of the fresh joint, leaving
the cord and part of the blanket exposed as shown in the
sketch at the left. Fill the space inside the rolled blanket
with fiberglass insulation or some other heat resistant
material to ensure that the blanket remains snugly against
the inside joint surface.
d
Apply alternating current (ac) at the voltage marked
on the heating blanket and mark the starting time on
the pipe. Make sure the blanket is operating and, in fact,
heats up.
9
Curing.
All adhesives are cured with and Ameron-approved
heating blanket. However, the proper cure time depends
on the choice of adhesive and the conditions of service.
For a pipe-to-pipe and a pipe-to-flange connection, mini-
mal curing time is 60 minutes. For a pipe-to-fitting joint
curing time is min. 90 minutes because wall thickness of
fittings is mostly thicker than pipe diameter. Also when
using pipe-to-pipe fittings with extra thick wall (such as
with series 2000M and 7000M) a curing time of min. 90
minutes is recommended.
Tip: Preparations for other assemblies can be handled
during this curing process.
Special Wrap for Flange Mounting
Standard Wrap for Pipe
and Fitting Joints
1997 Ameron - FP 170 A 11/97 (formerly BA-20). Page 6 of 8 Printed in Holland.
10
Check working of heating blanket regularly to ens-
ure the blanket is operating. When heating blanket
fails to operate correctly, e.g. by a temporary power loss,
the entire curing procedure should be repeated.
Recommended equipment for installing Bondstrand
Pipe
(a) Pipe shaver and arbors (Ameron)
(b) Hacksaw, saber saw, or abrasive wheel
(c) Winch and straps, for 150 mm (6) and larger,
Dayton No. 2Z096
(d) Pi Tape measuring tape
(e) White grease pencil or soapstone
(f) Rubber mallet, 2 lb. (Shore A Durometer 70-80)
60 to 75 mm (2
1
/2-3) diameter
(g) Pipefitters wrap-around
(h) Disc grinder or file (optional)
(I) Heat blanker (Ameron)
(j) Electric 6 mm (1/4 inch) drive drill motor,
1700-2000 rpm.
(k) Level
(l) Flapper wheel sander or sandpaper (Ameron)
(m) Folding rule, 3 m (10 inch)
(n) Tape, 15 m (50 inch)
(o) Duster brush or clean rags
(p) Portable power drive, Ridgid No. 700 or
Amaz-O-Thred 181 D.
(q) Pipe vise (Pilot No. 20) and is 6 mm (1/4 inch) thick
elastomer pad.
IMPORTANT
This literature and the information and recommendations
it contains are based on data reasonably believed to be
reliable. However, such factors as variations in environ-
ment, application or installation, changes in operating
procedures, or extrapolation of data may cause different
results. Ameron makes no representation or warranty,
express or implied, including warranties of merchantabili-
ty or fitness for purpose, as to the accuracy, adequacy, or
completeness of the recommendations or information
contained herein. Ameron assumes no liability whatsoe-
ver in connection with this literature or the information or
recommendations it contains.
Written comments regarding this document are invited.
Please write to the Engineering Manager,
Ameron Fiberglass Pipe Group,
P.O. Box 6 - 4190 CA Geldermalsen,
the Netherlands.
1997 Ameron - FP 170 A 11/97 (formerly BA-20). Page 7 of 8 Printed in Holland.
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.n
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet:www.ameron.com
email:marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Assembly Instructions
for Bondstrand Taper / Taper
adhesive-bonded joints
Bondstrand

Installation
Introduction
These instructions describe the assembly of the Bondstrand Taper / Taper adhesive-
bonded joint and show how to cut the pipe, prepare the pipe ends, mix and apply the
adhesive, make the joint and cure the adhesive.
They form complete assembly instructions together with the appropriate
G Bondstrand Adhesive Product Data sheet
G Bondstrand Pipe Shaver Instruction sheet
G Bondstrand Heating Blanket Data sheet
To determine the appropriate adhesive, refer to the Bondstrand Chemical Resistance
Guide or consult Ameron.
Bondstrand adhesives should be stored at temperatures between 5C and 35C.
Adhesives should not be used after the expiry date stamped on the adhesive
package.
Ameron 1997 FP564 A (10/97). Printed in The Netherlands.
pipe shaver heating blanket
2
1. Determine the desired length.
a Scribe the pipe using a pipe fitters wrap-around.
b When holding the pipe in a vice, use rubber padding or similar to protect the pipe from
damage.
c Contaminated pipe surfaces should be cleaned prior to machining the pipe ends.
2. Cut the pipe.
a Use a hacksaw or an abrasive wheel.
b Ensure that cut ends remain within the tolerances as shown in table A.
c These tolerances can be checked by using e.g. the arbor of the shaver flush with the cut
end of the pipe.
Table A: Maximum tolerance on squareness of cut spigot end
Pipe Size Range A
(mm) (inch) (mm)
25 - 100 1 - 4 1.5
150 - 400 6 - 16 3.0
400 - 1000 16 - 40 5.0
d Various types of shavers are available for shaving the pipe ends, subject to the pipe size
(table B).
Table B: Available taper shavers
Pipe Size range Type
(mm) (inch)
50 - 150 2 - 6 M86
150 - 400 6 -16 M87
400 - 600 16 - 24 M87XL
600 -1000 24 - 40 M95
Cutting of pipe
determining length scribing the pipe
squareness tolerance
pipe shaving set
3
3. Support and fix the pipe firmly.
a Prevent the pipe from being damaged.
4. Carefully insert the arbor into de pipe.
a Fix the arbor to the inside of the pipe by turning the central tensioning bolt clockwise.
5. Adjust the shaver to the required pipe size.
a Be sure to use the correct taper angle.
b Take care when shaving the first layer, because the pipewall may be not be equally thick
on all sides.
c For shaver information and operation instructions refer to the applicable Bondstrand
Pipe Shaver Operation Instructions .
Shaving
Tabl e C: Shavi ng di mensi ons per pressure cl ass
Pipe Size taper insert. nose spigot insert. nose spigot insert. nose spigot
angle depth thick. diam. depth thick. diam depth thick. diam
mm inch degr. mm mm mm mm mm mm mm mm mm
10 bar 12 bar 14 bar
50 2 1
3
/4 50 1 55.2 50 1 55.2 50 1 55.2
80 3 1
3
/4 50 1 83.8 50 1 83.8 50 1 83.8
100 4 1
3
/4 50 1 107.2 50 1 107.2 50 1 107.2
150 6 2
1
/2 50 1 161.0 50 1 161.0 50 1 161.0
200 8 2
1
/2 80 1 210.8 80 1 210.8 80 1 210.8
250 10 2
1
/2 80 1 264.9 80 1 264.9 110 1 264.9
300 12 2
1
/2 80 1 315.7 80 1 315.7 140 1 315.7
350 14 2
1
/2 80 1.5 347.4 80 1.5 347.4 140 1.5 347.4
400 16 2
1
/2 110 1.5 396.7 110 1.5 396.7 170 1.5 396.7
450 18 2
1
/2 110 1.5 436.8 110 1.5 436.8 170 1.5 436.8
500 20 2
1
/2 110 2 486.1 140 2 486.1 140 2 486.1
600 24 2
1
/2 110 2 582.6 170 2 582.6 170 2 582.6
700 28 1
3
/4 140 4 708 170 4 708 230 4 708
750 30 1
3
/4 140 4 758 200 4 758 260 4 758
800 32 1
3
/4 170 4 808 230 4 808 230 5.5 811
900 36 1
3
/4 200 4 908 260 4 908 260 6 912
1000 40 1
3
/4 200 4.5 1009 200/290 4.5 1009 290 6.5 1013
16 bar 20 bar 25 bar
50 2 1
3
/4 50 1 55.2 50 1 55.2 50 1 55.2
80 3 1
3
/4 50 1 83.8 50 1 83.8 80 1 83.8
100 4 1
3
/4 50 1 107.2 50 1 107.2 80 1 107.2
150 6 2
1
/2 50 1 161.0 80 1 161.0 110 1 161.0
200 8 2
1
/2 80 1 210.8 80 1 210.8 140 1 210.8
250 10 2
1
/2 110 1 264.9 110 1 264.9 170 1.5 265.9
300 12 2
1
/2 140 1 315.7 140 1 315.7 200 1.5 316.7
350 14 2
1
/2 140 1.5 347.4 140 1.5 347.4 170 2 348.4
400 16 2
1
/2 170 1.5 396.7 170 1.5 396.7 230 2.5 398.7
450 18 2
1
/2 170 1.5 436.8 170 1.5 436.8 200 2.5 438.8
500 20 2
1
/2 200 2 486.1 200 2 486.1 230 3 488.1
600 24 2
1
/2 230 2.5 583.6 230 2.5 583.6 260 3.5 585.6
700 28 1
3
/4 230 5.5 711 290 5.5 711 260/350 7 714
750 30 1
3
/4 260 6 762 230/320 6 762 290/380 8 766
800 32 1
3
/4 290 5.5 811 320 6.5 813 290/410 8.5 817
900 36 1
3
/4 260/350 6 912 260/350 7.5 915
1000 40 1
3
/4 230/320 8 1016
taper joint
insertion arbor with shaver
supporting of pipe
4
Pipe Size taper insert. nose spigot insert. nose spigot insert. nose spigot
angle depth thick. diam. depth thick. diam depth thick. diam
mm inch degr. mm mm mm mm mm mm mm mm mm
32 bar 40 bar 50 bar
50 2 1
3
/4 50 1 55.2 80 1 55.2 80 1 55.2
80 3 1
3
/4 80 1 83.8 80 1 83.8 110 1.5 84.8
100 4 1
3
/4 80 1 107.2 110 1.5 108.2 140 2 109.2
150 6 2
1
/2 110 1 161.0 140 1.5 162.0 170 2 163.0
200 8 2
1
/2 140 1 210.8 170 1.5 211.8 200 2.5 213.8
250 10 2
1
/2 170 1.5 265.9 200 2.5 267.9 260 3 268.9
300 12 2
1
/2 200 1.5 316.7 260 2.5 318.7 290 3.5 320.7
350 14 2
1
/2 230 2 348.4 260 3 350.4 320 4 352.4
400 16 2
1
/2 230 2.5 398.7 290 3.5 400.7 290/380 4 401.7
450 18 2
1
/2 260 2.5 438.8 320 4 441.8 350/440 4 441.8
500 20 2
1
/2 290 3 488.1 290/380 4 490.1 380/500 4 490.1
600 24 2
1
/2 350 3.5 585.6 380/470 4 586.6
Seri es 2000M / 7000M Seri es 2020
50 2 1
3
/4 (50) (1) (55.2)
80 3 1
3
/4 (50) (1) (83.8)
100 4 1
3
/4 (50) (1) (107.2)
150 6 2
1
/2 80 1 161.0
200 8 2
1
/2 (140) (1) (210.8) 80 1 210.8
250 10 2
1
/2 (170) (1.5) (265.9) 110 1 264.9
300 12 2
1
/2 (200) (1.5) (316.7) 140 1 315.7
350 14 2
1
/2 (170) (5.4) (348.4) 140 1.5 347.4
400 16 2
1
/2 (230) (6.4) (398.7) 170 1.5 396.7
450 18 2
1
/2 200 2.5 438.8 170 1.5 436.8
500 20 2
1
/2 230 3 488.1 200 2 486.1
600 24 2.5 260 3.5 585.6 230 2.5 583.6
700 28 1
3
/4 260 11.5 723.0
750 30 1
3
/4 260 13 776.0
800 32 1
3
/4 260 14 828.0
900 36 1
3
/4 260 16.5 933.0
1000 40 1
3
/4
Series 2000M / 7000M sizes up to 400 mm (16) and series 2020 sizes up to 100 mm (4) are with Quick-Lock joints.
Refer to Quick-Lock assembly guide.
Taper data for Quick-Lock sizes shown within (brackets) are only shown for Taper-Bonding reducing fittings, i.e. the
minor outlet of a reducer size 500 x 400 has a taper socket. In the minor outlet of those fittings a Taper to Quick-Lock
transition-adapter has to be bonded. This makes the minor outlet Quick-Lock (male).
In cases where 2 insertion depths are shown, such as 200/290, the first figure shows the insertion depth for pipe
series 3400 and the second for pipe series 2400.
taper joint
5
6. Shave the taper spigot.
a Maximum shaving depth / feed is 2 mm.
b Repeat the shaving action until the required spigot diameter / spigot nose thickness is
achieved (table C).
c Due to possible tolerance spreading it is recommended to use a nominal sized dummy
bell end. This may avoid too long or too short assembly lengths. If the insertion depth in
the dummy is too small, the spigot end to be shaved has to be adjusted.
d Shaving the diameter of a taper spigot 1 mm smaller, with a taper angle of 2.5 will result
in 23 mm additional insertion in the socket. For a taper angle of 1.75 this is 33 mm.
7. Sand all bonding surfaces.
a Thoroughly sand within 2 hours from assembly.
b Use flapper wheel sanders with a small drilling machine (1700 - 2000 rpm) or emery
cloth with a grid of 60.
c Bonding surfaces must be dry and clean before sanding. Refer to step 10.
d Sanded surfaces must have a dull, fresh finish, not a polished look.
8. Dry fit and mark the joint.
a Check the assembly length and mark pipe and fitting for alignment of elbows, flanges,
etc.
b Measure back from the edge of the spigot the required insertion depth plus 50 mm and
scribe a line. After assembly by pulling the joint together the scribe on the pipe should be
50 mm from the end of the bell.
Preparing for bonding
shaving to insertion tolerance
sanding of spigot
sanding of socket
alignment mark
insertion mark
6
c During final assembly the spigot may slip approximately 5 mm further into the bell,
therefor the dry fitted assembly should be approximately 5 mm longer per joint.
9. Install the band clamps.
a Install the band clamps on both components keeping sufficient space for the winches
when pulling the joint together.
Normally 2 winches will suffice. If needed more winches can be used.
10. Dry the bonding surfaces.
a If the relative humidity is higher than 75% or if the bonding surfaces are wet they should
be dried.
b A hot air blower or Ameron heating blanket can be used.
11. Pre-heat or cool down the bonding surfaces.
a It is recommended to keep the bonding surfaces between 15C and 40C.
b For warming up Ameron heating blankets can be used.
c If the sun will heat up the bonding surfaces to above 40C keep them in the shade if
possible.
12. Re-sand.
a If the sanded surfaces have been contaminated, or if initial sanding took place more
than 2 hours before assembling, the surfaces should be re-sanded.
13. Clean the sanded surfaces.
a Use a clean dry cloth or brush to remove sanding dust etc.
b Do not touch the sanded surfaces after sanding and cleaning.
position after assembly
use of winches
cleaning of socket
7
14. Select the proper size adhesive kit.
a Table D shows the quantity of adhesive needed for one joint.
b More joints may be assembled at the same time.
c Make sure the adhesive is not expired. Refer to date stamp on the package.
d Never split a package, always prepare complete kits.
e Do not use damaged or leaking adhesive kits.
15. Prepare the adhesive.
a Add the curing agent to the resin.
b Stir thoroughly until no streaks are visible and the mixture has an even colour (after 2 to 3
minutes).
Table E: Storage and usage of adhesive
Storing temperature 5 - 35C
Recommended mixing temperature 20 -35C
Bad processing at temperatures below 15C
Too fast curing at temperatures above 40C
Minimum curing temperature of adhesive 80C
c Make sure that before mixing the adhesive, all preparations have been done and all
parts to be bonded are ready for assembly, because mixed adhesive has a limited potlife
subject to the ambient temperature (table F).
d Apply the adhesive immediately after mixing.
Table F: Potlife of mixed adhesive in minutes
Temperature in C 20 25 30 35 40
Kit size
3 Oz/ 137 grams 45 40 35 30 25
6 Oz / 272 grams 40 35 30 25 20
e Never use adhesive that has started to cure. This is the case when the mixture gets
clotted and toughens.
Preparing the adhesive
Table D: Adhesive kits per joint. (for 3 Oz kits multiply by 2; for 9 Oz kits multiply by 2/3)
SIZE 10 12 14 16 20 25 32 40 50
inch mm bar bar bar bar bar bar bar bar bar
2 50 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1
3 80 0.1 0.1 0.1 0.1 0.1 0.2 0.2 0.2 0.3
4 100 0.2 0.2 0.2 0.2 0.2 0.3 0.3 0.4 0.5
6 150 0.2 0.2 0.2 0.2 0.4 0.5 0.5 1 1
8 200 0.3 0.5 0.5 0.5 1 1 1 2 2
10 250 1 1 1 1 1 2 2 2 3
12 300 1 1 2 2 2 2 2 3 3
14 350 1 1 2 2 2 2 3 3 4
16 400 2 2 3 3 3 3 3 4 5/6
18 450 2 2 3 3 3 3 4 5
20 500 2 3 3 3 3 4 5
24 600 2 4 3 4 5 5 7
28 700 4 4 6 6 7 6/8
30 750 4 5 7 7 6/8 7/9
32 800 5 6 6 8 8 8/11
36 900 6 8 8 8/10 8/10
40 1000 7 7/9 10 8/10
In cases where 7/9 or 5/6 etc are shown the first figure is valid for Series 3400 and the
second for Series 2400.
removing excessive adhesive
8
16. Apply a thin layer of adhesive
a Use a spatula or an adhesive scraper for applying the adhesive.
b All surfaces to be bonded (sanded areas) must be completely covered with adhesive,
approximately 0.5 mm in the bell and 1 mm on the spigot.
c A too thick layer of adhesive may result in flow restrictions.
d Make sure that also sufficient adhesive is applied on the cylindrical end of the spigot that
will be covered by the bell.
17. Insert the spigot in the bell.
a When inserting the spigot pay attention to the marks and position and keep the joint
together. Letting the spigot slip back or turning the spigot after complete insertion may
result in a bad joint.
b Hook the 2 winches in the band clamps and start pulling the joint further together in a
smooth movement until the joint is firmly fixed together and there is 50 mm between the
bell end and the mark. See step 8.
c It may be necessary to set a bridge (pieces of wood between winch cables and pipe
outside) to simplify placing of the heating blanket.
d Do not remove the winches until the adhesive has fully cured.
18. Remove excessive adhesive.
a For removing excessive adhesive, also from the inside if possible (flanges), a spatula
may be used.
Assembling the adhesive bonding joint
applying adhesive
adhesive surfaces
adhesive improper applied
use of winches
9
19. Apply the heating blanket.
a Wrap the required size Ameron heating blanket around the joint keeping the power
supply cable free from the blanket.
b Make sure the voltage is correct.
c The blanket should be applied as indicated in the appropriate Bondstrand Heating
Blanket Data sheet.
d The blanket should be tied down using heat resistant wire.
e Good blanket to pipe surface contact is essential for proper curing of the adhesive.
f When the temperature is below 10C or the wind has a cooling effect, insulation material
should cover the heating blanket. Insulation material should overlap the sides of the
blanket with at least 100 mm and should match to the pipe. It should not cover the
thermostat.
g Open pipe ends should be closed during curing preventing cooling down by draught.
Curing of the adhesive
write starting time
insulate heating blanket
10
20. Determine the curing time
a Curing time is mainly subject to the distance (= wallthickness) between blanket and
adhesive.
Table G: Curing time for taper pipe joints in hours
Series 3410 3412 3414 3416 3420 3425 3432 3440 3450
Pipe Size 2000M 2020
(mm) (inch) 7000M
50 2 1 1 1 1 1 1 1 1 1
80 3 1 1 1 1 1 1 1 1 1
100 4 1 1 1 1 1 1 1 1 1
150 6 1 1 1 1 1 1 1 1 1.5
200 8 1 1 1 1 1 1 1 1.5 2
250 10 1 1 1 1 1 1 1.5 2 3
300 12 1 1 1 1 1 1.5 2 3 4
350 14 1 1 1 1 1 1.5 2 3
400 16 1 1 1 1 1.5 2 3 4
450 18 1 1 1 1.5 1.5 2 3 4
500 20 1 1 1.5 1.5 2 3 4 4
600 24 1 1.5 1.5 2 2 4 4
700 28 1 1.5 2 3
750 30 1.5 1.5 2 3
800 32 1.5 2 2 3
900 36 1.5 2 3 4
1000 40 2 3 4 4
Table R: Curing time for taper fitting joints in hours
Series T10 T12 T14 T16 T20 T25 T32 T40 T50
Pipe Size 2000M 2020
(mm) (inch) 7000M
50 2 1 1 1 1 1 1 1 1 1
80 3 1 1 1 1 1 1 1 1 1
100 4 1 1 1 1 1 1 1 1 1.5
150 6 1 1 1 1 1 1 1.5 2 3
200 8 1 1 1 1 1 1.5 2 3 4
250 10 1 1 1 1.5 1.5 2 3 4 4
300 12 1 1 1.5 1.5 2 3 4 4
350 14 1 1 1.5 1.5 2 3 4 4
400 16 1 1.5 1.5 2 3 4 4
450 18 1.5 1.5 2 2 3 4 4
500 20 1.5 1.5 2 3 4 4
600 24 1.5 2 3 4 4
700 28 2 3 4 4
750 30 2 3 4 4
800 32 2 4 4 4
900 36 3 4 4
1000 40 4 4
Notes: Joint surfaces should be preheated when the laminate thickness between heating
blanket and adhesive is 40 mm or more and the temperature is below 20C.
For series 2000M and 7000M sizes 1 to 16 inch (25 to 400 mm) and series 2020
sizes 1 to 4 inch (25 to 100 mm) refer to the Quick-Lock Assembly Instructions.
11
21. Activate the heating blanket.
a Apply electrical power to the heating blanket and check if it heats up.
b Write down on the pipe next to the heating blanket the starting time.
c During the time of curing the functioning of the heating blanket should be checked
regularly; if a cold heating blanket is found, remedy the problem and start the complete
curing cycle again.
d During curing the joint should not be moved, vibrated or otherwise disturbed.
G Ameron shaving tool(s)
G Electrical power drive (available from Ameron)
G Hacksaw, disc grinder or power jigsaw
G Small electrical or air hand drilling machine (6 mm drive and 1700-2000 rpm)
G Flapper wheel sanders (available from Ameron) and / or coarse emery cloth; grid 60.
G Pairs of winches or come-alongs (available from Ameron).
G Pairs of band clamps with puller rings (available from Ameron).
G Measuring tape and / or folding rule.
G Pi-tape with vernier division (available from Ameron)
G Clean cloth or clean brush
G Pipe fitters wrap around, level and white paint pencil.
G Ameron heating blanket and eventual hot air blower.
G Insulation blankets.
G Pipe vice or stable supports (brackets) with pipe holding or clamping device with 6 mm
elastomeric pads.
G Gloves, dustmasks and goggles
G Tenting (subject to weather conditions).
G For health and safety data refer to appropriate Bondstrand Adhesive Product Data
sheet.
G Wear at all time suitable protective clothing, gloves and eye protection. Dust masks
should be used during machining and sanding.
G Use gloves when working with adhesive, the wet adhesive may cause irritation by skin
contact.
Recommended tools
Health and Safety
personal protection
1 psi = 6895 Pa = 0.07031 kg/cm
2
1 bar = 10
5
Pa = 14.5 psi = 1.02 kg/cm
2
1 MPa = 1 N/mm
2
= 145 psi = 10.2 kg/cm
2
1 inch = 25.4 mm
1 Btu.in/(hft
2
F) = 0.1442 W/(mK).
C = 5/9 (F - 32)
This product literature and the recommendations for usage it contains are based on test
data reasonably believed to be reliable. It is intended that this literature be used by
personnel having specialised training in accordance with currently accepted industry
practice and normal operating conditions. Variation in enviroment, changes in operating
procedures, or extrapolation of data may cause unsatisfactory results. We recommend that
your engineers verify the suitable of this product for your intended application. Since we
have no control over the conditions of service, we expressly disclaim responsibility for the
results obtained or for any consequential or incidental damages of any kind incurred.
Conversions
Important notice
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.n
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet:www.ameron.com
email:marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Assembly Instructions
for Bondstrand fiberglass flanges
Scope These instructions present Ameron's recommendations for the proper use of
Bondstrand fiberglass flanges in the following pipe series:
Series 2000 2000M
4000 5000 5000M
6000 7000 7000M
The mounting of flanges on pipe and fittings is addressed by the assembly
instructions for the particular Bondstrand jointing system used.
Gaskets Use full-face gaskets of an elastomer suitable for the service pressure and
temperature and fluids in the system. Gaskets should be
1
/8 inch (3 mm) thick with
a Shore A durometer hardness between 55 and 65. Refer to ASTM D1330
Specification for Sheet Rubber Gaskets, Grade I or II, to establish minimum
physical property requirements for use with water, except specify a Shore A
durometer hardness of 60 5. For dimensions other than thickness, refer to Table
5 of ANSI B16.21-1978 for Class 150 full-face gaskets.
Assembly First finger tighten all nuts. Bolt threads must be clean and lubricated to attain
proper torque. Use lubricated washers under both nuts and bolt heads to protect
flange back-facing.
Tighten all nuts following the sequences shown under tightening sequence. Do not
exceed the torque increments given in recommended bolt torques. After all bolts
have been tightened to the recommended torque, recheck the torque on each bolt
in the same sequence, since previously tightened bolts may have relaxed.
Caution: Excess torque can prevent sealing and can damage flanges.
Sealing. against valves Always follow these instructions carefully when joining Bondstrand flanges to
and other flanges raised-face steel flanges, flanges on lined pipe and fittings, and wafer valves of all
types. Molded flanges should not be connected to wafer valves or raised-face steel
flanges. Valves are frequently supplied with sealing details built into the flange
facing. Unless these details are known to seal without a gasket against Bondstrand
flanges, use the usual full-face,
1
/8-inch thick elastomeric gasket.
Safety factors Standard black or solid gray molded flanges in 4-through 12-inch sizes have a
safety factor to failure torque of 1.5 or greater when joined to another Bondstrand
flange or any flat-face flange in accordance with these instructions. All other
Bondstrand flanges have a safety factor to failure of 1.5 or greater when joined to a
raised-face steel flange or a valve in accordance with these instructions.
Ameron 1987 FP196A supersedes FP196 O 01/93 Printed in The Netherlands
Nuts and washers Nut Plain Washer
Flange Size Thickness OD Thickness
(in) (mm) (in) (mm) (in) (mm) (in) (mm)
1-1.5 25-40 .44 11 1.06 30 .12 3
2-4 50-100 .55 14 1.31 33 .12 3
6-8 150-200 .64 15 1.47 37 .16 4
10-12 250-300 .75 19 1.75 44 .16 4
14-16 350-400 1.00 25 2.00 51 .16 4
18-20 350-500 1.00 25 2.25 57 .16 4
22-30 550-750 1.06 27 2.50 64 .16 4
32-36 800-900 1.28 33 3.00 76 .16 4
Nuts and washers should conform to requirements of ANSI B18.2.2-1972 (R1983) Regular Hex Nuts and
ANSI B18.22.1-1965 (R1981) Type A, Plain, Narrow Series, respectively. Washer dimensions agree with
SAE Standard'' and ANSI/ASTM Specification F436.
Recommended bolt torques Torque Recommended Torque for
Flange Size Increments Full Pressure Seal
(in) (mm) (ft lb) (N m) (ftlb) (Nm)
1- 4 25-100 5 7 20 27
6-12 150-300 10 14 30 41
14-16 350-400 10 14 50 68
18-20 450-500 20 27 60 81
22-36 550-900 25 34 75 102
All flanges for the Bondstrand pipe series listed above in Scope mate with other Bondstrand flanges or with
flat-face steel flanges using these bolt torques.
Tightening sequence
Bolt lengths Recommended hex head bolt lengths for flanges with ANSI B1 6.5, Class 150
drilling are tabulated below. Stud bolt lengths may be determined by adding the
thickness of a nut plus three threads to the tabulated lengths. For orifice flange
assemblies add an additional 1 inches (40 mm). ALWAYS use washers under
both nuts and bolt heads to protect the back-facing of fiberglass flanges.
Filament-wound flanges
Flange Bolt Bolt Flange Combination
1
Size Diameter Count FW x FW FW x S HDFW x HDFWHDFW x S
(in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm) (in) (mm)
1 25 0.500 13 4 _ _ _ _ 3.50 89 3.00 76
1.5 40 0.500 13 4 _ _ _ _ 4.00 102 3.50 89
2 50
2
0.625 16 4 3.25 83 3.00 76 5.25 133 4.00 102
3 80
2
0.625 16 4 3.50 89 3.25 83 5.25 133 4.25 108
4 100
2
0.625 16 8 3.75 95 3.50 89 5.25 133 4.25 108
6 150 0.750 19 8 5.00 127 4.25 108 6,50 165 5.00 127
8 200 0.750 19 8 5.50 140 4.50 114 7.00 178 5.50 140
10 250 0.875 22 12 5.50 140 4.75 121 7.50 191 5.50 140
12 300 0.875 22 12 5.75 146 5.00 127 8.00 203 6.00 152
14 350 1.000 25 12 7.25 184 5.75 146 9.50 241 7.00 178
16 400 1.000 25 16 8.00 203 6.25 159 10.00 254 7.50 191
18 450 1.125 29 16 9.00 229 7.00 178 11.00 279 8.00 203
20 500 1.125 29 20 9.50 242 7.50 191 11.50 292 8.50 216
22 550 1.250 32 20 10.50 267 8.00 203 12.50 318 9.00 229
24 600 1.250 32 20 11.00 279 8.50 216 13.00 330 9.50 241
26 650 1.250 32 24 10.50 267 9.00 229 14.00 356 11.00 279
28 700 1.250 32 28 11.00 279 9.50 241 15.00 381 11.50 292
30 750 1.250 32 28 11.50 292 9.50 241 16.00 406 12.00 305
32 800 1.500 38 28 13.00 330 10.50 257 18.00 457 13.00 330
34 850 1.500 38 32 13.00 330 11.00 279 19.00 483 14.00 356
36 900 1.500 38 32 14.00 356 11.50 292 20.00 508 15.00 381
Molded flanges
Flange Bolt Bolt Flange Combination
1
Size Diameter Count M x M M x S
3
(in) (mm) (in) (mm) (in) (mm) (in) (mm)
1.5 40
3
0.500 13 4 _ _ 4.50 114
2 50 0.625 16 4 3.25 83 _ _
3 80 0.625 16 4 3.75 95 _ _
4 100 0.625 16 8 4.25 108 _ _
6 150 0.750 19 8 5.00 127 4.25 108
8 200 0.750 19 8 5.50 140 4.50 114
10 250 0.875 22 12 5.50 140 4.75 121
12 300 0.875 22 12 5,75 146 5.00 127
1) FW = Filament-wound
S = Steel
M = Molded
HDFVV - Heavy-duty filament-wound
Bolt lengths are determined using ASTM Standard Practice F704 and Annex "F'' of ANSI Standard B16.5-
1981 and include provision for washers under bolt heads and nuts abutting filament-wound or molded
flanges. Bolts should conform to requirements of ANSI 818.2.1-1972 Regular Hex Head Bolts.
2) Maintain bolt end point clearance on inside radius of 2-through 4-inch flanged ANSI 45
Bondstrand elbows by using additional washers or shims under boll heads as required.
3) Flat-face steel flanges.
4) Available only in 2 x 1 inch reducing configuration. Connect only to 1 inch steel flange.
Trouble shooting If assembled joint leaks, Ioosen and remove all bolts, nuts, washers and gaskets.
Check for alignment of assembly. Rebuild to correct alignment as required. Check the
gasket for damage. If damaged, discard and replace with new, undamaged gasket.
Check flanges for seal ring damage. In particular, check the condition of the inner seal
rings. Flanges with damaged inner seal rings must be removed and new, undamaged
flanges installed.
If leaks occur as a result of deficiencies in nonfiberglass components of the piping
system, consult the manufacturer of the defective components for recommended
corrective procedures.
Clean and relubricate old threads and washers before rejoining. Repeat the joining
procedure outlined above.
After corrective action has been taken, retest the joint to see if a seal has been made.
Important notice This literature and the information and recommendations it contains are based on data
reasonably believed to be reliable. However, such factors as variations in environment,
application or installation, changes in operating procedures, or extrapolation of data may
cause different results. Ameron makes no representation or warranty, express or implied,
including warranties of merchantability or fitness for purpose, as to the accuracy,
adequacy or completeness of the recommendations or information contained herein.
Ameron assumes no liability whatsoever in connection with this literature or the
information or recommendations it contains.
Written comments regarding this document are invited. Please write Engineering
Manager, Ameron Fiberglass Pipe Group.
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.n
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet:www.ameron.com
email:marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Assembly instructions for
but t-end joints and repair
Instructions
Inner sections (2)
Outer sections (2)
Hose Clamp
Areas to be sanded and
adhesive applied
1. Cutting the pipe -Before cutting the replacement length of pipe, allow the .
temperature of the existing system to stabilize to avoid length changes through
expansion or contraction. Measure the replacement piece carefully so that the space
between its ends and the ends of the pipe in the existing system will be no more
than 1/8 inch.
2. Positioning the coupling -Center the maintenance coupling over the joint and
mark the lap length on the pipe ends. Sand the pipe ends with a belt sander using
belts with a 40-grit abrasive. Sand inaccessible areas with a flapper sander or by
hand using a '"shoeshine" method. Sand until all gloss is removed from surfaces to
be bonded. Sand the cut ends of the pipe as well.
3. Checking for snugness of fit -Fit the parts together dry before final sanding.
The 180 inner sections placed around the pipe e-r\ds should, when held in contact
on one side, show from 0 to V8 inch separation on the opposite side. If, with zero
separation, the inner sections are not snug against the pipe surfaces, file back an
edge as required to get a snug fit. If the sections, when fitted snugly, show a
separation of more than 1/8 inch, correct any misalignment of pipe ends and sand to
fit. The outer sections of the coupling should show 1/8 inch or more of separation.
4. Final sanding -All mating surfaces must be clean and dry and must be sanded
within two hours of assembly. Sand using a V4-inch drill motor at 1700-2000 rpm and
a flapper type sander with a 40- 50 grit aluminum oxide abrasive, available from
Ameron. After sanding, bonding surfaces should show a dull fresh finish, not a
polished look.
Use special care in handling parts to avoid contamination. Handle the parts with new
gloves which are used only for this purpose or with clean, dry cotton cloths.
If the bonding surfaces are wet, warm them with a Bondstrand heating blanket until
dry, then resand. Protect the bonding surfaces from moisture during wet weather
with tenting over the work area.
5. Selecting the adhesive -Unless the project specifications or the Bondstrand
Corrosion Guide (FP132) recommends a special adhesive for your particular service,
use Bondstrand RP34C epoxy adhesive. Instructions for mixing and using the
adhesive are in the adhesive kit.
Larger couplings are more difficult to handle and assemble; once the adhesive has
been mixed, the time available for assembly is limited by the adhesive pot life. A
crew of two or three is suggested when assembling 8- through 16-inch couplings.
FP199C (11/96)
Instructions (cont.) 6. Applying the adhesive -With the spatula supplied in the adhesive kit, apply
adhesive to completely cover the cut pipe edges, the prepared pipe ends and the
inner surfaces of the two inner sections of the coupling. Use enough adhesive so
that any excess will be forced to flow to the edges of the sections when assembled
around the pipe ends. Assemble these two inner half sections by centering them
around the butted ends of the pipe. If the potlife of the adhesive is now more than
half expired, it may be necessary to defer further assembly and cure the inner
sections. If so, clamp the sections and cure according to the instructions provided in
the adhesive kit. After curing, let the parts cool completely, remove the clamps,
resand the remaining mating surfaces, mix a new batch of adhesive and proceed as
follows.
Apply adhesive to cover completely the outer surfaces of the inner sections.
Assemble the two outer sections with the split line about 90 away from the split line
in the inner sections. Place the steel clamping straps around the assembly and draw
them tight. Remove excess adhesive for a workmanlike appearance.
7. Curing the adhesive -Heat-cure the adhesive using Ameron heating blankets.
Cure time is 1 hour and 15 minutes for all diameters. Apply the heating blankets in
accordance with the instructions provided with the blanket, making certain that any
overlap of the blanket covers the thermostat. It is always a good idea to insulate
around the heating blanket and to close the ends of the piping system to prevent
movement of cold air inside the pipe while the adhesive is curing.
Maintenance coupling kit Kit includes inner and outer sections, hose clamps and assembly instructions.
Adhesive must be ordered separately.
Pipe Coupling Adhesive Pipe Coupling Adhesive
Size Code Length Usage"2 Size Code Length Usage1.2
(in) ~ (kits) (in) (inL (kits) -
8
10
12
14
16
80400801
A0400801
80400801
C0400801
00400801
5.38
5.88
6.38
7.38
8.38
3
4
4
6
8
-
2
3
4
6
-
20400801
30400801
40400801
60400801
-
4.00
4.00
4.00
4.88
2
2
Important notice
This literature and the information and recommendations it contains are based on data
reasonably believed to be reliable. However, such factors as variations in environment, appli-
cation or installation, changes in operating procedures, or extrapolation of data may cause
different results. Ameron makes no representation or warranty, express or implied, including
warranties of merchantability or fitness for purpose, as to the accuracy, adequacy or
completeness of the recommendations or information contained herein. Ameron assumes no
liability whatsoever in connection with this literature or the information or recommendations it
contains.
Fiberglass Pipe Group
Headqualters
P.O.Box801148
Houston TX 77280
U.S.A.
Phone: (+1)7136907777
Fax: (+1) 713690 2842
Internet.wwwameron.com
C '976 Ameron .FP199C (, '/96) supersedes FP'99B (4/95) .Printed In U.S.A. .5MI124]
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.n
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet:www.ameron.com
email:marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Ameron 1995. FP 599 C 08/04 supersedes FP 599 B 05/99 - Page 1 of 2. Printed in the Netherlands.
B
ondstrand pipe shavers are designed to prepare a spigot
on the cut end of a Bondstrand pipe as described in the individual assembly
instructions. Pipe is shipped from the factory with spigots, but when the pipe is cut to
length on the job site, a spigot must be shaved for assembly to the bell end of another
section of pipe, or to a fitting or coupling. Each shaver is centered and fixed on the
end of the pipe by an expanding arbor. Arbors are available for each pipe size. The
arbor slips in to the pipe and expands to grip the inside of the pipe when the tensioning
bolt(s)is/are tightened. As the frame is rotated around the stationary centre shaft, the
cutting tool advances automaticially.
Assembly technique
For the best possible joint reliability, Ameron draws on broad experience to provide
complete assembly instructions. These well-defined and repeatable assembly
techniques help the user avoid field-joining problems and assure succesful installation.
Training programmes and audio-visual aids are available and are especially helpful
for first-time users of Bondstrand Pipe Shavers.
The following series of pipe shavers are available :
Shaver Type Bonding system Size
B-1 Quick-Lock 1- 4
M74 Quick-Lock 2-16
M86 Taper/Taper 2-6
M86 XL Taper/Taper and Quick-Lock 2-10
M87 Taper/Taper and Quick-Lock 6-16
M87 XL Taper/Taper and Quick-Lock 16-24
M95 Taper/Taper 24-40
B-1 Pipe End Preparation Tool
The B-1 pipe tool is used to prepare the straight spigot end on Bondstrand fiberglass
pipe employing the Quick-Lock adhesive bonded joint. The tool is available for all
Bondstrand pipe sizes from 1 through 4 inch (25-100 mm) in diameter and has been
designed so that all critical dimensions such as spigot length and spigot outside
diameter are preset and require no adjustment by the operator.
M74 Pipe Shaver
The Bondstrand M74 Pipe Shaver is designed to prepare a cilindrical surface (spigot)
on the cut end of a Bondstrand pipe in sizes 2 through 16 inch (50-400 mm) in diam-
eter as described in the Bondstrand Assembly Instructions. When adjusted and used
as described in the instructions, the shaver prepares an excellent bonding surface
with a controlled tolerance on diameter. This unit can be rotated by hand or with a
portable power drive (supplied loose). A key in the portable power drive engages a
keyway in the power drive seat to rotate the unit.
Bondstrand Pipe Shavers
Ameron 1995. FP 599 C 08/04 supersedes FP 599 B 05/99 - Page 1 of 2. Printed in the Netherlands.
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet: www.ameron.com
email: marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.nl
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
M86 Pipe Shaver
The Bondstrand M86 Pipe Shaver is designed to prepare a tapered spigot on the cut
end of a Bond-strand pipe in sizes 2 through 6 inch (50-150 mm) diameter allowing to
fit a Bondstrand fitting with a matching tapered socket. The shaver is normally driven
by a portable power-drive adapter. A key in the portable power drive engages a keyway
in the power drive seat to rotate the shaver.
M86XL Pipe Shaver
The Bondstrand M86XL pipe shaver is designed to prepare a tapered or straight
spigot on the cut-end of a Bondstrand pipe in the sizes 2 through 10 inch (50-250
mm) diameter, allowing to fit a Bondstrand fitting with a matching tapered socket or
Quick-Lock socket, as well as preparing ends for mechanical coupling e.g. Helden,
Straub, Viking Johnson, etc. The shaver is driven by two fixed electric motors.
M87 Pipe Shaver
The Bondstrand M87 pipe shaver is designed to prepare a tapered or straight spigot
on the cut end of a Bondstrand pipe in the sizes 6 through 16 inch (150-400 mm)
diameter, allowing to fit a Bondstrand fitting with a matching tapered socket or Quick-
Lock socket, as well as preparing ends for mechanical coupling e.g. Helden, Straub,
Viking Johnson, etc. The shaver is driven by a portable power drive. A key in the
portable power drive engages in a matching slot on the power drive seat to rotate the
shaver.
M87XL Pipe Shaver
The Bondstrand M87XL pipe shaver is designed to prepare a tapered or straight spigot
on the cut end of a Bondstrand pipe in the sizes 16 through 24 inch (400-600 mm)
diameter, allowing to fit a Bondstrand fitting with a matching tapered socket or Quick-
Lock socket, as well preparing ends for mechanical coupling e.g. Helden, Straub,
Viking Johnson, etc. The shaver is driven by a portable power drive.
M95 Pipe Shaver
The Bondstrand M95 pipe shaver is designed to prepare a tapered or straight spigot
on the cut-end of a Bondstrand pipe in the sizes 24 through 40 inch (600-1000 mm)
diameter, allowing to fit a Bondstrand fitting with a matching tapered socket or Quick-
Lock socket, as well as preparing ends for mechanical coupling e.g. Helden, Straub,
Viking Johnson, etc. The shaver is driven by two fixed electric motors.
Ameron 1988. FP 810 03/99 supersedes FP376 B. Page 1 of 2. Printed in The Netherlands.
B-1 Pipe End Preperation Tool
Introduction
Advantages
The B-1 pipe tool is used to prepare the straight spigot end on Bondstrand
fiberglass pipe employing the Quick-Lock adhesive-bonded joint. The tool is
available for all Bondstrand pipe sizes from 1 through 4 inches in diameter and
has been designed so that all critical dimensions such as spigot length and
spigot outside diameter are preset and require no adjustment by the operator.
The B-1 tool offers the following advantages over previously used end
preparation tools from Ameron and end preparation methods offered by
competitive manufacturers:
No adjustments required: spigot length and diameter preset to Ameron
tolerances
No special tools required: uses ordinary power drills with 1/2-inch (13 mm)
chuck
Compact: can be used on installed buried pipe with minimal excavation
Reduced field labor time
Minimal set-up required
Light weight for ease of use.
The B-1 tool is available in 1- through
4-inch sizes for preparing spigot ends
for the Quick-Lock joint
Ameron 2004. FP 000 00/00. Page 2 of 0. Printed in The Netherlands.
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet: www.ameron.com
email: marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.nl
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
1. Clean the inside of the pipe to remove all dint, sand or foreign objects. Clean
tool of any large particles or shavings from previous use.
2. Inspect the cutter wheels on tool. If worn, loosen and rotate for new cutting
edge. If loose, tighten with Allen wrench.
3. Mount tool in chuck of 1/2-inch (13 mm) drill motor and tighten chuck
securely.
4. Except when working on installed pipe, the pipe must be held securely,
preferably in a pipe vise. Use a -inch (6 mm) thick rubber pad between
the clamps and the pipe to protect the pipe. Warning: Avoid inhaling dust
produced by cutting. Wear an approved dust mask.
5. Insert the spindle of the tool into the pipe so that the cuffing wheels remain
away from the end of the pipe. Grip the drill motor firmly and switch to on.
Slowly feed the tool into the pipe until the tool bottoms. Remove tool from
pipe.
6. Inspect the cut surface to insure that all glazed or resin-covered areas have
been removed. If such areas remain, sand by hand until the entire surface is
without a resin gloss.
This literature and the information and recommendations it contains are
based on data reasonably believed to be reliable. However, such factors as
variations in environment, application or installation, changes in operating
procedures, or extrapolation of data may cause different results. Ameron makes
no representation or warranty, express or implied, including warranties of
merchantability or fitness for purpose, as to the accuracy, adequacy or
completeness of the recommendations or information contained here in.
Ameron assumes no liability whatsoever in connection with this literature
or the information or recommendations it contains.
Written comments regarding this document are invited. Please write Engineering
Manager, Ameron Fiberglass-Composite Pipe Group.
Operating instructions
Important notice
Ameron 2004. FP 696 A 05/04 supersedes FP 696 05/94. Page 1 of 8. Printed in The Netherlands.
M74 Pipe Shaver
for Quick-Lock adhesive-bonded
pipe joints in sizes
2 to 16 inch (50-400 mm)
Introduction
The Bondstrand pipe shaver is designed to prepare a spigot on the cut end of a
Bondstrand pipe as described in the Bondstrand Assembly Instructions. Pipe is shipped
from the factory with spigots, but when pipe is cut to length on the job site, a spigot must
be shaved for assembly to the bell end of another section of Bondstrand Quick-Lock
pipe, or to a Bondstrand Quick-Lock fitting or coupling. Bondstrand Quick-Lock flanges
are provided with sockets for mounting to pipe spigots in the same way. Spigots can be
prepared on 2-inch through 16-inch pipe of any Bondstrand series with this tool.
Note: The M74 Shaving Tool is standard available in sizes 2-12 inch / 50-300 mm.
Sizes 14 and 16 inch are available on request.
The pipe shaver is centered and held at the cut end of a pipe by an expanding arbor.
There is an arbor for each diameter. The arbor slips into the pipe and the O-rings expand
to grip the inside pipe surface when the tie bar is tightened. As the frame is rotated
around the feed tube, the cutting tools advance and shave a cylindrical surface (spigot)
on the pipe. When adjusted and used as described in these instructions, the shaver
prepares an excellent bonding surface with a controlled tolerance on diameter.
Note: Arbors are not included and should be ordered separately.
This unit can be rotated by hand or with a portable power drive (optional). A key in the
portable power drive engages a keyway in the power drive seat to rotate the unit.
The shaver is driven by a portable power-drive adapter.
Note: The powerdrive is not included and should be separately.
Note: The use of this shaving tool is restricted to Bondstrand pipe material.
EG-STATEMENT OF AGREEMENT
According to machinery directive 98/37/EG, appendix II, under a, this shaver
complies with machinery directive 98/37/EG;
complies with the following harmonised European Standards: NEN-EN 1050,
NEN-EN 292-1 and NEN-EN 292-2.
Personal protection and safety
The following personal protection gear must be used when cutting, shaving, sanding
and grinding Glassfiber Reinforced Epoxy (GRE) material:
Safety shoes or boots;
Working gloves (GRE material can be very sharp and may cause cuts or splinters);
Proper fitting and buttoned up protective clothing must be worn when operating
the shaver;
A hard hat is to be used, if the situation requires so;
A hair net must be worn, if applicable, when shaving, cutting, grinding, etc;
An appropriate dust mask is to be used when cutting, shaving, grinding and
sanding.
Safety precautions
Ameron 2004. FP 696 A 05/04 supersedes FP 696 05/94. Page 2 of 8. Printed in The Netherlands.
Operational safety
For safe operation of the shaving tool, the following rules must be followed:
Use left hand to hold the grip of powerdrive and the right hand to operate the
power switch;
Immediately release the power switch when the shaver seizes to avoid injury,
or damage to tooling;
The optional power drive torque arm must never be used for safety reasons;
Pipe-shaver assembly must be at ergonomic height to be able to work in the
proper posture;
Ample rest should be taken to avoid physical and mental over stressing;
Only authorised persons are to be allowed in the shaving area;
Before starting the powerdrive, ensure that the shaver will run free from pipe bench,
table or support;
Shaving area must be clearly marked as such;
Shaving tool shall only be used to prepare spigots on Bondstrand pipe material;
Pipe shaver shall only be operated by trained persons;
No other type of power drive shall be used if this is working at a higher speed than
the Ridgid 700;
Powerdrive and shaving tool must be kept in good working order to guarantee
proper and safe operation. Defect parts must be exchanged, or repaired by
qualified persons only.
Note:
1. On special order, instructions of this shaver are available on CD-Rom, or DVD.
2. The noise level of the shaver and powerdrive is less than 70 dB (A).
The following procedure should be carefully followed to ensure satisfactory operation
of the shaver.
1. CHECK YOUR SHAVER
If this is your first use of the pipe shaver, check to see that all parts are included or
available. The following parts are included with M74 pipe shaver and case:
Shaving tool, complete with two* cutting tool assemblies. (*plus an additional two
for 14-16 inch applications.
Pipe shaver gauge with 0.015-inch feeler gauge attached.
Two turning handles and attaching cap screws - not needed if power drive is used.
Six Allen wrenches: sizes 3/32, 5/32, 7/32, 3/16, 5/16 and 3/8 inch.
Arbors, complete with O-rings, are available separately, (see Pipe Shaver Parts
Drawing) or as a set in a convenient carrying case.
A wrench, fitting a 1-1/8 inch hex head is required. The use of a portable power drive is
not necessary, but it will make the job much easier.
Remove the shaver from the case.
Remember, the shaver is a precision tool and must be handled with care.
Caution: Before handling the shaver, engage knurled slide sleeve (part no. 20) by
sliding it fully forward under the power drive seat. Handling of shaver with slide
sleeve disengaged may cause injury.
Safety precautions
Operating instructions
shaver and cutting tools
arbor
Ameron 2004. FP 696 A 05/04 supersedes FP 696 05/94. Page 3 of 8. Printed in The Netherlands.
2. LOCATE CUTTING TOOL ASSEMBLIES
Locate the cutting tool assemblies in the appropriate slots in the frame for the desired
pipe size, and assemble slide plate (part no. 13), washer (part no. 2) and socket head
cap screw (part no. 15) on each assembly, and tighten screws with the 3/8-inch Allen
wrench.
3. SET SPIGOT LENGTH INDICATOR
Loosen the socket head cap screw (part no. 3) on one of the tool retainer arms using
the 3/16-inch Allen wrench and slide the indicator (part no. 6) so that the outer pointer
lines up with the mark for the desired pipe size. Retighten screw.
The inner pointer will show you when the correct spigot length is.
4. ADJUST CUTTING EDGES
Disengage slide sleeve (part no. 20) by sliding it fully out from under the power
drive seat and draw tie bar (part no. 8) back so that feed tube (part no. 9) is fully
back into frame (part no. 22) and engage slide sleeve (part no. 20).
Remove nut (part no. 7) from tie bar (part no. 8). Remove arbor if one is on tie bar,
and slip pipe shaver gauge onto feed tube.
With the 5/16-inch Allen wrench, slightly loosen socket head cap screw (part no. 1)
on one cutting tool assembly. Adjust form tool (part no. 5) in toward or out from pipe
shaver gauge with adjusting screw until cutting insert is separated from pipe shaver
gauge by 0.015-inch feeler gauge.
Lock form tool in place by tightening socket head cap screw.
Recheck position of cutting insert after the form tool is locked in place, and adjust
if necessary.
Repeat procedure to set second form tool (part no. 5).
Remove gauge and slip arbor over feed tube (part no. 9).
Turn nut (part no. 7) onto tie bar (part no. 8) so that key on nut will engage slot in
arbor.
Note: Nut will be tightened later.
5. MOUNT SHAVER IN END OF PIPE
With your Bondstrand pipe cut to length and firmly held in position (see photos of
padded vise in the Bondstrand Assembly Instructions), you are now ready to mount the
shaver on the end of the pipe. Disengage slide sleeve and slide arbor and feed tube
forward, away from frame (part no. 22) and engage slide sleeve (part no. 20).
Slip arbor into Bondstrand pipe until the end of arbor nearest to frame is flush with end
of pipe. Now with a 1-1/8-inch wrench, tighten tie bar (looking toward frame, turn hex
head clockwise) so that arbor is locked firmly inside the pipe.
Lift shaver during tightning of tie bar to ensure proper allignment of shaving tool.
Disengage the slide sleeve, slide frame toward the pipe until cutting inserts are nearly
touching end of pipe, and engage the slide sleeve.
locate the cutting tool
spigot length indicator
engage slide sleeve
adjust cutting edge
shaver with mounted arbor
mounted shaver ready for use
Ameron 2004. FP 696 A 05/04 supersedes FP 696 05/94. Page 4 of 8. Printed in The Netherlands.
6. SHAVE THE SPIGOT
If a portable power drive is used to turn the shaver, slide the drive onto the power drive
seat. Remove turning handles when using power drive.
If you are going to turn the shaver by hand, attach handles.
Begin turning shaver frame clockwise (looking toward pipe), and continue turning and
shaving pipe surface until inner pointer on indicator (part no. 6) is flush with the end of
the pipe.
Caution: Do not reverse power drive to return cutting head to starting position. Do not
use power drive to advance cutting head beyond maximum pointer depth (about 3
inches/75 mm). Shaver will jam at end of travel possibly causing injury.
7. CHECK SHAVED DIAMETER
a. After shaving approx. 20 mm of the first spigot, you will need to check the shaved
diameter. First, disengage the slide sleeve, slide frame) away from pipe until cutting
inserts are at the starting position, and engage the slide sleeve.
With the arbor still firmly in place, measure the shaved diameter of the shaved part
using a Go-No Go Pi Tape. When using vernier reading Pi Tape, see Table 1 for
tolerance range on spigot diameters. Correct spigot length is obtained when the
spigot indicator is flush with pipe end.
If your measured diameter falls well within this tolerance range, you may proceed.
b. If the measured diameter was borderline or outside the recommended tolerance
range, a slight adjustment of the two form tools is required.
Loosen socket head cap screw slightly and adjust screw as required on both tools.
Spigot too small - go to Step 8 and cut off and discard shaved spigot. Reposition arbor
in pipe end and shave new spigot after adjustment, repeat these steps until the proper
diameter is obtained.
Spigot too large - after adjustment, repeat Step 7 until proper diameter is obtained.
8. REMOVE SHAVER FROM PIPE
To remove arbor from pipe, loosen tie bar using a 1-1/8 inch wrench (looking toward
frame, turn hex head counterclockwise).
With slide sleeve engaged, slide arbor out of the pipe.
9. RECHECK ADJUSTMENT FOR WEAR OR ABUSE
Once shaver is properly adjusted for a given pipe size, you will usually need to check
spigot diameters only at the beginning and middle of each shift, provided the shaver is
handled with care at all times, and not dropped, hit or abused in any way that might
cause a change in setting. After extensive use, the cutting inserts may get dull or show
wear. Simply loosen socket head cap screws (part nos 15-17) using 3/32-inch Allen
wrench and rotate both inserts 90 to obtain a new pair of cutting edges.
Adjust to obtain correct shaving diameters.
Ameron stocks replacement cutting inserts for your convenience.
shaving the spigot
using portable power drive
measuring the shaved diameter
spigot length indication
removing shaver from pipe
Ameron 2004. FP 696 A 05/04 supersedes FP 696 05/94. Page 5 of 8. Printed in The Netherlands.
Table 1 : Standard Spigot Dimensions
Nominal Shaved Diameter Shaved Length (see fig. 1)
Pipe Size [inch] [inch] [mm] [mm]
inch mm min. max. min. max. min. max. min. max.
2 50 1.284 1.296 32.6 32.9 1.122 1.240 28.5 31.5
3 80 3.449 3.456 87.6 88.0 1.870 1.988 47.5 50.5
4 100 4.429 4.445 112.5 112.9 1.870 1.988 47.5 50.5
5 125 5.492 5.508 139.5 139.9 2.303 2.431 58.5 61.5
6 150 6.543 6.560 166.2 166.6 2.303 2.431 58.5 61.5
8 200 8.547 8.563 217.1 217.5 2.559 2.677 65.0 68.0
10 250 10.681 10.697 271.3 271.7 2.776 2.894 70.5 73.5
12 300 12.685 12.701 322.2 322.6 3.051 3.168 77.5 80.5
14 350 13.929 13.945 353.8 354.2 3.602 3.721 91.5 94.5
16 400 15.909 15.925 404.1 404.5 4.055 4.173 103.0 106.0
Figure 1. Sketch of lap configuration in a typical Bondstrand Quick-Lock joint.
(Adhesive is not shown.)
Spigot dimensions
10. RESET FOR DIFFERENT PIPE DIAMETER
You will have to repeat these steps each time a change in pipe diameter is made.
Minimizing the number of diameter changes made on the shaver will help expedite your
project.
11. MAINTENANCE & STORAGE
Store you shaver in a dry location, protected from moisture, as you would any machine
tool.
Do not use oil and/or grease as dust will accumulate on oily surfaces.
Remove dust and dirt by means of a brush.
removing dust
Ameron 2004. FP 696 A 05/04 supersedes FP 696 05/94. Page 6 of 8. Printed in The Netherlands.
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Ameron 2004. FP 696 A 05/04 supersedes FP 696 05/94. Page 7 of 8. Printed in The Netherlands.
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Ameron 2004. FP 696 A 05/04 supersedes FP 696 05/94. Page 8 of 8. Printed in The Netherlands.
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
Internet: www.ameron-fpg.nl
email: info@ameron-fpg.nl
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, TX 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston, TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet: www.ameron.com
email: marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
Internet: www.ameron.com.sg
email: info@ameron.com.sg
Important notice This product literature and the recommendations for usage it contains are based on test
data reasonably believed to be reliable. It is intended that this literature be used by
personnel having specialised training in accordance with currently acceptable industry
practice and normal operating conditions. Variation in environment, changes in operating
procedures, or extrapolation of data may cause unsatisfactory results. We recommend
that your engineers verify the suitability of this product for your intended application. Since
we have no control over the conditions of service, we expressly disclaim responsibility for
the results obtained or for any consequential or incidental damages of any kind incurred.
Written comments regarding this document are invited. Please write to the Engineering
Manager, Ameron Fiberglass-Composite Pipe Group/Europe.
Ameron 2003. FP 919 09/03. Page 1 of 8. Printed in The Netherlands.
M86XL Pipe Shaver
for Taper/Taper and Quick-Lock
adhesive-bonded pipe joints
in sizes 2 to 10 inch (50-250 mm)
Introduction
Safety precautions
The Bondstrand M86XL Pipe Shaver is been designed to prepare a tapered or straight
spigot on the cut end of a Bondstrand pipe in the size 2 inch (50 mm) to 10 inch (250
mm) allowing to fit a Bondstrand fitting with a matching tapered socket or Quick-Lock
socket, as well as preparing ends for mechanical coupling e.g. Helden, Straub, Viking
Johnson, etc.
Each Bondstrand M86XL pipe shaver is supplied including the following loose items:
! one 6 mm Allen key for adjustment of tool holder and change of
angle setting block;
! one loose bronze guide block;
! one M86XL shaver instruction manual.
A 19 mm spanner (not included) is required to tighten the clamping bolt. A suitable pipe
vise (chain type or similar) is recommended to hold the pipe during shaving operations
The shaver is centred and fixed on the end of the pipe by an expanding arbor. Arbors are
available for each pipe size. The arbor slips in to the pipe and the O-rings expand to
grip the inside of the pipe when the tensioning bolt is tightened. The necessary arbors
are not included and have to be ordered separately.
The shaver is driven by a portable power-drive adapter.
This powerdrive is not included and has to be ordered seperately.
Note: The use of this shaving tool is restricted to Bondstrand pipe material.
EG-STATEMENT OF AGREEMENT
According to machinery directive 98/37/EG, appendix II, under a, this shaver
* complies with machinery directive 98/37/EG;
* complies with the following harmonised European Standards: NEN-EN 1050,
NEN-EN 292-1 and NEN-EN 292-2.
Personal protection and safety
The following personal protection gear must be used when cutting, shaving, sanding
and grinding Glassfiber Reinforced Epoxy (GRE) material:
* Safety shoes, or boots;
* Working gloves (GRE material can be very sharp and may cause cuts or splinters);
* Proper fitting and buttoned up protective clothing must be worn when operating
the shaver;
* A hard hat is to be used, if the situation requires so;
* A hair net must be worn, if applicable, when shaving, cutting, grinding, etc;
* An appropriate dust mask is to be used when cutting, shaving, grinding and
sanding.
Ameron 2003. FP 919 09/03. Page 2 of 8. Printed in The Netherlands.
Operational safety
For safe operation of the shaving tool, the following rules must be followed:
* Use left hand to hold the grip of powerdrive and the right hand to operate the
power switch;
* Immediately release the power switch when the shaver seizes to avoid injury, or
damage to tooling;
* The optional power drive torque arm must never be used for safety reasons;
* Pipe-shaver assembly must be at ergonomic height to be able to work in the
proper posture;
* Ample rest should be taken to avoid physical and mental over stressing;
* Only authorised persons are to be allowed in the shaving area;
* Before starting the powerdrive, ensure that the shaver will run free from pipe bench,
table, or support;
* Shaving area must be clearly marked as such;
* Shaving tool shall only be used to prepare spigots on Bondstrand pipe material;
* Pipe shaver shall only be operated by trained persons;
* No other type of power drive shall be used if this is working at a higher speed than
the Ridgid 700;
* Maximum cutting depth to be no more than 2mm or less if circumstances require
(larger diameters);
* Powerdrive and shaving tool must be kept in good working order to guarantee
proper and safe operation. Defect parts must be exchanged, or repaired by qualified
persons only.
Note: 1. On special order, a video instruction of the shaver can be supplied.
2. The noise level of the shaver and powerdrive is less than 70 dB (A).
The following procedure should be carefully followed to ensure satisfactory operation
of the shaver.
A. SET THE CORRECT DIAMETER AND ANGLE
See table 1A, 1B, or 1C (page 6-7) for required shaving angle in combination with the
pipe diameter.
Make sure that the correct bronze guide block (part no. 29 or 36) is mounted in the
correct slot (photo 1). The guide block must be resting on the support plate over its full
length. The long slot is to be used for 2.5 degree shaving angle and cilindrical shaving.
The short slot is to be used for 1.75 degree shaving angle.
Adjust the cutting blade holder for the required diameter and tighten the 2 bolts with the
6mm Allen key (photo 2). Tighten the outer screw on the guide block side manually (part
no. 41) in such a way that there is no play between the square shaft and guide block. Do
not tighten too much as this will cause jamming of the shaft (photo 3).
For shaving cilindrical spigots use the 2.5 degree angle slot in combination with the
bronze block with the 0 degree mark. When exchanging the bronze guide blocks make
sure the the loose pressure plate and screw (part no. 40 and 41) are put back in place.
B. FITTING THE ARBOR
1) The round nut (part no. 1) is removed from the tensioning bolt (part no. 21)
(photo 4).
2) The correct size arbor is placed on the shaft.
3) The nut is replaced taking care that the protrusions on the nut and on the shaver
shaft engage in the slots. The nut and tensioning bolt are not tightened
until the arbor has been fitted into the pipe to be shaved.
Safety precautions
Operating instructions
Photo 1
Photo 2 Photo 3
Photo 4
Ameron 2003. FP 919 09/03. Page 3 of 8. Printed in The Netherlands.
C. THE TAPER CUTTING ANGLE
Make sure that the correct taper angle (see table 1A, 1B, or 1C) is set on the shaver.
Warning: Incorrect angle setting will result in joint failure !
D. FIT THE SHAVER TO THE PIPE
The shaver with the appropriate fitted arbor is slid in to the pipe so the arbor is completely
in the pipe and flush with the cut pipe end. The shaver is then lifted somewhat whilst the
central tensioning bolt is firmly tightened. This to ensure that the shaver is mounted as
squarely as possible in to the pipe. After positioning the shaver on the pipe and tightening
the tensioning bolt, the power-drive is fitted on to the power-drive adapter on the shaft of
the shaver. Make sure that the springloaded key engages in the keyway.
E. ADJUST THE CUTTING TOOL
Loosen the toolholder clamping bolt (part no. 32) in order to turn the adjusting screw
(part no. 28) on the back of the cutting tool for changing the cutting depth. The cutting
tool should be adjusted to give a cut of max. 2 mm depth. One turn of the adjusting
screw on the back of the cutting tool changes the cutting depth by 1 mm. So, a maximum
of 2 mm cutting depth by two clock-wise turns, reduces the pipe spigot diameter by 4
mm (photo 5).
F. ENGAGE THE CUTTING TOOL FEED
The feed is engaged by moving the feed flock locking bar (part no. 15) as indicated in
photo 6., towards the arbor. Once engaged, rotate the shaver frame clock-wise around
the threaded feed tube with the power-drive (not included) and the cutting tool
automatically advances.
G. RETURN THE CUTTING TOOL
First turn the cutting tool free from the pipe. Then the feed is disengaged by moving the
slide mentioned in point F. away from the main frame and the cutting bar assembly.
Reset to its original position.
Repeat steps E and F until the required spigot diameter is achieved as indicated in
table 1A, 1B, or 1C. The M86XL shaver automatically disengages the feed mechanism
at the maximum limit of the tool holder travel.
After shaving, the spigot nose diameter at the end of the pipe should be measured and
have the dimension as per table 1A, 1B, or 1C.
H. RETRACT THE CUTTING TOOL
As in point G.
I. REMOVE POWER DRIVE
J. RELEASE CENTRAL TENSIONING BOLT
The shaver can now be removed from the pipe. Care should be taken to pull the shaver
straight out of the pipe in order not to damage the thin front edge of the spigot.
This shaver is designed to be a maintenance-free unit.
However,
1) Clean the shaver on a daily basis. Pay special attention to the threaded feed tube
and its associated components.
2) Check cutting blade twice a day (minimum). A dull cutting edge results in
unnecessary strain on the automatic feed components. The cutting edge can be
loosened using a crosshead type screwdriver and turned to provide a new sharp
edge. This can be done until the complete blade is dull.
Cutting blades are available from Ameron.
Photo 5
Photo 6
Ameron 2003. FP 919 09/03. Page 4 of 8. Printed in The Netherlands.
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Ameron 2003. FP 919 09/03. Page 5 of 8. Printed in The Netherlands.
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Ameron 2003. FP 919 09/03. Page 6 of 8. Printed in The Netherlands.
Shaving Joint Dimensions
Table 1a: For Taper joints Series 3400
Nom. Taper Nose Spigot Nose Spigot Nose Spigot
Pipe angle thickness dia at thickness dia at thickness dia at
Size nose nose nose
mm degr. A B A B A B
3410 3412 3414
50 1.75 1.0 55.2 1.0 55.2 1.0 55.2
75 1.75 1.0 83.8 1.0 83.8 1.0 83.8
100 1.75 1.0 107.2 1.0 107.2 1.0 107.2
150 2.50 1.0 161.0 1.0 161.0 1.0 161.0
200 2.50 1.0 210.8 1.0 210.8 1.0 210.8
250 2.50 1.0 264.9 1.0 264.9 1.0 264.9
. 3416 3420 3425
50 1.75 1.0 55.2 1.0 55.2 1.0 55.2
75 1.75 1.0 83.8 1.0 83.8 1.0 83.8
100 1.75 1.0 107.2 1.0 107.2 1.0 107.2
150 2.50 1.0 161.0 1.0 161.0 1.0 161.0
200 2.50 1.0 210.8 1.0 210.8 1.0 210.8
250 2.50 1.0 264.9 1.0 264.9 1.5 265.9
3432 3440 3450
50 1.75 1.0 55.2 1.0 55.2 1.0 55.2
75 1.75 1.0 83.8 1.0 83.8 1.5 84.4
100 1.75 1.0 107.2 1.5 108.2 2.0 109.2
150 2.50 1.0 161.0 1.5 162.0 2.0 163.0
200 2.50 1.0 210.8 1.5 211.8 2.5 213.8
250 2.50 1.5 265.9 2.5 267.9 3.0 268.9
Table 1b: For taper joints Series 2400
Nom. Taper Nose Spigot Nose Spigot Nose Spigot
Pipe angle thickness dia at thickness dia at thickness dia at
Size nose nose nose
mm degr. A B A B A B
2410 2412 2414
50 1.75 1.0 55.2 1.0 55.2 1.0 55.2
75 1.75 1.0 83.8 1.0 83.8 1.0 83.8
100 1.75 1.0 107.2 1.0 107.2 1.0 107.2
150 2.50 1.0 161.0 1.0 161.0 1.0 161.0
200 2.50 1.0 210.8 1.0 210.8 1.0 210.8
250 2.50 1.0 264.9 1.0 264.9 1.0 264.9
2416 2420 2425
50 1.75 1.0 55.2 1.0 55.2 1.0 55.2
75 1.75 1.0 83.8 1.0 83.8 1.0 83.8
100 1.75 1.0 107.2 1.0 107.2 1.0 107.2
150 2.50 1.0 161.0 1.0 161.0 1.0 161.0
200 2.50 1.0 210.8 1.0 210.8 1.0 210.8
250 2.50 1.0 264.9 1.0 264.9 1.5 265.9
2432 2440 2450
50 1.75 1.0 55.2 1.0 55.2 1.0 55.2
75 1.75 1.0 83.8 1.0 83.8 1.5 84.8
100 1.75 1.0 107.2 1.5 108.2 2.0 109.2
150 2.50 1.0 161.0 1.5 162.0 2.0 163.0
200 2.50 1.0 210.8 1.5 211.8 2.5 213.8
250 2.50 1.5 265.9 2.5 267.9 3.0 268.9
Note:
1. All dimenseions are in mm.
2. For insertion depth refer to pipe/fitting datasheets.
Ameron 2003. FP 919 09/03. Page 7 of 8. Printed in The Netherlands.
Table 1c: For Quick-Lock (straight taper) joints
Pipe Shave Spigot diameter Shaved length
diameter angle minimum maximum minimum maximum
mm degr. mm mm mm mm
50 0 59.18 59.59 46 49
75 0 87.63 88.04 46 49
100 0 112.52 112.93 46 49
125 0 139.50 139.90 59 62
150 0 166.22 166.62 57 60
200 0 217.02 217.42 64 67
250 0 271.27 271.68 70 73
Shaving Joint Dimensions
Important notice
This product literature and the recommendations for usage it contains are based on test
data reasonably believed to be reliable. It is intended that this literature be used by
personnel having specialised training in accordance with currently acceptable industry
practice and normal operating conditions. Variation in environment, changes in operating
procedures, or extrapolation of data may cause unsatisfactory results. We recommend
that your engineers verify the suitability of this product for your intended application. Since
we have no control over the conditions of service, we expressly disclaim responsibility for
the results obtained or for any consequential or incidental damages of any kind incurred.
Written comments regarding this document are invited. Please write to the Engineering
Manager, Ameron Fiberglass-Composite Pipe Group/Europe.
Ameron 2003. FP 919 09/03. Page 8 of 8. Printed in The Netherlands.
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
Internet: www.ameron-fpg.nl
email: info@ameron-fpg.nl
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, TX 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston, TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet: www.ameron.com
email: marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
Internet: www.ameron.com.sg
email: info@ameron.com.sg
Ameron 2004. FP 925 01/04. Page 1 of 12. Printed in The Netherlands.
M95 Pipe Shaver
for Taper/Taper and Quick-Lock
adhesive-bonded pipe joints
in sizes 24 to 40 inch (600-1000 mm)
Introduction
The BondstrandM95 Pipe Shaver has been designed to prepare a tapered spigot on
the cut end of a Bondstrand pipe in 24 to 40 inch (600-1000 mm) pipe diameter allowing
to fit a Bondstrand fitting with a matching tapered or Quick-Lock socket and prepare
cilindrical pipe ends for mechanical couplings such as Helden, Straub, Viking J ohnson,
Dresser, etc.
Due to the fact that the traditional cutting tool has been replaced by a diamond coated
grinding drum, the preparation time for a spigot has been reduced significantly. To
eliminate the dust and to increase the life cycle of the grinding drum, the shaving tool is
equipped with a water spray system. This system provides a water supply on the
grinding drum during operation.
The shaver is fixed and centered on the end of the pipe by an expanding arbor. The
arbor is inserted in the pipe end and provides the required grip when the arbor
contraction bolts are tightened.
Arbors are available in the following sizes :
! 24 - 26 - 28 - 30 - 32 - 34 - 36 - 38 - 40 inch
! 600 - 650 - 700 - 750 - 800 - 900 - 950 - 1000 mm.
The shaving tool is powered by means of two permanently fixed electric motors. One
for rotating the arbor (normal procedure), and one for driving the grinding drum. The
shaving tool also can be used to shave spigots on an excisting pipe system. In this
case the shaver has to be fitted with the (optional) counter balance weights.
Each M95 shaving tool is supplied in a rigid case including the following tools:
! 1 collapsable workshop crane
! 1 adjustable spreader bar
! 2 adjustable pipe supports with rollers
These tools are required to operate the shaving tool
Note: Counter balance weight and arbors are not included and should be ordered
seperately.
Note: The use of this shaving tool is restricted to Bondstrand pipe material.
EG-STATEMENT OF AGREEMENT
According to machinery directive 98/37/EG, appendix II, under a, this shaver
* complies with machinery directive 98/37/EG;
* complies with the following harmonised European Standards: NEN-EN 1050,
NEN-EN 292-1 and NEN-EN 292-2.
Ameron 2004. FP 925 01/04. Page 2 of 12. Printed in The Netherlands.
Personal protection and safety
The following personal protection gear must be used when cutting, shaving, sanding
and grinding Glassfiber Reinforced Epoxy (GRE) material:
* Safety shoes or boots;
* Working gloves (GRE material can be very sharp and may cause cuts or splinters);
* Proper fitting and buttoned up protective clothing must be worn when operating
the shaver;
* A hard hat is to be used, if the situation requires so;
* A hair net must be worn, if applicable, when shaving, cutting, grinding, etc;
* An appropriate dust mask is to be used when cutting, shaving, grinding and
sanding.
Operational safety
For safe operation of the shaving tool, the following rules must be followed:
* Pipe-shaver assembly must be at ergonomic height to be able to work in the
proper posture;
* Only use the shaving tool i.e. workshop crane on a solid and levelled surface
or floor;
* Ample rest should be taken to avoid physical and mental over stressing;
* Only authorised persons are to be allowed in the shaving area;
* Shaving area must be clearly marked as such;
* Shaving tool shall only be used to prepare spigots on Bondstrandpipe material;
* Pipe shaver shall only be operated by trained persons;
* Shaving tool must be kept in good working order to guarantee proper and safe
operation. Defect parts must be replaced or repaired by qualified personnel only.
Note: The noise level of the shaver and powerdrive is less than 70 dB (A).
Safety precautions
Ameron 2004. FP 925 01/04. Page 3 of 12. Printed in The Netherlands.
Operating instructions
Photo 1
Photo 2
Photo 3
Photo 4
The following procedure should be carefully followed to ensure satisfactory operation
of the shaver.
A. FITTING THE PIPE SUPPORTS
Assemble the two pipe supports with the rollers (Photo 1).
Position the rollers in such a way, that the pipe -when placed on the support- is running
free from the support frame. Adjust the distance between the two supports in such a
way, that the pipe section to be shaved gets maximum support. Make sure that the
supports are parallel.
Place the pipe section on the supports (Photo 2).
B. FITTING THE ARBOR
1) Check that the pipe is cut square and correct if necessary. Squareness shall be
within 0.5% of the pipe diameter. For example: if the pipe diameter is 900 mm, the
allowable unsquareness is 4.5 mm.
2) Make sure that the pipe is clean inside and there are no loose fibers inside the pipe.
3) Insert the arbor and ensure the arbor butts up agains the pipe end.
4) Tighten the contraction bolts with a suitable spanner (Photo 3).
C. FITTING THE SHAVING TOOL
Lift the shaver using the supplied workshop crane and spreader bar (Photo 4).
Shift the spreader bar lifting hook until shaving tool is horizontal.
Note: During lifting and handling the shaving tool must be disconnected from
power source to avoid accidental start of equipment.
Ameron 2004. FP 925 01/04. Page 4 of 12. Printed in The Netherlands.
Position the shaving tool with the 4 stub-bolts on the arbor hub and put the nuts in
place (Photos 5 and 6). Tighten the nuts. Lower the workshop crane until there is
only a slight tension left in the spreader bar chains. Most of the weight must rest on
the two supports.
Do not remove the workshop crane!
D. ADJUST THE SHAVING TOOL
Move the grinding drum away from the centre shaft using the crank. To set the
shaving angle, remove the two locking bolts, push the grinding drum towards the
center shaft, and turn the angle setting disk to obtain the desired angle setting
(Photo 7).
Replace and tighten the locking bolts (Photo 8).
The required shaving angle can be found in this manual (table no. 2 Shaving
dimensions, page 8).
Move the grinding drum towards the pipe until it is just running free from the pipe wall
(Photo 9).
E. HOOK UP OF THE WATER AND POWER SUPPLY
Connect the water supply to the spray tube connection.
Connect the shaving tool with the control box (Photo 10). Before connecting the shaving
tool control box to the power supply, enable the emergency stop button.
After connecting to the power supply disable the emergency stop button.
Check that the whole pipe and shaver assembly is stable and that the pipe can rotate
freely. Make sure that the power cables and water supply hose are not entangeled and
run free from the shaving tool.
Photo 6
Photo 5
Photo 7
Photo 8
Photo 9
Photo 10
Ameron 2004. FP 925 01/04. Page 5 of 12. Printed in The Netherlands.
Photo 13
Photo 14
Photo 11
Photo 12
F. GRINDING THE SPIGOT
Open the water supply valve and adjust so that there is a liberal flow of water coming
from the water nozzles (Photo 11).
Start the grinding drum.
Start the rotation motor.
(Photo 12)
Move the grinding drum slowly towards the pipe.
Move the grinding drum slowly towards the pipe after each completed revolution of
the pipe (Photo 13).
Do not exceed the following cutting depths:
* 1 mm for an effective grinding length of 100 mm.
* 0.5 mm for an effective grinding length from 100 to 200 mm.
* and 0.25 mm for an effective grinding length above 200 mm.
Avoid fast cutting depth changes and never do this when either rotation motor or
grinding drum motor is not running. Consult the shaving dimension table no. 1 in the
manual for the required nose thickness.
When the required shaving dimension is obtained allow the shaving tool to make 2
final revolutions while grinding drum is running. This to obtain a smooth spigot
surface.
Stop the grinding drum motor and move the grinding drum away from the pipe after
the grinding drum has come to a complete standstill. Stop the rotation motor and
close the water supply valve. Remove the shaver and arbor from the pipe.
When the shaving tool is not used or moved, it is recommended to lower the shaving
tool onto a wooden pallet or board which is placed on the crane outriggers
(Photo 14).
Ameron 2004. FP 925 01/04. Page 6 of 12. Printed in The Netherlands.
G. GRINDING A SPIGOT ON A FIXED PIPE
In situations where a spigot has to be shaved on an existing system and the pipe can
not rotate, the procedure will be as follows.
Fit the arbor and shaver as discribed above and remove the workshop crane.
Attach the counter balance weight rod to the shaver frame by means of the 4 supplied
bolts. Put the inner locking pin in the position. Place the required number of counter
weights on the rod (Photo 15).
Secure the weights by means of the outer locking pin and use the safety pin to
secure the locking pin (Photo 16). The number of counter weights to be used
depends on the pipe diameter to be shaved. For larger pipe sizes the counter weight
mass needs to be more in order to out balance the shaving tool. Check that the
shaving tool can rotate freely. Start the arbor motor and check that the shaving tool is
in balance.
Open the water supply valve and adjust such that there is a liberal flow of water
coming from the water nozzles. Start the grinding drum. Start the rotation motor.
Move the grinding drum slowly towards the pipe. Move the grinding drum slowly
towards the pipe after each completed revolution of the pipe. This can be done while
the shaver is rotating or during an intermediate stop of the rotation motor. During the
rotation of the shaving tool the power cables will twist. Untwist cables after each
spigot.
Note: Please avoid fast cutting depth changes and always make sure that both the
rotation motor and grinding drum are running!
Consult the Shaving Dimension table in the manual for the required nose thickness.
When the required shaving dimension is obtained, allow the shaving tool to make 2
final revolutions while the grinding drum is running. This to obtain a smooth spigot
surface.
Stop the grinding drum motor and move the grinding drum away from the pipe after
the grinding drum has come to a compliete standstill. Stop the rotation motor and
close the water supply valve.
Remove the shaver and arbor from the pipe after removal of the counter balance
weights.
Photo 15
Photo 16
Ameron 2004. FP 925 01/04. Page 7 of 12. Printed in The Netherlands.
H. MAINTENANCE AND SPARE PARTS
The M95 shaving tool (Photo 17) is designed as a maintenance free unit.
It is however recommended to keep it clean from grinding slurry and other dirt.
If the shaving tool is not going to be used for a longer period of time, it is
recommended to coat the grinding drum with a preservative. As the shaving tool is
designed with a minimum of moving parts, the number of spare parts can be kept to
a minimum. The grinding drum half on the motor end will be wearing faster than the
other half. In case the motor side drum half shows wear, it can be turned as it is a
symmetrical design. After this had been done, a new drum can be ordered.
Photo 17
Table 1: Quick-Lock (Straight Taper)
Nominal pipe size Minimum Maxi mum Insertion Minimum
spigot dia. spigot dia. depth shave length
[mm] [inch] [mm] [mm] [mm] [mm]
600 24 607.7 608.2 127 135
650 26 682.6 683.1 140 146
700 28 735.8 736.3 152 160
750 30 787.9 788.4 165 172
800 32 840 840.5 165 172
900 36 942.9 943.4 164 172
1000 40 1050.9 1051.4 230 237
Shaving Joint Dimensions
Ameron 2004. FP 925 01/04. Page 8 of 12. Printed in The Netherlands.
Table 2: For Taper joints Series 3400 and 2400
Nom. Taper Nose Spigot Nose Spigot Nose Spigot
Pipe angle thi ckness dia at thi ckness dia at thi ckness dia at
Size nose nose nose
mm degr. A B A B A B
3410/2410 3412/2412 3414/2414
600 2.50 2.0 583 2.0 583 2.0 583
650 1.75 4.0 658 4.0 658 4.0 658
700 1.75 4.0 708 4.0 708 4.0 708
750 1.75 4.0 758 4.0 758 4.0 758
800 1.75 4.0 808 4.0 808 5.5 811
850 1.75 4.0 858 4.0 858 5.5 861
900 1.75 4.0 908 4.0 908 6.0 912
950 1.75 4.0 958 4.0 958
1000 1.75 4.5
3416/2416 3420/2420 3425/2425
600 2.50 2.5 584 2.5 584 3.5 586
650 1.75 5.0 680 5.0 660
700 1.75 5.5 711 5.5 711
750 1.75 6.0 762 6.0 762
800 1.75 5.5 811
850 1.75 5.5 861
900 1.75 6.0 912
3432/2432 3440/2440 3450/2450
600 1.75 3.5 586 4.0 587 4.00 587
Note:
1. All dimensions are in mm.
2. For insertion depth refer to pipe/fitting datasheets.
Ameron 2004. FP 925 01/04. Page 9 of 12. Printed in The Netherlands.
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Ameron 2004. FP 925 01/04. Page 10 of 12. Printed in The Netherlands.
Partlist (Drawing Ref: 5-A2-1045.)
Part # Qty Descri pti on Dimension Drawi ng Remark
1......... 1......... Gear wheel ..................................................................................... 5-A1-1013......................................................
2......... 8......... Cylindrical screw ...................... M8x25.......................................... DIN 912...........................................................
3......... 4......... Nut............................................. M16.............................................. DIN 934...........................................................
4......... 4......... Ring ........................................... 30 x 17 x 3 ............................. DIN 125A ........................................................
5......... 4......... Stud bolt........................................................................................... 5-A1-1013......................................................
6......... 8......... Cylindrical screw ...................... M6x25.......................................... DIN 912...........................................................
7......... 1......... Ring ................................................................................................. 5-A1-1013......................................................
8......... 4......... Retaining ring............................. MB3 ............................................. 17 ........................................................ SKF
9......... 4......... Nut............................................. M17x1.......................................... KM3......................................................... SKF
10 ......... 1......... Gear wheel ..................................................................................... 5-A1-1013......................................................
11 ......... 2......... Plate................................................................................................. 5-A1-1014......................................................
12 ......... 2......... Strip ................................................................................................. 5-A1-1014......................................................
13 ......... 4......... Support ........................................................................................... 5-A1-1014......................................................
14 ......... 2......... Support ........................................................................................... 5-A1-1014......................................................
15 ......... 2......... Plate................................................................................................. 5-A1-1014......................................................
16 ......... 2......... Plate................................................................................................. 5-A1-1014......................................................
17 ......... 2......... Plate................................................................................................. 5-A1-1014......................................................
18 ......... 2......... Self-adjusting ball bearing ......... 35 x 15 x 4 ............................. Nr. 2202 E-2RSI ........................................ SKF
19 ......... 1......... Disk plate......................................................................................... 5-A1-1011 ......................................................
20 ......... 1......... Screw ....................................... M10x12........................................ ISO 7380 ........................................................
21 ......... 1......... Cover............................................................................................... 5-A1-1011 ......................................................
22 ......... 2......... Screw ....................................... 10
h8
x 60................................. Type UPS ...........................................Unbrako
23 ......... 2......... Washer...................................... 21 x 8,4 x 4 ............................ DIN 7349.........................................................
24 ......... 2......... Self-retaining nut ....................... M8................................................ Din 985...........................................................
25 ......... 1......... Plate................................................................................................. 5-A0-1010......................................................
26 ......... 1......... Cover........................................................................................................ 5-A0-1010......................................................
27 ......... 2......... Plate .......................................................................................................... 5-A0-1010......................................................
28 ......... 1......... Plate .......................................................................................................... 5-A0-1010......................................................
29 ......... 1......... Plate .......................................................................................................... 5-A0-1010......................................................
30 ......... 1......... Plate .......................................................................................................... 5-A0-1010......................................................
31 ......... 1......... Plate .......................................................................................................... 5-A0-1010......................................................
32 ......... 1......... Plate .......................................................................................................... 5-A0-1010......................................................
33 ......... 1......... Plate .......................................................................................................... 5-A0-1010......................................................
34 ......... 1......... Strip ................................................................................................. 5-A0-1010......................................................
35 ......... 1......... Plate................................................................................................. 5-A0-1010......................................................
36 ......... 1......... Support ........................................................................................... 5-A0-1010......................................................
37 ......... 1......... Support ........................................................................................... 5-A0-1010......................................................
38 ......... 1......... Strip ................................................................................................. 5-A0-1010......................................................
39 ......... 2......... Bush................................................................................................ 5-A0-1010......................................................
40 ......... 2......... Pivot pin........................................................................................... 5-A0-1010......................................................
41 ......... 2......... Support ........................................................................................... 5-A0-1010......................................................
42 ......... 1......... Plate................................................................................................. 5-A0-1010......................................................
43 ......... 2......... Plug.................................................................................................. 5-A0-1010......................................................
44 ........ 10......... Cylindrical screw ...................... M4x12.......................................... DIN 912...........................................................
45 ......... 2......... Strip ................................................................................................. 5-A1-1014......................................................
46 ......... 2......... Rubber strip..................................................................................... 5-A1-1014......................................................
47 ......... 8......... Cylindrical screw ...................... M4x12.......................................... DIN 912...........................................................
48 ......... 2......... Block................................................................................................ 5-A1-1015......................................................
49 ......... 1......... Cover............................................................................................... 5-A1-1015......................................................
50 ......... 2......... Square tube..................................................................................... 5-A1-1015......................................................
51 ......... 2......... Rod.................................................................................................. 5-A1-1015......................................................
52 ......... 1......... Plate................................................................................................. 5-A1-1015......................................................
53 ......... 1......... Bearing block................................................................................... 5-A1-1015......................................................
54 ......... 1......... Plate................................................................................................. 5-A1-1015......................................................
55 ......... 2......... Square tube..................................................................................... 5-A1-1015......................................................
56 ......... 4......... Cover............................................................................................... 5-A1-1015......................................................
57 ......... 1......... Plate................................................................................................. 5-A1-1015......................................................
58 ......... 1......... Plate................................................................................................. 5-A1-1015......................................................
59 ......... 1......... Tube ................................................................................................ 5-A1-1015......................................................
60 ......... 1......... Plate................................................................................................. 5-A1-1015......................................................
61 ......... 1......... Bearing block................................................................................... 5-A1-1015......................................................
62 ......... 2......... Plate................................................................................................. 5-A1-1015......................................................
63 ......... 1......... Plate................................................................................................. 5-A1-1015......................................................
64 ......... 1......... Conical roller bearing ................. 90 x 55 x ................................ Nr. 32011X ............................................... SKF
65 ......... 1......... Retaining ring............................. 55.............................................. MB11 ....................................................... SKF
66 ......... 1......... Nut............................................. M55x2.......................................... KM11 ....................................................... SKF
67 ......... 1......... Flange.............................................................................................. 5-A1-1013......................................................
Ameron 2004. FP 925 01/04. Page 11 of 12. Printed in The Netherlands.
Part # Qty Descri pti on Dimension Drawi ng Remark
68............ 1............ Shaft ......................................... 5-A1-1013.....................................................................................................
69............ 1............ Ring.......................................................................................................... 5-A1-1013 ......................................
70............ 2............ Felt ring .................................................................................................... 5-A1-1013 ......................................
71............ 1............ Reduction gear .......................... SEW-R40D63+DFT80K-6.................... Vector.............................................
72............ 4............ Adjustable bolt.......................................................................................... 5-A1-1013 ......................................
73............ 4............ Hexagonal bolt........................... M8x30................................................... DIN 931...........................................
74............ 4............ Cylindrical screw...................... M4x16................................................... DIN 912...........................................
75............ 4............ Block ........................................................................................................ 5-A1-1011 ......................................
76............ 2............ Angle setting disk..................................................................................... 5-A1-1011 ......................................
77............ 2............ Retaining screw........................ M8x20................................................... DIN 913...........................................
78............ 1............ Shaft ........................................................................................................ 5-A1-1011 ......................................
79............ 2............ Screw....................................... 20
h8
x 60 ............................................ Type UPS ........................... Unbrako
80............ 4............ Nipple ....................................................................................................... 5-A1-1014 ......................................
81............ 4............ Guide bush................................ 25 x 40 x 58 .................................... KB0 2558.................................. INA
82............ 2............ Guide rod .................................. 25 x 675 - RVS .................................. TSSW 25 VA............................. INA
83.......... 22 ............ Cylindrical screw...................... M8x30................................................... DIN 912...........................................
84.......... 22 ............ Retaining ring............................. 8.1x 12.7 x 2 ................................... DIN 7980 .........................................
85............ 4............ Cylindrical screw...................... M8x80................................................... DIN 912...........................................
86............ 2............ Nut............................................. M10 ...................................................... DIN 582...........................................
87............ 2............ Cylindrical screw...................... M10x16................................................. DIN 912...........................................
88............ 4............ Cylindrical screw...................... M12x40................................................. DIN 912...........................................
89............ 4............ Cylindrical screw...................... M12x40................................................. DIN 912...........................................
90............ 1............ Disk .......................................................................................................... GN184-16 ............................ Drabbe
91............ 1............ Screw....................................... M4x12................................................... DIN 7991 .........................................
92............ 1............ Crank......................................... GN472.3-80-V10 (GN598.3) ................. Drabbe............................................
93............ 1............ Vernier ring ............................... GN164-30-R14-MCR ............................. Drabbe............................................
94............ 1............ Plate ......................................................................................................... 5-A1-1013 ......................................
95............ 4............ Screw....................................... M4x20................................................... DIN 7991 .........................................
96............ 2............ Block ........................................................................................................ 5-A1-1011 ......................................
97............ 1............ Electric motor............................. Perske KC 72.24-2.......................... Bakker.............................................
98............ 2............ Adjustable lever ........................ GN300-63-M10-20-SW......................... Drabbe............................................
99............ 2............ Block ........................................................................................................ 5-A1-1011 ......................................
100............ 1............ Ring.......................................................................................................... 5-A1-1013 ......................................
101............ 1............ Ball bearing ............................... 35 x 17 x 10 .................................... Nr. 6003-2RSI ........................... SKF
102............ 1............ Bearing plate ............................................................................................ 5-A1-1013 ......................................
103............ 4............ Cylindrical screw...................... M6x16................................................... DIN 912...........................................
104............ 1............ Threaded spindle...................................................................................... 5-A1-1011 ......................................
105............ 1............ Nut............................................................................................................ 5-A1-1011 ......................................
106............ 1............ Cylindrical screw...................... M8x35................................................... DIN 912...........................................
107............ 2............ Cylindrical screw...................... M10x40................................................. DIN 912...........................................
108............ 2............ Block ........................................................................................................ 5-A1-1012 ......................................
109............ 4............ Screw...................................................................................................... 5-A1-1012 ......................................
110............ 1............ Grinding drum........................................................................................... 5-A2-1009 ......................................
111............ 2............ Pivot pin.................................................................................................... 5-A2-1009 ......................................
112............ 2............ Helicoil ...................................................................................................... 5-A1-1012 ......................................
113............ 2............ Bush......................................................................................................... 5-A1-1012 ......................................
114............ 1............ Frame ....................................................................................................... 5-A1-1012 ......................................
115............ 2............ Helicoil ...................................................................................................... 5-A1-1012 ......................................
116............ 1............ Bearing housing ....................................................................................... 5-A1-1011 ......................................
117............ 3............ Key............................................ 8 x 10 x 30 ........................................... DIN 6885 A......................................
118............ 1............ Connecting shaft ...................................................................................... 5-A1-1011 ......................................
119............ 2............ Ball bearing ............................... 52 x 25 x 18 ................................... Nr. 62205-2RSI ......................... SKF
120............ 1............ Nut............................................................................................................ 5-A1-1011 ......................................
121............ 1............ Coupling ................................................................................................... 5-A1-1011 ......................................
122............ 1............ Adjusting screw........................ M10x12................................................. DIN 915...........................................
123............ 1............ Retaining ring............................. AS 12
h11
............................................ DIN 6799 .........................................
124............ 1............ Disk .......................................................................................................... 5-A1-1014 ......................................
125............ 1............ Screw....................................... M6x25................................................... DIN 7991 .........................................
126............ 2............ Lifting eye ................................................................................................ 5-A0-1015 ......................................
127............ 4............ Nut............................................. M8 ........................................................ DIN 934...........................................
128............ 1............ Conical roller bearing................. 95 x 60 x 23 .................................... Nr. 32012X............................... SKF
129............ 2............ Nozzle ...................................................................................................... 5-A1-1014 ......................................
130............ 2............ Tube ......................................................................................................... 5-A1-1014 ......................................
131............ 2............ Nozzle ...................................................................................................... 5-A1-1014 ......................................
132............ 1............ Tube ......................................................................................................... 5-A1-1014 ......................................
133............ 1............ Tube ......................................................................................................... 5-A1-1014 ......................................
134............ 2............ Block ........................................................................................................ 5-A1-1014 ......................................
135............ 4............ Cylindrical screw...................... M6x30................................................... DIN 912...........................................
Partlist (Drawing Ref: 5-A2-1045.) continued
Ameron 2004. FP 925 01/04. Page 12 of 12. Printed in The Netherlands.
Fi ber gl ass-Composi t e
Pi pe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
Internet: www.ameron-fpg.nl
email: info@ameron-fpg.nl
Fi ber gl ass-Composi t e
Pi pe Group
The Ameri cas
P.O. Box 878
Burkburnett, TX 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fi ber gl ass-Composi t e
Pi pe Group
Headquart ers
P.O. Box 801148
Houston, TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet: www.ameron.com
email: marcom@ameronfpd.com
Fi ber gl ass-Composi t e
Pi pe Group
Asi a
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
J urong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
Internet: www.ameron.com.sg
email: info@ameron.com.sg
Important notice
This product literature and the recommendations for usage it contains are based on test
data reasonably believed to be reliable. It is intended that this literature be used by
personnel having specialised training in accordance with currently acceptable industry
practice and normal operating conditions. Variation in environment, changes in operating
procedures, or extrapolation of data may cause unsatisfactory results. We recommend
that your engineers verify the suitability of this product for your intended application. Since
we have no control over the conditions of service, we expressly disclaim responsibility for
the results obtained or for any consequential or incidental damages of any kind incurred.
Written comments regarding this document are invited. Please write to the Engineering
Manager, Ameron Fiberglass-Composite Pipe Group/Europe.
Ameron 2004. FP 730 B 06/04 supersedes FP 730 A 04/00. Page 1 of 2. Printed in The Netherlands.
Electric Heating Blankets
Heat source for forced curing
adhesive-bonded joints in Bondstrand
Glassfiber Reinforced Epoxy (GRE)
piping systems
Introduction
Bondstrand

heating blankets are specially designed to heat cure adhesive-bonded


joints in pipe and fittings. Requiring either 120 Volts or 230 Volts alternating current,
the blankets are quickly and easily applied. They provide thermostatically controlled
heat, ensuring maximum joint strength and reliability.
Ameron supplies heating blankets for pipe sizes varying from 1 to 40 inch
(25 -1000 mm) controlled by either one or two thermostats.
There are two types of blankets, Type A and Type B.
TYPE A : Inner joint heating blanket for pipe sizes 1-3 inch (25-75 mm).
This type of blanket is specially designed for curing bonded flange joints by inserting
the pre-formed shape in to the pipe.
TYPE B : Single-zone heating blankets for pipe sizes 1-40 inch (25-1000 mm).
This type of blanket is placed around or inside the bonded joint (with exception of 1"
through 3" flange joints).
Type B blankets are divided in the following diameter ranges:
! 1-2 inch (25-50 mm) ! 18-20 inch (450-500 mm)
! 3 -4 inch (75-100 mm) ! 22-24 inch (550-600 mm)
! 6 -8 inch (150-200 mm) ! 28-32 inch (700-800 mm)
! 10-12 inch (250-300 mm) ! 34-40 inch (850-1000 mm)
! 14-16 inch (350-400 mm)
Note:
For sizes 28-32 inch (700-800 mm) and 34-40 inch (850-1000 mm) operating at 120
Volts two zone blankets are used.
TYPE A :
1) Insert the blanket flush with the end of pipe after removal of excess adhesive from
the joint and leave the power cord exposed from the joint.
2) Ensure that the pre-formed blanket remains snugly against the inside joint surface
by locking beginning and end with each other.
3) At removal after the recommended curing time beware not to pull the blanket by
power cord when fixed by excess adhesive.
4) Release first before removal in order to avoid damage to the thermostat.
TYPE B :
1) Place the thermostat end against the assembled joint with the thermostat facing out
from the joint.
2) Wrap the remainder of the blanket around the joint so that any overlap
will cover the thermostat.
3) Tie the blanket in place with heat-resistant wire (copper, or soft iron).
Instructions
Type A
Type B
Ameron 2004. FP 730 B 06/04 supersedes FP 730 A 04/00. Page 2 of 2. Printed in The Netherlands.
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
Internet: www.ameron-fpg.nl
email: info@ameron-fpg.nl
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, TX 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston, TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet: www.ameron.com
email: marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
Internet: www.ameron.com.sg
email: info@ameron.com.sg
Instructions
Handling precautions
Flange mounting requires a special wrap.
Lay the blanket with the thermostat down and, starting with the thermostat end, roll up
the blanket. Insert the rolled blanket in to the pipe end for the depth of the joint be
cured, leaving the power cord and part of the blanket exposed as shown.
Keep the blanket snugly against the inside joint surface by a flexible non metallic rod.
1) Do not lift or hold the blanket by the power cord.
2) Do not apply alternating current (A.C.) when standing in water, or on wet surfaces.
3) Apply alternating current only at the voltage marked on the heating blanket.
4) Do not step on the blanket or create sharp folds in it.
5) Inspect the blanket and power cord for loose wire connections and bare wires
prior to applying alternating current.
6) Make sure the blanket is operating, in fact heats up (at all heating zones when
applicable).
7) For required curing times and detailed assembly instructions, please refer to the
applicable joint Assembly Instructions.
8) Use the blanket only for pipe sizes as indicated on the blanket.
For further information regarding the use of the blankets, please refer to the respective
Bondstrand

Assembly Instructions.
SPECIAL WRAP FOR FLANGE MOUNTING
STANDARD WRAP FOR PIPE AND FITTING JOINTS SPECIAL WRAP FOR FLANGE MOUNTING
Ameron 2004. FP 905 08/04. Page 1 of 4. Printed in The Netherlands.
Bondstrand installed at
Phase 1 & 2 of the ACG Full
Field Development project
Owner
Project
Pipe system
Phase 1 and 2 of the Azeri Chiraq and Deep Water Gunashli (ACG) Full Field
Development (FFD) project located in the Azerbaijan sector of the Caspian Sea
at approx. 120 km south east of Baku.
Phase 1: Comprises two platforms, Central Azeri (CA) production
platform and the Compression and Water injection platform
(C&WP) bridge-linked to CA.
Phase 2: Comprises two additional production platforms, West Azeri
(WA) and East Azeri (EA).
Azerbaijan International Operating Company (AIOC) operated by BP.
Bondstrand series 7000 and 3416 conductive pipe and fittings with Quick-
Lock and Taper/Taper adhesive bonded joints.
Diameters: 1-30 inch (25-750 mm).
Total length: 16,000 metres pipe (approx. 4,000 metres per platform).
Design pressure: 16 bar - Design Temperature: 65C - Test pressure: 24 bar.
Phase 1: Phase 2:
CA platform: completed Q4 - 2004. WA platform: completed Q4
C&WP platform: completed Q3 - 2005. EA platform: completed Q3 2006.
Design conditions
Installation date
Taper/Taper
joint
Quick-Lock
joint
Ameron 2004. FP 905 08/04. Page 2 of 4. Printed in The Netherlands.
In September 1994, a PSA (Production Sharing Agreement) was signed in
Azerbaijan between the State Oil Company of the Azerbaijan Republic (SOCAR)
and the Azerbaijan International Operating Company (AIOC). This PSA grants
the consortium the rights to develop and manage the hydrocarbon reserves found
in the ACG field termed the "Contract Area" for a period of 30 years. In July
1999, British Petroleum (BP) was appointed operator for the PSA on behalf of
the AIOC member companies.
Part of the objective is to produce the recoverable reserves in the central part of
the Azeri Field. The project will require offshore drilling and production facilities,
a means of transferring the produced hydrocarbons to shore. It has estimated oil
reserves of 4.6 million barrels of oil and 3.5 trillion cubic feet of natural gas.
The contract to provide design and procurement for the Full Field Development
of the ACG offshore fields, was awarded to Kellogg Brown & Root (KBR).
J. Ray McDermott won the contract for fabrication, assembly, hook-up and
commissioning of the CA, WA and EA platforms.
The ATA consortium (Azfen/Tekfen/Amec) was awarded C&WP topsides
fabrication within the ACG FFD Phase 1 programme.
The scope of work comprises material supply as well as supply of service.
The pipework scope of supply for the Azeri project platforms includes:
Seawater
Firewater
Coolingwater
Sewage
Non-hazardous open drains
Atmospheric vent.
All Bondstrand Glassfiber Reinforced Epoxy (GRE) pipework is designed to
the UKOOA specification and all pipe and components are conductive. All
normally wetted and filled pipework meets the requirements of IMO A753 L3
standard for fire rating. The dry deluge pipework is rated for a 5-minute
resistance to jet fire. Favuseal fire protection is applied to meet this
requirement.
Project Description
Scope of Supply
Phase 2
Phase 1
Phase 2
Phase 3
Chirag
Deep Water
Gunashli
Shallow Water
Gunashli
Central Azeri
West Azeri
East Azeri
DEVON
5.6%
ITOCHU
3.9%
DELTA
HESS 2.7%
BP
34.1%
SOLAR
10.0%
UNOCAL
10.3%
LUKoil
10.0%
STATOIL
8.6%
Exxon
Mobil
8.0%
TPAO
6.8%
AIOC members
Ameron 2004. FP 905 08/04. Page 3 of 4. Printed in The Netherlands.
Scope of Supply Ameron tendered and won the project and acted as overall Project Managers
with regards to the GRE scope of supply. Ameron reviewed the specification and
technical documents and reviewed the stress analysis. Furthermore, Ameron
manufactured the Glassfiber Reinforced Epoxy (GRE) pipe and fittings and free
issued the pipe and fittings for prefabrication.
In addition to the material supply for the above systems, Ameron
additionally provided:
Component dimensions in computerized form suitable for direct
input into the 3D PDMS model.
Qualified personnel at the fabrication site to train and supervise spool
installation, personnel training, testing and storage. Two Ameron field
service engineers are permanently based in Baku to supervise spool
fabrication and spool installation.
Qualified design personnel to check design calculations and isometrics.
Appropriate qualification test data for all components to be supplied.
Fabrication of spools for CA platform (sub-contracted to Amerplastics).
PIPEX (Ameron distributor for the United Kingdom):
Supported Ameron in securing the project;
Wrote the project specification, now being the KBR GRE project
standard;
Reviewed the isometrics for fabrication, testing and fire protection;
Tracked the isometrics drawings from KBR to MCCI and following
the Pipex review, final isometrics were issued to Ameron (Amerplastics).
AMERPLASTICS (Ameron distributor for the Benelux)
Received free issue material from Ameron to prefabricate
spools for the CA platform;
Produced spool shop drawings and prefabricated the spools;
Hydrotested and conductivity tested the spools;
Applied Favuseal to the spools (fire protection);
Prepared the spools for shipment.
Installation of Bondstrand seawater line Bondstrand cooling water line
Ameron 2004. FP 905 08/04. Page 4 of 4. Printed in The Netherlands.
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet: www.ameron.com
email: marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.nl
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Advantages
Systems used Diameter Working Pressure Test Pressure
(inch) (bar) (bar)
Fire water (wet & dry) 2-10 15 24
Seawater 1-12 16 24
Cooling water 2-30 4-8 24
Non-hazardous open drains 1-8 Atm. Leak test
Sewage 1-8 Atm. Leak test
Atmospheric vents 6-8 Atm. Leak test
Reduction in installation costs and time;
Reduction in pumping costs;
Minimum long term service life 30 years;
Corrosion resistant;
Reduced marine growth;
Maintenance free;
Light weight material;
Scope of Supply (C'tnd)
Dry deluge pipework with Favuseal fire protection
Bondstrand drain line under cellar deck
"Cajun Express", "Sedco Express" and "Sedco Energy".
"Cajun Express": PPL Pte Limited, Singapore.
"Sedco Express/Sedco Energy": DCN Brest, France.
Transocean Sedco Forex - United States of America.
Bondstrand Glassfiber Reinforced Epoxy pipe systems were used for:
water ballast F vent lines F tank gauging F brine lines F drill water F wash down
sea water cooling F fresh water cooling F dry bulk F mud & cement F chilled water
F sprinkler.
Bondstrand 2000M and Bondstrand 7000M with Quick-Lock adhesive-bonded
joints. Diameter: 1 through 16 inch (25-400 mm).
Operating pressure: 5-16 bar
Operating temperature: 0-30 C.
Design pressure: 16 bar
Design temperature: 93C.
1999.
Service
Glassfiber Reinforced Epoxy
pipe systems for
semi-submersible rigs
using Bondstrand 2000M and 7000M
GRE pipe and fittings with
Quick-Lock adhesive-bonded joints
Ameron 2001 FP 883 - 05/01. Printed in The Netherlands.
Shipyard
Owner
Pipe system
Project
Operating conditions
Bondstrand

Case History
Installation date
Quick-Lock
Description Bondstrand Glassfiber Reinforced Epoxy pipe systems were used extensively at
these fifth generation mobile semi-submersible vessels, that operate world-wide.
The main reason that Bondstrand 2000M and 7000M pipe systems were used so
extensively, is the considerable weight saving that was achieved allowing operators to
increase the pay load on these rigs.
Bondstrand Glassfiber Reinforced Epoxy (GRE) pipe systems were selected for their
light-weight and ease of installation. Excellent GRE flow characteristics versus metallic
options avoids biological build-up and reduced operation costs. Corrosion resistance
was obviously an important factor.
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.n
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet:www.ameron.com
email:marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Deep draught suction
deluge line
using Bondstrand 3416 and 2000M
glassfiber reinforced epoxy (GRE) pipe and
fittings with Taper/Taper and Quick-Lock
adhesive-bonded joints
Ameron 2001 FP 878 - 04/01. Printed in The Netherlands.
Platform
Owner
Pipe system
Location
Operating conditions
North Sea (United Kingdom sector Offshore).
"Janice A".
Kerr Mc Gee.
Design & Engineering: Kerr McGee North Sea (UK) Limited and
Kvaerner Oil & Gas Limited.
Prefabrication: Pipex Ltd. - United Kingdom.
Bondstrand 3416 - 18 inch with Taper/Taper pipe and fittings.
Bondstrand 2000M - 10, 8, 4 and 3 inch pipe with Quick-Lock fittings.
Operating pressure: 11 bar
Operating temperature: +5 to +20C.
Design pressure: 16 bar
Design temperature: -6 to +40C.
2001.
Installation date
Taper/Taper
Quick-Lock
Description The seawater cooling water system on the semi submersible section of the platform
was extracted from the upper surface of the ocean through deluge pumps situated at
high level on the pontoon. It was found that there was a build up of algal bloom in the
pumps due the preponderance of algae and plankton in the upper surface where the
water was being drawn from. In order to eliminate this, it was decided to pump the
water from lower depths were there was no algal growth that could be drawn into the
pumps.
Bondstrand Glassfiber Reinforced Epoxy (GRE) pipe systems were chosen for their
light-weight and ease of installation. Excellent GRE flow characteristics versus metallic
options avoids biological build-up and reduced operation costs. Corrosion resistance
was obviously an important factor.
heavy-duty flanges
and typical
pipe support
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.n
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet:www.ameron.com
email:marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Operating conditions
Wandoo field, Dampier - Australia.
Wandoo Alliance.
Bondstrand series 2000M and 7000M with Quick-Lock adhesive-bonded
joints in diameters 2 through 30 inch.(50-750 mm). Quantity: > 3.000 m.
Service: open drain seawater
ballast water biocide
caisson sodium hypochloride
* Bondstrand serie 5000 was used (sizes 2-2") for Sodium Hypochloride Line).
Pressure: max. 12 bar.
Operating temperature: 65C.
1996.
Wandoo Concrete
Gravity Substructure
using Bondstrand fiberglass pipe and
fittings with Quick-Lock adhesive-bonded
joints for crude oil distribution and seawater
ballasting
Client
Location
Installation date
Pipe system
Ameron 1998 FP 348 04/98. Printed in The Netherlands
Description
In the middle of 1995, Wenco was awarded the subcontract by the Wandoo
Alliance partner Leighton Contractors to supply and install Bondstrand fiberglass
piping in to the Wandoo CGS at the specially constructed casting basin in Bunbury
(200 km South of Perth, WA). Amongst other things, This contract was awarded co
was awarded because of price, technical compliance of the product and the ability
to provide a comprehensive delivery and installation service as and when required.
Bondstrand was distributed in three main areas being:
Base pad (seawater ballasting)
Roof structure (crude oil distribution and)
Shaft 4 (crude oil transfer and general services).
The pictures on the frontpage represent the inside of shaft four showing the main
crude oil pump caissons inside the shaft.
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.n
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet:www.ameron.com
email:marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Bondstrand

Case History
1 Ameron 1996 FP 671 03/96. Printed in Holland.
Client
Pipe system
Operating conditions
Location
Offshore floating hydrocarbon
production unit
using Bondstrand pipe and fittings
with Quick-Lock and Taper/Taper
adhesive-bonded joints
NKP barge, Nkossa field - offshore Congo, Africa.
Elf Congo
Bondstrand series 2000M pipe with Quick-Lock and Taper/Taper adhesive-bonded
joints. A total quantity of over 14.000 m. and almost 10.000 fittings in diameters
varying from 50 mm (2 inch) to 450 mm (18 inch).
Fire Main* Ballast lines Sumps Potable water
Design pressure: 16 bar 3.5 bar Full vacuum 5
Design temperature : 60C 25C 25C Ambient
Working pressure: 16 bar 3 bar Full vacuum 5 bar
Operating temperature: Ambient 25C 25C Ambient
Test pressure: 24 bar 5.3 bar Air test 0.8 bar 7 bar
* For both dry (deluge) and wet networks.
Completed in 1995. Installation date
2
Wet and dry fire mains, ballast lines and process lines.
The NKP barge (dimensions: 220m x 46m x 16m) is the largest pre-stressed
vessel ever built. It is also the largest vessel mounted hydrocarbon production
plant. The barge is connected to a steel platform installed at 170 m. depth, using
high pressure hoses and it is used for oil treatment, gas compression and for the
processing of LPG and gas as well as for water reinjection. Furthermore, it has
lifequarters to accommodate 160 people.
Main advantages of using Bondstrand
fiberglass pipe were:
Corrosion resistance
Fire resistant
Designed to last platform lifetime
Marine growth resistant
Little to no maintenance
Lightweight material
Application
Description
Advantages
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.nl
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet: www.ameron.com
email: marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Bondstrand

Case History
1 Ameron 1995 FP 663 09/95. Printed in Holland
Hamilton Oil DA Platform "Pioneer" - Liverpool Bay Development,
United Kingdom.
BHP Petroleum Ltd.
Bondstrand series 3400/2020 with Taper/Taper coupling adhesive joints.
2 off 900 mm internal diameter seawater pump.
1 off 700 mm internal diameter firewaterpump.
1 off 700 mm internal diameter auxiliary pump.
Length of caissons varied from 50 to 70 m. with 2.5 m. diver protection cage
fabricated in yard and supplied in two halves for final jointing within the platform
legs. Each caisson is supported by a fiberglass stub end flange. Protection cage
base plates were secured with Key-Lock mechanical joints.
October 1994.
Pipe system
Caisson systems for
offshore platforms
using Bondstrand Glassfiber
Reinforced Epoxy pipe and fittings with
Taper/Taper adhesive-bonded joint
Client
Location
Installation date
Advantages Main advantages of using Bondstrand fiberglass pipe were:
Reduction in Capital and Operational expenditure
Reduction in installation costs and time
No hot work
Designed to last platform lifetime
Corrosion resistant
Marine growth resistant
Little or no maintenance
Lightweight material
Axial tensile;
Static flexural strength;
Cyclic flexural strength for fatigue behaviour;
The above tests resulted in certification by Lloyd's Register.
Schematic presentation
of a caisson pipe.
Testing
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.n
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet:www.ameron.com
email:marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Project FPSO Belanak, West Natuna Field, Indonesia.
Shipyard Dalian New Shipyard, China.
Owner Conoco Indonesia Inc. Ltd, Singapore.
Pipe system Bondstrand 2416C conductive pipe and fittings with
Taper/Taper adhesive bonded joints.
Diameters: 2 16 inch (50 - 400 mm).
Total pipe length: 3.682 metres.
Operating conditions Operating pressure: 5.2 bar Operating Temperature: 120 F / 48.9C
Design pressure: 7.6 bar Design Temperature: 149 F / 65 C
Test pressure: 24 bar
Installation date Completed: August 2003.
FPSO Hull piping systems
Bondstrand

2416 C Glassfiber Reinforced


Epoxy (GRE) conductive pipe system
using Taper/Taper adhesive-bonded joints
Expansion coupling
Taper/Taper
joint
Ameron 2004. FP 924 03/04. Page 1 of 4. Printed in The Netherlands.
Project Description FPSO Belanak was completed in mid-August at Chinas Dalian New Shipyard under
a subcontract from Halliburton Dresser Kellogg Energy Services. The Belanak will
act as the central processing facility from Block B and will be the first offshore
liquefied petroleum gas facility on a floating vessel in the Asia Pacific region. The
installation is expected to produce 14,700b/d of propane and 7800b/d of butane.
Construction of the 175,000dwt hull began in March 2002, with the work scope also
including the fabrication of a marine electrical module and 120-bed living quarters.
Following integration of the 25,000t process topsides, the completed FPSO is
expected to be towed to its installation site in the Belanak field in Indonesias South
Natuna Sea Block B, some 200 km Northeast of Singapore, in September 2004.
First oil is anticipated before the end of 2004.
Classification Society:
American Bureau of Shipping.
Advantages Advantages
- Reduction in installation costs and time;
- Reduction in pumping costs;
- Minimum long term service life 30 years;
- Corrosion resistant;
- Reduced marine growth;
- Maintenance free;
- Light weight material;
Scope of Supply The Purchase Order for complete design, procure, fabricate, deliver spools and field
service engineering was awarded to Pipex Ltd in 2001.
Pipex produced General Arrangement drawings, isometrics and material
take offs.
Ameron BV performed stress analysis of all pressure critical systems.
Ameron (Pte) Asia supplied all spool fabrication 100% tested.
Pipex supplied full Project Management, Field Service Engineering, training
of local workforce and inspection of systems.
A total of 3.682 metre pipe was installed in 885 spools including 1617 fabrication
joints and 775 adhesive field joints with a zero failure rate.
aft seawater cooling 14 inch overboard
discharge lines
14 inch ballast pump suction and
discharge lines
Ameron 2004. FP 924 03/04. Page 2 of 4. Printed in The Netherlands.
Scope of Supply (continued) Systems Diameter Working Test
Used Pressure Pressure
(inch) (bar) (bar)
Ballast 4, 6, 10, 12, 14 5.2 16
Seawater Cooling 2, 4, 6, 8, 10, 12,14,16 5.2 24
Inert Gas Tank Purging 8 - -
Tank Sounding 2 - -
Level Protection 4 - -
Inert Gas Cooling 8, 10 5.2 4
Inert Gas Deck Seal 3, 14 5.2 24
Slop Tank Dip Pipe 3, 6, 8, 10 - -
Mooring Chain Cooling 2 - -
Incinerator Quench 6 - -
Pipex Ltd. Received the Belanak Gold Award for turn-key package solution of GRE
design, supply, procure, project manage, manufacture, fabricate, drawing production
with Pipe engineers seconded to Halliburton, full training of local workers, final QA
reports and critical site joints in China. Pipex offered the client single point
responsibility including product and installation warranties for critical GRE systems.
machinery space seawater cooling system
lines
machinery space seawater cooling system
lines to main deck
machinery space cooling lines from 16 inch
seawater header
12 inch ballast suction bell mouth and 8 inch
inert gas tank purging
Ameron 2004. FP 924 03/04. Page 3 of 4. Printed in The Netherlands.
14 inch ballast header Bondstrand prefabrication joints
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston, TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet: www.ameron.com
email: marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, TX 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, TX 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
J urong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
Internet: www.ameron-com.sg
email: info@ameron-com.sg
Ameron 2004. FP 924 03/04. Page 4 of 4. Printed in The Netherlands.
Ameron 2002 - FP 889 12/02. Page 1 of 4. Printed in the Netherlands.
Floating Production Storage and Offloading (FPSO) vessel 'Girassol'.
Hyundai Heavy Industries - Ulsan, Korea.
TOTALFINAELF along with other major partners, including Exxon, BP, Statoil
and Norsk Hydro.
A total of 21.000 m. Glassfiber Reinforced Epoxy (GRE) pipe was supplied for
this most complex and sophisticated FPSO. Bondstrand 2000M, 7000M and
2000M-FP pipe systems with Quick-Lock and Taper/Taper adhesive-bonded
joints were used in diameters ranging from 50-900 mm (2-36 inch).
Operating pressure: up to 16 bar (232 psi)
Operating temperature: up to 60C. (140F).
Design pressure: up to 16 bar (232 psi).
Design temperature: up to 100C. (212F).
Test pressure: up to 24 bar (348 psi).
2001.
Installation date
Pipe system
Operating conditions
Vessel
Shipyard
Glassfiber Reinforced Epoxy
(GRE) pipe systems for
FPSO Girassol
using Bondstrand

2000M/7000M and
2000M-FP pipe and fittings with Quick-Lock

and Taper/Taper adhesive-bonded joints


Owner
Quick-Lock
Taper/Taper
Girassol under
final construction
Ameron 2002 - FP 889 12/02. Page 2 of 4. Printed in the Netherlands.
To date, FPSO 'Girassol' is the largest FPSO in terms of size and working water
depth capability. It has a capacity of 343.000 DWT; a storage capacity of 2.000.000
barrels of oil and a processing capability of 200.000 barrels of oil per day. The
30.000 ton topsides have oil processing, gas treatment and re-injection, metering,
handling and offloading facilities.
Description
The vessel was designed with a hull fatigue life twice that of the anticipated 20-
year service life of the Girassol Field, located at 210 km NNE of Luanda, Angola.
Bondstrand piping was used throughout the vessel. Double bottom tanks were
piped with Bondstrand 7000M. Both bonded joints and double O-ring expansion
couplings were installed and the support system designed to absorb expansion
and contraction during operation, as well as movements from the hogging and
sagging of the hull. Series 7000M is a robust product, fully able to withstand the
external pressure such a system will encounter in the tank bottom.
The water injection system piping used Bondstrand 2000M, to provide a cleaner,
purer and ion-free fluid. Huge 30-inch suctions draw water directly from the sea to
feed large bore piping supplying the cooling water, fire water and water injection
systems. Bondstrand 2000M-FP was used for dry deluge applications throughout
the vessel. Series 2000M-FP also supplies water to the water curtains, used to
protect all critical components on the modules.
Seawater cooling line
for all topside modules
Water injection system
Dry deluge piping for water curtains
Ameron 2002 - FP 889 12/02. Page 3 of 4. Printed in the Netherlands.
Wet and dry
fire water systems
INSTALLED SYSTEMS
Water ballast in tanks;
Sea water cooling for all top side modules;
Water injection systems;
Wet and Dry fire water systems;
Raw sea water;
De-mineralized sea water;
Drinking water.
Extensive consultations with Hyundai Heavy Industries, the Korean contractor in
charge of the construction, and MPG, the French Engineering contractor, took
place. Ameron (Pte) Asia provided the engineering support, including the supply
of detail spool piece drawings. Ameron fabricated, produced and marked each
individual spool piece.
General service piping
General service piping
Ameron 2002 - FP 889 12/02. Page 4 of 4. Printed in the Netherlands.
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
Internet: www.ameron-fpg.nl
email: info@ameron-fpg.nl
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, TX 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston, TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet: www.ameron.com
email: marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
Internet: www.ameron.com.sg
email: info@ameron.com.sg
As part of Ameron's policy, each fabricated spool was hydro-tested to
the client's requirement and witnessed by an independant party. Within
a three month time span, over 6.000 spool pieces, ranging from 50-900
mm (2-36 inch) were prefabricated, packed and shipped for immediate
installation on-board.
With this project, Ameron and this customer have raised the standard
of what can be achieved with GRE piping on oil & gas producing vessels.
Only by joining in a close, team-work relationship, with a clear objective
and understanding of the scope of the work and the strict time frame
under which it was to be accomplished, was this possible.
Ameron has proven itself to be capable and committed to fully meeting
the customer's requirements with a full range of quality products, expert
service, design and logistics support and in-service performance.
Seawater suction
Topside Process Water
Systems for F.P.S.O.
"North Sea Producer"
using Bondstrand 2000M and 7000M
glassfiber reinforced epoxy (GRE)
pipe and fittings
Ameron 2000 FP 860 - 08/00. Printed in The Netherlands.
Owner
Pipe system
Operating conditions
Vessel
FPSO "North Sea Producer".
MacCulloch Field Development for Conoco.
Odebrecht SLP, Teeside United Kingdom.
(formerly: J.V. Maersk)
Bondstrand 2000M and 7000M in diameters 2-12 inch (50-300mm) with
Quick-Lock adhesive-bonded joints.
Contract value: 50.000.
Operating pressure: 16 bar. Test pressure: 24 bar.
Ambient temperature: -5 /+35 C.
1997. Installation date
Shipyard
Description In 1997, a Maersk Oil tanker was converted into the FPSO "North Sea Producer"
at the Odebrecht SLP Yard, Teeside, United Kingdom. Ameron Bondstrand Series
7000M pipes, fittings and flanges were installed running along the A frame from
close to the forward turret, aft to process units adjacent to the Bridge and crew
accommodation areas. The main sea water pipe run was in 12" diameter with
various branch offtakes in smaller sizes. Pipework was prefabricated, installed
and tested on the vessel by Pipex Ltd.
A number of deck mounted skid process units using Ameron Bondstrand Series
2000M pipes, fitting and flanges up to 12" diameter were supplied to the project
by Baker Hughes Ltd for hook up to the main sea water system.
All systems were supplied on schedule and continue in trouble free service on the
FPSO.
Reduction in installation costs and time
Minimum long-term service life of 20 years
Corrosion resistance
Reduced marine growth
Maintenance-free
Light-weight material
Advantages
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.n
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet:www.ameron.com
email:marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Cooling water, fire water and
produced water lines for
F.P.S.O. "Bleo Holm"
using Bondstrand 7000 and 3410, 3416,
3420 and 3440 conductive fiberglass
pipe and fittings
Ameron 2000 FP 851 - 08/00. Printed in The Netherlands.
Owner
Pipe system
Operating conditions
Vessel
FPSO "Bleo Holm" - Ross Field, North Sea.
U.I.E. Clydebank Shipyard - Scotland. Contractor: Pipex Ltd.
Bluewater Hoofddorp, the Netherlands.
Bondstrand 7000 with Quick-Lock adhesive-bonded joints.
Bondstrand 3410, 3416 and 3420 and 3440 conductive with Taper/Taper
adhesive-bonded and Key-Lock mechanical joints and butt & wrap joints in
diameters 1 through 28 inch (25-700 mm).
Contract value: 3,500.000.
Operating pressure: 10, 16, 20 and 38 bar. Test pressure: 15-50 bar.
Operating temperature: 80 C. Ambient temperature: -10 C to 24 C.
1998.
Installation date
Shipyard
Description
Climatic conditions
Advantages
The Bleoholm was designed and constructed to produce 40,000 barrels of wet
crude oil per day; store and offload 32,000 barrels per hour to shuttle tankers.
The Bondstrand Glass Reinforced Epoxy (GRE) pipework systems used on the
Bleoholm were:
GRE1: The main cooling water feed and return system.
Maximum design pressure 10 bar and design temperature -10/+93 C.
GRE2: The firewater ring main and firewater feed lines.
Maximum design pressure 16 bar and design pressure temperature
-10/+93 C.
GRE3: Produced water and brine water lines.
Maximum design pressure 20 bar and design temperature -10/+93 C.
GRE4: High-pressure seawater feed and return system.
Maximum design pressure 38 bar and design temperature -10/+93 C.
Bondstrand filament wound epoxy pipework series 7000, 3410, 3416, 3420 and
3440 conductive were installed with diameters ranging from 1 to 28 inch (25-700
mm). Quick-Lock and Taper/Taper adhesive bonded joints were used in conjuction
with butt and wrap joints. The F.P.S.O was built under Lloyd's Register classification.
For additional information, please refer to TB-6:"Bleo Holm Functionality Check".
G
Reduction in installation costs and time
G
Minimum long-term service life of 20 years
G
Corrosion resistance
G
Reduced marine growth
G
Maintenance-free
G
Light-weight material
Minimum temperature: -10 C Maximum temperature: +24 C
Minimum humidity: 70% Maximum humiditiy: 100%
Windforce hourly: At +10m above sealevel 36 m/s (average)
At +60m above sealevel 45 m/s (average)
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.n
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet:www.ameron.com
email:marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Fiberglass Pipe Group division Europe
P.O. Box 6 - 4191 CA Geldermalsen - Holland
tel. +31 345 587 587 - fax +31 345 587 561
Functionality check
Glassfiber Reinforced Epoxy systems
on board the FPSO Bleoholm
1. Introduction Owner : Bluewater Terminal Systems N.V.
Engineering : Fluor Daniel B.V. Haarlem Holland
Builder : U.I.E Scotland
GRE contractor : Pipex Ltd, Tiverton United Kingdom
GRE vendor : Ameron B.V. FPD Europe
Author : Jeroen van Brakel
The Bleoholm is an FPSO (Floating Production Storage and
Off-loading) designed to function as a floating oil
production and oil storage vessel. These types of production
vessels are getting more common to develop smaller oilfields
with a shorter lifetime. If an oilfield becomes empty, the vessel
can easily be employed on another oilfield. This, in contrast to
a fixed platform that can not be moved once it has been
positioned on the seabed.
In principal, an FPSO is a classic tanker with modules placed
on deck which take care of the oil production. The ships tanks
are used as storage tanks for the produced oil. Once these
tanks are filled, the oil is pumped over to another tanker which
will bring the oil on-shore. This avoids the need for expensive
subsea pipelines.
TB-6 - 06/99
Technical Bulletin 6
June 1999
2
Ameron was selected to supply the Glassfiber Reinforced
Epoxy piping for various systems. Included in this order was,
that Ameron had to carry out the functionality check of the
various GRE systems, designed by Fluor Daniel.
2. GRE system
description
The Glassfiber Reinforced Epoxy piping was divided into four
main systems:
GRE1- Cooling water feed and return & seawater feed and
return system.
Maximum pressure 10 bar and maximum temperature 60 C.
GRE2- Firewater ringmain and fire water feed lines.
Maximum pressure 16 bar and maximum temperature 40 C.
GRE3- Produced water and brine water lines.
Maximum pressure 20 bar and maximum temperature 80 C.
GRE4- High-pressure seawater feed & return system.
Maximum pressure 38 bar and maximum temperature 60 C.
3. Problem description The main difference between this FPSO and regular on-shore
piping systems is, that the ship is expected to have "Sagging
and Hogging". Sagging and hogging is the elongation and
compression of the ship parallel to ships centreline". This
sagging and hogging is induced by wave action and loading, or
offloading of oil from the ships storage tanks. This means, that
two "fixed" points on deck could move from, or towards each
other. This has major impact on the supporting of piping on
deck.
The ship also pitches and rolls due to wave action. This
induces horizontal and vertical acceleration (g) forces on the
piping systems. This also has impact on the supporting.
The functionality check of the Glassfiber Reinforced Epoxy
systems contains checking the piping layout as designed by
Fluor Daniel Haarlem B.V., indicating the support type, support
location, forces on supports and forces on flanged nozzle
connections.
4. Software description The functionality check of the Glassfiber Reinforced Epoxy
systems was performed using the stress analysis software
CAESAR II from COADE Inc.
This software package is an engineering tool used in the
mechanical design and analysis of piping systems. The user
creates a model of the piping system using simple beam
elements and defines the loading conditions imposed on the
system.
With this input, CAESAR II produces results in the form of
displacements, loads and stresses throughout the system.
Additionally, CAESAR II compares these results to limits
specified by recognised codes, specifications and standards.
Technical Bulletin 6
June 1999
3
5. Specification used For the design of this piping system the UKOOA specification
was used. The UKOOA is a five part Document Suite
developed to provide for GRE pipe systems used in the
offshore oil and gas industry. It primarily defines the
requirements for low to medium pressure (up to 40 bar) GRE
piping systems in diameters 25mm to 1200mm at working
temperatures between 40 C and 95 C for non-hydrocarbon
applications on offshore installations.
For every system in this project, Lloyds type approval was
required. For the GRE-2 system, firewater ringmain and fire
water feed lines, maximum pressure 16 bar and maximum
temperature 40 C, IMO L3 was required. However, in the
Engine- and Pump room partly IMO L1 and L2 were required.
6. Description of work
performed
Design calculation
Ameron did assist in the design of the glass reinforced piping
system on board of this vessel. More than 500 isometrics of
glass reinforced epoxy piping have been inputted in the Caesar
ll program.
The calculation output of the Caesar II analysis was checked
amongst others for large movement of the pipe due to the
sagging and hogging or the horizontal and vertical acceleration.
The analysis was based on the UKOOA code for evaluation of
the calculated stresses
Support design
The Caesar II program calculated the forces and moments on
the supports. These forces and moments were used by both
Pipex and Fluor Daniel Haarlem B.V. to design the supports.
Load calculation
The Caesar II program also calculated the loads on flange
connections to nozzles of vessels, coolers, skids, pumps etc.
These loads were checked against the allowable nozzle loading
of the equipment.
Expansion loops
Because the space was limited for expansion loops on board of
the vessel, special glass reinforced epoxy expansion couplings
were designed by Ameron to take up the large movement of the
pipeline
Figure 1: Fire main with expansion coupling
Technical Bulletin 6
June 1999
4
7. Installation The entire Bondstrand piping system was installed by Pipex, a
UK-based company, experienced with the installation of
Glassfiber Reinforced Epoxy pipes and fittings. The installation
at UIE Scotland was done by making spools at shore in a so
called prefab shop. These spools which could still be handled
are then transported on board of the ship were they were jointed
together (see figure 2).
A Pipex crew of some 60 people, worked on this project for 11
months, during the day and sometimes also in nightshifts. Once
a part of the lines were completed, they were pressure tested
for a period of at least one hour at 1,5 times the design
pressure. After this the pipe system was commissioned.
Fig. 2 Feed and return seawater system
February 17, 1999: A historic day as the Bleoholm sails away
Ameron 1996. FP 689 07/96. Page 1 of 2. Printed in The Netherlands.
Floating Production Storage
and Offloading Vessel
using Bondstrand 7000M fiberglass pipe
and fittings with adhesive-bonded joints and
double O-ring joints
Shipyard
Vessel FPSO "Cossack Pioneer".
Keppel Shipyard, Singapore.
Woodside Offshore Petroleum Pty Ltd, Western Australia.
Bondstrand 7000M with adhesive-bonded joints in sizes 2 - 24 inch
(50 - 600 mm). Quantity: 1.000 m.
Service:
process cooling
deck wash
produced water piping
deck drains
1995
Owner
Pipe system
Installation date
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
Internet: www.ameron-fpg.nl
email: info@ameron-fpg.nl
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, TX 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston, TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet: www.ameron.com
email: marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
Internet: www.ameron.com.sg
email: info@ameron.com.sg
Whether in conversions or new purpose built F.P.S.O.s Bondstrand
piping is extensively used in systems which are prone to corrosion from
internal sea water medium, or external sea spray on exposed weather
decks.
Why Bondstrand fiberglass pipe was selected:
Reduction in Capital and Operational expenditure
Reduction in installation costs and time
Minimum long term service life of 20 years
Corrosion resistance
Reduced marine growth
Little or no maintenance
Lightweight material
Service: seawater, produced water
Operating pressure: up to 10 bar
Test pressure: 15 bar
Operating temperature: up to 93C
Velocity: up to 4.5 m/s
Classification: American Bureau of Shipping
Bondstrand Series 7000M pipes and fittings,
incorpoarating conductive carbon filaments
Description
Advantages
Operating Conditions
Ameron Fiberglass-Composite Pipe Group/Europe - Approval Overview - dated 07/04 - page 1 of 2
Please visit www.ameron-fpg.nl to download a copy of any of the above certificate
Approval Overview
Certifying Body Product Unit Number Description Validity Market
American Bureau of Shipping 2000M U.S.A. HS322284-X Type Approval yearly review Marine
American Bureau of Shipping 2000M+FP, 7000M, PSX L3, -JF Singapore 01-SG110000-X Type Approval yearly review Marine
American Bureau of Shipping 2410, 2412, 2414, 2416, 2420, 2425 Singapore 01-SG110000-X Type Approval yearly review Marine
American Bureau of Shipping 7000M U.S.A. HS322284-X Type Approval yearly review Marine
American Petroleum Institute Bondstrand Europe 15LR-0006.1 Type Approval 21-oct-05 Oil & Gas, Offshore
American Petroleum Institute Bondstrand Singapore 15LR-0012 Type Approval 18-mrt-05 Oil & Gas, Offshore
American Petroleum Institute Bondstrand Singapore 15HR-0008 Type Approval 18-mrt-05 Oil & Gas, Offshore
American Petroleum Institute Centron U.S.A. 15LR-0007 Type Approval 13-jan-05 Oil & Gas
American Petroleum Institute Centron U.S.A. 15HR-0003 Type Approval 13-jan-05 Oil & Gas
Bureau Veritas 2000M Europe 07796/B0 BV Type Approval 20-jan-08 Marine
Bureau Veritas 2000M Singapore 07797/B0 BV Type Approval 5-mrt-08 Marine
Bureau Veritas 2000M U.S.A. 01407/EO BV Type Approval 7-jul-04 Marine
Bureau Veritas 7000M Europe 07798/B0 BV Type Approval 20-jan-08 Marine
Bureau Veritas 7000M Singapore 07795/B0 BV Type Approval 5-mrt-08 Marine
Bureau Veritas 7000M U.S.A. 01409/EO BV Type Approval 7-jul-04 Marine
Det Norske Veritas 2000 Europe K-2109 Type Approval 30-jun-05 Marine
Det Norske Veritas 2000 Singapore K-2114 Type Approval 30-jun-05 Marine
Det Norske Veritas 2000M Europe K-2110 Type Approval 30-jun-05 Marine
Det Norske Veritas 2000M Singapore K-2115 Type Approval 30-jun-05 Marine
Det Norske Veritas 2410-2425 Singapore K-2208 Type Approval 31-dec-06 Marine
Det Norske Veritas 2410-2425 Conductive Europe K-2176 Type Approval 31-dec-06 Marine
Det Norske Veritas 2410-2425 Conductive Singapore K-2198 Type Approval 31-dec-06 Marine
Det Norske Veritas 3410-3425 Conductive Europe K-2354 Type Approval 31-dec-06 Marine
Det Norske Veritas 7000M Europe K-2111 Type Approval 30-jun-05 Marine
Det Norske Veritas 7000M Singapore K-2116 Type Approval 30-jun-05 Marine
Det Norske Veritas Double O-ring joint Singapore K-2127 Type Approval 30-jun-05 Marine
Det Norske Veritas ISO 9001, 2000 Europe 08379-2003-AQ-ROT-RvA Quality Approval 13-nov-06 All
Det Norske Veritas ISO 9001, 2000 U.S.A. 03326-2003-AQ-HOU-RvA/RAB, Rev. 1 Quality Approval 8-oct-06 All
Det Norske Veritas ISO 9001, 2000 Singapore 0136-1996-AQ-SIN-RvA Quality Approval 24-jul-05 All
Det Norske Veritas S 3400, 2000(M),(G), 4000, 7000(M), 6000(FM) and 2400 Europe ISO/FDIS 14692 Other - All
Deutsches Institut fr Bautechnik 2000, 2000G, 4000, 6000-FM Europe Z-40.13-290 Type Approval 31-may-06 Industry
Germanischer Lloyd 2000M, 7000M Europe 73-788-94 HH Type Approval 6-aug-06 Marine
Gostekhadzor, Kazakhstan Centron Europe 7/55-80 Type Approval 15-jun-06 Oil & Gas
Korean Register of Shipping 2000M, 7000M Singapore SGP02568-GP001 Type Approval 23-feb-06 Marine
Lloyds Register 2000 Europe 99/00095 Type Approval 16-jun-04 Marine
Lloyds Register 2400 Singapore 01/00041 Type Approval 11-mrt-06 Marine
Lloyds Register 3400 Europe 99/00127 Type Approval 25-aug-04 Marine
Lloyds Register 7000 Europe 99/00092 Type Approval 6-jun-04 Marine
Lloyds Register 2000M, 7000M Europe 89/00102(E4) Type Approval 23-jul-05 Marine
Lloyds Register 2000M, 7000M Singapore 91/00292(E3) Type Approval 1-aug-06 Marine
Lloyds Register Expansion coupling Europe 99/00094 Type Approval 16-jun-04 Marine
Ameron Fiberglass-Composite Pipe Group/Europe - Approval Overview - dated 07/04 - page 2 of 2
Please visit www.ameron-fpg.nl to download a copy of any of the above certificate
Approval Overview
Certifying Body Product Unit Number Description Validity Market
Marina Militare 7000M Europe M.13768 Other - Marine
Nippon Kaiji Kyokai 2000M, 5000M, 7000M, S2000M-FP, PSX-L3 Singapore 04HG0001PP Type Approval 20-jan-09 Marine
NSF International Bondstrand U.S.A. 80680/80681 Type Approval - Industry
Registro Italiano Navale 2000 Europe MAC/148800/2/TO/02 Type Approval 25-jun-07 Offshore
Registro Italiano Navale 3400 Europe MAC/148800/3/TO/02 Type Approval 26-jun-07 Offshore
Registro Italiano Navale 7000 Europe MAC/148800/1/TO/02 Type Approval 25-jun-07 Offshore
Registro Italiano Navale 2000M Europe MAC/26201/2/TO/01 Type Approval 9-jul-06 Marine
Registro Italiano Navale 2000M Singapore MAC/127200/2/TO/00 Type Approval 24-sep-05 Marine
Registro Italiano Navale 7000M Europe MAC/26201/1/TO/01 Type Approval 9-jul-06 Marine
Registro Italiano Navale 7000M Singapore MAC/127200/1/TO/00 Type Approval 24-sep-05 Marine
Water Regulations Advisory Scheme 2000G, 3400 Europe 9911528 Type Approval nov-04 Industry
INTERNATIONAL MARITIME A.18/Res. 753
ORGANISATION 22 November 1993
Original : ENGLISH
ASSEMBLY - 18th session
Agenda item 11
RESOLUTION A.753(18)
adopted on 4 November 1993
GUIDELINES FOR THE APPLICATION OF PLASTIC PIPES ON SHIPS
THE ASSEMBLY,
RECALLING Article 15(j) of the Convention on the International Maritime Organization
concerning the functions of the Assembly in relation to regulations and guidelines
concerning maritime safety and the prevention and control of marine pollution from ships,
NOTING that there is increasing interest within the marine industry in the use of
materials other than steel for pipes and that there are no specific requirements for plastic
and reinforced plastic pipes and piping systems in existing regulations,
RECOGNIZING that guidelines, covering acceptance criteria for plastic materials in
piping systems, appropriate design and installation requirements and fire test performance
criteria for assuring ship safety, are needed to assist maritime Administrations to determine,
in a rational and uniform manner, the permitted applications for such materials,
RECOGNIZING ALSO that the framework of the guidelines should provide the
freedom to permit the development of international and national standards and allow the
natural development of emerging technology,
HAVING CONSIDERED the recommendation made by the Maritime Safety Committee
at its sixtyfirst session,
1. ADOPTS the Guidelines for the Application of Plastic Pipes on Ships, set out in the
Annex to the present resolution;
2. INVITES Governments:
(a) to apply the Guidelines when considering the use of plastic piping on board
ships flying the flag of their State: and
(b) to inform the Organisation on the development of national standards
and emerging technology on plastic piping;
3. REQUESTS the Maritime Safety Committee to keep the Guidelines under review
and amend them as necessary.
W/0322a
For reasons of economy, this document is printed in a limited number. Delegates are
kindly asked to bring their copies to meetings and not to request additions copies
ANNEX
GUIDELINES FOR THE APPLICATION OF PLASTIC PIPES ON SHIPS
TABLE OF CONTENTS
1. INTRODUCTION
1.1 Purpose
1.2 Scope
1.3 Philosophy and contents
1.4 Definitions
2. MATERIAL DESIGN PROPERTIES AND PERFORMANCE CRITERIA
2.1 REQUIREMENTS APPLICABLE TO ALL PIPING SYSTEMS
.1 General
.2 Internal pressure
.3 External pressure
.4 Axial strength
.5 Temperature
.6 Impact resistance
.7 Ageing
.8 Fatigue
.9 Erosion resistance
.10 Fluid absorption
.11 Material compatibility
2.2 REQUIREMENTS APPLICABLE TO PIPING SYSTEMS DEPENDING ON SERVICE AND/OR LOCATIONS
.1 Fire endurance
.2 Flame spread
.3 Smoke generation
.4 Toxicity
.5 Electrical conductivity
.6 Fire protection coatings
3. MATERIAL APPROVAL AND QUALITY CONTROL DURING MANUFACTURE
4. INSTALLATION
4.1 Supports
4.2 External loads
4.3 Strength of connections
4.4 Control during installation
4.5 Testing after installation on board
4.6 Penetrations of fire divisions
4.7 Penetrations of watertight bulkheads and decks
4.8 Methods of repair
APPENDICES
Appendix 1 - Test method for fire endurance testing of plastic piping in the dry condition
Appendix 2 - Test method for fire endurance testing of water-filled plastic piping
Appendix 3 - Test method for flame spread of plastic piping
Appendix 4 - Fire endurance requirements matrix.
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1. INTRODUCTION
1.1 Purpose
1.1.1 The International Maritime Organization recognizes
that there is increasing interest within the marine industry
to use materials other than steel for pipes and that there
are no specific requirements for plastic pipes in existing
regulations.
1.1.2 These guidelines provide acceptance criteria for
plastic materials in piping systems to assist maritime
Administrations to determine, in a rational and uniform way,
the permitted applications for such materials. These
guidelines give appropriate design and installation
requirements and, for each application, fire testing
performance criteria necessary to ensure that vessel safety
is adequately addressed.
1.1.3 Within the framework of these guidelines, there is
freedom to permit development of international and
national standards, and allow the natural development of
emerging technology.
1.2 Scope
1.2.1 The status of these guidelines is advisory. They
are intended to cover the design and installation of plastic
pipes, both with and without reinforcement, in either
essential or non-essential systems, inboard of the shipside
valves.
1.2.2 These guidelines are intended to comply with
existing SOLAS regulations, MSC circulars, or other equi-
valent international criteria.
1.2.3 These guidelines are applicable to rigid pipes only.
The use of flexible pipes and hoses and mechanical
couplings which are accepted for use in metallic piping
systems is not addressed.
1.3 Philosophy and contents
1.3.1 The International Convention for the Safety of Life
at Sea (SOLAS 74), as amended, specifies steel should
be used in some cases, but in other instances it is clear
that materials other than steel are anticipated, subject to
the Administrations acceptance. Guidelines to enable
Administrations to make decisions on the use of plastic
piping, and the possibility of extending its application, are
therefore needed.
1.3.2 Certain material design properties and performance
criteria are common to all piping systems, regardless of
system or location, and these are addressed in section
2.1.
1.3.3 Section 2.2 addresses fire safety aspects and
provides specific requirements applicable to piping
systems depending on service and/or locations.
1.3.4 Section 3 addresses material approval and
prescribes certain controls during manufacture of piping
that should be considered in order to ensure the proper
mechanical and physical characteristics.
1.3.5 Shipboard piping should be properly installed and
tested to ensure the degree of safety necessary. Section
4 addresses these concerns, and incorporates MSC/Circ.
449 Guidance on installation of fibre glass reinforced pipe
and fittings.
1.3.6 The fire test methods and the fire endurance
requirements matrix, referenced in section 2.2, are given
in appendices I to IV.
1.4 Definitions
1.4.1 Plastic(s) as used in these guidelines refers to both
thermoplastic and thermosetting plastic materials, with or
without reinforcement, such as uPVC and fibre reinforced
plastics - FRP.
1.4.2 Piping/Piping systems - The terms piping and piping
systems include the pipe, fittings, system joints, method
of joining and any internal or external liners, coverings and
coatings required to comply with the performance criteria.
For example, if the basic material needs a fire protective
coating to comply with the fire endurance requirements,
then the piping should be manufactured and tested with
both the basic material and coating attached and submitted
to the Administration for approval as a material system.
1.4.3 Joint - The term joint refers to the permanent
method of joining pipes by adhesive bonding, laminating,
welding, etc.
1.4.4 Fittings - The term fittings refers to bends, elbows,
fabricated branch pieces, etc., of plastic material.
2. MATERIAL DESIGN PROPERTIES AND
PERFORMANCE CRITERIA
2.1 Requirements applicable to all piping systems
2.1.1 General
2.1.1.1 The requirements of this section apply to all piping
and piping systems independent of service or location.
2.1.1.2 The specification of the piping should be to a
recognized standard acceptable to the Administration and
should meet the additional performance guidelines that
follow.
2.1.1.3 The piping should have sufficient strength to take
account of the most severe coincident conditions of
pressure, temperature, the weight of the piping itself and
any static and dynamic loads imposed by the design or
environment.
2.1.1.4 For the purpose of assuring adequate robustness
for all piping including open ended piping (e.g. overflows,
vents and open-ended drains), all pipes should have a
minimum wall thickness to ensure adequate strength for
use on board ships, also to withstand loads due to
transportation, handling, personnel traffic, etc. This may
require the pipe to have additional thickness than otherwise
required by service considerations.
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W/0322a
2.1.1.5 The performance requirements for any component
of a piping system such as fittings, joints, and method of
joining are the same as those requirements for the piping
system they are installed in.
2.1.2 Internal pressure
2.1.2.1 A piping system should be designed for an internal
pressure not less than the maximum working pressure to
be expected under operating conditions or the highest set
pressure of any safety valve or pressure relief device on
the system, if fitted.
2.1.2.2 The nominal internal pressure for a pipe should
be determined by dividing the short-term hydrostatic test
failure pressure by a safety factor of 4 or the long-term
hydrostatic (>100.000 h) test failure pressure by a safety
factor of 2.5, whichever is the lesser. The hydrostatic test
failure pressure should be verified experimentally or by a
combination of testing and calculation methods to the
satisfaction of the Administration.
2.1.3 External pressure
2.1.3.1External pressure should be taken into account in
the design of piping for any installation which may be sub-
ject to vacuum conditions inside the pipe or a head of liquid
acting on the outside of the pipe.
2.1.3.2Piping should be designed for an external pressure
not less than the sum of the maximum potential head of
liquid outside the pipe, plus full vacuum (1 bar). The
nominal external pressure for a pipe should be determined
by dividing the collapse test pressure by a safety factor of
3. The collapse test pressure should be verified
experimentally or by a combination of testing and
calculation methods to the satisfaction of the
Administration.
2.1.4 Axial strength
2.1.4.1The sum of the longitudinal stresses due to
pressure, weight and other dynamic and sustained loads
should not exceed the allowable stress in the longitudinal
direction. Forces due to thermal expansion, contraction
and external loads, where applicable, should be considered
when determining longitudinal stresses in the system.
2.1.4.2In the case of fibre reinforced plastic pipes, the sum
of the longitudinal stresses should not exceed half of the
nominal circumferentional stress derived from the nominal
internal pressure determined according to paragraph
2.1.2.2, unless the minimum allowable longitudinal stress
is verified experimentally or by a combination of testing
and calculation methods to the satisfaction of the
Administration.
2.1.5 Temperature
2.1.5.1Piping should meet the design requirements of
these guidelines over the range of service temperatures it
will experience.
2.1.5.2High temperature limits and pressure reductions
relative to nominal pressures should be according to the
recognized standard, but in each case, the maximum
working temperature should be at least 20C lower than
the minimum heat distortion temperature (determined
according to ISO 75 method A, or equivalent) of the resin
or plastic material. The minimum heat distortion
temperature should not be less than 80C.
2.1.5.3 Where low temperature services are considered,
special attention should be paid to material properties.
2.1.6 Impact resistance
2.1.6.1Piping should have a minimum resistance to im-
pact to the satisfaction of the Administration.
2.1.7 Ageing
2.1.7.1Before selection of a piping material, the
manufacturer should confirm that the environmental effects
including but not limited to ultraviolet rays, saltwater
exposure, oil and grease exposure, temperature, and
humidity, will not degrade the mechanical and physical
properties of the piping material below the values
necessary to meet these guidelines. The manufacturer
should establish material ageing characteristics by
subjecting samples of piping to an ageing test acceptable
to the Administration and then confirming its physical and
mechanical properties by the performance criteria in these
guidelines.
2.1.8 Fatigue
2.1.8.1In cases where design loadings incorporate a sig-
nificant cyclic or fluctuating component, fatigue should be
considered in the material selection process and taken
into account in the installation design.
2.1.8.2In addressing material fatigue, the designer may
rely on experience with similar materials in similar service
or on laboratory evaluation of mechanical test specimens.
However, the designer is cautioned that small changes in
the material composition may significantly affect fatigue
behaviour.
2.1.9 Erosion resistance
2.1.9.1In the cases where fluid in the system has high
flow velocities, abrasive characteristics or where there are
flow path discontinuities producing excessive turbulence
the possible effect of erosion should be considered. If
erosion cannot be avoided then adequate measures should
be taken such as increased wall thickness, special liners,
change of materials, etc.
2.1.10 Fluid absorption
2.1.10.1 Absorption of fluid by the piping material
should not cause a reduction of mechanical and physical
properties of the material below that required by these
guidelines.
2.1.10.2 The fluid being carried or in which the pipe
is immersed should not permeate through the wall of the
pipe. Testing for fluid absorption characteristics of the pipe
material should be to a recognized standard.
2.1.11 Material compatibility
2.1.11.1 The piping material should be compatible
5
A 18/Res.753
W/0322a
with the fluid being carried or in which it is immersed such
that its design strength does not degenerate below that
recognized by these guidelines. Where the reaction bet-
ween the pipe material and the fluid is unknown, the
compatibility should be demonstrated to the satisfaction
of the Administration.
2.2 Requirements applicable to piping systems
depending on service and/or locations
2.2.1 Fire endurance
2.2.1.1General
Pipes and their associated fittings whose functions
or integrity are essential to the safety of ships are required
to meet the minimum fire endurance requirements given
below.
2.2.1.2Fire endurance requirements
The fire endurance of a piping system is the
capability to maintain its strength and integrity (i.e. capable
of performing its intended function) for some predetermined
period of time, while exposed to fire that reflects anticipated
conditions. Three different levels of fire endurance for plas-
tic are given. These levels consider the different severity
of consequences resulting from the loss of system integrity
for the various applications and locations. The highest fire
endurance standard (level 1) will ensure the integrity of
the system during a full scale hydrocarbon fire and is
particularly applicable to systems where loss of integrity
may cause outflow of flammable liquids and worsen the
fire situation. The intermediate fire endurance standard
(level 2) intends to ensure the availability of systems
essential to the safe operation of the ship, after a fire of
short duration, allowing the system to be restored after
the fire has been extinguished. The lowest level (level 3) is
considered to provide the fire endurance necessary for a
water filled piping system to survive a local fire of short
duration. The systems functions should be capable of
being restored, after the fire has been extinguished.
2.2.1.2.1 Level 1 - piping systems essential to the
safety of the ship and those systems outside machinery
spaces where the loss of integrity may cause outflow of
flammable fluid and worsen the fire situation should be
designed to endure a fully developed hydrocarbon fire for
a long duration without loss of integrity under dry
conditions. Piping having passed the fire endurance test
method specified in appendix 1 for a duration of a mini-
mum of one hour without loss of integrity in the dry condition
is considered to meet level 1 fire endurance standard.
2.2.1.2.2 Level 2 - piping systems essential to the safe
operation of the ship should be designed to endure a fire
without loss of the capability to restore the system function
after the fire has been extinguished. Piping having passed
the fire endurance test specified in appendix 1 for a duration
of a minimum of 30 min in the dry condition is considered
to meet level 2 fire endurance standard.
2.2.1.2.3 Level 3 - piping systems essential to the safe
operating of the ship should be designed to endure a fire
without loss of the capability to restore the system function
after the fire has been extinguished. Piping having passed
the fire endurance test specified in appendix 2 for a duration
of a minimum of 30 minutes in the wet condition is
considered to meet level 3 fire endurance standard.
2.2.1.3 System/location matrix
2.2.1.3.1 The matrix in appendix 4 establishes fire
endurance requirements, which are system and location
dependent, that pipe materials installed in a specific system
and location should possess to meet accepted minimum
levels of safety.
2.2.1.3.2 Where, according to the matrix, remotely
closed valves are required when permitting the use of plas-
tic piping, the remote operation system should be designed
such that its function will not be inhibited after being
exposed to an equivalent level 1 fire endurance test.
Remote operation is defined as an accessible, safe location
outside the space in which the valves are installed. In the
case of valves on the main deck of a tanker, remote
operation should be from outside the cargo block.
2.2.1.3.3 Where the matrix stipulates endurance le-
vel L2, pipes of endurance level L1 may also be used.
Similarly, where the matrix stipulates endurance level L3,
pipes of endurance level L2 and L1 may be used.
2.2.2 Flame spread
2.2.2.1All pipes, except those fitted on open decks and
within tanks, cofferdams, void spaces, pipe tunnels and
ducts should have low flame spread characteristics as
determined by the test procedures given in resolution
A.653(16) as modified for pipes.
2.2.2.2In resolution A.653(16) the test sample
configuration only considers flat surfaces. Procedure
modifications to A.653(16) are necessary due to the
curvilinear pipe surfaces. These procedure modifications
are listed in appendix 3.
2.2.2.3Piping materials giving average values for all of the
surface flammability criteria not exceeding the values listed
in IMO resolution A.653(16), (Surface flammability crite-
ria, bulkhead, wall and ceiling linings) are considered to
meet the requirements for low flame spread in
accommodation, service and control spaces. In other areas
or where the quantity of pipes is small, the Administration
may allow equivalent acceptance criteria.
2.2.3 Smoke generation
2.2.3.1Criteria for smoke production need only be applied
to pipes within the accommodation, service, and control
spaces. SOLAS regulations II-2/34.7 and 49.2 are
applicable to exposed interior surfaces which are
interpreted as including the surface finish of piping
systems.
2.2.3.2A fire test procedure is being developed and when
finalized and appropriate smoke obscuration criteria have
been recommended, this test will be incorporated into
these guidelines. In the meantime, an absence of this test
6
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W/0322a
need not preclude the use of plastics. However,
Administrations should consider this hazard when
approving piping materials.
2.2.4 Toxicity
2.2.4.1Toxicity testing is still being investigated and crite-
ria developed. Before meaningful conclusions can be
made, further experimentation and testing is needed. In
the absence of a toxicity test, the use of plastics need not
be precluded. However, Administrations should consider
this hazard when approving piping materials.
2.2.5 Electrical conductivity
2.2.5.1Electrostatic charges can be generated on the
inside and outside of plastic pipes. The resulting sparks
can create punctures through pipe walls leading to leakage
of pipe contents, or can ignite surrounding explosive
atmospheres. Administrations should consider these
hazards when approving plastic piping systems carrying
fluids capable of generating electrostatic charges (static
accumulators) inside the pipe, and when approving plas-
tic piping systems in hazardous areas (i.e. areas that could,
either in normal or fault conditions, contain an explosive
atmosphere), for the possibility of electrostatic charges
outside the pipe.
2.2.5.2. In practice, fluids with conductivity less than
1,000 pico siemens per metre (pS/m) are considered to
be non-conductive and therefore capable of generating
electrostatic charges. Refined products and distillates fall
into this category and piping used to convey these liquids
should therefore be electrically conductive. Fluids with
conductivity greater than 1,000 pS/m are considered to
be static non-accumulators and can therefore be conveyed
through pipes not having special conductive properties
when located in non hazardous areas.
2.2.5.3Regardless of the fluid being conveyed, plastic
piping should be electrically conductive if the piping pas-
ses through a hazardous area.
2.2.5.4Where conductive piping is required, the resistance
per unit length of the pipe, bends, elbows, fabricated branch
pieces, etc., shout not exceed 1 x 10
5
Ohm/m and the
resistance to earth from any point in the piping system
should not exceed 1 x 10
6
Ohm. It is preferred that pipes
and fittings be homogeneously conductive. Pipes and
fittings having conductive layers may be accepted subject
to the arrangements for minimizing the possibility of spark
damage to the pipe wall being satisfactory. Satisfactory
earthing should be provided.
2.2.5.5After completion of the installation, the resistance
to earth should be verified. Earthing wires should be
accessible for inspection.
2.2.6 Fire protection coatings
2.2.6.1Where a fire protective coating of pipes and fittings
is necessary for achieving the fire endurance standards
required, the following requirements apply:
2.2.6.1.1 Pipes should be delivered from the
manufacturer with the protective coating on in which case
on-site application of protection would be limited to what
is necessary for installation purposes (e.g. joints).
Alternatively pipes may be coated on site in accordance
with the approved procedure for each combination, using
the approved materials of both pipes and insulations.
2.2.6.1.2 The liquid absorption properties of the
coating and piping should be considered. The fire
protection properties of the coating should not be
diminished when exposed to saltwater, oil or bilge slops.
The Administration should be satisfied that the coating is
resistant to products likely to come in contact with the
piping.
2.2.6.1.3 Fire protection coatings should not degrade
due to environmental effects over time, such as ultraviolet
rays, saltwater exposure, temperature and humidity. Other
areas to consider are thermal expansion, resistance
against vibrations, and elasticity. Ageing of the fire
protection coatings should be demonstrated to the
satisfaction of the Administration in a manner consistent
with the ageing test specified above.
2.2.6.1.4 The adhesion qualities of the coating should
be such that the coating does not flake, chip, or powder,
when subjected to an adhesion test acceptable to the
Administration.
2.2.6.1.5 The fire protection coating should have a
minimum resistance to impact to the satisfaction of the
Administration.
2.2.6.1.6 Pipes should be an appropriate distance
from hot surfaces in order to be adequately insulated.
2.2.6.2Special testing may be required as part of the
approval procedure.
3. MATERIAL APPROVAL AND QUALITY CONTROL
DURING MANUFACTURE
3.1 The Administration may require piping, as defined
in chapter I, 4.0, to be prototype tested to ensure that the
piping meets the performance requirements of these
guidelines.
3.2. The manufacturer should have a quality system that
meets ISO 9001, Quality systems - Model for quality
assurance in design/development, production, installation
and servicing, or equivalent. The quality system should
consist of elements necessary to ensure that pipe and
fittings are produced with consistent and uniform
mechanical and physical properties in accordance with
recognized standards. Control during manufacture should
be certified by the manufacturer to the satisfaction of the
Administration.
3.3. Dimensions and tolerances for pipes should con-
form to a recognized standard.
7
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3.4 Piping and fittings should be permanently marked
with identification in accordance with a recognized
standard. Identification should include pressure ratings,
the design standard that the pipe or fitting is manufactured
in accordance with, and the material system with which
the pipe or fitting is made.
3.5 Each length of pipe should be tested at the
manufacturers production facility to a hydrostatic pressure
not less than 1.5 times the rated pressure of the pipe. Other
test criteria may be accepted by the Administration.
3.6 Samples of pipe should be tested to determine the
short-term and/or long-term hydrostatic design strength.
These samples should be selected randomly from the
production facilities at a frequency to the satisfaction of
the Administration.
3.7 For piping required to be electrically conductive,
representative samples of pipe should be tested to
determine the electrical resistance per unit length. The
test method and frequency of testing should be acceptable
to the Administration.
3.8 Random samples of pipe should be tested to
determine the adhesion qualities of the coating to the pipe.
The test method and frequency of testing should be
acceptable to the Administration.
4. INSTALLATION
4.1. Supports
4.1.1 Selection and spacing of pipe supports in shipboard
systems should be determined as a function of allowable
stresses and maximum deflection criteria. Support spacing
should be not greater than the pipe manufacturers
recommended spacing. The selection and spacing of pipe
supports should take into account pipe dimensions,
mechanical and physical properties of the pipe material,
mass of pipe and contained fluid, external pressure,
operating temperature, thermal expansion effects, loads
due to external forces, thrust forces, water hammer,
vibration, maximum accelerations to which the system may
be subjected, and the type of support. The support spans
should also be checked for combinations of loads.
4.1.2 Each support should evenly distribute the load of
the pipe and its contents over the full width of the support
and be designed to minimize wear and abrasion.
4.1.3 Heavy components in the piping system such as
valves and expansion joints should be independently
supported.
4.1.4 Suitable provision should be made in each pipeline
to allow for relative movement between pipes made of plas-
tics and the steel structure, having due regard to:
.1 the difference in the coefficients of thermal
expansion;
.2 deformations of the ships hull and its structure.
4.1.5 When calculating the thermal expansions, account
should be taken of the system working temperature and
the temperature at which assembling is performed.
4.2 External loads
4.2.1 Where applicable, allowance should be made for
temporary point loads. Such allowances should include at
least the force exerted by a load (person) of 100 kg at mid-
span on any pipe of more than 100 mm nominal outside
diameter.
4.2.2 Pipes should be protected from mechanical
damage where necessary.
4.3 Strength of connections
4.3.1 The requirements for connections are the same as
those requirements for the piping system in which they
are installed, as stated in paragraph 2.1.1.5.
4.3.2 Pipes may be assembled using adhesive-bonded,
flanged or mechanically coupled joints.
4.3.3 Adhesives, when used for joint assembly, should
be suitable for providing a permanent seal between the
pipes and fittings throughout the temperature and pressure
range of the intended application.
4.3.4 Tightening of flanged or mechanically coupled joints
should be performed in accordance with the manufacturers
instructions.
4.4 Control during installation
4.4.1 Joining techniques should be in accordance with
MSC/Circ.449. This circular requires the fabrication to be
in accordance with the manufacturers installation
guidelines, that personnel performing these tasks be
qualified to the satisfaction of the Administration, and that
each bonding procedure be qualified before shipboard
piping installation commences.
4.4.2 To qualify joint bonding procedures, the tests and
examinations specified herein should be successfully
completed. The procedure for making bonds should
include: all materials and supplies, tools and fixtures,
environmental requirements, joint preparation, dimensional
requirements and tolerances, cure time, cure temperature,
protection of work, tests and examinations and acceptance
criteria for the completed test assembly.
4.4.3 Any change in the bonding procedure which will
affect the physical and mechanical properties of the joint
should require the procedure to be requalified.
4.4.4 The employer should maintain a self-certification
record available to the Administration of the following:
- the procedure used, and
- the bonders and bonding operators employed by
him, showing the bonding performance
qualifications, dates and results of the qualification testing.
4.4.5 Procedure qualification testing should conform to
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the following:
A test assembly shall be fabricated in accordance with the
bonding procedure to be qualified and shall consist of at
least one pipe-to-pipe joint and one pipe-to-fitting joint.
When the test assembly has been cured, it shall be
subjected to a hydrostatic test pressure at a factor of safety
acceptable to the Administration times the design pressure
of the test assembly, for not less than one hour with no
leakage or separation of joints. The test shall be conducted
so that the joint is loaded in both the circumferential and
longitudinal directions similar to that to be experienced in
service. The size of the pipe used for the test assembly
shall be as follows:
(1) When the largest size to be joined is 200 mm
nominal outside diameter, or smaller, the test
assembly shall be the largest piping size to be joined.
(2) When the largest size to be joined is greater than
200 mm nominal outside diameter, the size
of the test assembly shall be either 200 mm or 25% of the
largest piping size to be joined, whichever is greater.
4.4.6 When conducting performance qualifications, each
bonder and bonding operator should make up a test
assembly consisting of one pipe-to-pipe joint and one pipe-
to-fitting joint in accordance with the qualified bonding pro-
cedure. The size of the pipe used for the test assembly
should be the same as required in 4.5. The joint should
successfully pass the hydrostatic test described in 4.5.
4.5 Testing after installation on board
4.5.1 Piping systems for essential services should be
subjected to a test pressure not less than 1.5 times the
design pressure of the system.
4.5.2 Piping systems for non-essential services should
be checked for leakage under operational conditions.
4.5.3 For piping required to be electrically conductive,
the resistance to earth should be checked. Earthing wires
should be accessible for inspection.
4.6 Penetrations of fire divisions
4.6.1 Where A or B class divisions are penetrated for
the passage of plastic pipes, arrangements should be
made to ensure that the fire resistance is not impaired.
These arrangements should be tested in accordance with
Recommendations for fire test procedures for A B and
F bulkheads (resolution A.517(13), as amended.
4.7 Penetrations of watertight bulkheads and decks
4.7.1 Where plastic pipes pass through watertight
bulkheads or decks, the watertight integrity and strength
integrity of the bulkhead or deck should be maintained.
4.7.2 If the bulkhead or deck is also a fire division and
destruction by fire of the plastic pipes may cause the inflow
of liquids from tanks, a metallic shut-off valve operable
from above the freeboard deck should be fitted at the
bulkhead or deck.
4.8 Methods of repair
4.8.1 At sea, the pipe material should be capable of
temporary repair by the crew, and the necessary materials
and tools kept on board.
4.8.2 Permanent repairs to the piping material should be
capable of exhibiting the same mechanical and physical
properties as the original base material. Repairs carried
out and tested to the satisfaction of the Administration may
be considered permanent provided the strength is ade-
9
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quate for the intended service.
APPENDIX 1
TEST METHOD FOR FIRE ENDURANCE TESTING
OF PLASTIC PIPING IN THE DRY CONDITION
Test method
1 A furnace test with fast temperature increase likely
to occur in a fully developed liquid hydrocarbon fire. The
time/temperature of the furnace should be as follows:
at the end of 5 min. 945C
at the end of 10 min. 1,033C
at the end of 15 min. 1,071C
at the end of 30 min. 1,098C
at the end of 60 min. 1,100C
Notes:
1 The accuracy of the furnace control should be as follows:
1.1 During the first 10 min. of the test the area under
the curve of mean furnace temperature should not
vary by more than + 15% of the area under the standard
curve.
1.2 During the first half hour of the test the area under
the curve of mean furnace temperature should not vary by
more than + 10% of the area under the standard curve.
1.3 For any period after the first half hour of the test
the area under the curve of mean furnace temperature
should not vary by more than + 5% of the area under the
standard curve.
1.4 At any time after the first 10 min of the test the
mean furnace temperature should not differ from the
standard curve by more than + 100C.
2 The locations where the temperatures are measured,
the number of temperature measurements and the
measurement techniques are to be agreed by the
Administration taking into account the furnace control
specification as set out in paragraph 3.1.3 of the Annex of
Assembly resolution A.517(13).
Test specimen
2 The test specimen should be prepared with the
joints and fittings intended for use in the proposed
application. The number of specimens should be sufficient
to test typical joints and fittings including joints between
non-metal and metal pipes and fitting to be used. The ends
of the specimen should be closed. One of the ends should
allow presssurized nitrogen to be connected. The pipe ends
and closures may be outside the furnace. The general
orientation of the specimen should be horizontal and it
should be supported by one fixed support with the
remaining supports allowing free movement. The free
length between supports should not be less than 8 times
the pipe diameter.
Notes: 1 Most materials other than steel used for
pipes will require a thermal insulation to be able to
pass this test. The test procedure should include the
insulation and its covering.
2. The number and size of test specimens
required for the approval test should be specified by
the Administration.
Test conditions
3 If the insulation contains, or is liable to absorb,
moisture the specimen should not be tested until the
insulation has reached an air-dry condition. This condition
is defined as equilibrium with an ambient atmosphere of
50% relative humidity at 20 + 5C. Accelerated
conditioning is permissible provided the method does not
alter the properties of component material. Special
samples should be used for moisture content determination
and conditioned with the test specimen. These samples
should be so constructed as to represent the loss of water
vapour from the specimen by having similar thickness and
exposed faces.
4 A nitrogen pressure inside the test specimen should
be maintained automatically at 0.7 bar + 0.1 bar during
the test. Means should be provided to record the pressure
inside the pipe and the nitrogen flow into and out of the
specimen in order to indicate leakage.
Acceptance criteria
5 During the test, no nitrogen leakage from the
sample should occur.
6 After termination of the furnace test, the test speci-
men together with fire protection coating, if any, should be
allowed to cool in still air to ambient temperature and then
tested to the rated pressure of the pipes as defined in
paragraphs II-1/2.2 and II-1/3.2 of these guidelines. The
pressure should be held for a minimum of 15 min. without
leakage. Where practicable, the hydrostatic test should
be conducted on bare pipe, that is pipe which has had all
of its coverings including fire protection insulation removed,
so that leakage will be readily apparent.
7 Alternative test methods and/or test procedures
considered to be at least equivalent including open pit
testing method, may be accepted in cases where the pipes
are too large for the test furnace.
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APPENDIX 2
TEST METHOD FOR FIRE ENDURANCE TESTING
OF WATER-FILLED PLASTIC PIPING
1 Test method
A propane multiple burner test with a fast
temperature increase should be used.
For piping up to 152 mm in diameter, the fire source
should consist of two rows of 5 burners as shown in Figure
1. A constant heat flux averaging 113.6 kW/m
2
(+10%)
should be maintained 12.5 + 1 cm above the centreline
of the burner array. This flux corresponds to a pre-mix
flame of propane with a fuel flow rate of 5 kg/h for a total
heat release rate of 65 kW. The gas consumption should
be measured with an accuracy of at least +3% in order to
maintain a constant heat flux. Propane with a minimum
purity of 95% should be used.
For piping greater than 152 mm in diameter, one
additional row of burners should be included for each 31
mm increase in pipe diameter. A constant heat flux
averaging 113.6 kW/m
2
(+10%) should still be maintained
at the 12.5 + 1 cm height above the centreline of the burner
array. The fuel flow should be increased as required to
maintain the designated heat flux.
The burners should be type Sievert No. 2942 or
equivalent which produces an air mixed flame. The inner
diameter of the burner heads should be 29 mm (see figure
1). The burner heads should be mounted in the same plane
and supplied with gas from a manifold. If necessary, each
burner should be equipped with a valve in order to adjust
the flame height.
The height of the burner stand should also be
adjustable. It should be mounted centrally below the test
pipe with the rows of burners parallel to the pipes axis.
The distance between the burner heads and the pipe
should be maintained at 12.5 + 1 cm during the test. The
free length of the pipe between its supports should be .8
+0.05 m.
2 Test specimen
Each pipe should have a length of approximately
1.5 m. The test pipe should be prepared with permanent
joints and fittings intended to be used. Only valves and
straight joints versus elbows and bends should be tested
as the adhesive in the joint is the primary point of failure.
The number of pipe specimens should be sufficient to test
all typical joints and fittings. The ends of each pie speci-
men should be closed. One of the ends should allow
pressurized water to be connected.
If the insulation contains, or is liable to absorb,
moisture the specimen should not be tested until the
insulation has reached an air-dry condition. This condition
is defined as equilibrium with an ambient atmosphere of
50% relative humidity at 20 + 5C. Accelerated
conditioning is permissible provided the method does not
alter the properties of the material
Special samples should be used for moisture content
determination and conditioned with the test specimen.
These samples should be so constructed as to represent
the loss of water vapour from the specimen by having
similar thickness and exposed faces.
The pipe samples should rest freely in a horizontal
position on two V-shaped supports. The friction between
pipe and supports should be minimized. The supports may
consist of two stands, as shown in figure 2.
A relief valve should be connected to one of the
end closures of each specimen.
3 Test conditions
The test should be carried out in a sheltered test
site in order to prevent any draught influencing the test.
Each pipe specimen should be completely
filled with deaerated water to exclude air bubbles.
The water temperature should not be less than
15C at the start and should be measured continuously
during the test.
The water inside the sample should be stagnant
and the pressure maintained at 3 + 0.5 bar during the test.
4 Acceptance criteria
During the test, no leakage from the sample(s)
should occur except that slight weeping through the pipe
wall may be accepted.
After termination of the burner regulation test, the
test sample, together with fire protection coating, if any,
should be allowed to cool to ambient temperature and then
tested to the rated pressure of the pipes as defined in
paragraphs II-1/2.2 and II-1/3.2 of these guidelines. The
pressure should be held for a minimum of 15 minutes wit-
hout significant leakages, i.e. not exceeding 0.2 1/min.
Where practicable, the hydrostatic test should be
conducted on bare pipe, that is pipe which has had all of
its coverings including fire protection insulation removed,
so that leakage will be readily apparent.
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APPENDIX 3
TEST METHOD FOR FLAME SPREAD OF PLASTIC PIPING
Flame spread of plastic piping should be determined by
IMO resolution A.653(16) entitled Recommendation on
Improved Fire Test Procedures for Surface Flammability
of Bulkhead, Ceiling, and Deck Finish Materials with the
following modifications.
1 Tests should be made for each pipe material and
size.
2 Test sample should be fabricated by cutting pipes
lengthwise into individual sections and then assembling
the sections into a test sample as representative as
possible of a flat surface. A test sample should consist of
at least two sections. The test sample should be 800 + 5
mm long. All cuts should be made normal to the pipe wall.
3 The number of sections that must be assembled
together to form a test sample should be that which
corresponds to the nearest integral number of sections
which should make a test sample with an equivalent
linearized surface width between 155 and 180 mm. The
surface width is defined as the measured sum of the outer
circumference of the assembled pipe sections that are
exposed to the flux from the radiant panel.
4 The assembled test sample should have no gaps
between individual sections.
5 The assembled test sample should be constructed
in such a way that the edges of two adjacent sections
should coincide with the centreline of the test holder.
6 The individual test sections should be attached to
the backing calcium silicate board using wire (No. 18
recommended) inserted at 50 mm intervals through the
board and tightened by twisting at the back.
7 The individual pipe sections should be mounted
so that the highest point of the exposed surface is in the
same plane as the exposed flat surface of a normal surface.
8 The space between the concave unexposed
surface of the test sample and the surface of the calcium
silicate backing board should be left void.
9 The void space between the top of the exposed
test surface and the bottom edge of the sample holder
frame should be filled with a high temperature insulating
wool if the width of the pipe segments extend under the
side edges of the sample holding frame.
APPENDIX 4
FIRE ENDURANCE REQUIREMENTS MATRIX
A18/Res.753
A B C D E F G H I J K Location
CARGO (Flammable cargoes f.p. < 60C)
1 Cargo lines 9 A. Machinery spaces of Category A.
2 Crude oil washing lines 9 B. Other machinery spaces and
3 Vent lines 9 pump rooms
INERT GAS C. Cargo pump rooms
4 Water seal effluent line 1 1 1 1 1 D. Ro-ro cargo holds
5 Scrubber effluent line 1 1 1 1 E. Other dry cargo holds
6 Main line 6 F. Cargo tanks
7 Distribution lines G. Fuel oil tanks
FLAMMABLE LIQUIDS (f.p. > 60C) H. Ballast water tanks
8 Cargo lines 3 9 I. Cofferdams void spaces pipe
9 Fuel oil 3 tunnel and ducts
10 Lubricating J. Accommodation service and
11 Hydraulic oil control spaces
SEAWATER (1) K. Open decks
12 Bilge main and branches
13 Fire main and water spray Not Applicable
14 Foam system Bondstrand approved systems
15 Sprinker system Not allowed
16 Ballast 9
17 Cooling water, essential services
18 Tank cleaning services fixed machines 2
19 Non essential systems
FRESH WATER
20 Cooling water, essential services
21 Condensate return
22 Non essential systems
SANITARY/DRAINS/SCRUPPERS
23 Deck drains (internal) 4 4 4
24 Sanitary drains (internal)
25 Scuppers and dischargers (overboard) 1-7 1-7 1-7 1-7 1-7 1-7
SOUNDING/AIR
26 Water tanks/ dry spaces 9
27 Oil tanks (f.p.> 60C) 3 9
MISCELLANEOUS
28 Control air 5 5 5 5 5 5 5
29 Service air (non essential)
30 Brine
31 Auxiliary low pressure steam < 7 bar) 8 8 8 8 8
W/0322a 13
14
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LOCATI ON DEFI NI TI ONS
Locati on Definition
A - Machi nery spaces of category A Machi nery spaces of category A as defi ned i n SOLAS*
regulation II-2/3.19.
B - Other machi nery spaces and pump rooms Spaces, other than category A machi nery spaces and
cargo pump rooms, contai ni ng propul si on machi nery,
boi l ers, steam and i nternal combusti on engi nes,
generators and maj or el ectri cal machi nery, pumps, oi l
filling stations, refrigerating, stabilizing, ventilation and air-
condi ti oni ng machi nery, and si mi l ar spaces, and trunks to
such spaces.
C - Cargo pump rooms Spaces contai ni ng cargo pumps and entrances and trunks
to such spaces.
D - Ro-ro cargo hol ds Ro-ro cargo hol ds are ro-ro cargo spaces and speci al
category spaces as defi ned i n SOLAS* regul ati on II-2/3.14
and 3.18.
E - Other dry cargo hol ds Al l spaces other than ro-ro cargo hol ds used for non-l i qui d
cargo and trunks to such spaces.
F - Cargo tanks Al l spaces used for l i qui d cargo and trunks to such spaces.
G - Fuel oi l tanks Al l spaces used for fuel oi l (excl udi ng cargo tanks) and
trunks to such spaces.
H - Bal l ast water tanks Al l spaces used for bal l ast water and trunks to such
spaces.
I - Cofferdams, voi ds, etc. Cofferdams and voi ds are those empty spaces between
two bul kheads separati ng two adj acent compartments.
J - Accommodati on, servi ce, Accommodati on spaces, servi ce spaces and control
stati ons as defi ned i n SOLAS* regul ati on II-2/3.10, 3.12,
3.22
K - Open decks Open deck spaces as defi ned i n SOLAS* regul ati on II-
2/26.2.2(5).
* SOLAS 74 as amended by the 1978 SOLAS Protocol and the 1981 and 1983 amendments (consol i dated text).
A) Machinery spaces of category A
B) Other machinery spaces and pump rooms
C) Cargo pump rooms
D) Ro-ro cargo holds
E) Other dry cargo holds
F) Cargo tanks
G) Fuel oil tanks
H) Ballast water tanks
I) Cofferdams void spaces pipe tunnel and ducts
J) Accommodation service and control spaces
K) Open decks
ABBREVIATIONS:
L1 Fire endurance test (appendix 1) in dry conditions,
60 min.
L2 Fire endurance test (appendix 1) in dry conditions,
30 min.
L3 Fire endurance test (appendix 2) in wet conditions,
30 min.
O No fire endurance test required
NA Not applicable
X Metallic materials having a melting point greater
than 925C.
FOOTNOTES:
1/ Where non-metallic piping is used, remotely
controlled valves to be proved at ships side (valve is to be
controlled from outside space).
2/ Remote closing valves to be provided at the cargo
tanks.
3/ When cargo tanks contain flammable liquids with
f.p. >60C. O may replace NA or X.
4/ For drains serving only the space concerned, O
may replace L1.
5/ When controlling functions are not required by
statutory requirements or guidelines, O may replace L1.
6/ For pipe between machinery space and deck wa-
ter seal, O may replace L1.
7/ For passenger vessels, X is to replace L1.
8/ Scuppers serving open decks in positions 1 and 2,
as defined in regulation 13 of the International Convention
on Load Lines, 1966, should be X throughout unless
fitted at the upper end with the means of closing capable
of being operated from a position above the freeboard deck
in order to prevent downflooding.
9/ For essential services, such as fuel oil tank heating
and ships whistle, X is to replace O.
10/ For tankers where compliance with paragraph 3(f)
of regulation 13F of Annex I of MARPOL 73/78 is required,
NA is to replace O.
Bondstrand

DesignManual
for Marine Piping Sys tems
F P 7 0 7 A (4/01) Supersedes FP707
1 Introduction
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Products Range and Series . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Standards and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.4 Classification Society Approvals . . . . . . . . . . . . . . . . . . . . . . . . .2
1.5 Uses and Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.6 Joining Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.7 Fittings and Flange Drillings . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.8 Corrosion Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.9 Economy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2 Design for Expansion and Contraction
2.1 Length Change due to Thermal Expansion . . . . . . . . . . . . . . . . .5
2.2 Length Change due to Pressure . . . . . . . . . . . . . . . . . . . . . . . . .6
2.3 Length Change due to Dynamic Loading . . . . . . . . . . . . . . . . .10
2.4 Flexible Joints, Pipe Loops, Z & L Bends . . . . . . . . . . . . . . . . .11
2.5 Design with Flexible Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.6 Design with Pipe Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.7 Design using Z Loops and L Bends . . . . . . . . . . . . . . . . . . . . .16
3 Design for Thrust (Restrained Systems)
3.1 General Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.2 Thrust in an Anchored System . . . . . . . . . . . . . . . . . . . . . . . . .19
3.3 Thrust due to Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.4 Thrust due to Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.5 Formulas for Calculating Thrusts in
Restrained Pipe Lines (With Examples) . . . . . . . . . . . . . . . . . . .20
3.6 Longitudinal Stress in Pipe & Shear Stress in Adhesive . . . . . .21
4 Support Location and Spacing
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
4.2 Abrasion Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
4.3 Spans Allowing Axial Movement . . . . . . . . . . . . . . . . . . . . . . . .28
4.4 Span Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
4.5 Suspended System Restrained from Movement . . . . . . . . . . . .30
4.6 Euler and Roark Equations . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
4.7 Support of Pipe Runs Containing Expansion Joints . . . . . . . . .33
4.8 Support for Vertical Runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
4.9 Case Study: Vertical Riser in Ballast Tank . . . . . . . . . . . . . . . . .38
5 Anchors and Support Details
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
5.2 Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
6 Internal and External Pressure Design
6.1 Internal Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
6.2 External Collapse Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
7 Hydraulics
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
7.2 Head Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
7.3 Formulas for Calculating Head Loss in Pipe . . . . . . . . . . . . . . .59
7.4 Head Loss in Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
7.5 Cargo Discharge Time & Energy Savings . . . . . . . . . . . . . . . . .66
Appendices
A. Using Metallic Pipe Couplings to Join Bondstrand . . . . . . . . .A.1
B. Grounding of Series 7000M Piping . . . . . . . . . . . . . . . . . . . . .B.1
C. Sizing of Shipboard Piping . . . . . . . . . . . . . . . . . . . . . . . . . . .C.1
D. Miscellaneous Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D.1
E. Piping Support for Non-Restrained Mechanical Joints . . . . . . .E.1
Table of Contents
1
1.1 GENERAL
Historically, offshore exploration, production platforms and ship owners have had to face the grim reality
of replacing most metal piping two or three times during the average life of a vessel or platform. This has
meant, of course, that piping systems end up costing several times that of the original investment since
replacement is more expensive than new installation. When you add the labor costs, the downtime and
the inconvenience of keeping conventional steel or alloy piping systems in safe operating condition, the
long-term advantages of fiberglass piping become very obvious.
1.2 PRODUCT RANGE AND SERIES
Bondstrand

provides four distinct series of filament-wound pipe and fittings using continuous glass
filaments and thermosetting resins for marine and naval applications:
Series 2000M
A lined epoxy pipe and fittings system for applications which include ballast lines, fresh and saltwater
piping, sanitary sewage, raw water loop systems and fire protection mains where corrosion resis-
tance and light weight are of paramount importance.
Series 2000M-FP
A lined epoxy system covered with a reinforced intumescent coating suitable for dry service in a jet fire.
Series 2000USN
An epoxy system meeting the requirements of MIL-P-24608B (SH) for nonvital piping systems on
combatant and non-combatant vessels. Available in sizes from 1 to 12 inches (25 to 300mm).
Series 5000M
A lined vinylester pipe and fittings system in 2 inch diameter (50mm) for seawater chlorination.
Series 7000M
An epoxy pipe and fittings system with anti-static capabilities designed for white petroleum products
and applications passing through hazardous areas. Properly grounded Series 7000M prevents the
accumulation on the exterior of the pipe of dangerous levels of static electricity produced by flow of
fluids inside the pipe or by air flow over the exterior of the pipe. This is accomplished by Amerons
patented method of incorporating electrically conductive elements into the wall structure of pipe and
fittings during manufacture.
PSX

L3
A polysiloxane-modified phenolic system for use in normally wet fire protection mains - also suitable
for confined spaces and living quarters due to low smoke and toxicity properties. Also available in a
conductive version.
PSX

J F
A polysiloxane-modified phenolic system for use in deluge piping (normally dry). PSX

JF has an
exterior jacket which allows the pipe to function even after 5 minutes dry exposure to a jet fire (follow
by 15 minutes with flowing water). Also available in a conductive version.
1.0 Introduction
2
1.3 STANDARDS AND SPECIFICATIONS
Bondstrand

marine pipe and fittings are designed and manufactured in accordance with the follow-
ing standards and specifications:
MIL-P-24608A (SH)
U.S. Navy standards for fiberglass piping systems onboard combatant and noncombatant ships.
ASTM (F1173)
U.S. standards for fiberglass piping systems onboard merchant vessels, offshore production and
explorations units.
1.4 CLASSIFICATION SOCIETY APPROVALS
Ameron works closely with agencies worldwide to widen the scope of approved shipboard applica-
tions for fiberglass pipe systems. Certificates of approval and letters of guidance from the following
agency concerning the use of Bondstrand piping on shipboard systems are currently available from
Ameron. Others are pending.
1.5 USES AND APPLICATIONS
Series 2000M
Approved for use in air cooling circulating water; auxiliary equipment cooling; ballast/segregated bal-
last; brine; drainage/sanitary service/sewage; educator systems; electrical conduit; exhaust piping;
fire protection mains (IMO L3) fresh water/service (nonvital); inert gas effluent; main engine cooling;
potable water; steam condensate; sounding tubes/vent lines; and tank cleaning (saltwater system);
submersible pump column piping; raw water loop systems and drilling mud pumping systems.
Series 2000M-FP
Designed for use where pipe is vulnerable to mechanical abuse or impact or for dry deluge service.
Series 5000M
Approved for use in seawater chlorination.
Series 7000M
Approved for use in ballast (adjacent to tanks); C.O.W. (crude oil washing); deck hot air drying (cargo
tanks); petroleum cargo lines; portable discharge lines; sounding tubes/vent cargo piping; stripping
lines and all services listed for Series 2000M in hazardous locations.
American Bureau of Shipping
Biro Klasifikasi Indonesia
Bureau Veritas
Canadian Coast Guard, Ship Safety Branch
Det Norske Veritas
Dutch Scheepvaartinspectie
DDR-Schiffs-Revision UND-Klassifikation
Germanisher Lloyd
Korean Register of Shipping
Lloyds Register of Shipping
Nippon Kaiji Kyokai
Polski Rejestr Statkow
Registro Italiano Navale
Register of Shipping
The Marine Board of Queensland
United States Coast Guard
USSR Register of Shipping
3
PSX

L3
Designed and approved for use in fire protection ring mains and for services in confined spaces of
living quarters where flame spread, smoke density and toxicity are critical.
PSX

J F
Designed and approved for dry deluge service where pipe may be subject to a directly impinging jet fire.
1.6 J OINING SYSTEMS
Bondstrand

marine and naval pipe systems offer the user a variety of joining methods for both new
construction and for total or partial replacement of existing metallic pipe.
All Series:
1-to 16-inch ....................Quick-Lock

straight/taper adhesive joint;


2-to 24-inch (2000M)......Van stone type flanges with movable flange rings for easy bolt alignment.
1-to 36-inch ....................One-piece flanges in standard hubbed or hubless heavy-duty configuration.
2-to 36-inch ....................Viking-Johnson or Dresser-type mechanical couplings.
1.7 FITTINGS AND FLANGE DRILLINGS
Ameron offers filament-wound fittings, adaptable for field assembly using adhesive, flanged, or rub-
ber-gasketed mechanical joints. Tees, elbows, reducers and other fittings provide the needed com-
plete piping capability.
Bondstrand marine and naval flanges are produced with the drillings listed below for easy connection
to shipboard pipe systems currently in common use. Other drillings, as well as undrilled flanges, are
available.
ANSI B16.5 Class 150 & 300;
ISO 2084 NP-10 & NP-16;
JIS B2211 5kg/cm
2
;
JIS B2212 10kg/cm
2
;
JIS B2213 16kg/cm
2
;
U.S. Navy MIL-F-20042
1.8 CORROSION RESISTANCE
Bondstrand pipe and fittings are manufactured by a filament-winding process using highly corrosion-
resistant resins. The pipe walls are strengthened and reinforced throughout with tough fiberglass and
carbon fibers (Series 7000 only) creating a lightweight, strong, corrosion-resistant pipe that meets
U.S. Coast Guard Class II and U.S. Navy MIL-P-24608A (SH) standards for offshore and most ship-
board systems.
1.9 ECONOMY
Bondstrand offshore piping and Bondstrand marine and naval pipe systems have corrosion resistance
surpassing copper-nickel and more exotic alloys, but with an installed cost less than carbon steel.
Numerous shipyards have recorded their Bondstrand installation costs on new construction projects and
report savings from 30 to 40 percent compared to traditional steel pipe.
4
5
2.1 LENGTH CHANGE DUE TO THERMAL EXPANSION
Like other types of piping material, in an unrestrainted condition, Bondstrand fiberglass reinforced
pipe changes its length with temperature. Tests show that the amount of expansion varies linearly
with temperature, in other words, the coefficient of thermal expansion in Bondstrand pipe is con-
stant, it equals to 0.00001 inch per inch per degree Fahrenheit (0.000018 millimeter- per millimeter
per degree centigrade).
The amount of expansion can be calculated by the formula:
L = L T
where L = change in length (in. or mm),
= coefficient of thermal expansion (in./in./F or mm/mm/C),
L = length of pipeline (in. or mm), and
T = change in temperature (F or C).
Example: Find the amount of expansion in 100 feet (30.48 meter) of Series 2000M pipe due to a
change of 90F (50C) in temperature:
a. English Units:
L = L T
where = 10 x 10
-6
in./in./F
T = 90F
L = 100 ft. = 1200 in.
L = (1200 in.) (10 x 10
-6
in./in./F) (90F)
L = 1.08 in.
b. Metric Units:
L = L T
where = 18 x 10
-6
mm/mm/C
T = 50C
L = 30.48 m = 30480 mm
L = (30480 mm) (18 x 10
-6
mm/mm/C) (50C)
L = 27.4 mm
Note that 27.4 mm is equal to 1.08 in. which is the calculated thermal expansion for the same length
of pipe due to the same amount of temperature change.
In normal operating temperature range, the length change - temperature relationship can be repre-
sented by a straight line as illustrated in Figure 2-1 on the next page.
2.0 Design for Expansion & Contraction
2.2 LENGTH CHANGE DUE TO PRESSURE
2.2.1 Unrestrained System
Subjected to an internal pressure, a free Bondstrand pipeline will expand its length due to thrust
force applied to the end of the pipeline. The amount of this change in the pipe length depends on the
pipe wall thickness, diameter, Poissons ratio and the effective modulus of elasticity in both axial and
circumferential directions at operating temperature.
L = L
The first term inside the bracket is the strain caused by pressure end thrust while the second term,
is the axial contraction due to an expansion in the circumferential direction, the Poissons effect. The
result is a net increase in length which can be calculated by the simplified formula:
L = L
where L = length of pipe (in. or cm.),
p = internal pressure (psi or kg./cm
2
),

lc
= Poissons ratio for contraction in the longitudinal direction due to the
strain in the circumferential direction.
E
c
= circumferential modulus of elasticity (psi or kg./cm
2
),
p ID
2
4t D
m
E
l
p ID
2
2t D
m
E
c

lc
p ID
2
2t D
m
E
c

lc
p ID
2
4t E
l
D
m
E
l
E
c
1 2
lc
Fig. 2-1
L
E
N
G
T
H

C
H
A
N
G
E
M
M

/

1
0
0

M

O
F

P
I
P
E
TEMPERATURE CHANGE (DEG F)
TEMPERATURE CHANGE (DEG C)
6
7
E
l
= longitudinal modulus of elasticity (psi or kg./cm
2
),
D
m
= mean diameter of pipe wall = ID + t,
ID = inside diameter of the pipe (in. or cm.), and
t = thickness of pipe wall (in. or cm.)
Example: Find the length change in 10 meters of Bondstrand Series 2000M, 8-inch pipe which is
subjected to an internal pressure of 145 psi (10 bars) at 75 F (24C).
a.English Units:
The physical properties of the pipe can be found from BONDSTRAND SERIES 2000M
PRODUCT DATA (FP194):

lc
= 0.56
E
c
= 3,600,000 psi
E
l
= 1,600,000 psi
ID = 8.22 in.
t = 0.241 in.
D
m
= 8.46 in.
p = 145 psi
L = 394 in.
Note: Physical properties vary with temperature. See Bondstrand Series 2000M Product Data (FP194).
Fig. 2-2
8
L = (394 in.)
L = 0.147 in.
b. Metric Units:

lc
= 0.56
E
l
= 113490 kg/cm
2
D
m
= 21.5 cm
ID = 20.9 cm
t = 0.612 cm
p = 10 bars = 10.02 kg/cm
2
L = 1000 cm
L = (1000 cm)
L = 0.373 cm
Table 2-I provides the calculated length increase for 100 feet (30.48 meters) of Bondstrand Series 2000M
Pipe caused by 100 psi (7 kg/cm
2
) internal pressure. The Table is valid through the temperature range of
application. (The effect of temperature on length change due to pressure is small.)
Obtain length increase for other pressure by using a direct pressure ratio correction. For example, to
find the length change caused by 150 psi pressure in a 6-inch pipe, multiply 0.4 inch by the pressure
ratio 150/100 to obtain an amount of 0.6 inch length increase.
145 psi (8.22 in.)
2
4 (.241 in.) (8.46 in. ) 1,600,000 psi
1,600,000 psi
3,600,000 psi
1 - 2 (.56)
10.02 kg/cm
2
(20.9 cm)
2
4 (.612 cm) (21.5 cm ) (113490 kg/cm
2
)
113490 kg/cm
2
253105 kg/cm
2
1 - 2 (.56)
Size Length Increase
(in.) (mm.) (in.) (mm)
2 50 0.2 5.0
3 80 0.3 7.8
4 100 0.3 7.6
6 150 0.4 10.2
36 900 0.4 10.2
Table 2-I
2.2.2 Restrained Systems
In the piping system, shown in Figure 2-3, all longitudinal thrusts are eliminated by the use of fixed
supports; therefore, the pipe is subjected only to load in the circumferential direction. Without the
end thrust present, the first term in the equation is dropped and the length change becomes:
L = L
where L = length of pipe (in. or cm),
p = internal pressure (psi or kg/cm
2
),

lc
= Poissons ratio
E
c = circumferential modulus of elasticity, (psi or kg/cm
2
)
ID = inside diameter of the pipe (in. or cm),
t = thickness of pipe wall (in. or cm),
D
m
= mean diameter of pipe wall = ID + t.
Example: Find the change in length in 12 meters (39.4 feet) of restrained Bondstrand Series 2000M,
8-inch diameter pipe operating at 10 bars (145 psi) internal pressure.
a. English Units:

lc
= .56
p = 145 psi
ID = 8.22 in.
t = 0.241 in.
D
m
= 8.46 in.
E
c
= 3,600,000 psi
L = 472 in.
Fig. 2-3
p ID
2
2t E
c
D
m
-
lc
MECHANICAL COUPLING
(Dresser Type)
W.T. BHD.
9
L = (472 in.)(-.56)
L = -.175 in. or .175 in. reduction in length
b.Metric Units:

lc
= .56
p = 10.02 kg/cm
2
ID = 20.9 cm
D
m
= 21.5 cm
t = 0.612 cm
E
c
= 253105 kg/cm
2
L = 1200 cm
L = (1200 cm) (-.56)
L = - .442 cm or .442 cm reduction in length
As indicated by the formula and demonstrated by the example, in a restrained installation where a
mechanical coupling is used, application of pressure will result in a contraction of the pipe. This
shortening effect is found favorable in most applications where the designer can use the reduction in
length to compensate for thermal expansion. Conversely, allowances should be made where operat-
ing temperature is significantly lower than the temperature at which the system is installed.
2.3 LENGTH CHANGE DUE TO DYNAMIC LOADING
Piping installed on board ship is often subjected to another type of load at the supports which results
from sudden change of the supports relative location. This dynamic loading should be accounted for
in the design. The degree of fluctuation in length between the two support points depends on the
ships structural characteristics, i.e., the ship size, the size of the dynamic load, etc. This type of
movement in the piping system should be considered with other length changes previously dis-
cussed; however, calculation of expansion and contraction due to dynamic loading is beyond the
intended scope of this manual.
2.3.1 Equipment Vibration
Under normal circumstances, Bondstrand pipe will safely absorb vibration from pumping if the pipe
is protected against external abrasion at supports.
Vibration can be damaging when the generated frequency is at, or near, the natural resonance fre-
quency of the pipeline. This frequency is a function of the support system, layout geometry, tempera-
ture, mass and pipe stiffness.
145 psi (8.22 in.)
2
2 (.241 in.) (8.46 in. ) 3,600,000 psi
10.02 kg/cm
2
(20.9 cm)
2
2 (0.612 cm) (21.5 cm) (253105 kg/cm)
2
10
11
There are two principal ways to control excessive stress caused by vibration. Either install, observe
during operation, and add supports or restraints as required; or add an elastometric expansion joint
or other vibration absorber.
2.4 FLEXIBLE J OINTS, PIPE LOOPS, Z AND L TYPE BENDS
Bondstrand piping is often subjected to temperature change in operation, usually in the range of
50F to 100F (32C to 82C). Since a piping system operating at low stress level provides
longer service life, it is good practice to reduce the amount of stress caused by thermal and/or pres-
sure expansion. This can be accomplished by using one or more of the following:
A. Flexible Joints
a.1 Mechanical coupling (Dresser-type), or
a.2 Expansion joint.
B. Pipe Loops
C. Z type configurations or change of direction at bends.
2.5 DESIGN WITH FLEXIBLE J OINTS
Both Dresser-type couplings and expansion joints are recognized as standard devices to absorb
thermal expansion. They are easy to use and commercially available.
2.5.1 Mechanical Couplings (Dresser-type)
These are primarily designed to be used as mechanical connection joints. The elastomeric seal offers
some flexibility that will relieve thermal expansion in the pipe; however, this can only absorb a limited
amount of axial movement, usually about 3/8 in. (10mm) per coupling. Thus, more than one coupling
must be used if the expected movement is greater than 3/8 in. (10mm).
It should be noted here that fixed supports are always required in a mechanical system. In moderate
temperature and pressure application, such as often found in ballast piping systems, the total expan-
sion of a 40-foot Bondstrand pipe is within the coupling recommended limit. For additional informa-
tion on mechanical type couplings see Appendix A.
2.5.2 Expansion J oints
Expansion joints are widely accepted as standard devices to relieve longitudinal thermal stress.
Unlike the mechanical coupling, this joint offers a wider range of axial movement giving more flexibili-
ty in design. This is advantageous in long section of pipe such as in cargo piping which sometimes
runs the entire length of the ship. An expansion joint is normally not needed in ballast piping system
where short sections of pipe are anchored at bulkheads.
When an expansion joint is used in the pipeline to relieve longitudinal stress, it must be fairly flexible,
such as a teflon bellows which is activated by the thrust of a low modulus material.
Support for expansion joints must be correctly designed and located to maintain controlled deflec-
tion. Besides adding weight, most of these joints act as partial structural hinges which afford only
limited transfer of moment and shear. Where the expansion joint relies on elastomers of thermoplas-
tics, the structural discontinuity or hinging effect at the joint changes with temperature.
When using an expansion joint in a pipeline carrying solids, consider the possibility that it could stiff-
en or fail to function due to sedimentation build up in the expansion joint. Failure of the expansion
joint could cause excessive pipe deflection. Regular schedule maintenance and cleaning of the
expansion joint is recommended to assure adequate function of the piping system.
2.6 DESIGN WITH PIPE LOOPS
Where space is not a primary concern, expansion loops are the preferred method for relieving the
thermal stress between anchors in suspended piping systems since it can be easily fabricated using
pipe and elbows at the job site.
Loops should be horizontal wherever possible to avoid entrapping air or sediment and facilitate drainage.
For upward loops, air relief valves aid air removal and improve flow. In pressure systems, air
removal for both testing and normal operation is required for safety.
For downward loops, air pressure equalizing lines may be necessary to permit drainage.
In both cases, special taps are necessary for complete drainage.
The size of the loop can be determined by using the Elastic-Center Method. The concept is out-
lined as follows:
Consider a properly guided expansion loop as shown in Figure 2-4. The centroid 0 of this structure
is located at the center of the guides A and B, and the line of thrust will lie parallel to a line joining
the guides. The only force that acts on this loop is in the x direction and can be found by the equa-
tion.
F
x
= EI
I
x
where = total linear expansion which will be absorbed by the loop,
F
x
= force in the x direction,
E = modulus of elasticity of the pipe,
I = beam moment of inertia of the pipe, and
I
x
= moment of inertia of the line about the x axis of the centroid.
Fig. 2-4
12
Since I
x = + + =
4 2
2
2 2
2
4
2
3
4 2
F
x
= 4 EI
3
Substituting M = F
x
and
S
A
= M D
2 I
and arranging the required length in terms of other known values we obtain:
= ED
1/2
SA
Where M = bending moment, maximum at elbows,
SA = allowable stress,
D = outside diameter of pipe,
= required length of the expansion loop.
It should be noted here that similar result can be obtained using the Guided Cantilever Method of
pipe flexibility calculation.
Where
=
1 F
3
=
M
2
=
SA
2
2 4 EI 4EI 2ED
and again
=
ED
1/2
S
A
Calculation example: Determine the required expansion loop for 8-inch Bondstrand Series 2000M
piping subjected to the following condition:
Operating temperature: 65C (149F)
Installation temperature: 20C (68F)
Total length of pipe between anchors: 100 meter (328 ft)
From PRODUCT DATA SHEET FOR BONDSTRAND 2000M (FP194) we obtain at 150F (66C):
Allowable bending stress = 548 kg/cm
2
= 183 kg/cm
2
(2600 psi)
3
Thermal expansion coefficient = 18 x 10
-6
m/m/C (10 x 10
-6
in/in/F)
Modulus of elasticity at 65C = 91,400 kg/cm2 (1,300,000 psi)
Pipe O.D. = 22.1 cm (8.7 inch)
First determine the total thermal expansion for the entire length of the pipe section in question:
L = L T
= 18 x 10
-6
/C (45C) (100 x 10
2
) cm
= 8.1 cm
2
13
14
Then
=
ED
1/2
S
A
=
8.1 cm (91,400 kg/cm
2
) (22.1 cm)
1/2
= 299 cm
183 kg/cm
2
= 2.99 meter
Calculation of length can also be performed in English units:
=
3.18 in (1,300,000 psi) 8.7 in
1/2
= 118 in
2,600 psi
= 9 ft. - 10 in.
which is equivalent to 2.99 meters.
1/2
15
T
a
b
l
e

2
-
I
I

t
a
b
u
l
a
t
e
s

t
h
e

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h

o
f

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p

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n

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t

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a
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.
T
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B
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2
-
I
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:

R
E
Q
U
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L
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F
O
R

E
X
P
A
N
S
I
O
N

L
O
O
P
16
2.7 DESIGN USING Z LOOPS AND L BENDS
Similarly the Z-loop and L-bends can be analyzed by the same guide cantilever method.
= F
x
3
= M
2
= S
A
2
4EI 4EI 2ED
= 2 ED
1/2
S
A
Fig. 2-5
17
Note: In special cases where the pipe is insulated, longer length is needed to compensate for the
stiffer loop members.
The required length in this case should be adjusted by a factor
(EI
insulated pipe
/EI
bare pipe
)
1/2
which was derived as follows:
For the same application condition:
bp
=
ip
ip
=
bp
EI
ip/
EI
bp
1/2
Loops using 90 elbows change length better than those using 45 elbows. Unlike a 90 turn, a 45
turn carries a thrust component through the turn which can add axial stress to the usual bending
stress in the pipe and fittings. Alignment and deflection are also directly affected by the angular dis-
placement at 45 turns and demand special attention for support design and location.
A 45 elbow at a free turn with the same increment of length change in each leg will be displaced 86
percent more than a 90 elbow. The relative displacement in the plane of a loop is also more of a
problem. Figure 2-6 illustrates the geometry involved.
Comparison of Displacement in 90 vs. 45 elbows caused by a Unit Length Change:
Fig. 2-6
A. Relative displacement of
elbows permitted to move
freely in a pipe run.
B. Relative displacement
configuration of loops
bp
= M
2
bp bp
= 2
bp
EI
bp
/2
2EI
bp
M
ip
= M
2
ip
ip = 2
ip
EI
ip
2
2EI
ip
M
1/2
1/2
18
T
a
b
l
e

2
-
I
I
I

t
a
b
u
l
a
t
e
s

t
h
e

l
e
n
g
t
h

o
f

l
o
o
p

o
r

b
e
n
d

i
n

f
e
e
t

a
n
d

m
e
t
e
r
s

r
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q
u
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o

a
b
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b

e
x
p
a
n
s
i
o
n
.
T
A
B
L
E

2
-
I
I
I
:

R
E
Q
U
I
R
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D

L
E
N
G
T
H

F
O
R

Z

T
Y
P
E

L
O
O
P

A
N
D

L

B
E
N
D
3.1 GENERAL PRINCIPLES
Occasionally, the layout of a system makes it impossible to allow the pipe to move freely, as for
example, a ballast line running thwart-ships between longitudinal bulkheads. Or it may be necessary
to anchor certain runs of an otherwise free system. In a fully restrained pipe (anchored against move-
ment at both ends), the designer must deal with thrust rather than length change. Both temperature
and pressure produce thrust which must be resisted at turns, branches, reducers and ends. Knowing
the magnitude of this thrust enables the designer to select satisfactory anchors and check the axial
stress in pipe and shear stress in joints. Remember that axial thrust on anchors is normally indepen-
dent of anchor spacing.
Caution: In restrained systems, pipe fittings can be damaged by faulty anchorage or by untimely
release of anchors. Damage to fittings in service can be caused by bending or slipping of an improp-
erly designed or installed anchor. Also, length changes due to creep are induced by high pressures
or temperatures while pipe is in service. When anchors must later be released, especially in long pipe
runs, temporary anchors may be required to avoid excessive displacement and overstress of fittings.
3.2 THRUST IN AN ANCHORED SYSTEM
Both temperature and pressure produce thrust, which is normally independent of anchor spacing. In
practice, the largest compressive thrust is normally developed on the first positive temperature cycle.
Subsequently, the pipe develops both compressive and tensile loads as it is subjected to tempera-
ture and pressure cycles. Neither compressive nor tensile loads, however, are expected to exceed
the thrust on the first cycle unless the ranges of the temperature and pressure change.
3.3 THRUST DUE TO TEMPERATURE
In a fully restrained Bondstrand pipe, length changes induced by temperature change are resisted at
the anchors and converted to thrust. The thrust developed depends on thermal coefficient of expan-
sion, the cross-sectional area, and the modulus of elasticity.
3.4 THRUST DUE TO PRESSURE
Thrust due to internal pressure in a suspended but restrained system is theoretically more complicat-
ed. This is because in straight, restrained pipelines with all joints adhesive bonded or flanged, the
Poisson effect produces considerable tension in the pipe wall.
As internal pressure is applied, the pipe expands circumferentially and at the same time contracts
longitudinally. This tensile force is important because it acts to reduce the hydrostatic thrust on
anchors. In lines with elbows, closed valves, reducers or closed ends, the internal pressure works on
the cross-sectional area of the ends. This thrust tends to be about twice as great as the effect of
pressure on the pipe wall.
The concurrent effects of pressure and temperature must be combined for design of anchors.
Similarly, on multiple pipe runs, thrusts developed in all runs must be added for the total effect on
anchors.
3.0 Design for Thrust (Restrained Systems)
19
20
3.5 FORMULAS FOR CALCULATING THRUST IN RESTRAINED PIPELINES
3.5.1 Thrust Due To Temperature Change In An Anchored Line
The thrust due to temperature change in a system fully restrained against length change is calculated
by:
P = TAE
l
where P = thrust (lbf or kg),
= coefficient of thermal expansion (in./in./F or m/m/C),
T = change in temperature (F or C),
E
l
= longitudinal modulus of elasticity at lower temperature (psi or kg/cm
2
),
A = average cross-sectional area of the pipe wall (in.
2
or cm
2
),
See Table 4-IV.
For example:
= 10 x 10
-6
in./in./F
T = 150F
A = 4.23 in
2
for 6 inch pipe
E
l
= 1.6 x 10
6
psi
then P = (10 x 10
-6
)(150)(4.23)(1.6 x 10
6
) = 10,150 lbf. or from Table 3-1
P = 6,770 x 1.5 = 10,150 lbf.
3.5.2 Thrust Due To Pressure In An Anchored System
In a fully restrained system, calculate the thrust between anchors induced by internal pressure using:
P = (-
lc
)
where P = internal pressure (psi or kg/cm
2
),
ID = internal diameter (in. or cm),
E
l
= longitudinal modulus of elasticity (psi or kg/cm
2
),
E
c
= circumferential modulus of elasticity (psi or kg/cm
2
), and

lc
= Poissons ratio.
Note: Use elastic properties at lowest operating temperature to calculate maximum expected thrust.
pD
m
ID
2
E
l
E
c
21
For example, assume that
ID = 6.26 in.,
D
m
= 6.44 in.,
P = 100 psi.
E
l
= 1.6 x 10
6
psi,
E
c
= 3.6 x 10
6
psi, and

lc
= 0.56
then P = (0.56) =1,580 lbf (tension)
or read the value of 1,580 lbf from Table 3-Il.
3.5.3 Thrust Due To Pressure On A Closed End
Where internal pressure on a closed end exerts thrust on supports, calculate thrust
using:
P = p
where ID = inside diameter of the pipe (in. or cm).
Values are given in Table 3-Ill.
For example: If there is 100 psi in a 6-inch (6.26 ID) pipe, thrust is
P = x 100 = 3,080 lbf
3.6 LONGITUDINAL STRESS IN PIPE AND SHEAR STRESS IN ADHESIVE
Stress in the pipe is given in each of the above cases by:
f =
where f = longitudinal stress (psi or kg/cm
2
).
In the last example for pressure on a closed end:
f = = 728psi
The allowable stress is one third of the longitudinal tensile strength at the appropriate temperature as
given in the Bondstrand Product Data Sheet. For Series 2000M and Series 7000M pipe the allowable
stress at 70F is 8,500 psi/3.0 = 2830 psi (199 kg/cm2). For short-term effects such as those result-
ing from green sea loads, a higher allowable stress may be justified.
3.14 (100) (6.44) (6.26)
2
ID
2
4
3.14 (6.26)
2
4
P
A
3,080
4.23
(1.6)
(3.6)
22
Shear stress in an adhesive bonded joint is:
=
where = shear stress in adhesive (psi or kg/cm
2
),
D
j
= joint diamater (in. or cm), see Table 3-IV.
L
b
= bond length (in. or cm), see Table 3-IV.
For example: In the case of 100 psi pressure on a closed end 6-inch pipe, as previously calculated:
P = 3,080 lbf
= = 67 psi
The allowable shear stress for RP-34 adhesive (normally used with Series 2000M products) is 250 psi
(17.6 kg/cm
2
). The allowable shear stress for RP-60 adhesive (normally used with Series 7000M prod-
ucts) is 212 psi (14.4 kg/cm
2
).
P
D
j
L
b
3,080
3.14 (6.54) 2.25
23
TABLE 3-I
THRUST IN AN ANCHORED PIPELINE DUE TO TEMPERATURE CHANGE
FOR BONDSTRAND PIPING
Note: 1. For temperature change other than 100F or 100C use linear ratio for
thrust.
2. Calculations are based on elastic properties at room temperature.
3. Calculations are based on IPS dimensions for sizes 2 to 24 inch, MCI
dimensions for 28 to 36 inch.
24
TABLE 3-II
THRUST FORCE DUE TO INTERNAL PRESSURE IN AN ANCHORED PIPELINE
FOR BONDSTRAND PIPING
Note: 1. For temperature change other than 100 psi or 10 kg/cm
2
, use linear ratio for tensile
force.
2. Calculations are based on elastic properties at room temperature.
3. Calculations are based on IPS dimensions for sizes 2 to 24 inch, MCI dimensions for
28 to 36 inch.
25
TABLE 3-III
THRUST DUE TO PRESSURE ON A CLOSED END
FOR BONDSTRAND PIPING
Note: 1. For temperature change other than 100 psi or 10 kg/cm
2
, use linear ratio for thrust.
2. Calculations are based on IPS dimensions for sizes 2 to 24 inch, MCI dimensions for
28 to 36 inch.
26
TABLE 3-IV
ADHESIVE BONDED J OINT DIMENSIONS
Note: 1. Joint Diameters are based on IPS dimensions for sizes 2 to 24 inch, MCI
dimensions for 28 to 36 inch.
2. Adhesive bonded joints are available for field joining of pipe and fittings in size
range 2 to 16 inch. Only adhesive bonded flanges are available for field joints
above 16 inch.
27
4.1 GENERAL
This section gives recommendations on placement of supports and maximum support spacing.
These recommendations give minimum support requirements. Additional support may be needed
where pipe is exposed to large external forces as for example, pipe on desk subject to green wave
loading.
Techniques used in determining support requirements for Bondstrand are similar to those used for
carbon steel piping systems; however, important differences exist between the two types of piping.
Each requires its own unique design considerations. For example, Bondstrand averages 16 percent
of the weight of schedule 40 steel, has a longitudinal modulus 14 times smaller, and a thermal coeffi-
cient of expansion 50 percent larger.
4.2 ABRASION PROTECTION
Bondstrand should be protected from external abrasion where it comes in contact with guides and
support, particularly in areas of significant thermal expansion, in long runs of pipe on weather decks,
or in passageways which would be affected by dynamic twisting of the ships structure. Such protec-
tion is achieved through the use of hanger liners, rider bars or pads made of teflon or other accept-
able material. Refer to Table 4-I for details.
4.0 Support Location & Spacing
TABLE 4-I
PIPE HANGER LINER, RIDER BAR, OR PAD MATERIAL
FOR ABRASION PROTECTION
28
4.3 SPANS ALLOWING AXIAL MOVEMENT
Supports that allow expansion and contraction of pipe should be located on straight runs of pipe
where axial movement is not restricted by flanges or fittings. In general, supports may be located at
positions convenient to nearby ships structures, provided maximum lengths of spans are not
exceeded.
4.4 SPAN RECOMMENDATIONS
Recommended maximum spans for Bondstrand pipe at various operating temperatures are given in
Table 4-Il. These spans are intended for normal horizontal piping arrangements, i.e., those which
have no fittings, valves, vertical runs, etc., but which may include flanges and nonuniform support
spacings. The tabular values represent a compromise between continuous and single spans. When
installed at the support spacings indicated in Table 4-Il, the weight of the pipe full of water will pro-
duce a long-time deflection of about 1/2 inch, (12.7 mm), which is usually acceptable for appearance
and adequate drainage. Fully continuous spans may be used with support spacings 20 percent
greater for this same deflection; in simple spans, support spacings should be 20 percent less. For
this purpose, continuous spans are defined as interior spans (not end spans), which are uniform in
length and free from structural rotation at supports. Simple spans are supported only at the ends and
are either hinged or free to rotate at the supports. In Table 4-Il, recommendations for support spac-
ings for mechanical joints assume simple spans and 20 ft. (6.1m) pipe length. For additional informa-
tion regarding the special problems involved in support and anchoring of pipe with mechanical joints,
see Appendix E.
4.4.1 Formula for Calculating Support Spacing for Uniformly Distributed Load
Suspended pipe is often required to carry loads other than its own weight and a fluid with a specific
gravity of 1.0. Perhaps the most common external loading is thermal insulation, but the basic princi-
ple is the same for all loads which are uniformly distributed along the pipeline. The way to adjust for
increased loads is to decrease the support spacing, and conversely, the way to adjust for decreased
loads is to increase the support spacing. An example of the latter is a line filled with a gas instead of
a liquid; and longer spans are indicated if deflection is the controlling factor.
For all such loading cases, support spacings for partially continuous spans with a permissible deflec-
tion of 0.5 inch are determined using:
L = 0.258
(EI)
w
1/4
29
TABLE 4-II
RECOMMENDED MAXIMUM SUPPORT SPACINGS FOR
PIPE AT 100F (38C) AND 150F (66C) OPERATING TEMPERATURES
(FLUID SPECIFIC GRAVITY =1.0)
Note: 1. For 14- through 36-inch diameters, loads tabulated are for Iron Pipe Size and are 7 to 12 percent
less than for Metric Cast Iron sizes. However, recommended spans are suitable for either.
2. Span recommendations apply to normal horizontal piping support arrangements and are calculated
for a maximum long-time deflection of 1/2 inch to ensure good appearance and adequate drainage.
3. Includes Quick-Lock adhesive bonded joints and flanged joints.
4. Maximum spans for mechanically joined pipe are limited to one pipe length.
5. Modulus of elasticity for span calculations:
E = 2,100,000 (psi)-6000 (psi/F) x T (F). See Table 4-III.
30
where L = support spacings, ft.
(EI) = beam stiffness (lb-in
2
, from Table 4-Ill and 4-IV)
w = total uniformly distributed load (lb/in.).
In metric units:
L = 0.124
where L = support spacings (m)
(El) = beam stiffness (kg-cm
2
) (from Table 4-Ill and 4-IV)
w = total uniformly distributed load (kg/m)
For example: Calculate the recommended support spacing for 6-inch Bondstrand Series
2000M pipe full of water at 150F:
L = 0.258 16.5 ft.
4.5 SUSPENDED SYSTEM RESTRAINED FROM MOVEMENT
Anchors may be used to restrict axial movement at certain locations (see Section 5 for anchor
details). Such restriction is essential:
Where space limitations restrict axial movement.
To transmit axial loads through loops and expansion joints.
To restrain excessive thrusts at turns, branches, reducers, and ends
To support valves. This is done not only to support the weight of valves and to reduce thrust, but
it also prevents excessive loads on pipe connections due to torque applied by operation of
valves.
Refer to Section 3 for determining thrust in an anchored system.
(EI)
w
1/4
1,200,000 x 19.0
1.36
1/4
TABLE 4-III
MODULUS OF ELASTICITY FOR CALCULATIONS OF SUPPORT SPACINGS
31
In pipe runs anchored at both ends, a method of control must be devised in order to prevent exces-
sive lateral deflection or buckling of pipe due to compressive load. Guides may be required in conjunc-
tion with expansion joints to control excessive deflection. Tables 4-V and 4-VI give recommendations
on guide spacing versus temperature change for marine pipe with restrained ends.
4.6 EULER AND ROARK EQUATIONS
The Euler equation is first used to check the stability of the restrained line.
L =
where L = unsupported length or guide spacing (in. or cm),
I = beam moment of inertia (in
4
or cm
4
) see Table 4-IV,
= coefficient of thermal expansion (in./in./F or m/m/C),
A = cross-sectional area (in
2
or cm
2
) see Table 4-IV,
T = change in temperature (F or C).
The equation gives maximum stable length of a pipe column when fixed ends are assumed.
In Tables 4-V and 4-VI this maximum length is reduced by 25 percent to allow for non-Euler behavior
near the origin of the curve.
I
T A
1/2
32
Notes:
1. Outside diameters approximate those for iron pipe size, ISO International Standard 559 - 1977 and for
cast iron pipes, ISO Recommendation R13-1965 as follows:
2. Values are for composite moment of area of structural wall and liner cross-section in terms of the
structural wall for Series 2000M. Beam second moment of area is also known as beam moment of
Inertia.
TABLE 4-IV
PIPE DIMENSIONS AND SECOND MOMENT OF AREAS (SERIES 2000M)
IRON PIPE SIZE (IPS)
METRIC IRON SIZE
Using the length developed by the Euler equation, the weight of and the physical properties at the
operating temperature deflection of a horizontal pipe is calculated using the equation from Roark
1
:
y = (tan - )
where K = P/(E
l
)
P = = TAE
E
l
= longitudinal modulus of elasticity (psi or kg/cm
2
), see Table 4-Ill
w = uniform horizontal load (lb/in or kg/cm),
L = guide spacing (in. or cm).
If y is less than 0.5 inch (1.27cm), the L obtained using the Euler equation is the recommended
guide spacing. If y is greater than .5 inch (1.27cm), choose a shorter length L and solve the Roark
equation again for y . A final length recommendation is thus determined by trial and error when y
closely approximates 0.5 inch (1.27cm).
4.7 SUPPORT OF PIPE RUNS CONTAINING EXPANSION .J OINTS
The modulus of elasticity for Bondstrand pipe is approximately 1/14th that of steel pipe. For this rea-
son, the force due to expansion of Bondstrand pipe is not great enough to compress most varieties
of expansion joints used in steel piping systems. Bondstrand requires elastomeric expansion joints.
The use of elastomeric expansion joints has somewhat limited marine applications. These joints have
very limited resistance to external forces and, therefore, are not suitable for use in the bottom of
tanks. However, it can be used for piping systems installed in the double bottoms were hydrostatic
collapse pressure is not a requirement. During the installation careful consideration must be given to
the proper support and guidance.
(1) R.J . Roark, Formulas for Stress and Strain, 3rd Edition, McGaw-Hill Book Co., New York, 1954.
-wL
2KP

2
(E
l
)
L
2
KL
4
KL
4
1/2
33
34
T
A
B
L
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35
36
There are also very distinct advantages to these expansion joints. They reduce vibration caused by
equipment, are very compact and lightweight, and will compensate for axial movement.
When using an expansion joint to allow movement between anchors, the expansion joint should be
placed as close as possible to one anchor or the other. The opposite side of the expansion joint
should have a guide placed no further than five times the pipes diameter from the expansion joint
with a second guide positioned farther down the pipe. To determine the spacing for the second
guide, find manufacturers specifications on force required to compress the joint and refer to Figure
4-1 for recommended spacing.
The horizontal line at the top of each curve represents maximum support spacing for a totally unre-
strained system. The lower end of the curve also becomes horizontal at the value for maximum guide
spacing for a totally restrained system. This graph only shows values for pipes smaller than 12 inch
diameter. In large diameters, the slightly increased guide spacing is not great enough to compensate
for the added cost of the expansion joint.
The guide spacing for variable end thrust as produced by an expansion joint may be calculated as
follows:
L = =
L = guide spacing (in. or cm.)
F = TAE
l
= force of compressing an expansion joint (lb or kg),
= coefficient of thermal expansion (in/in/F or m/m/C).
E
l
= longitudinal modules of elasticity at the highest operating temperature
(psi or kg/cm
2
), see Table 4-Ill
T = change in temperature (F or C),
A = cross-sectional area (in
2
or cm
2
), see Table 4-lV.
I = beam second moment of area (in
4
or cm
4
), see Table 4-IV.
The values shown in Fig. 4-1 are calculated at 100F (38C) and reduced by 25 percent. Within the
cross-hatched area, the pipe will crush prior to compression of the expansion joint based on a com-
pressive allowable stress of 20,000 psi (1400 kg/cm
2
).
I
TA
1/2
IE
l
F
1/2
F
I
G
U
R
E

4
-
1
A
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A
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M A X I M U M G U I D E S P A C I N G
( M E T E R S )
( F E E T )
(
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)
(
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)
37
4.8 SUPPORTS FOR VERTICAL RUNS
Install a single support anywhere along the length of a vertical pipe run more than about ten feet
(3mm) long. See Section 5 for suggested details. If the run is supported near its base, use loose col-
lars as guides spaced as needed to insure proper stability.
Vertical runs less than ten feet (3mm) long may usually be supported as part of the horizontal piping.
In either case, be sure the layout makes sufficient provision for horizontal and vertical movement at
the top and bottom turns.
In vertical pipe runs, accommodate vertical length changes if possible by allowing free movement of
fittings at either top or bottom or both. For each 1/8 inch (3mm) of anticipated vertical length change,
provide 2 feet (62cm) of horizontal pipe between the elbow and the first support, but not less than 6 feet
(1.9m) nor more than 20 feet (6.1m) of horizontal pipe. If the pipeline layout does not allow for
accommodations of the maximum calculated length change, there are two possible resolutions:
Anchor the vertical run near its base and use intermediate guides at the spacing shown in Tables
4-V or 4-VI, or
Anchor the vertical run near its base and use intermediate Dresser-type couplings as required to
accommodate the calculated expansion and contraction.
Treat columns more than 100 feet (30m) high (either hanging or standing) as special designs; support
and provision for length change are important. The installer should be especially careful to avoid
movement due to wind or support vibration while joints are curing.
4.9 CASE STUDY: VERTICAL RISER IN BALLAST TANK
A 210,000 DWT Tanker trades between Alaska and Panama. Segregated ballast tanks next to cargo
tanks are served by 16 inch (400mm) Bondstrand Series 7000M pipe with RP-60 adhesive as shown
in Figure 4-2. Maximum working pressure is 225 psi (15.5 bars). Maximum cargo temperature is
130F (54C). Minimum cargo temperature is 70F (21C). Minimum ballast water temperature in
Alaska is 30F (-1C). Length of riser is 80 ft. (24.4m). Ambient temperature at time of pipe installation
is 70F (21C). Maximum ambient temperature in Panama is 110F (43C).
4.9.1 What relative movement is expected between bottom of riser and bulkhead assum-
ing no restraint on riser and no dresser-type couplings in the riser pipe?
Maximum relative movement due to temperature occurs when the steel bulkhead is at cargo temper-
ature (1300F) and the fiberglass pipe is at minimum ballast water temperature (300F); i.e. at time of
loading cargo in Alaska.
Expansion of bulkhead = L T
= 6.38 x 10
-6
(80 x 12) (130 - 70)
= 0.37 inches
Contraction of pipe = L T = 10 x 10
-6
(80 x 12) (70 - 30)
= 0.38 inches
Total relative movement due to temperature
= 0.37 + 0.38 = 0.75 inch
Note that pressure in the pipe under these conditions will cause the pipe to lengthen and reduce the
relative movement between pipe and bulkhead.
Maximum relative movement due to pressure will occur at ambient temperature during ballasting in
Panama.
38
VERTICAL RISER IN BALLAST TANK
FIGURE 4-2
39
40
L = (80 x 12) 1-2 (.56)
= 0.53 inches or see Table 2-I
Thus the maximum expected relative movement is 0.75 inch as caused by temperature.
4.9.2 Does the pipeline layout below the riser allow enough flexibility to absorb the expect-
ed relative movement?
The eductor is rigidly anchored to prevent vibration; therefore, the riser support forms a Z loop.
Interpolating from Table 2-Ill for a length change of 0.75 inch, the required leg length is 9.5 ft. Since
the layout provides only 3 ft., there is insufficient flexibility to absorb movement.
Two solutions are possible:
A. Anchor the riser pipe near the bottom and provide guides as required to prevent buck-
ling.
B. Insert Dresser-type couplings into the riser pipe to absorb the expected movement.
4.9.3 Solution A: Restrain the riser pipe
E
l
at 30F = 2,100,000 6,000 (30) = 1,920,000 psi
Force on anchor, P = E
l
A L/L
= 1,920,000 (22.5) 0.75/(80x12)
= 33,750 lbf. due to temperature change
Note that pressure causes a reduction in anchor force due to temperature.
From Table 3-Il, the force due to pressure alone is
P = 9260 (225/100) = 20,840 lbf.
Thus the anchor must be designed for 33,750 lbf.
The guide spacing should be established for a condition of empty ballast tank in Panama (110F) and
full cargo tank at 70F. The pipe T = 110-70=40F. From Table 4-VI the guide spacing is 52 feet.
Since the maximum unguided length is 30 ft., no additional guides would be required.
Check maximum tensile stress in pipe wall: In this case, assume hot cargo tank, cold ballast tank
and maximum pressure occur simultaneously.
f = (33,750 + 20,840)/22.5
= 2,426 psi < 2,830 psi allowable
Check shear stress in RP60 adhesive (See Table 3-IV):
a = (33,750 + 20,840)/[ir(15.91)(4.00)]
= 273 psi > 212 psi allowable
Solution A is not feasible due to shear stress in adhesive.
225 (15.19)
2
4 (.47) 1,6000,000 (15.66)
1.6
3.6
41
4.9.4 Solution B: Dresser-type couplings. Contraction in riser pipe due to pressure:
L = (80 x 12) (.56)
= 0.53 inches
Thus the total contraction due to pressure and temperature is 0.75 + 0.53 = 1.28 inches. Each cou-
pling allows 0.375 inch movement (See Appendix A) without gasket scuffing. However, considering
the infrequent nature of the worse-case condition, two couplings should be sufficient. Light duty
anchors will be required between couplings.
The riser bottom should be anchored against closed-end force. From Table 3-Ill, the force is:
P = 18,100 (225/100) = 40,740 lbf.
For anchor details see Section 5.
225 (15.9)
2
2(.47) 3,600,000 (15.19 + .47)
42
43
5.1 INTRODUCTION
Proper support of fiberglass piping systems is essential far the success of marine fiberglass installa-
tions. In dealing with installations of fiberglass pipe by shipyards, riding crews, arid owners through-
out the world, the need for a Chapter dedicated to commonly used installation details has become
evident.
The recommendations and details herein are based on sound engineering principles and experience
in successful fiberglass piping installations. They are offered as alternatives and suggestions for eval-
uation, modification and implementation by a qualified Marine Engineer. Taking short cuts to save
material or cost can cause grave consequences.
Notes: 1. Unless otherwise indicated, details are considered suitable for all approved piping systems.
2. Details are not intended to show orientation. Assemblies may be inverted or turned horizontal for
attachment to ships structure, bulkhead or deck. Good practice requires that support lengths in pipe
runs provide the minimum dimensions needed for clearance of nuts and bolts.
3. Location, spacing and design of hangers and steel supports are to be determined by the shipyard,
naval architect, or design agency. The necessary properties of fiberglass pipe are found in Chapters 2,
3 and 4.
4. Fiberglass piping systems on board ships are often designed to absorb movement and length changes
at mechanical joints. To control deflections, the designer must allow for the weight and flexibility (hinge
effect) introduced by mechanical couplings or expansion joints. See Appendix E.
5. Detailed dimensions are in inches and (mm) unless otherwise indicated.
6. Flange gaskets shall be 1/8 in. (3mm) thick, full face elastomeric gaskets with a Shore A Durometer
hardness of 60 + 5. A Shore flurometer hardness of 50 or 60 is recommended for elastomeric pads.
7. Refer to ASTM F708 for additional details regarding standard practice for design and installation of
rigid pipe hangers.
5.2 DETAILS
5.2.1 Water Tight Bulkhead Penetration, Flanged One End (Figure 51 On Following Page)
All water tight bulkheads and deck penetrations must be accomplished in steel and/or a non-ferrous
metal capable of being welded water tight to the steel structure and must comply with classification
societies rules. Fiberglass pipe can be attached to this penetration by a mechanical coupling
(Dresser-type) between the metallic spool piece and fiberglass plain end. A step down coupling can
also be used when the diameter of the metallic spool piece differs from the outside diameter of the
fiberglass pipe.
Note: All spool pieces must be aligned with the longitudinal axis of the piping system within tolerance per-
mitted by the mechanical coupling manufacturer regardless of the deck or bulkhead slope.
5.0 Anchor And Support Details
44
5.2.2 Water Tight Bulkhead Penetration, Flanged Both Ends (Figure 52 )
The difference between this water tight spool piece and the previous one is the incorporation of
flanges at both ends of the water tight bulkhead. This spool piece penetration is commonly used if a
valve must be attached at the bulkhead penetration as required for design, safety reasons or classifi-
cation society rules.
The alignment between the steel and fiberglass flanges must be within the tolerance discussed later
in Paragraph 5.2.13 and shown by Figure 513. Special attention is required when valves are
mounted on the flanges; lock washers shall be placed on the steel side (compressed by the nut) and
flat washers on the fiberglass side (supported by the bolt).
5.2.3 Adjustable Water Tight Bulkhead Penetration, Flanged or Plain End. (Figure 53)
This particular spool piece connection allows tack welding at the bulkhead prior to final assembly so
that the pipe is truly aligned, thus relieving fabrication stresses in the system. Two tanks can be
aligned simultaneously with the use of this adjustable bulkhead penetration for proper alignment of
the fiberglass pipe and fittings.
Fig. 51
Fig. 52
45
5.2.4 Anchor Supports. (Figure 54)
This particular detail uses fiberglass saddle stock halfcollars to anchor the pipe and prevent longitu-
dinal displacement along the axis. The gap between each 1800 saddle and the flat bar type clamp is
1/8 in. (3mm). These steel clamps are fabricated by the shipyard conforming to I.P.S. or M.C.I. out-
side diameters.
Notes: 1. The steel clamp should fit squarely against the angle bar support where the clamp will be bolted.
Inserts, washers and spacers should not be used.
2. For thickness of the steel clamps refer to Note 3 under Paragraph 5.1.
5.2.5 Pipe Anchor Using 1800 Saddle Stock Full Collar (Figure 55 On Preceding Page)
This anchor support is accomplished in the same manner as Figure 54. It restricts the pipe from
axial movement. The additional saddles will increase the area of contact between the saddle and the
pipe to accommodate axial forces.
Calculations of thrust are discussed in Chapter 3. If the shear value of the adhesive to be used on a
particular systems is exceeded (see Section 3.6), alternate types of anchors should be used; espe-
cially at fittings. See Figures 58 and 59 for examples.
Fig. 53
Fig. 54
46
5.2.6 Anchor Supports Using Full Metal Clamp (Figure 56)
The flat bar clamp is designed to restrain the pipe from axial movement. Saddle stock is installed on
both sides of the steel clamp. In order to hold the pipe without damage see Table 51 below for
recommended space between the bottom part of the clamp and upper part of the clamp.
For small pipe diameters 16 in. (25150mm) it is useful to use a 1/4 thick (6mm) neoprene pad
(Durometer A 5060) compressed between the pipe and metal clamp. This will not prevent move-
ment of the pipe in the axial direction. To prevent movement, the pipe must be properly anchored
with saddle supports using half or full collars depending on the thrust imposed by the hydrostatic
pressure or temperature change in the piping system.
Notes: 1. The steel clamp should fit squarely against the angle bar support where the clamp will be bolted.
Inserts, washers and spacers should not be used.
2. For thickness of the steel clamps refer to Note 3 under Paragraph 5.1.
Fig. 55
Clearance At Bolts
NPS (Without Liner)
(in) (mm)
1 1/8 3
11/2 1/8 3
2 1/8 3
3 1/4 6
4 1/4 6
6 3/8 10
8 3/8 10
10 1/2 12
12 1/2 12
14 5/8 16
16 5/8 16
18 5/8 16
Clearance At Bolts
NPS (Without Liner)
(in) (mm)
20 5/8 16
22 5/8 16
24 5/8 16
26 5/8 16
28 5/8 16
30 5/8 16
32 5/8 16
34 5/8 16
36 5/8 16
TABLE 5I
47
5.2.5 Pipe Anchor Using 180 Saddle Stock Full Collar (Figure 55)
This anchor support is accomplished in the same manner as Figure 54. It restricts the pipe from
axial movement. The additional saddles will increase the area of contact between the saddle and the
pipe to accommodate axial forces.
Calculations of thrust are discussed in Chapter 3. If the shear value of the adhesive to be used on a
particular systems is exceeded (see Section 3.6), alternate types of anchors should be used; espe-
cially at fittings. See Figures 58 and 59 for examples.
5.2.6 Anchor Supports Using Full Metal Clamp (Figure 56)
The flat bar clamp is designed to restrain the pipe from axial movement. Saddle stock is installed on
both sides of the steel clamp. In order to hold the pipe without damage see Table 51 below for
recommended space between the bottom part of the clamp and upper part of the clamp.
For small pipe diameters 16 in. (25150mm) it is useful to use a 1/4 thick (6mm) neoprene pad
(Durometer A 5060) compressed between the pipe and metal clamp. This will not prevent move-
ment of the pipe in the axial direction. To prevent movement, the pipe must be properly anchored
with saddle supports using half or full collars depending on the thrust imposed by the hydrostatic
pressure or temperature change in the piping system.
Fig. 56
Fig. 57
5.2.7 Anchor Supports Using Flat Bar Top Half and Steel Shape Bottom (Figure 57 Previous Page)
This type of anchor support is similar in purpose to that shown in Figure 56. Many shipyards prefer
this type.
Caution: Dimensions of the steel clamp must provide for a loose fit around the fiberglass pipe when attached to
the steel angle shape below. If the pipe is clamped against the flat steel surface on the bottom half, the
force imposed at the tangential point of contact between the pipe and steel can damage the fiberglass
pipe. (See Table 5I). For diameters greater than 8 inches this problem is less severe due to increased
thickness of the pipe wall. (See Chapter 4, Table 4IV)
Note: The supports shown in Figs. 54, 55, 56 and 57 are designed to restrain axial movement of the
pipe when they are fitted with 180 deg. saddles.
5.2.8 Thrust Support For 90 and 45 Elbows (Figure 58 on Following Page)
The thrust support plate of Figure 58 is used when the hydrostatic force or thrust in the piping sys-
tem will exceed the shear strength of the adhesive bonded joint. It is recommended that this type of
support be used in transferring the load from the joint directly into the body of the fitting. The fitting
will absorb thrust imposed on the piping system. The support plate will be permanently attached to
the standard foundation detail produced by the shipyard with addition of a torsional support plate
bolted directly onto a flange of the elbow to prevent a torsional displacement of the fitting.
It is recommended that a .394 in. (10mm) thick neoprene pad with a Durometer A of 50-60 be
installed between the thrust support plate and the outside of the elbow completely covering the
inside curved surface which will contact the pipe. The neoprene pad should be fully compressed
against the thrust plate. If the thrust plate support cannot be made into a smooth radius, an alterna-
tive method is to weld together straight plates (Lobster-Back configuration). In this case the neo-
prene pad must be sufficiently thick so that when the pad is compressed between the fitting and the
Lobster-Back support, a full contact of the outside diameter of the pipe is accomplished with the
compression of the neoprene pad. This assures that the forces will be transmitted directly to the
steel thrust support plate and no slippage will occur by an improperly compressed neoprene pad.
Note: It is recommended that a mechanical coupling (Dresser-type only) be incorporated on either side of the
fitting using thrust support plates to allow axial movement in the piping system and relieve part of the
thrust imposed on the fitting. This practice has been used successfully in previous installations. See
Note in Section 5.2.9.
5.2.9 Thrust Support Plate For Tees (Figure 59 On Page 5.8)
The thrust support plate of Figure 59 is used when the hydrostatic force or thrust in the piping sys-
tem will exceed the shear strength of the adhesive bonded joint. It is recommended that this type of
support be used in transferring the load from the joint directly into the body of the fitting. The fitting
will absorb thrust imposed on the piping system. The thrust support plate for the tee is simpler in
design than the previous thrust support for elbows. The construction is straight and simple without
compound curvature and can be accomplished by rolling the plate to conform to the outside diame-
ter of the tee.
48
49
Fig. 58
The accommodation of the neoprene pad will be the same as Figure 58 with the objective to trans-
fer the thrust force of the piping system into the thrust support plate and not into the flange or bond-
ed joints of the tee. Because of the geometrical configuration of the tee, a torsional plate will not be
required. All the rest of the recommendations previously discussed in Figure 58 are also applicable
to the tee support.
Note: It is advisable to coat the U bolts which hold the elbows and tees against the thrust support plates
with Amercoat, urethane or similar coatings to protect against corrosion, and also cushion between the
fittings and the U bolt. Another method used by some shipyards is to introduce a neoprene sleeve
around the U bolts. This Note applies to all supports using U bolts.
5.2.10 Anchor Support Plate Bolted to a Flanged Fitting (Figure 510 On Following Page)
This anchor support is used for flange fittings when the hydrostatic forces imposed by the design of
the piping system do not exceed the adhesive shear stress value. (See Section 3.6 of this manual.)
Figure 510 shows the plate pattern covering a minimum of four bolts (for all pipe sizes). Figure 5
10 shows a design used by shipyards to anchor large diameter elbows. See Note 3 on page 5.2.
5.2.11 Steel Supports for Large and Small Valves (Figure 511 On Page 5.10)
The steel supports shown in Figure 511 apply for various kinds of valves. Valves in sizes 4 in. and
under are relatively light can normally be supported with a single support. Gate valves and similar
large and heavy valves in sizes 6 in. and up require two supports to accommodate the weight and
directly transmit it to the ships structure. Valves such as globe or gate valves with reach rods
extending to the above decks require double support.
See Table 5Il below for required number of bolts in support plates.
50
Fig. 59
Flanged plates must be properly designed to support the weight of valves and transmit it directly to
the ships structure. It is recommended that all steel components in a piping system be supported.
This will prevent shifting the weight to the fiberglass piping system.
TABLE 5Il
Note: Flanges should be two-hole oriented as a general practice in shipbuilding.
51
Fig. 510
Required Minimum
Number Of Bolts
Flange Attached To
Size Support Plate
20 8
22 8
24 10
26 10
28 10
30 12
32 12
34 12
36 12
Required Minimum
Number Of Bolts
Flange Attached To
Size Support Plate
1 2
11/2 2
2 2
3 4
4 4
6 4
8 4
10 6
12 6
14 6
16 6
18 8
52
5.2.12 Guidance Support for Fiberglass Pipe. Teflon Sliding Pad (Figure 512)
This simple design has been adopted almost universally for guides in ship construction. Teflon has
selflubricating properties which help to reduce friction between the surface of the pipe and the
steel without inducing abrasion on the fiberglass component. Teflon also is inert to most chemicals
and petroleum derivatives used in tank ships, white product, and chemical carriers. The minimum
thickness of the teflon pad is recommended to be 1/5 inch (5mm). Teflon thickness should be
increased proportionally to the largest size of the piping system i.e., 1/4 inch (6mm) for 20 inches and
above. The teflon pad can be utilized (or installed) in different configurations, some shipyards feel
that the teflon pad in conjunction with the holes for the U bolt will be sufficient. Others shipyards pre-
fer to have an indentation on the teflon pad to prevent any sliding in the center between the two
holes supporting the pad. The third anchor point will be in the center of the teflon pad and the metal
bar as shown as an alternative on Figure 512. It is also recommended that the U bolts be coated
with Amercoat, urethane or hot dip coating to prevent corrosion.
5.2.13 Maximum Flange Misalignment Allowance (Figure 513)
The Table in Figure 513 shows allowable misalignment for flanges from 116 inches diameter and
from 1836 inches diameter. It is recommended that these allowances not be exceeded in order to
accomplish a proper seal between flanges without inducing unacceptable stresses.
Fig. 511
53
Fig. 513
Fig. 512
54
5.2.14 Pipe Misalignment Between Supports (Figure 514)
The Table in Figure 514 shows allowable misalignment for different sizes of pipe assuming 20 ft.
(6m) between supports. Figure 514 also provides a formula to calculate the maximum misalign-
ment between supports for other support spacings.
Note: When joints are made with mechanical couplings, see manufacturers literature for permissible
misalignment.
Notes: 1. For supports spans other than 20 feet the total misalignment can be calculated using the
above formula
2. Misalignment applicable applicable to any direction parallel to axis
H = H
20
x
Where
H = Total allowable
misalignment in (in.)
C = Support span in (ft.)
H
20 = See Table
C
2
400
Fig. 514
6.0Internal and External Pressure Design
6.1 INTERNAL PRESSURE
P
i
=
Where: P
i
= rated internal pressure, psi or kg/cm2,
s = allowable hoop stress, 6000 psi. (422kg/cm2) for Series 2000M
and 7000M Bondstrand pipe,
OD = minimum outside diameter (in. or cm) see Table 4IV,
t = minimum reinforced wall thickness (in. or cm) = tt ti,
tt = minimum total thickness (in. or cm) see Table 4IV,
t
l
= liner thickness, 0.020 in. (0.51 cm) for Series 2000M, zero for
Series 7000M.
(OD - t) = ID + t + 2t
l
ID = inside diameter (in. or cm).
To convert pressure in psi to bars, divide by 14.5. To convert pressure in kg/cm
2
to bars, divide by
1.02.
Based on the formula given above, the rated operating pressure for Series 2000M and Series 7000M
pipe is tabulated in Table 6I. This provides longterm performance in accordance with the cyclic
Hydrostatic Design Basis (ASTM D2992, Method A) and provides a 4 to 1 safety factor on short
term hydrostatic performance as required by proposed ASTM Marine Piping Specifications.
Note: Fittings and/or mechanical couplings may reduce the system working pressure below that
shown in Table 6I. See Bondstrand Product Data Sheets FP168 and FP169 and coupling manufac-
turers literature.
55
2st
(ODt)
TABLE 6I
Rated Internal Operating Pressure for Series 2000M and Series 7000M Pipe
Rated Internal
Nominal Operating Pressure
Diameter at 2000F (930C)
in. mm psi bar
2 50 550 38
3 80 450 31
4 100 450 31
6 150 300 21
8 200 300 21
10 250 300 21
12 300 300 21
14 350 300 21
16 400 300 21
18 450 300 21
20 500 300 21
24 600 300 21
28 700 300 21
30 750 300 21
36 900 300 21
Note: Fittings and flanges have a lower pressure rating than the pipe.
6.2 EXTERNAL COLLAPSE PRESSURE.
P
c
=
Where P
c
= external collapse pressure (psi or kg/cm
2
),
E
c
= effective circumferential modulus of elasticity (psi or kg/cm
2
), see Table
6Il,
t
a
= average reinforced wall thickness (in. or cm), .875 is used because the
minimum thickness is 87.5% of nominal.
= (tt / .875) t
l
t
t
= minimum total thickness (in. or cm) see Table 4IV,
t
l
= liner thickness, 0.020 in. (0.51 cm) for Series 2000M, zero for Series
7000M,
ID = pipe inside diameter (in. or cm), see Table 4IV,

l
= Poissons ratio for contraction in the circumferential direction due to
tensile stress in the longitudinal direction, see Table 6Il,

c
= Poissons ratio for contraction in the longitudinal direction due to the
tensile stress in the circumferential direction, see Table 6II.
56
2E
c
t
a
3
(1-
c

l
) ID
3
To convert external pressure in psi to bars, divide by 14.5. Atmospheric pressure at sea level is 14.7
psi. To convert kg/cm
2
to bars, divide by 1.02.
When installing pipe in the bottom of tanks, the pipe must resist the combined external fluid pressure
and internal suction. It is assumed that a positive displacement pump can pull a maximum of 75 per-
cent vacuum. The designer should also allow for a safety factor of 3 in accordance with proposed
ASTM Specifications. Thus the allowable hydrostatic head, H in ft. is:
H = 2.31 11.0
Tabulated values of allowable hydrostatic head are shown in Table 6Ill on page 6.6 for tempera-
tures of 1000F(380C) and 2000F(930C). For example, calculate the collapse pressure and
allowable hydrostatic head in English units for 12 inch Series 2000M pipe at 2000F:
ID = 12.35 inch
t
t
= 0.351 inch
t
l
= 0.020 inch
t
a
= (.351/.875) .020 = .381 inch
P
c
= = 181 psi
H = 2.31 11.0 = 114 ft.
Or read the appropriate values from Table 6Ill.
Table 6Il
Elastic Properties for Calculation of External Collapse Pressure for Series 2000M and 7000M Pipe
Temperature E
c
F C psi kg/cm
2

l
70 21 3.15 x 106 2.21 x 10
5
0.56 0.37
100 38 3.06 x 106 2.15 x 10
5
0.57 0.38
150 66 2.90 x 106 2.04 x 10
5
0.60 0.39
200 93 2.20 x i06 1.55 x 10
5
0.70 0.41
Note: Ec is based on external collapse tests per ASTM D2924. Values of Poissons ratio are based on
tests per ASTM D1599
57
P
c
3.0
[ ]
[ ]
2(2.20 x 10
6
).381
3
[ 1 - .7 (.41)] 12.35
3
181
3.0
58
TABLE 6Ill
External Collapse Pressure and Allowable Hydrostatlc Head
for Series 2000M and Series 7000M Pipe
1000F(380C) 2000F(930c)
Nom. Pipe Collapse Allowable Collapse Allowable
Size Pressure Hydrostatic Head Pressure Hydrostatlc Head
(in) (mm) (psi) (Bars) (ft) (in) (psi) (Bars) (ft) (in)
2 50 2,331 160 1,770 540 1,855 565 1,403 427
3 80 637 43.9 465 142 507 35.0 365 111
4 100 703 48.5 516 157 559 38.6 405 123
6 150 234 16.1 155 47 186 12.8 118 36
8 200 231 15.9 153 47 184 12.7 116 35
10 250 231 15.9 153 47 184 12.7 116 35
12 300 228 15.7 150 46 181 12.5 114 35
14 350 228 15.7 150 46 181 12.5 114 35
16 400 228 15.7 150 46 181 12.5 114 35
18 450 227 15.6 149 45 181 12.5 114 35
20 500 227 15.6 149 45 181 12.5 114 35
24 600 226 15.5 149 45 180 12.4 114 35
28 700 226 15.5 149 45 180 12.4 114 35
30 750 226 15.5 149 45 180 12.4 114 35
36 900 225 15.5 148 45 179 12.3 112 34
7.1 INTRODUCTION
When comparing Fiberglass and carbon steel piping systems it becomes evident that selection of
Fiberglass pipe can result in significant savings due to favorable hydraulic properties.
7.2 HEAD LOSS
The frictional head loss in a pipe is a function of velocity, density, and viscosity of the fluid; and of
the smoothness of the bore, and the length and diameter of the pipe. Therefore, the best means of
minimizing this pressure drop in a particular piping service is to minimize the internal roughness of
the pipe. This internal roughness causes movement of the fluid particles in the boundary layer adja-
cent to the pipe wall, which causes flow through the pipe to be impeded.
Fiberglass pipe has a smoother inner surface than new steel piping. There is an even more significant
difference between the inner surface of Fiberglass and steel pipe after the pipes have been in service
for a while. In most systems Fiberglass maintains its low head loss performance for life.
Fiberglass does not scale, rust, pit or corrode electrolytically or galvanically. It resists growth of bac-
terial algae, and fungi that could build up on the inner surface. Also, Fiberglass has high chemical
and abrasion resistance. In marine applications, where pipelines are usually short, the major portion
of the total pressure drop in a system occurs in the valves and fittings. It is customary to express the
resistance of valves and fittings in terms of equivalent length of pipe, these are added to the actual
length for purposes of pressure drop calculation for the total system.
7.3 FORMULAS FOR CALCULATING HEAD LOSS IN PIPE
The Hazen-Williams equation is convenient for calculating head loss. For full flow, this equation, with
a C factor of 150, predicts head loss with sufficient accuracy for nearly all water piping situations.
Fluids other than water require a more universal solution such as given by the Darcy-Weisbach equa-
tion. This section gives the information needed to solve these head loss problems for fluids such as
crude oil and salt brine. Head loss for two-phase fluids such as sludges and slurries is not covered.
7.3.1 HazenWilliams Equation (For Water Pipe, Full Flow)
An equation commonly used for calculating head loss in water piping is that published by Hazen and
Williams. Solving for head loss, this equation becomes
H
L
= 1046
Where HL = head loss (feet per 100 feet of pipe),
Q = discharge (gallons per minute), (U.S. gallon)
C = Hazen-Williams Factor (C = 150 for Bondstrand), and
ID = inside diameter of pipe (inches).
59
7.0Hydraulics
1 . 852
Q
C ID
2.63 [ ]
In International System (SI) units, this equation is
H
L
= 1068
where H
L
= head loss (meters per 100 meters of pipe),
Q = discharge (cubic meters per second),
C = HazenWilliams factor (C = 150 for Bondstrand), and
ID = inside diameter of pipe (meters).
7.3.2 Darcy-Weisbach Equation (For All Fluids, Full Flow)
The solution of the Darcy-Weisbach equation is complicated by the fact that the Darcy friction factor,
f, is itself a variable. Solutions for f may be obtained using handbooks, or by using a programmable
calculator, for both laminar and turbulent flow conditions.
Figure 7-1 gives the head loss versus discharge for water flowing in Bondstrand pipe based on the
Darcy-Weisbach equation
H
L
= f
Where HL = frictional resistance (meters),
f = Darcy friction factor,
L = length of pipe run (meters),
ID = internal diameter of pipe (meters),
V = average velocity of fluid (meters per second), and
g = gravitational constant = 9.806 meters per second
2
.
The frictional resistance is obtained in feet by the same equation if all units of length are changed to
feet and the gravitational constant is changed to 32.2 feet per second
2
. When using Figure 7-1, con-
vert discharge in gal/mm to cu in/sec by multiplying by 0.0000631.
The variable Darcy friction factor can be determined for any fluid in the turbulent range of flows by
use of the Moody equations.
f = 0.0055 1 + 20,000 +
in which = pipe roughness (meters),
R = = Reynolds Number,
Where = kinematic viscosity of the fluid (square meters per second).
60
1 . 852 Q
C ID
2.63 [ ]
1/3
10
6
R

ID [ ]
[ ]
L
ID
V
2
2g
[ ]
ID

If the Reynolds Number falls below 2000, the flow can be assumed to be laminar. Then the Darcy
friction factor becomes
f =
Roughness Parameter
The smoothness of the inside pipe surface over the life of Bondstrand pipe produces lower frictional
head loss compared to most other piping materials. The lower head loss means lower pressures will
be required to produce an equivalent discharge, thereby also conserving pumping energy.
Tests of Bondstrand pipe show that the roughness is 5.3 x 10
6
meters (1.7 x 10
6
feet). There is a high
probability that this low level roughness will be sustained, and will not be increased due to corrosion
and incrustation as often the case with steel piping, which may double in roughness under certain
conditions.
Kinematic Viscosity of Fluid
Increase in fluid viscosity leads to increased head loss. Table 7I illustrates the effect of kinematic
viscosity on head loss for several common fluids. Kinematic viscosity is defined as the absolute vis-
cosity divided by the density. It varies with temperature. The kinematic viscosity for water at room
temperature is 0.000001115 square meters per sec (0.000012 sq. ft per sec)
Figure 7-2 shows how head loss and flow are affected by kinematic viscosity. The transition between
laminar flow and turbulent flow in 6-in. pipe is seen in the plot for a fluid having a kinematic viscosity
of 0.001 square feet per second.
7.4 HEAD LOSS IN FITTINGS
Head loss for water flow in fittings 2 through 36 in. in diameter may be determined by the above
methods after obtaining their equivalent pipe lengths using Figure 7-3. For example, find the equiva-
lent pipe length (L
e
) for water flowing through a 6-in. diameter elbow at a rate of 0.003 meters
3
per
second. Beginning at the bottom of the chart given in Figure 7-3 at a flow of 0.003 meters
3
per sec-
ond, proceed vertically to intersect the 6-in. diameter curve, and read L
e
= 6 meters on the left ordi-
nate. Multiply this value by the resistance coefficient, K, given for 90 degree elbows in Table 7-Il to
obtain equivalent pipe length,
L
e
= 6 x 0.5 = 3 meters.
Head loss in the fitting is then determined as the head loss in this equivalent length of pipe. The
resistance coefficients from Table 7-III may be used in similar fashion for reducers.
Although the Darcy friction factor, f, for water was used in the development of Figure 7-3, the equiva-
lent pipe length obtained may then be used to estimate head loss for the actual fluid in the system.
With a known Darcy friction factor, the equivalent length of pipe for any size and type of fitting can
be determined using the appropriate resistance coefficient, K, from Table 7-Il and the equation
L
e
= K ID/f
provided L
e
and ID are given in the same units.
61

64
R
62
F
i
g
u
r
e

7

1
H
e
a
d

L
o
s
s

F
o
r

W
a
t
e
r

a
s

a

F
u
n
c
t
i
o
n

o
f

F
l
o
w

R
a
t
e
Figure 72
Effect of Kinematic Viscosity on Head Loss vs. Discharge for 6-inch Pipe Flowing Full
Table 7-I
Head Loss for Various Flowing at 500 GPM in a 6-Inch Bondstrand Marine Pipe
63
64
F
i
g
u
r
e

7
-
3
E
q
u
i
v
a
l
e
n
t

P
i
p
e

L
e
n
g
t
h

o
f

F
i
t
t
i
n
g
s
TABLE 7-Il
Resistance Coefficients for Bondstrand Fittings and Metal Valves
Description K
45 Elbow Standard 0.3
45 Elbow Single Miter 0.5
90 Elbow Standard 0.5
90 Elbow Single Miter 1.4
90 Elbow Double Miter 0.8
90 Elbow Triple Miter 0.6
180 Return Bend 1.3
Tees >T 0.4
>T 1.4
>T 1.7
Gate Valve Open 0.17
3/4 Open 0.9
1/2 Open 4.5
1/4 Open 24.0
Diaphragm Valve Open 2.3
3/4 Open 2.6
1/2 Open 4.3
1/4 Open 21.0
Globe Valve Bevelseal, Open 6.0
1/2 Open 9.5
Check Valve Swing 2.0
Disk 10.0
Ball 70.0
Note: Coefficients are for fittings with no net change in velocity.
65
TABLE 7-Ill
Resistance Coefficients for Bondstrand Reducers, Tapered Body
SIZE K SIZE K
1
1/2
X 1 0.5 12 X 8 0.8
2 X 1 2.8 12 X 10 0.1
2 X 1
1/2
0.3 14 X 10 0.12
3 X 1
1/2
3.7 14 X 12 0.01
3 X 2 0.7 16 X 12 0.08
4 X 2 2.9 16 X 14 0.03
4 X 3 0.1 18 X 14 0.16
6 X 3 3.1 18 X 16 0.02
6 X 4 0.7 20 X 16 0.13
8 X 4 3.3 20 X 18 0.02
8 X 6 0.1 24 X 18 0.17
10 X 6 1.5 24 X 20 0.07
10 X 8 0.2 30 X 24 0.22
7.5 CARGO DISCHARGE TIME AND ENERGY SAVINGS
The advantage of low friction loss in Fiberglass smooth bore pipe has been explained in EB-19,
HEAD LOSS IN BONDSTRAND VERSUS STEEL. This section will focus on another aspect of this
topic, namely energy savings in cargo tank discharge, and how loading and unloading time can be
reduced by using Bondstrand piping products.
7.5.1 Pump Flow Rate
Consider a typical pump operating at a certain pressure P
1
to overcome friction loss in the piping
system as shown in Figure 7-4. At this pressure the pump will discharge a certain flow rate Q
1
. This
same pump will discharge a higher flow rate Q
2
if somehow the friction loss in the pipeline can be
reduced, bringing the pumps operating head down to a lower level, P
2
. The increase in volume flow
rate, as a result of the reduction in operating pressure, depends largely on the pump performance
characteristics which vary from pump to pump. This flow variation with pressure can be found in the
pump manufacturers literature, thus it is omitted from further discussion here.
66
Fig. 7-4
Pumping Pressure vs. Discharge
7.5.2 FullPipe Flow Of Water In LowFriction Fiberglass Pipe
Lets now focus our discussion only to the pipeline and examine how low friction pipe can improve
the volume flow rate of the system.
For example consider two pipelines - Schedule 40 steel and Bondstrand Series 2000M pipe - both
designed to transport water 100 meters. We will compare the volume flow rate. The friction head loss
in the pipelines can be calculated by the Hazen-Williams formula as stated before. In metric units:
H
L
= 1068
Where H
L
= head loss (meters per 100 meters of pipe)
Q = discharge (cubic meters per second),
C = Hazen-Williams Factor (C = 150 for Bondstrand), and
ID = inside diameter of pipe ( meters).
With the same energy consumption rate to overcome the friction loss in the pipeline, the rate of dis-
charge will be different due to the differences in friction coefficient in the pipe. In other words, using
the same head loss for both pipe, we obtain:
H
L
= 1068 = 1068
Rearrange the above expression to show the flow rate in Bondstrand pipe in terms of flow rate in
steel pipe:
Q
BS
= Q
steel
Examining the above formula, we can conclude that for the same head loss, Fiberglass pipe will
deliver more volume flow rate that that of the same nominal diameter steel pipe since the product
of and is always greater than 1.0.
Table 7-IV lists the calculated value of the flow ratio Q
BS
/ Q
steel
where C
BS
= 150 and C
steel
= 120 or
70. A C value of 120 represents a very slightly corroded steel pipe. A C value of 70 represents a
severely corroded steel pipe.
67
1 . 852
Q
C ID
2.63 [ ]
1 . 852
2.63
Q
steel
C
steel
ID
steel
2.63
[ ]
C
BS
C
steel
[ ]
ID
BS
ID
steel
C
BS
C
steel
ID
BS
ID
steel
[ ]
1 . 852
Q
BS
C
BS
ID
BS
2.63
[ ]
Table 7-IV
Flow in Bondstrand and Steel Pipe for Same Head Loss
Bondstrand Steel
NPS Pipe ID Pipe ID C=120 C=70
(in) (mm) ( inches) (inches) QBS/QSteel QBS/QSteel
2 50 2.095 2.067 1.30 2.22
3 80 3.225 3.068 1.43 2.45
4 100 4.140 4.026 1.35 2.31
6 150 6.265 6.065 1.36 2.33
8 200 8.225 7.981 1.35 2.31
10 250 10.350 10.020 1.36 2.33
12 300 12.350 12.000 1.35 2.31
14 350 13.290 13.25 1.26 2.16
16 400 15.190 15.25 1.24 2.13
18 450 17.080 17.25 1.22 2.09
20 500 18.980 19.25 1.20 2.06
24 600 22.780 23.25 1.18 2.02
7.5.3 Flow Of Fluids Other Than Water
In Marine applications, however, most cargo tankers carry fluids other than water. In such cases, cal-
culations of head loss are slightly more complicated because direct comparison of volume flow rates
between the two pipes is not possible. Comparison of volume flow rate can only be done in steps as
illustrated below:
Step 1:
The head loss of one pipeline, usually the steel line, is chosen as a standard for comparison. This is
determined using the Darcy-Weisbach method as discussed before.
H
L
= f
Where HL = frictional resistance (meters),
f = Darcy friction factor,
L = length of pipe run (meters),
ID = internal diameter of pipe (meters),
V = average velocity of fluid (meters per second),
g = gravitational constant = 9.806 meters per second
2
.
68
L
ID
V
2
2g
The variable Darcy friction factor can be determined for any fluid in the turbulent range by use of the
Moody equation,
f = 0.0055 1 + 20,000 +
in which = pipe roughness (meters), and
R = = Reynolds Number,
where = kinematic viscosity of the fluid (square meters per second).
Step 2:
From the head loss calculated in Step 1 above, the flow velocity (the only unknown quantity in the
equation for Bondstrand system) can be found by trial and error. A programmable calculator will
speed this calculation considerably. Subsequently, the volume flow rate can be easily determined.
For example, 1000 cubic meters of 1400F, 24.4 degree Baum~ crude oil with kinematic viscosity of
0.00001115 square meters per second is to be unloaded through a 1000-meter long standard
Schedule 40, 8-in. diameter steel pipeline at a rate of 500 cubic meters per hour. How much time can
be saved unloading the same amount of crude through Bondstrand Series 2000M, 8-in. pipeline?
Steel Pipe Bondstrand Pipe
Data Given Schedule 40 Series 2000M
Inside Diameter (in) 0.2027 0.2089
Roughness (in) 0.0000457 0.0000053
Flow Velocity (m/sec) 4.30 To Be Found
Reynolds Number 78200 To Be Found
Step 1:
The total head loss is calculated for the steel pipeline.
H
L
= .0055 1 + ( 20000 + )
H
L
= 94 meters
69
1/3
10
6
R

ID [ ]
[ ]
V ID

1/3
0.0000457
0.2027 [ ]
1000 ( 4.30 )
2
.2027 ( 2 ) 9.806
1000000
78200
Step 2:
With 94 meters of friction head loss, the flow velocity for Bondstrand piping system can be found
from the equation.
94 = .0055 1 + ( 20000 + + )
By trial and error V = 4.55 meters per second, and R = 85,250.
As illustrated in the above example, for the given conditions, Bondstrand Series 2000M 8-in. pipe will
deliver 560 cubic meters per hour, emptying the tank in less than 1.8 hours, a 10% saving in both
unloading time and energy.
It is important to note here that the roughness value of new steel was used. The difference in volume
flow rate would have even been higher had the roughness value of old steel pipe been used in the
calculation.
7.5.4 Energy Savings Using Bondstrand Fiberglass vs. Steel Piping
Users of piping products have long known that Fiberglass piping has far lower friction factors than
carbon steel piping. It is equally important to recognize the energy cost savings which accrue over
the life of the installed system as a result of the lower friction factors.
The largest savings is found simply in lower pumping costs, where the power consumption can often
be cut in half. For example, let us assume a 6-in. line is to deliver 500 gallons per minute of water on
a year-round basis and determine energy cost per 100 feet. At this flow the average velocity is about
5 feet per second. Over a 10-year service life, a Bondstrand line can be expected to maintain a
Hazen-Williams C factor of 150, whereas for carbon steel the average C factor can be estimated
to be about 110. In English units:
H
L
= 1046
Where H
L
= head loss (ft. per 100 ft. of pipe), Q = discharge (gpm),
ID = internal diameter of pipe (inches), and
C = Hazen-Williams frictional factor depending on smoothness of pipe bore.
For a 100 foot run in the example described above, this formula yields 1.28 feet for Bondstrand and
2.65 feet for schedule 40 carbon steel pipe. To overcome this head loss, the horsepower demand
may be calculated as
For Bondstrand:
= .162 hp
For Steel:
= .335 hp
70
1/3
0.0000053
0.2089 [ ]
0.0000115
0.2089
1000 V
2
.2089 ( 2 ) 9.806
1000000
V
1 . 852
Q
C ID
2.63 [ ]
500 gpm x 8.34 lb of water/gal x 1.28 ft
33,000 ft-lb/mm/hp
500 gpm x 8.34 lb of water/gal x 2.65 ft
33,000 ft-lb/mm/hp
Then, the energy required for full-time operation for a one month period is:
For Bondstrand:
= 146 hp-hr/month
For Steel:
= 301 hp-hr/month
It is impossible to make a generalization on the cost of electricity on board ship which is dependent
on the efficiency of the ships plant; however, if we assume that the ship is connected to shore
power, we could expect to pay approximately 10 cents per kilowatt-hour or 7.5 cents per horsepow-
er-hour. This cost is significantly lower than ship-based generation. The cost per month is then
For Bondstrand:
146 hp-hr/month x U.S. $.075/hp-hr = U.S. $10.95/month/100 ft. of pipe
For Steel:
301 hp-hr/month x U.S. $.075/hp-hr = U.S. $22.58/month/100 ft. of pipe
Difference = U.S. $11.63
For a ship using 500 feet of Bondstrand fiberglass pipe the annual savings could be:
U.S.S11.63/month/100 ft. x 12 months x 500 ft. = U.S. $69,780 (Annual Savings)
The annual savings shown above for one ship during one year of operation can increase substantially
if the owner implements the usage of fiberglass for all the vessels in his fleet.
If you add up this savings over a ten-year period for every hp-hr for every 100 feet the saving is very
significant and Bondstrand pipe can be used for the life of the vessel while steel pipe probably must
be replaced several times.
In addition to time and energy saving, there are also savings due to purchase and maintenance of
significantly smaller pumps in terms of horsepower rating.
71
.162 x 24 hr/day x 30 day/month
.80 efficiency
.335 x 24 hr/day x 30 day/month
.80 efficiency
References
1. Flow through a Circular Pipe, PPX Program 628040, Texas Instruments Calculator Products
Division.
2. King, Reno C., Fluid Mechanics, Piping Handbook 5th ed. (King, Reno C. and Sabin Crocker,
McGraw-Hill Book Co., N.Y., 1967), pp. 3-135.
3. Hydraulic Institute Engineering Data Book, Hydraulic Institute, Cleveland, 1979, pp. 23-42.
4. Solution to Pipe Problems, PPX Program 618008, Texas Instruments Calculator Products
Division.
5. Guislain, Serge J., Friction Factors in Fluid Flow Through Pipe, Plant Engineering, 1980, pp. 134-
140.
6. Hydraulic Institute Engineering Data Book, op-cit, p. 15-19.
7. Nolte, Claude B., Optimum Pipe Size Selection, Gulf Publishing Co., 1979, pp. 268-275.
8. Anin, M.B. and Maddox, R.N., Estimate Viscosity vs. Temperature, Hydrocarbon Processing,
Dec., 1980, pp. 131-135.
9. Ehrlich, Stanley W., Cryogenic-Systems Piping, Piping Handbook, (McGraw-Hill Book Co.,
5th ed., N.Y., 1967), pp. 11-37,38.
10. Flow of Fluids Through Valves, Fittings and Pipe, Technical Paper 410, Crane Co., 1976,
p. A-26.
72
APPENDIX A
USING METALLIC PIPE COUPLINGS TO J OIN BONDSTRAND
Over the years, metallic pipe couplings have proven to be reliable and economical in certain
Bondstrand piping systems. However, when joining Bondstrand, the recommended procedure is
somewhat different than when joining rigid pipe materials such as steel and ductile iron. This bulletin
describes the joining of Bondstrand pipe using Viking Johnson Couplings* along with a brief review
of the couplings design, construction and operating features. Because of the similarity of design, the
same recommendations generally apply also to the use of Rockwell** or Dresser*** couplings.
DESCRIPTION
Viking Johnson mechanical couplings are manufactured in many different sizes and configurations to
meet many pipe joining requirements. Ease in close quarter installation and disassembly allow them
to be used in many areas where other pipe jointing methods would be impractical. The elastomeric
seals in the couplings help absorb movements such as length changes due to temperature or the
flexing of a ship, and help dampen vibrations such as are produced by a pump.
The Viking Johnson Coupling consists of a cylindrical center sleeve, two end flanges, two elastomer-
ic sealing rings and a set of D neck cup-head bolts. (See Figure1)
Tightening the bolts pulls the end flanges together, compressing the sealing rings between the pipe
wall and center sleeves, producing a flexible, reliable seal.
a. Sealing Ring Materials
The grade T ring is made from Nitrile and is, according to Viking Johnson literature the ring
most commonly used. It is recommended for use on lines carrying gases, air, fresh and salt
water, petroleum products, alkalies, sugar solutions and some refrigerants, and for tempera-
tures from 20 to +100C (-4F to +212F). Other grades such as EPDM E
Polychloroprene V, Polyacrylic A, Fluoroelastomer 0, and Silicone, L, are also
available.
A.1
* Viking Johnson is a trade name of the Viking Johnson International division of the Victaulic Co. Plc England
** Rockwell is a trade name of the Municipal and Utility Division of Rockwell International Corp.
*** Dresser is a registered trademark of Dresser manufacturing Division of Dresser Industries Inc.
Fig. 1
F L A N G E
S E A L I N G R I N G
S L E E VE
DESCRIPTION (cont.)
b. Pressure Plating
Maximum pressure ratings of the Viking Johnson Couplings are determined on the basis of
Barlows formula using a working stress equal to twothirds the minimum yield of the center
sleeve material. All pressure ratings exceed the minimum requirements for 10 bar (150 psi)
piping systems.
c. Chemical Resistance
Viking Johnson Couplings can serve in most chemical environments. This is accomplished
by changing the type of sealing rings and using different types of protective coatings on the
coupling.
d. Electrical Grounding
On special order, Viking Johnson provides a stud welded connection for grounding the cen-
ter sleeve to the end flanges. Wires from the end flanges are bolted onto the stud on the
center sleeve, and the connection is bolted down. Connecting the wiring on the center
sleeve may be carried out prior to the assembly on the Bondstrand pipe ends.
e. Locating Plug
Where there is any possibility of coupling movement along the pipe, due to repeated expan-
sion and contraction or under vibration conditions, it is preferable to use a locating plug
which centralizes the coupling over the pipe ends. If the coupling is to be slipped back along
the pipe at a later date, the plug can be removed and subsequently refitted. Locating plugs
are mandatory with most approval authorities when couplings are used on board ships. (See
Figure 2).
J OINT FUNCTION
The sealing ring used in the Viking Johnson coupling is not intended to slide. The coupling will
accommodate up to 9.5mm (3/8 in.) longitudinal pipe movement per joint as the rings deform (roll
slightly) in response to such movement.
Important: Where pipe movement out of the coupling might occur, proper anchorage of the pipe
must be provided.
A . 2
Fig. 2
C ro ss se c tio n o f c e n te r sle e ve
with o u t c e n te r re g iste r
C ro ss se c tio n o f c e n te r sle e ve
with lo c a tin g p lu g
C ro ss se c tio n o f c e n te r sle e ve
with m o ld e d stu d re g iste r
Individual couplings must be protected against movements greater than 9.5mm (3/8 in.). Anchorage
must be provided to prevent excessive accumulation of movement, particularly at all points which
produce thrust, including valves, bends, branches and reducers.
LENGTH CHANGES IN BONDSTRAND
Bondstrand pipe lengths change due to both temperature and pressure. Estimate these changes by
referring to Chapter 2 Design for Expansion and Contraction contained in this manual.
ASSEMBLY PROCEDURE
Joining of Bondstrand pipe using Viking Johnson Couplings is similar to joining of steel pipe, but
there are important differences. You may need suitable coatings for the cut and sanded surfaces.
(See step d. below). Also, you will need the following tools:
1. Torque wrench reading in increments of 5 footpounds or metric equivalent.
2. Hacksaw, saber saw or abrasive wheel.
3. Duster brush or clean rags.
4. Bondstrand pipe shaver or belt sander.
Although Bondstrand pipe can be supplied with prepared ends, you may need to cut pipe to length
on site. If so, you will need one or more of the following:
1. For 100mm, 4-in. and smaller pipe, emery cloth strips to shoeshine pipe ends.
2. For 150mm to 300mm (6 to 12 in.) pipe - Bondstrand MBO Pipe Shaver (Ameron CC
#34342) plus arbor sizes as required. Arbors used are same as for M74 shaver.
3. For 350 to 600mm (14 to 24 in.) pipe Bondstrand M81 Pipe shaver (Ameron CC #34354).
4. For 350 to 900mm (14 to 36 in.) pipe - Bondstrand M81 Pipe shaver (Ameron CC #34355).
Caution: Be aware that the standard assembly instructions for these couplings are intended for rigid metallic
pipe materials and MAY DAMAGE THE BONDSTRAND PIPE. Instead, follow this step- by-step proce-
dure:
a. Cutting Pipe to Length
When necessary to cut a pipe to length, measure the desired length and scribe the pipe
using a pipefitters wrap-around. Place the pipe in a vise, using 6mm (1/4 inch) thick rubber
pad to protect pipe from damage. Cut pipe with hacksaw, saber saw or abrasive wheel. Pipe
should be square within 3mm (1/8 in.). Use a disc grinder or file to correct squareness as
required.
b. Sand Cut Ends of Pipe
End surfaces of the plain end pipe should be either hand sanded using a 4050 grit alu-
minum oxide sanding surface or, if many ends are to be prepared, use a 6mm (1/4 inch) drill
motor, 1700-2000 RPM, and flapper type sander available from Ameron. Be sure to remove
all sharp edges by sanding the inside and outside edges of the pipe end. Do not touch the
sanded surface with bare hands or other articles that would leave an oily film.
A . 3
c. Prepare Gasket Sealing Surfaces
Machining the surface of Bondstrand pipe is not required for a tight seal between the gasket
and pipe wall. However, the winding techniques used in the manufacture of Bondstrand
fiberglass pipe sometimes produce a somewhat oversized outside diameter. This increase in
diameter sometimes may not permit the Viking Johnson Coupling to slide over the pipe ends
when installing plain-end pipe section.
d. Coat the Cut and Sanded Surfaces
Ends must be clean and dry. Select and apply a coating to the sanded end surfaces of the
pipe and allow to dry thoroughly. A coating such as Amercoat 90, manufactured by Amerons
Protective Coating Division, is suitable for water and other mildly corrosive services.
Note: On special order, Ameron can supply full-length Bondstrand pipe for couplings with ends prepared in
accordance with steps b, c, and d.
e. Lubricate the J oining Surfaces
Clean and lubricate the sealing rings and the outside surface of the pipe with the coupling
manufacturers recommended lubricant. The ring lubricant makes it easier to slip the rings
onto the pipe, and enables rings to seat properly when tightening bolts.
f. Mount and Assemble the Coupling
Slide the end flanges onto the pipe, followed by the lubricated sealing rings. Align the pipes,
being careful not to bump or damage the pipe ends, and assemble the couplings over the
center of the joint. The assembly of the coupling to Bondstrand fiberglass pipe should take
place with the pipe supported in its final installation position.
g. Tighten the Bolts
Torque each bolt to 7 N-m (5 ft-lbs) in a diametrically opposite sequence. At 7 N-m (5 ft-lbs)
torque, check to make sure that both end flanges are compressed evenly on the sealing
rings. If the end flanges are not even, loosen the nuts and re-check alignment of pipe. Also
check to make sure that the end flanges are not binding on the pipe wall or the center sleeve
and that there is clearance between the pipe ends.
Caution: Excess torque can damage pipe. Instructions that accompany Viking Johnson Couplings show general
assembly instructions and specify 70-90 foot-pounds (100-125 N-m) torque. This torque has been
shown to damage Bondstrand pipe.
h. Check Bolt Torque
After each bolt has been tightened to the required torque, re-check the torque on all bolts in
the same sequence. Bolts previously tightened may have relaxed as subsequent bolts were
tightened.
TESTING
Be sure all pipe, fittings and appurtenances are properly and securely anchored before testing.
Remember, the couplings themselves will not resist longitudinal load. Replace all air in the piping
system with water and test to 1-1/2 times the operating pressure for four hours, or as required by the
project specifications.
A . 4
TROUBLE SHOOTING
If proper procedures have been followed, no difficulty should be experienced. If troublesome prob-
lems occur, try the following suggestions:
1. Loosen all bolts and nuts.
2. Check for alignment of assembly. Rebuild to correct alignment if out of alignment.
3. Check the alignment of assembly. Replace damaged rings.
4. Measure the diameter of the pipe at the ring location. This measurement should be within the
limits shown on Table 1.
A . 5
Table 1
Permissible Outside Diameter Limits at Pipe Ends for Metallic Pipe Couplings
Note: Tolerances apply only for a length of 6 inches back from pipe ends
* Straub. Flex is a trade name of Straub Kupplungen, AG, Wangs, Switzerland and Thornhill, Ontario, Canada.
STRAUB-FLEX COUPLINGS*
Straub-Flex couplings may be used as mechanical joints for Bondstrand pipe much like Dresser-type
couplings. Tests of the Straub design show that the seal is effected without grinding or sanding of
the pipes outer surface. The coupling is suitable for fire, salt water and crude oil lines and various
other services normally provided by Series 1600, 2000. 2000M, 6000 and 7000 piping, either sus-
pended or buried. It may also be used with Series 4000 and 5000 piping in certain slurry applica-
tions.
The coupling design, shown in Figure 1, incorporates a stainless steel outer casing split longitudinally
at one point on the circumference. The casing encloses a rubber gasket with a patented lip seal,
which is pressed in place by a relatively low radial pressure. The coupling is installed on plain-end
pipe using a torque wrench with a hex bit to tighten two socket-head cap screws. These features
permit installation on Bondstrand pipe using the same bolt torques as recommended for steel pipe.
Straub-Flex couplings are not designed to withstand longitudinal forces. They allow 3/8-in. (10mm)
longitudinal pipe movement per joint without slippage of the gasket lip on the pipe surface. Individual
joints should be protected against movements greater than 3/8-in. (10mm) to prevent gasket wear.
Anchorages must be provided to prevent excessive accumulation of movement, particularly at thrust
points such as valves, turns, branches or reducers.
The rubber gasket both dampens vibration and allows flexing of joints such as in piping on a ship.
With proper support the coupling also allows up to 2 degrees of angular movement. This added flexi-
bility, along with the couplings added weight, must be considered in the analysis of deflections and
spans in suspended systems.
A . 6
Fig. 3 Straub-Flex Coupling
MATERIALS
Casing
Straub-Flex Type LS couplings have type 304 stainless steel casings and galvanized steel lock bolts.
Type LS Special couplings are made of the same materials but have thicker casings. Types 316 and
316L stainless steel casings and stainless steel lock bolts are available on special order.
Gaskets. Two synthetic rubber gaskets are available:
a. EPDM (ethylene propylene diene rubber)a high quality synthetic rubber with excellent
resistance to fresh or salt water, clean air, and sewage, and resistant to most moderately
corrosive liquids in a pH range from 2 to 11. This rubber is not recommended for use with
petroleum products.
b. Buna-N (nitrile rubber)-a synthetic rubber for use with oil, gasoline, natural gas and most
petroleum products.
PRESSURE RATING
All types of Straub-Flex couplings shown in Table 1 are rated for at least 150 psi pressure. Contact
the manufacturer for possible lower ratings if stainless steel bolts are specified. Ratings include an
allowance for test pressures up to 50 percent higher than rated pressure according to the manufac-
turer. Higher pressure ratings are available in all sizes.
The pressure ratings are for continuous service at 180F (82C) with the EPDM gasket, and for con-
tinuous services at 160F (71C) with the Buna-N gasket.
OPTIONAL PROTECTION SLEEVE**
Heat-shrinkable thermoplastic sleeves may be used to provide a moisture and soil barrier around the
couplings after joint assembly. An adhesive inside the sleeve seals it against the pipe on the outside
to encapsulate the coupling.
ELECTRICAL GROUNDING
A Straub-Flex coupling may act as a joint insulator. If electrical continuity is required across the pipe
joint for Bondstrand Series 7000 pipe, a separate electrical bonding strip should be placed across
the outside of the Straub-Flex casing, and connected to the pipe on both sides of the coupling.
LENGTH CHANGES IN BONDSTRAND
Bondstrand pipe changes length due to changes in temperature and pressure. Estimate these
changes by referring to Chapter 2 Design for Expansion and Contraction contained in this manual.
A . 7
** Heat-shrinkable sleeves are produced by the Pipe Production Division of Raychem Corp., Redwood City, CA., by
Chemplast, Inc., Wayne, NJ, and outside the U.S. by Canusa Coating Systems, Ltd., Rexdale, Ontario, Canada.
ASSEMBLY PROCEDURE
Using Straub-Flex couplings, joining Bondstrand is similar to joining steel pipe, except for sealing cut
pipe ends. Depending on chemical exposure, you may need a suitable coating to cover exposed
glass fibers on the cut ends. It is usually not necessary to sand or shave the outer surface of
Bondstrand pipe as the Straub couplings make a tight seal on the as-wound surface. Exceptions are
given in step c of this procedure.
You may use the standard joining instructions for Straub-Flex couplings as used with steel pipe. You
will need the following tools:
1. Torque wrench reading in increments of 5 ft-lbs (7 N-m.)
2. Hacksaw, saber saw or abrasive wheel.
3. Duster brush or clean rags.
Steps b and d given below are recommended for piping in which the cut pipe ends must be pro-
tected against chemical attack or abrasion. In slurry applications, the user should be aware that the
joint cavity may fill with sediment, restricting flexibility.
a. Cut Pipe to Length
When cutting is necessary, measure the desired length and scribe the pipe using a pipefit-
ters wraparound. Place the pipe in a vise, using 1/4-inch (6mm) thick rubber pad to protect
pipe from damage. Cut pipe with hacksaw, saber saw or abrasive wheel. Pipe end cut
should be square within 1/8-inch (3mm). Use a disc grinder or file to correct squareness as
required.
b. Sand Cut Ends of Pipe
End surfaces of cut pipe should be sanded either by hand using a 40-50 grit aluminum oxide
sanding surface or using a 1/4-in. (6mm) drill motor 1700-2000 RPM with a flapper-type
sander available from Ameron. Be sure to remove all sharp edges by sanding the inside and
outside edges of the pipe end. Do not touch the sanded surface with bare hands or articles
that leave an oily film.
c. Prepare Gasket Sealing Surfaces
Machining the gasket sealing surfaces at the ends of Bondstrand pipe is not generally
required for a tight seal between the gasket and pipe wall. However, two-inch (50mm) pipe
will require shaving of the ends, since its average outside diameter of 2.42 in. (61.5mm) is
larger than can be fitted by the two-inch Straub-Flex coupling (Article No. 005761).
The coupling manufacturer recommends that the difference in outside diameters of mating pipe ends
be no greater than 0.12 in. (3mm), to avoid distortion of the coupling and damage to the cap screws
while joining. Using a diameter tape, measure the outside diameters of pipe ends to ensure that this
difference is not exceeded. If the difference is larger than permissible, milling or shaving of the larger
end is necessary. Because Bondstrand Series 2000M and Series 7000 pipe in sizes 10 and 12 in.
(250 and 300mm) have outside diameters larger than steel pipe, their ends must be shaved to mate
to standard outside diameters of steel pipe and fittings.
A . 8
d. Coat the Cut Ends and Gasket Sealing Surfaces (Lined Pipe Only)
Surfaces must be sanded, clean and dry for coating. Select and apply a coating to the cut
ends and shaved gasket sealing surfaces of the pipe and allow to dry thoroughly. A coating
such as Amercoat 90, manufactured by Amerons Protective Coatings Division, covers
exposed glass fibers and is suitable for water and other mildly corrosive services.
Bondstrand PSX
TM
-34 adhesive may also be suitable.
Note: On special order, Ameron can supply full-length Bondstrand pipe for Straub couplings with ends pre-
pared in accordance with steps b, c and d.
e. Fit the Coupling
With the pipe ends ready for joining, chalk a mark on each end at a distance equal to half
the coupling width. Joining of the pipe should be done with the pipe supported in its final
installation position.
Couplings are supplied loosely assembled. Slide the coupling onto the end of one pipe up to the
chalks mark. Align the second pipe end and slide it into the coupling, using care not to bump or
damage the pipe ends. Center the coupling over the two pipe ends, leaving a small clearance
between the pipe ends.
Note: Do not soap the inside surfaces of the gaskets or the outside surface of the pipe.
f. Tighten the Bolts
Using a torque wrench with a hex bit, alternately torque each of the two socket-head cap
screws to the recommended torques. Ensure that there is clearance between pipe ends.
TESTING
Because Straub-Flex couplings do not resist longitudinal load, make sure all pipe, fittings and appur-
tenances are properly and securely anchored before testing. Replace all air in the system with water,
and test to 1-1/2 times the operating pressure for four hours or as required by the project specifica-
tions.
TROUBLE SHOOTING
If proper procedures have been followed, no difficulty should be experienced. If a joint leaks, try the
following:
1. Disassemble the leaky coupling and an adjacent coupling and remove a pipe section for
examinaton of the rubber gasket and the pipe ends.
2. If the gasket is damaged, replace with another coupling.
3. If the pipe end is not within the diameter limits shown in Table 2, or has abnormally rough
surface or grooves, sand the pipe end surfaces and reinstall the pipe.
A . 9
A . 1 0
Table 2
Application Data for Straub-Flex Couplings
1. Article number gives OD range of coupling in millimetres.
2. 8 and 10 in. (200-250 mm) sizes must be ordered with special casing thickness because the standard coupling only pro-
vides (15 bar) and (12 bar) maximum pressure. Casing does provide > 225 psi (10 bar) minimum pressure rating.
3. Couplings with higher pressure ratings are available on special order.
APPENDIX B
GROUNDING OF SERIES 7000M PIPING
Electrical charges generated within flowing fluids with low conductivity such as liquid hydrocarbon
fuels can cause hazardous static charges to build up on the surfaces of the pipe. To overcome this
problem and still offer the advantages inherent in RTB piping, Ameron has developed special piping
systems-Bondstrand Series 7000 and 7000M. These piping systems provide electrical continuity
throughout by incorporating conductive elements into the structural wall of the pipe, flanges and the
interior surface of the fittings, and through the use of a specially formulated adhesive which provides
the conductivity required at the bonded joints.
Proper installation and grounding is important for the safe operation of Series 7000 and 7000M pipe
when carrying these charge-generating fluids. This bulletin explains how these products are to be
installed, grounded and checked to verify their electrical continuity.
ASSEMBLY OF PIPE
All Series 7000 and 7000M piping are assembled using electrically conductive Bondstrand PSX
TM
-60
adhesive. This special two-component epoxy adhesive is supplied in kit form. Detailed application
instructions are contained in Bondstrand Assembly Instructions, PSX
TM
-60 Epoxy Adhesive, FP827.
ADHESIVE MOUNTING OF GROUNDING SADDLE
Grounding saddles provide a positive method of electrically grounding the piping system. On the
pipe, determine where the grounding saddle will be located. Using a flapper sander, sand until the
surface gloss is removed from at least a 3-in. width around the pipe circumference as needed to fit
the saddle on the area selected. This exposes the conductive elements in the pipe wall and produces
a clean, fresh surface suitable for bonding the grounding saddle to the pipe surface.
Before bonding on saddle, place probes from a standard ohmmeter at least two in. apart on conduc-
tive elements exposed by sanding pipe surface. If measured resistance exceeds 10
6
ohms, more
sanding is required.
If measured resistance is below 10
6
ohms, bond the grounding saddle onto the clean, dry surface
within two hours using PSX
TM
-60 Epoxy Adhesive. After continuity checks recommended herein,
grounding cable must be attached to ship structure.
METALLIC FITTINGS
All metallic fittings must be individually grounded. Tees, elbows, etc. should be welded or otherwise
connected directly to the ship or other grounding structure. Metallic mechanical joints such as
Dresser or Straub must be grounded. If mechanical joints are used, at least one grounding saddle will
be required for each length of pipe.
B . 1
ELECTRICAL CONTINUITY CHECK
Prefabricated Spools.
This may be done in one of three ways:
a. Non-Flanged Prefabricated Spools.
After shop fabrications but before onboard installation and grounding, spools should be
checked for electrical continuity. Sand lightly around the pipe surface at each end of the
spool where the steel hose clamps will attach. Mount the two steel hose clamps over the
prepared surface and measure the resistance between them as shown on Figure 1.
b. Flanged Prefabricated Spools.
Flange assemblies should be checked by placing a bolt with washer and nut through each of
the flanges and tightening, then measuring the resistance between the flanges at each end
of the assembly as shown on Figure 2.
B . 2
Fig. 1 Electrical Continuity Check Diagram for Non-flanged Prefabricate Spools
Fig. 2 Electrical Continuity Check Diagram for Flanged Prefabricate Spools
C. Flanged One End Only Spools.
This assembly should be checked by following the procedure established in b. above for the
flanged end and the procedure established in a. above for the plain end as shown in Figure 3.
Apply sufficient voltage between the hose clamps to measure the electrical resistance in the spool
using a standard generator- type insulation tester
*
capable of applying up to 1,500 volts dc. The
measured resistance should not exceed 10
6
ohms.
Onboard Check During New Construction.
Piping should be checked electrically as installation proceeds onboard ship. After mounting a
grounding saddle (A) as shown on Figure 4, the length of piping from the grounding saddle to the
end of the pipe run should be electrically insulated by placing a layer of nonconducting rubber (B)
temporarily between the remaining unattached supports and the free end of the pipe.
Attach a steel hose clamp over the pipe surface at the free end and use the tester to measure the
resistance between the hose clamp and the ship structure. Current must flow back through the pipe,
fittings and joints to the nearest grounding support clamp to complete the circuit as shown in Figure
1. As before, the measured resistance must not exceed 10
6
ohms between any two grounding sup-
ports.
After the electrical continuity of the piping has been verified, the non-conducting rubber pads at the
grounding supports should be removed. Proceed to bond the pipe into the remaining grounding sad-
dle.
B . 3
Fig. 3 Electrical Continuity Check Diagram for Flanged One End Only
* Ameron recommends the use of a Megger Mark IV Insulation Tester, Cat. No. 211805, James G. Biddle Co., or equal.
Onboard Check During Drydock for Maintenance and Repair
Fiberglass piping systems using Series 7000 and 7000M pipe and fittings should be checked during
each drydock inspection while the tanks are gas freed to ensure that the systems are still properly
grounded. This can be done using either of the following procedures:
a. Electrically Isolated Piping
The straps attached to the grounding saddle utilized to ground the piping system must be
disconnected and the pipe electrically isolated from the structure of the ship shown on
Figure 4. Tightly fasten two steel hose clamps at opposite ends of the pipe spool being test-
ed and measure the resistance between them using a standard generatortype insulation
tester capable of applying 1,500 volts dc. The resistance should not exceed 10
6
ohms. Now
attach one of the grounding cables to the structure of the ship and in like fashion check the
resistance between the pipe and the structure of the ship.
Important: To ensure that each grounding saddle is functioning properly, no more than one grounding strap at
a time should be connected to the ships structure during the test.
b. Grounded Piping
If it is impossible to electrically isolate the system, each section of pipe must be checked
separately. This may be done by placing a steel hose clamp on each section of pipe (defined
as a length between bonded joints) and measuring the resistance between it and the nearest
grounding location as described above.
B . 4
Fig. 4 Test Setup For Electrical Continuity Check of Piping During New Construction and Drydock Periods
APPENDIX C
SIZING OF SHIPBOARD PIPING
Shipyards and design agencies have used various methods to evaluate and select velocities for each
application. These methods have yielded acceptable sizes, pressure drops and efficiency losses and
have allowed adaptation of the nearest standard pipe size in the preliminary design stages.
The method discussed herein uses the inside diameter factor to calculate maximum velocities and
flow in gallons per minute for Nominal Pipe Size (NPS) 1 to 36 with Iron Pipe Size (IPS) and Metric
Cast Iron (MCI) internal diameters.
For Bondstrand fiberglass piping systems a maximum allowable velocity of 15 ft./sec. has been
established. This is to prevent erosion which might occur at higher fluid velocities. Table 1 shows
inside diameter factors
ID
1/2
; ID
1/3
; and ID
2
For NPS 1 to 36 IPS and MCI internal diameter configurations. Table 2 shows fourteen inside diame-
ter functions for different shipboard piping systems.
Applying the IDF (inside diameter function) for a given piping system, maximum velocity value for dif-
ferent pipe sizes can be obtained as follows:
Example A:
Calculate the maximum velocity and maximum flow rate for a 6-in. IPS fiberglass pipe to be used in
a feed discharge system.
IDF for feed discharge = 220 ID
1/2
= (From Table 2)
I.D. Factor for 6 in. (IPS) = ID
1/2
= 2.50 (From Table 1)
V(fpm) = 220 x 2.50 = 550 fpm.
V(fps) =
= 9.17 fps (Max. allowable velocity)
9.17 fps < 15 fps (Ok to use fiberglass)
C . 1
[ ] [ ] [ ]
550
60
To establish maximum flow rate:
Q(gpm) =
Q(gpm) =
Q(gpm) = 879.42 (gpm)
Where:
Q(gpm) = Maximum (Gallons per minute) Flow Rate.
V(fpm) = Maximum Allowable Velocity (Feet per Minute)
ID
2
= Pipe inside diameter (in
2
) (See Table 1)
24.51 = Constant
C . 2
ID2 x Vfpm
24.51
39.19 x 550
24.51
Table 1
Example B:
Check for maximum velocity and maximum flow rate for a sea water discharge for 10-in. IPS.
IDF for water discharge = 300 ID
1/2
= (From Table 2)
I.D. Factor for 10inch (I.P.S.) = ID
1/2
= 3.22 (From Table 1)
V(fpm) = 300 x 3.22 = 966 fpm
V(fps) =
= 16.1 fps (Maximum allowable velocity)
16.1 fps > 15 fps. (not recommended to use with fiberglass)
To establish maximum flow rate:
Q(gpm) =
Q(gpm) =
Q(gpm) = 4,221.87 gpm (Maximum Flow Rate)
Where:
Q(gpm) = Maximum (Gallons per minute) Flow Rate.
V(fpm) = Maximum Allowable Velocity (Feet per Minute)
ID
2
= Pipe inside diameter (in.
2
)
24.51 = Constant
Based on the required system flow rate, the correct pipe size can be determined by trial and error.
C . 3
966
60
ID
2
x Vfpm
24.51
107.12 x 96824.51
24.51
C . 4
Table 2
* See Table 1 for inside diameter coresponding to the NPS selection.
Note: For bilge suction use V=400 fpm (feet per minute) for all NPS selections
APPENDIX D
Miscellaneous data
D.1 Adhesive Requirements (PSX
tm
-34 ; PSX
tm
-60)
The number of joints that can be made using 3 oz., 5 oz., or 8 oz. Kits of PSX
tm
-34 and/or PSX
tm
-60
are shown on the Table below.
D . 1
Note: a. Joint sizes 18 thru 36 require minimum of 2 persons
to make up a joint.
b. Minimum required curing time with heating blanket is
45 minutes for all size joints.
Nominal KIT SIZE
Pipe Size 3 oz. 5 oz. 8 oz.
1 10
1.5 6 10
2 4 7 10
3 3 5 8
4 2 3 6
5 1 2 5
6 1 1 3
8 .50 1 2
10 .50 1 2
12 .50 1 1
14 .50 1
16 .50 1
D2. Rated Pressures, Volumes and Weights of Pipe
D . 2
Note: 1) System internal operating pressures may be limited by mechanical joints, fittings or anchoring requirements to
values below the rating of the pipe itself.
2) Pipe design resists collapse due to combined internal suction head and external fluid pressure. For example, a
63-psi (4.3-bar) external pressure rating allows for 120 ft (37 m) of water plus a 75% (suction head) with a
safety factor of 2 to minimum ultimate collapse pressure
APPENDIX E
PIPING SUPPORT FOR NON-RESTRAINED MECHANICAL J OINTS
This bulletin offers suggestions for supporting and anchoring Bondstrand piping systems joined with
bolted coupling mechanical joints which do not offer axial restraint. These bolted couplings are the
standard designs offered by Dresser, Viking- Johnson, Rockwell, Straub, R.H. Baker and others
which seal by means of an elastomeric gasket or gland seal against the outside diameter of the pipe.
The flexibility allowed by bolted couplings must be accounted for in calculating allowable span
lengths. Also, provisions for anchoring against hydrostatic thrusts must be incorporated into the
design.
Span Recommendations
Recommended maximum spans for Bondstrand pipe joined with bolted couplings can be determined
by use of the following equation:
L = 0.207
Where L = support spacing (ft),
E
I
= beam stiffness psi (lb-in2), see Tables 43 and 4-4
w = Total uniformly distributed load (Ib/linear in.),
In metric units:
L = 0.0995
Where L = support spacing (in),
E
I
= beam stiffness psi (kg-cm
2
), see Tables 43 and 4-4
w = Total uniformly distributed load (kg/mm).
These spans are intended for normal horizontal piping support arrangements as shown in Figure 1;
i.e., those which have no fittings, valves, or vertical runs incorporated within the span.
Anchoring Recommendations
Bolted couplings, not designed to withstand longitudinal forces, allow 3/8-in. (10mm) longitudinal
pipe movement per joint without slippage of the gasket lip on the pipe surface. Individual joints
should be protected against movements greater than 3/8-in. (10mm) to prevent gasket wear as well
as preventing, in severe cases, the pipe from moving out of the coupling. Anchors must be provided
at thrust points such as valves, turns, branches, or reducers, as well as at locations where excessive
movement may occur (see Figure 1).
Figure 2 shows how mechanically coupled pipe should be supported and anchored at fittings.
Supports must be designed to carry the weight of the pipe and its contents. Anchors are located at
the terminal points of the piping system or where there is a change in direction and should be
designed to withstand thrusts due to internal line pressure.
E . 1
1/4
E
I
w
[ ]
1/4
E
I
w
[ ]
Fig. 1 Support Arrangements
Fig. 2 Support and Anchors at Fitting
Note: Each Pipe length (L) should be anchored at least once to keep pipe ends from moving out of couplings
or jamming together and abrading.
E . 2
Note: Anchors may be affixed to pipe using saddles as shear conntectors or bolted to flanges
FIBERGLASS - COMPOSITE PIPE GROUP - HEADQUARTERS
P.O. Box 801148 Houston, TX 77280 Tel: (713) 690-7777 Fax: (713) 690-2842 http://www.ameron.com
Europe
Ameron B.V.
J.F. Kennedylaan 7
4191 MZ Geldermalsen
The Netherlands
Tel: +31 345 587 587
Fax: +31 345 587 561
Americas
P.O. Box 878
Burkburnett, TX 76354
Tel: (940) 569-1471
Fax: (940) 569-2764
Centron International
P.O. Box 490
600 FM 1195 South
Mineral Wells, Texas 76068
Tel: (940) 325-1341
Fax: (940) 325-9681
Asia
Ameron (Pte) Ltd.
No. 7A, Tuas Avenue 3
Singapore 639407
Tel: 65 861 6118
Fax: 65 862 1302/861 7834
This literature and the information and recommendations it contains are based on data
reasonably believed to be reliable. However, such factors as variations in environment,
application or installation, changes in operating procedures, or extrapolation of data
may cause different results. Ameron makes no representation or warranty, express or
implied, including warranties of merchantability or fitness for purpose, as to the
accuracy, adequacy or completeness of the recommendations or information
contained herein. Ameron assumes no liability whatsoever in connection with this
literature or the information or recommendations it contains.
Important notice
1 psi = 6895 Pa = 0.07031 kg/cm
2
1 bar = 10
5
Pa = 14.5 psi = 1.02 kg/cm
2
1 MPa = 10
6
Pa = 145 psi = 10.2 kg/cm
2
1 GPa = 10
9
Pa = 145,000 psi = 10,200 kg/cm
2
1 in = 25.4 mm
1 ft = 0.3048 m
1 lbin = 0.113 Nm
1 in
4
= 4.162 x 10
-7
m
4
1 ft/sec = 0.304 m/sec
1 gpm = 6.31 x 10
-7
m
3
/sec
C =
5
/9 (F - 32)
Conversions
Ameron 2004. FP 934 09/04. Page 1 of 2. Printed in The Netherlands.
Engineering and design
support services for
Bondstrand Glassfiber Reinforced
Epoxy (GRE) pipe systems
Introduction
With PDS, PDMS and TRIBON, Ameron offers engineering and design support
services for Bondstrand Glassfiber Reinforced Epoxy (GRE) pipe systems that
are used in industrial, offshore, oil & gas, marine and other associated industries.
These piping specifications and related files are created specifically to meet
Bondstrand piping material standards. Specifications may be modified to suite
specific contractor needs based on project requirements, or company standards.
Ameron may provide revisions to these specifications or files as and when the
need arises. The reference data files and configuration files will continue to have
revisions to fine-tune the deliverables.
Use this software during the initial design stage will result in faster turn-around
time from order placement to start of manufacturing and spool fabrication. The
result is quality work in spool drawings and on-time delivery.
Upon completion of modelling of the piping system in PDMS, PDS or TRIBON,
isometric drawings with idf or pcf extensions can be issued to Ameron. Ameron
can immediately generate Material Take Off (MTO) for order processing and
thereafter use SPOOLGEN to convert isometric to spool drawings
The following Bondstrand Glassfiber Reinforced Epoxy (GRE) pipe systems
are available in:
Pipe systems
PDS PDMS TRIBON
series 2410 / 2410 C series 2000M / 7000M series 2000M / 7000M
series 2416 / 2416 C series 2000M-FP series 2000 / 7000
series 2420 / 2420 C series 2410 to 2432 series 4000 / 6000
series 2425 / 2425 C series 3410 to 3432 series 2410 to 2425
series 3410 / 3410 C series 2410C to 2425C
series 3416 / 3416 C
series 3425 / 3425 C
series 2000M / 7000M
From time to time new catalogues are developed and added to the above list.
Please contact Ameron when catalogues for a specific Bondstrand product are
not listed above.
Fiberglass-Composite
Pipe Group
The Americas
P.O. Box 878
Burkburnett, Texas 76364
U.S.A.
Phone: (+1) 940 569 1471
Fax: (+1) 940 569 2764
Fiberglass-Composite
Pipe Group
Headquarters
P.O. Box 801148
Houston TX 77280
U.S.A.
Phone: (+1) 713 690 7777
Fax: (+1) 713 690 2842
Internet: www.ameron.com
email: marcom@ameronfpd.com
Fiberglass-Composite
Pipe Group
Europe
Ameron B.V.
P.O. Box 6
4190 CA Geldermalsen
The Netherlands
Phone: (+31) 345 587 587
Fax: (+31) 345 587 561
internet: www.ameron-fpg.nl
email: info@ameron-fpg.nl
Fiberglass-Composite
Pipe Group
Asia
Ameron (Pte) Ltd
No. 7A, Tuas Avenue 3
Jurong
Singapore 639407
Phone: (+65) 6861 6118
Fax: (+65) 6862 1302/6861 7834
internet: www.ameron.com.sg
email: info@ameron.com.sg
Prior to installing the software, customers are requested to contact Ameron to
ensure the latest data are used.
We appreciate receiving your feedback on discrepancies, errors and data
related queries at info@ameron.com.sg.
Important notice
January 2003

CEAC 1
CEAC GL 2003-0101
Fiberglass Pipe for Offshore
Exploration and Production Systems
Engineering Guideline
Table of Contents
1 General 1
1.1 Introduction 1
1.2 Scope 1
1.3 Industry Standards & Guidelines 2
1.4 Definitions 4
2 Advantages Of Fiberglass Pipe 4
2.1 Light Weight 5
2.2 Corrosion Resistance 5
2.3 Cost 5
2.4 Fire Endurance 5
2.5 Safety 5
2.6 Flow Characteristics 5
3 Application Guidelines 6
3.1 Common Applications 6
3.2 Regulatory Agencies and Classing
Societies 6
3.3 Fire Endurance Requirements 7
3.4 Conductivity Requirements 8
4 Engineering Considerations 9
4.1 Hydraulic Design 9
4.2 Pressure Ratings 9
4.3 Line Layouts 9
4.4 Piping Stress Analysis 9
4.5 Special Design Considerations 10
5 Project Engineering 12
5.1 Evaluation of Alternative Materials 12
5.2 Cost Analysis 15
5.3 Product Selection 15
6 Project Execution 15
6.1 System Design 15
6.2 The Procurement Process 16
6.3 Installation 20
7 References 21

Appendix A Fire Endurance Requirements 22
Appendix B - Example Cost Analysis For
Alternative Piping Materials 25
Appendix C Schematic of Piping System
Example 32
1 GENERAL
1.1 Introduction
This document provides guidance for the use of fiberglass pipe in offshore exploration and
production (E&P) operations. The document is intended for use by engineers involved in the
evaluation of alternative materials for piping systems, design of piping systems, the
specification of piping materials for procurement, and the procurement of piping materials.
The intent of this document is to provide guidance for the evaluation of fiberglass as an
alternative material and to cover issues that are unique to fiberglass pipe.
1.2 Scope

This guideline document is applicable to the use of FRP pipe on offshore production
systems, fixed platforms and floating production systems such as tension leg platforms
(TLPs), SPARs and floating production/storage/offload systems, (FPSOs). This
recommended practice is also applicable to mobile offshore drilling units (MODUs).
This document is applicable to pipe and fittings manufactured from fiber reinforced
thermoset resin by filament winding, centrifugal casting, resin transfer molding (RTM) or
January 2003

CEAC 2
hand lay-up. Fiber reinforced thermoset pipe will be called fiberglass pipe and fittings in
this document.
1.3 Industry Standards and Guidelines
Various organizations have developed standards or specifications that can be adapted to
piping systems for offshore platforms. The publications listed below are useful to persons
responsible for material selection, system design, vendor selection, materials procurement or
installation. The application area and the function of each document is shown in Table 1.0.
The latest edition should always be used. If the document is in revision, the latest revision
draft may be the most useful.
1. ABS GUIDE FOR BUILDING AND CLASSING FACILITIES ON OFFSHORE
INSTALLATIONS 2000
2. ASTM F1173-2001 Standard Specification for Thermosetting Resin Fiberglass Pipe
and Fittings to be used for Marine Applications
3. UKOOA Specification and Recommended Practice for the use of GRP Piping

4. ISO 14692 Specification and Recommended Practice for the use of GRP Piping in the
Petroleum and Natural Gas Industries
5. IMO Resolution A.753(18) Guidelines for the Application of Plastic Pipes on Ships
6. US Coast Guard NVIC 11-86, Guidelines Governing the Use of Fiberglass Pipe on
Coast Guard Inspected Vessels
7. US Coast Guard PFM 1-98, Guidelines on the Fire Testing Requirements for Plastic
Pipe Per IMO Resolution A.753(18)
8. API RP14G Recommended Practice for Fire Prevention and Control on Open Type

9. API RP 5000 Recommended Practice for Classification of Locations for Electrical
Installations at Petroleum Facilities Classified as Class I, Division 1 and Division 2
10. API Specification 15LR Specification for Low Pressure Fiberglass Line Pipe
11. API Specification 15HR Specification for High Pressure Fiberglass Line Pipe
12. ANSI/API RP 500-1998 Recommended Practice for Classification of Locations for
Electrical Installations at Petroleum Facilities Classified as Class I, Division 1 and Division 2.
13. ASME B31.3-1996 Edition, Process Piping, Chapter VII, Nonmetallic Piping and
Piping Lined with Nonmetals
14. ANSI/AWWA C950-95 AWWA Standard for Fiberglass Pressure Pipe
15. AWWA Manual M45, Fiberglass Pipe Design
16. NFPA 30 Flammable and Combustible Liquids Code
January 2003

CEAC 3
Table 1.0 FIBERGLASS PIPE INDUSTRY DOCUMENTS


APPLICATION AREA


Marine
Worldwide
Marine
GOM
Offshore E&P
Systems
Worldwide
Offshore
E&P Systems
GOM
Onshore
E&P
Chemical
Process
Water
Supply
Buried Pipe

Guideline
IMO
A.753(18)
ABS Guide
USCG
NVIC 11-
86
UKOOA
This CEAC
Document

ABS Guide

API RP 500


Fire Test
Requirements
ASTM
F1173
ASTM
F1173
PFM 1-98
ASTM F1173
ASTM F1173
USCG
PFM 1-98


Procurement*

ASTM
F1173

ASTM
F1173
ASTM F1173
UKOOA
ISO 14692

ASTM F1173
API 15 HR
API 15 LR

ASME
B31.3

AWWA C950

Design
UKOOA
ISO 14692
API 14G

API 14G

AWWA M45

Installation
UKOOA
ISO 14692

* - Includes performance requirements (pressure ratings, fire integrity, conductivity etc.) and quality assurance requirements in manufacturing
and shipping.
January 2003

CEAC 4
1.4 Definitions
The following definitions provide clarification for regulatory requirements related to the use
of plastic pipe offshore. While API RP 500 is the source for most of the definitions, some
have been taken from USCG documents.
1. Flammable: Capable of igniting easily, burning intensely or spreading flame rapidly.
2. Flammable fluid: Any fluid, regardless of its flash point, capable of feeding a fire, is to
be treated as flammable fluid. Aviation fuel, diesel fuel, hydraulic oil (oil based),
lubricating oil, crude oil, and hydrocarbon, are to be considered flammable fluids.
Flammable liquid (Class I Liquid): Any liquid having a closed-cup flash point below
37.8C (100F) as determined by the test procedures and apparatus specified in
NFPA 30. Flammable liquids are subdivided into classes IA, IB and IC.
3. Combustible liquid: Any liquid having a closed cup flash point at or above 100F
(38C) as determined by the test procedures and apparatus specified in NFPA 30.
Combustible liquids are subdivided as follows:
Class II liquids liquids with flash point at or above 37.8C (100F) and
below 60C (140F).
Class IIIA liquids liquids having flash points at or above 60C (140F) and
below 93C (200F).
Class IIIB liquids liquids having flash points at or above 93C (200F)
4. Flash point: The minimum temperature at which a liquid gives off vapor in sufficient
concentration to form an ignitable mixture with air immediately above the liquid surface.
5. Hazardous location: Synonymous to Classified Area.
6. Classified Area: A location in which flammable gases or vapors are, or may be, present
in the air in quantities sufficient to produce explosive or ignitable mixtures.
7. Class I, Division 1 location: A location in which ignitable concentrations of flammable
gases or vapors are expected to exist under normal operating conditions
8. Class I, Division 2 location: A location in which flammable gases or vapors may be
present, but normally are confined within closed systems or are prevented from
accumulating by adequate ventilation.
9. Hazardous liquid: any liquid that is combustible, flammable or toxic.
10. Essential systems: Systems that are vital to the safety of the vessel, fire fighting and
protection of personnel.
2 ADVANTAGES OF FIBERGLASS PIPE
Fiberglass pipe products have unique characteristics, which offer distinct advantages in
offshore piping systems. Some of the advantages are highlighted below.
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CEAC 5
2.1 Light Weight
Fiberglass pipe systems are 40 to 50 percent of the weight of competitive metallic pipe
materials. Piping systems typically constitute 5 percent of total topsides weight. If 20
percent of the piping is replaced with fiberglass, a weight savings of 30 to 50 tons can be
achieved through the use of fiberglass pipe.
2.2 Corrosion Resistance
Fiberglass pipe products do not corrode as metallic products do. Fiberglass firewater
systems are reliable because there is no corrosion debris to clog the nozzles. Corrosion
inhibitors are not required in piping systems that handle corrosive fluids. Fiberglass systems
require little maintenance and should provide good service for the entire life of most
projects.
2.3 Cost
The installed cost of fiberglass pipe systems may be less than coated steel and is typically
less than that for corrosion resistant alloys (CRA). Low maintenance cost is also a major
advantage of fiberglass systems. The life cycle cost of fiberglass systems is typically
substantially less than carbon steel as well as CRA systems. Fiberglass pipe requires less
maintenance and since hot work is not required, interruptions in production are not a factor
during repair or modification procedures.
2.4 Fire Endurance
Fiberglass products can offer significant performance advantages for fire water systems.
Fiberglass pipe is more resistant to hydrocarbon fires than Schedule 10 copper-nickel pipe.
Fiberglass has low thermal conductivity, which keeps the ID of dry deluge piping from
getting as hot as metal piping in a fire. (Dry metal piping can get very hot in a fire resulting in
the formation of high pressure steam when the deluge system is activated.) Some fiberglass
products are resistant to jet fires and others have very low smoke and toxicity ratings that
allow usage in inaccessible spaces in accommodation and control areas. The fire endurance
of normally wet (water filled) systems is very good.
2.5 Safety
Improved work place safety is a very significant advantage of using fiberglass piping
materials. The light weight of fiberglass results in fewer back and hand injuries during
construction. Hot work is not required during fabrication or repair of fiberglass systems and
that eliminates many potential injuries that can occur during construction and during
operations.
2.6 Flow Characteristics
Fiberglass pipe has excellent flow characteristics. The smooth I.D. surface of fiberglass
results in less resistance to fluid flow. The Hazen Williams coefficient for fiberglass is 150 as
compared to 130 for new welded galvanized steel. Accounting for the good flow
characteristics of fiberglass in the hydraulic design of piping systems can result in significant
cost savings. The cost savings can be realized in either of two ways. The proposed pipe
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CEAC 6
diameter may be decreased while maintaining the specified flow rate, or smaller pumps can
be specified with the original pipe diameter and flow rate [Reference 1]. The smooth I.D.
surface of fiberglass also inhibits the build up of marine growth.
2.7 Marine Growth
The smooth bore of fiberglass pipe also results in good resistance to marine growth. Marine
organisms may attach themselves to fiberglass surfaces under static conditions, but are
normally removed from the bore by flow of the effluent.
3 APPLICATION GUIDELINES
3.1 Common Applications
There are many piping systems on an offshore production platform. In the Gulf of Mexico
(GOM), fiberglass piping generally can be considered for water systems that are non-
essential, non-hazardous and non-flammable (see definitions in Section 1.4). However,
fiberglass products can also be used in firewater systems, an essential system, if the chosen
products pass the specified fire tests and are approved by the authority having jurisdiction
(see Section 3.2). The following is a list of the more common offshore applications at this
time.
Fire water systems
Seawater cooling systems
Injection water
Produced water
Potable water
Drain piping
Sanitary piping
Ballast water
Column piping
Crude oil cargo piping for FPSOs
3.2 Regulatory Agencies and Classing Societies
Fiberglass piping systems on offshore E&P facilities will be subject to review and approval
by the regulatory organizations with jurisdictional authority in the region of deployment. The
U.S. Coast Guard (USCG), for example, has regulatory responsibilities for floating facilities
in the GOM, and they have some responsibilities for fixed platforms as well. The U.S.
Minerals Management Service (MMS) is another regulatory agency with jurisdiction over
platforms in the GOM. The USCG and the MMS share the jurisdiction for various areas on
GOM platforms in accordance with the Memorandum of Understanding (MOU) that that
has been issued by these agencies. The Norwegian Petroleum Directorate (NPD) and the
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CEAC 7
UK Health and Safety Executive (HSE) have regional jurisdiction for E&P facilities in the
North Sea.
The USCG requirements for fiberglass pipe are stated in NVIC 11-86 , GUIDELINES
GOVERNING THE USE OF FIBERGLASS PIPE ON COAST GUARD INSPECTED
VESSELS and IMO Resolution A.753 (18), GUIDELINES FOR THE APPLICATION
OF PLASTIC PIPE ON SHIPS. Policy file memoranda such as PFM 1-98 are issued to
clarify the IMO document.
The American Bureau of Shipping (ABS), a classing society, often has responsibility for
enforcement of USCG requirements in the GOM. ABS has guidelines (rules) for plastic
pipe that usually reflect USCG requirements. The ABS rules for plastic pipe are stated in
Appendix 1 of the ABS GUIDE FOR BUILDING AND CLASSING FACILITIES ON
OFFSHORE INSTALLATIONS 2000. There are several classing societies including Det
Norske Veritas (DNV), Lloyds Register (LR), Bureau Veritas (BV) and Nippon K (NK-
Japan). Any one of these societies may be responsible for the enforcement of regulatory
requirements on behalf of the authority having jurisdiction.
Offshore projects may also be located in parts of the world where there is no regulatory
agency. In this case owners often choose to have a classing society oversee the
construction of E&P systems. Each of the classing societies has rules that can be used to
assure the integrity of materials and designs for offshore facilities.
It is best if commercial products are qualified to the performance requirements of the
regulatory agencies and the classing societies prior to use on a project. Products that have
been qualified by these agencies are said to have Type Approval. The approval process is
incumbent on the manufacturers of fiberglass products since many agencies are used
globally in the E&P business. Products without Type Approval must be approved by the
authority on a project to project basis. This adds a time consuming step to the process, so
project teams will not usually accept products not having Type Approval.
It is important to know what set of requirements are assured by a Type Approval
certificate. A Type Approval granted by the USCG provides assurance that the product
meets all the performance criteria required by the USCG. However, a classing society may
grant a Type Approval to any specification desired by the manufacturer. A list of products
with ABS Type Approval can be found at http://www.eagle.org/typeapproval/contents.html.
3.3 Fire Endurance Requirements
The USCG and ABS both provide a list of piping applications that might be considered for
the use of fiberglass in the Fire Endurance Requirements Matrix. This matrix covers the
various piping applications and the locations of all eligible piping systems on offshore
facilities. The ABS fire endurance matrix is shown in Appendix A of this document. The
categories having Level 3 (L3), Level 3 wet/dry (LWD) or zero (0) fire endurance
requirements are current candidates for fiberglass piping. Level 3 endurance requires
survival of a 30-minute fire test conducted on pipe samples filled and pressurized with
stagnant water. Level 3 wet/dry endurance requires survival of fire tests conducted on pipe
samples that are dry for 5 minutes, then filled with water for 25 minutes (flow allowed). A
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CEAC 8
fire endurance of 0 indicates an application category that has no fire endurance
requirements. The fire endurance levels are defined under the fire endurance matrix in
Appendix A.
The fire endurance matrix allows fiberglass pipe in many applications. The matrix has many
cells with either Level 3 (L3) or no (0) fire endurance requirement. Most applications of
interest for offshore platforms, however, are in the open deck areas (column K) of the fire
endurance matrix. If one considers the sea water applications on open decks, all non-
essential systems are allowed to use fiberglass products that have no fire endurance rating.
Fiberglass products with L3 ratings can be used in firewater ring mains if installed in
accordance with the requirements of PFM 1-98. Fiberglass products with LWD or jet
fire ratings are allowed for dry deluge systems. Fiberglass products have not yet been
qualified to Level 2 endurance tests, so none are presently allowed in seawater systems for
essential services. Seawater systems that are allowed in other areas of the platform include
ballast water piping in enclosed areas and column pipes.
Fresh water systems have similar restrictions. Fiberglass products without fire endurance
ratings can be used for potable water, for condensate returns and for non-essential services.
Fire endurance ratings of L3 are required for fresh-water cooling of essential service
systems.
Fiberglass piping can be used for deck drains in most locations. Fiberglass can also be used
for sanitary drains. Phenolic-based fiberglass products have unusually low smoke and
toxicity characteristics and can be used for sanitary piping in inaccessible or concealed areas
of accommodation, service and control spaces. Drain lines that transmit hydrocarbons, even
in low concentrations, are not currently allowed in fiberglass by the USCG.
3.4 Conductivity Requirements
IMO RESOLUTION A.753.(18), Section 2.2.5.3 states that all plastic piping in
hazardous areas must be electrically conductive regardless of the fluid conveyed. The IMO
requirement applies to all hazardous areas, both Division 1 and Division 2. The ABS rules
include an identical requirement. Where electrically conductive pipe is required by ABS, the
resistance per unit length of pipes and fittings must not exceed 1x10
5
Ohm/m, and the
resistance to earth (ground) from any point in the system must not exceed 1.0 megohm.
Most pipe manufacturers provide conductive products for the offshore market.

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CEAC 9
4 ENGINEERING CONSIDERATIONS
Fiberglass pipe systems can be quite robust with proper attention to system design. It is
also true that inadequate attention to system design can result in premature system failures.
Piping analysis and design are similar to metal systems, but input values for stress allowables
and elastic properties are different. Fiberglass systems have some unique characteristics that
designers must take into consideration.
4.1 Hydraulic Design
Fiberglass products have advantages in hydraulic performance as compared to steel
products. The ID of fiberglass products is normally larger than carbon steel for the same
nominal diameter. The smooth interior surface of fiberglass has a Hazen Williams coefficient
of 150, resulting in less friction loss and higher flow rates per unit horsepower. Further, the
interior surface remains smooth over time. The interior surface of carbon steel is not as
smooth when new, and the roughness will increase 30 to 40 percent over twenty years
service. These factors can have a significant impact on pipe size, pump size (horsepower) or
electric power usage over time. Reference 1 provides useful guidelines for the optimization
of the hydraulic performance of fiberglass systems.
4.2 Pressure Ratings
The pressure ratings for fiberglass offshore piping systems are normally based on the
pressure limits of connections and fittings. The pressure rating should include a safety factor
of 4.0, minimum, if based on short term burst tests of fittings and connections. Pressure
ratings may also be based on long or medium term pressure endurance tests as defined in
Appendix A, ASTM F1173. Manufacturers should always provide the basis when pressure
ratings are cited.
4.3 Line Layouts
Fiberglass pipe and fittings do not have standardized dimensions. A line layout for an
offshore system or spool isometric drawings for one product will usually apply to a second
product, but the pipe cut lengths may vary from product to product.
4.4 Piping Stress Analysis
It is very important that a piping stress analysis is performed on each fiberglass system. A
static analysis should be performed on wet systems considering the effects of all combined
loading. A dry system such as deluge piping should be analyzed for the dynamic conditions
created when a deluge system is activated and filled suddenly with pressurized water. The
analysis of all systems should include considerations of water hammer and other dynamic
pressure conditions.
It is important to obtain the properties and the stress allowables needed for stress analysis
directly from the manufacturer. The manufacturer should provide design allowables as well
as typical properties. Allowables are needed for both long term and short term loads. The
analysis software needs to have provisions for non-isotropic pipe materials.
January 2003

CEAC 10
The following are typical properties for a 55 filament wound glass/epoxy pipe products.
The manufacturer should be consulted to obtain appropriate design properties for any
specific product.

70 F 150 F 200 F
Tensile Modulus, Hoop direction (msi) 3.7 3.4 3.2
Tensile Modulus, Axial direction (msi) 1.6 1.4 1.2
Beam Bending Modulus (msi) 1.7 1.3 1.0
Shear Modulus (msi) 0.9 0.8 0.8
Axial Tensile Strength
Short Term (0:1) (ksi) 11.4 10.3 9.2
Long Term (2:1) (ksi) 8.8
Long Term (0:1) (ksi) 6.4 5.8 5.3
Hoop Tensile Strength
Short Term Weep (2:1) (ksi) 24.0
Long Term (2:1) (ksi) [HDB] 17.7
Poissons Ratio 0.4 0.4
Thermal Expansion Coefficient
Axial (in/in/F) 10.0
Thermal conductivity
BTU/(ft.
2
)(hr.)(F/in.) 2.8

The analysis needs to check for excessive stress that may result from internal pressure
combined with loadings caused by thermal expansion, bending, momentum, water hammer,
etc. Fiberglass pipe is generally designed to resist internal pressure and does not have the
same level of reserve strength in the axial direction as steel pipe. All service conditions that
produce axial stress or bending stress need to be included in the stress analysis to preclude
failures due to excessive axial stresses. The analyses are needed to locate and size anchors
and guides for the system. Manufacturers will provide assistance with the stress analysis and
most will take responsibility for the analysis for a fee.
4.5 Special Design Considerations
Fiberglass pipe for the marine market normally has added thickness to provide more
resistance to impact loading, handling and vacuum. However, fiberglass materials are not
ductile like carbon steel and some additional design considerations are needed.
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CEAC 11
Supports
Special attention is needed in the design of supports for fiberglass systems. The following
rules should be followed in design of supports, anchors and guides:
Avoid point loads
Protect against abrasion with support pads
Comply with recommended maximum support span dimensions
Provide independent steel supports for valves and other heavy components
Avoid excessive bending. (Small branch lines will be subjected to excessive
bending if the main line is not anchored in the area of the branch line.)
Provide adequate support for vertical runs
Abuse
Fiberglass pipe may need protection during installation and service to prevent inadvertent
damage. Situations that may result in damage to the pipe include:
Small diameter piping that may be stepped on for personnel support
Piping subject to impact from dropped objects
Piping subject to impact from booms, cables, chains etc.
Impact shielding may be needed in some situations.
Transient Pressure Loads
Fiberglass piping is more susceptible to damage from transient pressure loads than carbon
steel. Special attention should be given to the following system design features:
Minimize pressure spikes due to pump startups.
Reduce valve closure speeds to eliminate water hammer.
Incorporate air release valves at high points in system to bleed all air from
system.
Incorporate vacuum breakers in long vertical runs to prevent pipe failure from
internal vacuum pressure during system draining.
Train all personnel in the correct operation of system valves.
It is important that transient pressure loads are minimized to preclude premature failures in
the piping system.
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CEAC 12
5. PROJECT ENGINEERING
Projects for offshore production facilities are often organized into five phases:
Phase I: The evaluation & development of alternative system concepts
Phase II: Feasibility studies & selection of one system concept
Phase III: Front-end engineering for selected concept
Phase IV: Detailed engineering, construction & installation
Phase V: Operation and evaluation
Fiberglass is an alternative piping material that could be of interest for any offshore facility.
The consideration of alternative materials for piping systems normally occurs in the third
stage of the project when engineering options are explored. A materials engineer can
provide a list of qualified commercial products, potential vendors and specifications for
fiberglass piping.
5.1 Evaluation of Alternative Materials
Some project personnel may have limited experience with alternative piping materials. If
alternative materials such as fiberglass are to be considered, the project team will need
updated information to make valid comparisons and good engineering decisions in product
selection. One member of the team should be assigned responsibility for collecting
comparative data for commercial products that are appropriate for offshore facilities.
Comparative product data should include the following information:
Brand names & product series
Fire endurance rating
System pressure ratings by diameter (pipe & fittings)
Basis for pressure ratings
System temperature ratings
Type Approvals
Fittings construction method
Construction resin
Special features (low flame spread, electrical conductivity, etc.)
A spreadsheet incorporating the above data will be quite helpful in selecting the best
candidate products. An example is shown in Table 5-1.
January 2003

CEAC 13
Table 5-1, Features of Commercial Pipe Products

Pipe
Applications
Applicable
Products Series Features
Fire
Endurance
System
Pressure/
Temperature
Ratings Other
Qualification
Documents
Type
Approvals
Joint
Style
Fittings
Constructio
n
Constructio
n
Resin
Manufacture
r
Series 1

USCG
ABS
Product A
Series 2
Conductive
fiber
throughout
wall
Level 3
150 psi, or
225 psi (1" - 40")/

200F

IMO A.753(18)
USCG PFM 1-98
USCG
ABS
Bell Spigot
Adhesive
Filament
Wound
Oven
Cured
Epoxy
(265F Tg)
Company X
Series 1
Impact
resistant
exterior-
provides 2
minute dry
jet fire
resistance
Product B
Series 2
Conductive
fiber
throughout
wall
Level 3
225 psi (2" - 24")/

266F
Flame
Spread,
Smoke,
Toxicity*
IMO A.753(18)
USCG PFM 1-98
USCG
ABS
Bell Spigot
Adhesive
Filament
Wound
Oven
Cured*
Phenolic
(370F Tg)
Company Y
Series 1

Product C
Series 2
Conductive
exterior
Level 3
200 psi (2"-12")
150 psi (14"-18")
100 psi (20" - 24")/

150F
IMO A.753(18)
USCG PFM 1-98
USCG
ABS
Butt & Wrap/
Hand Layup
Hand
Layup
Ambient
Cure
Vinyl Ester
(230F Tg)
Company Z
Series 1

Firewater
Ring Main
Product D
Series 2
Resin rich
liner
Level 3
230 psi (2" - 16")/

200F

IMO A.753(18)
USCG PFM 1-98
USCG
ABS
Bell Spigot
Adhesive
Filament
Wound
Oven
Cured
Epoxy
(300F Tg)
Company ZZ

January 2003

CEAC 14
Table 5-1, Features of Commercial Pipe Products (Continued)
Pipe
Applications
Applicable
Products Series Features
Fire
Endurance
System
Pressure/
Temperature
Ratings Other
Qualification
Documents
Type
Approvals
Joint
Style
Fittings
Constructio
n
Constructio
n
Resin
Manufacture
r
Series 1
Jet fire test
results for 2"
Firewater
Deluge
(dry/wet)
Product E



Series 2
Conductive
fiber
throughout
wall
Jet Fire
&
Modified
Level 3
(wet/dry)
225 psi (1" -16")/

266F
Flame
Spread,
Smoke,
Toxicity*
IMO A.753(18)
USCG PFM 1-98
USCG
ABS
Bell-Spigot
Adhesive
Filament
Wound
Oven
Cured*
Phenolic
(370F Tg)
Company Y
Series 1
Jet fire test
results for 2"

Product F
Series 2
Conductive
exterior
Jet Fire,
Level 3, &
Modified
Level 3
(wet/dry)
200 psi (2" - 4")/

150F

IMO A.753(18)
USCG PFM 1-98
USCG
ABS
Butt & Wrap/
Hand Layup
Hand
Layup
Ambient
Cure
Vinyl Ester
(230F Tg)
Company Z
* - Oven cured on mandrel & post cured after mandrel removed

January 2003

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15
5.2 Cost Analysis
Economics is one of the most important factors in the evaluation of alternative materials.
Materials can be compared based on material costs, installed costs or life cycle costs. It takes
more effort to determine installed costs or life cycle costs, but these steps are essential to
develop a valid cost comparison of alternative materials. A cost analysis example is included in
Appendix B. This example includes installation and maintenance cost estimates for fiberglass,
Schedule 80 carbon steel and Schedule 40 copper nickel piping systems. The costs shown are
based on several assumptions and the reader is encouraged to perform an independent analysis
using material, labor and maintenance costs that are applicable to the project under
consideration.
5.3 Product Selection
Product selection should be based on the best match of product features and the performance
requirements for a given piping system. There is considerable variation in the features of
available fiberglass products as shown in Table 5-1. It is important that the characteristics for
each product are well understood and are evaluated carefully before selecting final candidates.
The projected cost is always an important consideration in product selection. Pipe
manufacturers will provide budgetary prices for use in the selection of acceptable product
candidates for a given project. However, budgetary pricing information needs to be evaluated
carefully. For example, fittings constitute a high percentage of the materials cost for a typical
offshore system, so the price for fittings is far more important than the price for pipe. Also,
manufacturers offer different levels of service with the sale of piping materials. It is important to
understand what services are included with budgetary price estimates so a direct comparison is
made.
If possible, two or more products should be selected for consideration in the procurement
stage of the project. Two or more approved products will assure that competitive prices are
obtained for the project. Two approved products also provide assurance of a second source
of qualified product in the event that adequate supplies are not available from the first source.
6 PROJECT EXECUTION
6.1 System Design
Detailed design of offshore piping systems are normally accomplished by the engineering
contractor for topsides facilities. A quality assurance review of the design phase should be
considered to assure that the interests of all stakeholders, system owner (Owner), operators
and regulators, are addressed in each phase of the system design. The quality plan can address
the assumptions, the criteria and the analyses required to address all the requirements of
applicable specifications, regulatory rules and Owner requirements. Oversight of the design
review should be the responsibility of an Owner employee or a project team member.
Detailed design of a piping system will include hydraulic design, selection of pumps and valves,
routing of the pipe, location of air release valves to bleed air from the system, design of anchors
January 2003

CEAC

16
(and guides) and structural analysis of the system. The structural analyses should be conducted
using software that complies with the specifications for the project. The structural analysis
should consider all static loads, dynamic loads (filling of the dry deluge system) and combined
loads specified in the design requirements provided by the project team. The location of guides
and anchors should be adjusted and the system reanalyzed until the specified safety factors are
realized throughout the system. Stress allowables and physical properties for the fiberglass pipe
should be obtained from the manufacturer and approved by the Owner. After approval, the
results of the detailed engineering work should be used to specify the piping system in the job
specification. The job specification will be used for the procurement process.
6.2 The Procurement Process
Two key documents are needed to assure that qualified products are selected in the
procurement process, a job specification and a procurement specification.
The piping engineer should prepare the job specification and it should contain all the data and
the performance requirements that are applicable to a specific project. The data should include
a line lay out that will enable potential vendors to prepare an accurate materials list. The job
specification should also include all the performance specifications for the job as summarized
below:
System type
Pipe diameter
Design temperature
Design pressure
Piping fluid
Location
Layout drawings
Bill of materials
Regulatory Authority having jurisdiction
Procurement Specification
The procurement specification can be an industry document from ASTM, API or ISO. ASTM
F1173 is written specifically for offshore facilities. The procurement specification may also be
an internal company specification that references an industry document. The procurement
specification will define the general performance requirements that products must satisfy to
qualify for the job. General performance requirements will include properties such as pressure
ratings (pipe and fittings), fire endurance, flame spread, electrical conductivity, etc.
Procurement specifications may include test procedures that must be used as well as the test
results that must be obtained. The procurement specification should also define the quality

January 2003

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17
assurance procedures that must be used in manufacturing, handling and shipping.
Manufacturers who want to participate in the procurement process must submit the data
required to show that proposed products do in fact meet the requirements of the procurement
specification. The procurement officer should work closely with the piping engineer and others
with the expertise needed to evaluate the qualification data from prospective suppliers.
Table 6-1 shows criteria covered by IMO Resolution A.753(18), USCG PFM 1-98, ABS
Rules for Plastic Pipe Installations, ASTM F1173-01 and ISO 14692, all procurement
specifications applicable to fiberglass piping systems for offshore platforms.
The use of Type Approvals can streamline the procurement process. With Type Approvals,
third party agencies such as ABS assume the task of qualifying commercial products to one or
more of the applicable specifications. The agencies also perform periodic audits to assure
ongoing compliance with the specifications. It is important, however, that the user understands
which requirements are assured by any given Type Approval. Table 6-2 demonstrates the
criteria or specifications that are usually covered by USCG Type Approvals and by ABS Type
Approvals.
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18
Table 6-1 Alternative Qualification Specifications for FRP Pipe on Offshore Platforms
and the Criteria Covered by Each

Qualification Criteria

IMO Res.
A.753(18)
USCG
PFM 1-98
ABS Rules,
Plastic Pipe
Installations
ASTM
F1173-01
ISO
14692
Service Parameters
Acceptable Applications Yes Yes
Diameter Range Yes Yes Yes
Maximum Service Temperature Yes Yes Yes
Performance Criteria for Products
Pressure Rating Method Yes Yes Yes Yes
Fire Endurance Yes Yes Yes Yes
Flame Spread, Smoke & Toxicity Yes Yes Yes Yes
Conductivity Yes Yes Yes Yes
Qualification Test Requirements
Pressure Tests Yes Yes Yes Yes
Fire Endurance Tests Yes Yes Yes Yes Yes
Flame Spread Tests Yes Yes Yes Yes Yes
Smoke & Toxicity Tests Yes Yes Yes Yes Yes
Conductivity Tests Yes Yes Yes
Manufacturing QA
QC Plan Yes Yes Yes Yes
ISO 9001, or equivalent Yes Yes Yes
QC Tests & Inspections Yes Yes Yes
Fabrication & Installation QA
Per Mfg. Recommendations Yes
Certification of Bonders etc. Yes Yes Yes
Installation Guidelines Yes Yes Yes
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19

Table 6-2 Typical Performance Criteria or Specifications Covered by
Fiberglass Pipe Type Approvals for Offshore Applications

Criteria or Specification Covered
USCG
Type Approval
ABS
Type Approval*
Product Designation
Yes Yes
Pipe Diameters Yes
Max Service Temperature Yes
USCG NVIC 11-86 Yes
IMO Resolution A.753(18) Yes Yes
USCG PFM 1-98 Yes Yes
ABS Rules, Plastic Pipe Installations Yes
Quality Assurance Program for Manufacturing Yes
Periodic Audits Yes Yes

* - ABB may provide Type Approvals to other specifications. The user must check the Type Approval
certificate to ascertain coverage of each specific approval.
Purchase of Manufacturer Services
The procurement documents should state clearly the services that are expected of the
manufacturer. Fiberglass pipe manufacturers provide piping material, pipe and fittings, but they
often offer the additional services listed below, services that can be extremely valuable to a project
team.
Assistance with system design
Stress analysis of piping systems
Fabrication of pipe spools
Training of fabrication and supervisory personnel
Fabrication of systems on the construction site
Fit-up of fiberglass system to mating valves, vessels, piping etc.
Proof test of piping system
Training of operations personnel
Inspection services
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20
The procurement documents should clearly define the level of service desired in each of these
areas.
Turnkey Purchase Option
Fiberglass pipe manufacturers usually offer the option of supplying a turnkey installation as
opposed to supplying materials and selected services. A turnkey procurement means that the
manufacturer takes full responsibility not only for the quality of the piping material, but also the
fabrication of spools, the installation of the piping on the platform, fit up of the fiberglass piping
to mating hardware such as pipes and tanks, and proof test of the installed system. Turnkey
installations may also include an extended warranty with associated inspection and maintenance
services.
6.3 Installation
Certification of Installation Personnel
Fiberglass pipe can be installed by the manufacturer, by a subcontractor to the manufacturer or
by the general contractor. All the above are used successfully. However, it is extremely
important that fiberglass pipe is always installed by personnel who are trained and certified to a
specification approved by the owner. ASME B31.3, for example, provides procedures for the
installation personnel. This includes the laborers who make up the joints and install the fittings,
and the inspectors who supervise the work. Training and certification of installation personnel is
a very important requirement for successful installations of fiberglass piping.
Construction Quality Assurance
It is recommended that the Owner establish a formal quality assurance (QA) program to
review the manufacture and construction phase of the project. Owner inspectors should review
the manufacturing facilities and operations periodically to assure that the quality provisions of
the procurement specification are satisfied. The QA plan for the construction phase should be
written, reviewed and agreed to by all stakeholders prior to the start of construction activities.
The Owners inspector or his representative should have oversight responsibility for all the
fabrication work and fit up work that is conducted on the construction site. The Owners
inspector should assure that all construction personnel are trained and certified. The Owners
inspector should witness the proof test of the total system.
Proof Test
All closed fiberglass systems should be tested with hydrostatic pressure after installation. The
test should be conducted in accordance with specifications approved by the owner. The ISO
14692 specification provides good guidelines for conducting a system pressure test. Fiberglass
systems are usually required to withstand a test pressure of 1.5 times the operating pressure or
1.1 times design pressure for a minimum of one hour without visible signs of leakage.
Individual pipe joints and fittings are subject to proof testing of 1.5 times pressure rating on a
lot basis during the manufacturing process. Individual spools may also be subjected to proof
testing before installation. Therefore, the primary purpose of the system proof test is to identify
January 2003

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21
system leaks and it is not usually necessary to subject the entire system to pressure 1.5 times
the system rating.
6.4 Project Quality Assurance Plan

A formal quality assurance (QA) plan is recommended for project execution. The QA plan should
include a review of each stage of the project; system design, procurement and construction. The
QA process should identify the project team members involved and define the roles and
responsibilities of each member. The QA review process should be clearly defined. A basic QA
plan is outlined below.

Piping stress analysis review
Analysis software capabilities
Design properties provided by the manufacturer
Load cases and combined loads to be analyzed
Analysis output, maximum stresses, deflections, anchor locations, etc.
Procurement process review
Job specific specifications
Purchase specification
Product qualification data or Type Approval
Construction process
Certification requirements for bonders, laminators and supervisors
Inspection program for manufacturing of pipe and fittings, spool fabrication, installation
on construction site and fit-up to non-fiberglass system components.
Construction site engineering change process
Execute inspection program
System proof test
Proof test plan
System readiness for proof test
Witness proof test
Witness system draining and preparation for service


January 2003

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22
7 REFERENCES
1. Cagle, Larry, Fiberglass Pipes Fringe Benefit, Chemical Engineering, November 1991,
by McGraw Hill, Inc.
2. Smith Fiberglass Manual No. C3345, August 1999, Competitive Materials Installed Cost
Comparison
3. NACE Publication 3C-194, Economics of Corrosion
























January 2003

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23

January 2003

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24
APPENDIX A ABS FIRE ENDURANCE REQUIREMENTS


January 2003

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25


January 2003

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26
Appendix B - Example Cost Analysis for Alternative Piping Materials

Cost of Materials - Pipe and Fittings
Economics is an important factor in engineering studies of alternative piping materials. This section is
included to provide an example cost analysis for alternative piping materials. This example provides
comparative values for three alternative materials. The format and much of the data is taken from Reference
2. The materials are fiberglass, Schedule 80 carbon steel and Schedule 40 copper-nickel.
It should be noted that Schedule 40 carbon steel and Schedule 10 copper-nickel are lower cost metallic
systems that might also be candidates for an off shore system. The reader is encouraged to perform an
independent cost analysis using data that is applicable to the piping materials and the system under
consideration for a specific project.
A cost analysis for fiberglass and competing corrosion resistant piping materials should start with a
spreadsheet of the weights and the cost of competing pipe materials. Table B-1 shows typical unit weights
for fiberglass, Schedule 80 carbon steel and Schedule 40 copper-nickel piping for 2, 3, 4 and 6
diameters. Table B-2 is a summary of typical prices for each piping material at 2, 3, 4 and 6
diameters.



Table B-1, Pipe Weights (Lbs/ Foot)






Table B-2, Pipe Material Cost per Foot

Pipe Materials
2 3 4 6
Fiberglass 0.8 1.2 2.0 3.1
Sch. 80 Carbon Steel 5.0 10.3 15.0 28.6
Sch. 40 Copper-Nickel 90/10 4.2 8.8 12.9 19.7
Pipe Materials
2 3 4 6
Fiberglass $7.50 $9.30 $11.60 $17.55
Sch. 80 Carbon Steel 3.00 6.18 8.75 17.80
Sch. 40 Copper-Nickel 90/10 8.74 17.17 23.05 43.82
January 2003

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27
Cost of Installed Piping Systems
Weight and cost data for competing piping materials can provide a preliminary comparison of competitive
materials. However, it is best to compile data for installed piping systems. Table B-3 is a materials list for
the piping system used in Reference 2 and illustrated in Appendix C of this document. The cost of
alternative piping materials and the corresponding installation labor can be assembled in a separate
spreadsheet to determine the total installed cost of systems constructed from competing materials.
Labor units for the installation of carbon steel pipe and fittings are shown in Reference 2 and attributed to
The Richardson System Process Plant Construction Estimating Standards, Volume 3, 1997 edition,
published by Richardson Engineering Services, Inc., Mesa Arizona. The labor units for copper-nickel
were assumed to be 30 percent greater than those for carbon steel. The labor units for fiberglass were
provided by a manufacturer of fiberglass systems for the offshore market. A summary of the installation
labor for four-inch (4) piping systems is shown in Table B-4.
An average labor rate of $29.10 was assumed to calculate the total labor costs for an installation of 4
piping in the configuration shown in Appendix C. The installed costs for the competitive materials in 4
piping are summarized in Table B-5.


Table B-3 Typical Pipe System Materials List


Item CS or CuNi Fiberglass
Pipe 280 280
Elbows, 90 11 11
Tees 3 3
Reducer, FxF 2 2
Flange 13 13
Coupling 2 0
Bolt sets 17 17
Pipe to Pipe Bonded joints 7
Welded Joints 58
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28
Table B-4 Labor Units in Hours for 4 Pipe

Pipe
(Hr/ft)
Elbow Tee Reducer Coupling Flange Bolt
Set
Field
Cut &
Bevel
Erection
Butt
Weld
Fiber-
glass
0.185

0.850 1.275 0.850 0.850 0.425 1.700 (1) (1)
Sch
80 CS
0.298 6.200 9.300 5.400 3.100 1.900 1.700 0.840 6.900
Sch.
40
CuNi
0.387 8.060 12.090 7.020 4.03 2.47 2.21 1.092 8.97
(1) Field cutting, tapering and adhesive bonding included in pipe and fittings labor units

Table B-5 Installed Cost Comparison for 4Pipe


PIPE
MATERIAL
COST
FITTINGS
MATERIAL
COST
BOLTS &
ADHESIVE
COST
FIELD
LABOR
COST
(PIPE)
FIELD
LABOR
COST
(FITTINGS)
TOTAL
INSTALLED
COST
Fiberglass $3,250 $5,766 $830 -- $2,860
2
$13,706
Sch 80 CS 2,450 524 722 $2,428 6,623 12,747
Sch 40
CuNi
6,454 2,798 722 3,153 8,610 21,737
(2) Field labor cost for pipe and fittings

Cost of Maintenance
Maintenance should be considered in the analysis if the cost of maintenance is significantly different for the
piping materials under consideration. The effect of maintenance costs on total cost or life cycle costs can be
quantified for each materials candidate. The analysis requires an estimate of the cash flow required for
installation and maintenance on each system for each year of the project life. Annual cash flow would
include expenditures for inhibitors, cathodic protection, exterior coatings, inspection, cleaning, repairs,
deferred production, etc. If it is normal to replace the system once or twice during the project life, the total
cost of the replacement should be included in the cash flow schedule. The anticipated expenditures can be
entered in a net present value (NPV) spreadsheet to determine the total cost for each material option.
January 2003

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29
The following is an example of cash flow summaries that might be assumed for the materials that have been
discussed above.
System 1: Fiberglass Pipe, 4 diameter (nom), 225 psi pressure rating
Installed cost - $13,706 (Table 5-5)
Maintenance Costs
Flush system every 2 years - $2,000
Exterior coating at year 12 $4,500
Repairs at years 12 & 18 - $5,000 each

System 2: Carbon Steel, 4 diameter (nom), Schedule 80
Installed cost - $12,747
Maintenance costs
Internal clean & flush every year - $2,000
Replace system at year 7 & 15 $22,000

System 3: Copper Nickel, 90/10, 4 diameter (nom), Schedule 40
Installed cost - $21,737
Maintenance costs
Internal clean and flush every year - $2,000
Repairs at years 6, 12 & 18 - $6,000 each

Life Cycle Cost Analysis
The net present value (NPV) method can be used to compare the project life-cycle costs, or the total costs
for the alternative materials. Readers are referred to Reference 3, NACE Publication 3C-194, Economics
of Corrosion for a thorough explanation of the present value method. The NACE document describes a
spreadsheet tool that can be used to enter the annual cash flow associated with each material option, and
the spreadsheet is used to calculate the annual cost or the total cost for each. The results of the NPV
analysis, Table B-6, indicates the installed cost and the annual cost for a 25-year project life for each
material. The analysis also provides the results in terms of the net present value for projects of 10 and 25
years in duration. Based on the assumptions used in this example, fiberglass is the low cost option.
However, fiberglass may not always be the low cost option and the reader is encouraged to perform a cost
analysis that is specific to the materials and the system under consideration for a given project. The entry
data for NPV analysis is shown in Table B -7.
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30

Table B-6 Comparative Results of NPV Analysis for Offshore Piping Materials

Table B-7 Net Present Value Input Data
Initial Data
Project Piping System for Offshore Platform

Financial
Factors
Inflation 4.00%
Cost of Capital 8.00%
Tax Rate 34.00%


System 1 Fiberglass Pipe, 4" D, 225 psi
Initial $12,598 Estimated Life 25 Salvage $ 0 Abandonment 0
Yearly Expense Costs
Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10
0 2,000 0 2,000 0 2,000 0 2,000 0 2,000

Year 11 Year 12 Year 13 Year 14 Year 15 Year 16 Year 17 Year 18 Year 19 Year 20
0 11,500 0 2,000 0 2,000 0 7,000 0 2,000

Year 21 Year 22 Year 23 Year 24 Year 25
0 2,000 0 2,000 0
Piping Material Initial Cost Annual Cost
(25yr Proj)
NPV (10yrs) NPV (25yrs)
Fiberglass
(4D, 225 psi)
$12,598 $2,077 $12,458 $22,176
Carbon Steel
(4D, Schedule 80)
12,747 4,230 28,174 45,153
Copper-Nickel 90/10
(4D, Schedule 40)
21,373 3,714 26,102 39,647
January 2003

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31

System 2
Carbon Steel, 4" D, Schedule
80
Initial $ 12,747
Estimated
Life 25Salvage $ 0
Abandonme
nt 0
Yearly Expense Costs
Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10
2,000 2,000 2,000 2,000 2,000 2,000 22,000 2,000 2,000 2,000
Year 11 Year 12 Year 13 Year 14 Year 15 Year 16 Year 17 Year 18 Year 19 Year 20
2,000 2,000 2,000 2,000 22,000 2,000 2,000 2,000 2,000 2,000
Year 21 Year 22 Year 23 Year 24 Year 25
2,000 2,000 2,000 2,000 2,000



System 3 Copper-Nickel, 90/10, 4" D, Schedule 40
Initial $

21,373
Estimated
Life 25Salvage $ 0
Abandonme
nt 0
Yearly Expense Costs
Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10
2,000 2,000 2,000 2,000 2,000 8,000 2,000 2,000 2,000 2,000
Year 11 Year 12 Year 13 Year 14 Year 15 Year 16 Year 17 Year 18 Year 19 Year 20
2,000 8,000 2,000 2,000 2,000 2,000 2,000 8,000 2,000 2,000
Year 21 Year 22 Year 23 Year 24 Year 25
2,000 2,000 2,000 2,000 2,000
January 2003

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32
APPENDIX C - PIPING SYSTEM USED IN COST ANALYSIS EXAMPLE

CEAC-GL-2002-0101
Guideline
Fiberglass Products for Offshore Platforms


Acknowledgement: Contents contributed by Steve Groves, BP, and Bill Cole, CEAC Consultant
2

Fiberglass Pipe

The use of Fiberglass (FRP or GRP) pipe on offshore topsides has increased significantly
since the mid 90s. The use of fiberglass in firewater systems accounts for much of the
increase, but fiberglass products are candidates for several systems on offshore platforms.

Advantages of Fiberglass Pipe

Lightweight FRP pipe systems weigh approximately 40% of equivalent steel systems.

Corrosion free FRP piping does not corrode. FRP firewater systems are reliable
because there is no corrosion debris to clog the nozzles. Chemical inhibitors are not
needed to handle corrosive fluids. FRP systems need little maintenance and replacement
is seldom required.

Low cost Installed cost of FRP systems is usually less than coated steel or copper
nickel systems. The life cycle cost of FRP systems is typically lower than competitive
metal systems.

Safety FRP products are easy to handle by hand and no hot work is required. The result
is fewer injuries in the workplace during construction and operations.

Products for Offshore Applications

Fiberglass pipe is a candidate for seawater systems, ballast systems, open drains,
produced water piping, injection lines, potable water, fire water systems, column pipe and
sanitary drains. Table 1 shows some of the products available for general use
applications.

Table 1 - Fiberglass Pipe Products for Offshore Water Service*

Product Series Pressure Rating
(PSI)
Resin Manufacturer
Bondstrand 2000M 250 (1-16
225 (18-40)
Epoxy Ameron
International
Fiberbond 20HV 200 (2 - 12)
150 (14 18)
100 (20 - 24)
Iso Polyester EDO
Specialty Plastics
Green
Thread
175
250
175 (2-36)
250 (1-36)
Epoxy Smith Fibercast
Wavistrong EST 20 250 Epoxy Future Pipe
*Conductive version of each product is available
3



Fiberglass products for firewater ring mains must
be qualified to Level 3 fire endurance ratings. A
summary of qualified products is shown in
Table 2.

Ameron and Smith Fibercast both have products
with low smoke and toxicity characteristics when
exposed to fire. These products are suitable for
sprinkler and sanitary piping in enclosed areas
such as accommodation modules.

Table 2 - Fiberglass Pipe Products Qualified
for Fire Water Ring Main Service*

Product Series Type
Approval
Pressure
Rating (PSI)
Resin Manufacturer
Bondstrand 2000M

USCG
ABS
250 (2-16)
225 (18-40)
Epoxy Ameron
International
Bondstrand PSX-L3 USCG
ABS
250 (2- 6)
225 (8 16)
Phenolic Ameron
International
Fiberbond 20FRE** USCG
ABS
200 (2-12)
150 (14-18)
100 (20-24)
Vinyl
Ester
EDO
Specialty Plastics
Green
Thread
250

USCG
ABS
250 (2-36) Epoxy Smith Fibercast
* - Conductive version of each product is available
** - Series 20FR20 a vinyl ester product available with
pressure ratings of 290 psig to 12 & 260 psig to 18



Fiberglass products for dry deluge piping
must be qualified with modified Level 3
fire tests or with jet fire tests. The products
that are currently qualified for deluge systems
are shown in Table 3.



4

Table 3 - Fiberglass Pipe Products Qualified for Fire Water Dry Deluge Piping*

Product Series Type
Approvals
Pressure
Rating (PSI)
Resin Manufacturer
Bondstrand PSX JF USCG
ABS
225 (1-12) Phenolic Ameron
International
Bondstrand 2000M FP USCG
ABS
250 (1 16) Epoxy Ameron
International
Fiberbond 20JF USCG
ABS
200 (2- 10) Vinyl
Ester
EDO
Specialty
Plastics
Green
Thread
250-F USCG
ABS
250-F (1- 24) Epoxy Smith
Fibercast
* - Modified Level 3 fire endurance is required for deluge piping. Pipe qualified by jet fire testing is also
acceptable for deluge service. Conductive versions of each product are available

Engineering Considerations

Typical applications include fire water, main and deluge, sea water supply, sea water
cooling, water injection, potable water, sanitary water, ballast water and drain lines.
Pressure ratings for offshore products are normally based on the pressure limits of
connections and fittings. The pressure rating should include a safety factor of 4.0,
minimum, on the burst strength of fittings and connections.
The fire performance of FRP firewater piping is better than CuNi. Products for ring
main systems are resistant to pool fires when filled with water. Products approved for
deluge piping must be resistant to pool fires or jet fires for five minutes in a dry
condition, followed by flowing water.
Engineering analysis of fiberglass piping systems is critical to the prevention of
premature failures due to inadequate support, improper location of supports, water
hammer, etc.
It is extremely important that fiberglass pipe be installed by bonders and inspectors
who have been trained and certified to a specification approved by the owner.
Offshore grades have increased wall thickness for enhanced resistance to impact, but
severe impact events can still cause crazing in the pipe wall. FRP pipe should be
located to reduce the occurrence of impact loads when possible.
Industry standards are available to govern the specification of FRP piping systems.
Fiberglass pipe manufacturers will provide system engineering assistance, supply
material, fabricate spools, provide onsite construction, provide onsite inspection and
conduct proof tests. It is advisable to use the services of the manufacturer as much as
possible

5

Fiberglass Grating

Fiberglass grating (FRP) has become a very successful product for offshore topsides.
Designers have gained experience with FRP grating and more contractors have
experience with FRP grating following several large projects in the late 90s. FRP
grating is becoming the standard for TLPs, SPARS and FPSOs. FRP grating is also
being used on fixed platforms when weight savings is important.

Advantages of Fiberglass Grating

Lightweight Fiberglass grating is approximately one third the weight of steel grating
when installed. More than 200,000 square feet of FRP grating was used on the Shell Ursa
platform resulting in weight savings of 700 ton.

Ease of installation - Fiberglass grating panels are easily handled by two laborers, and
can be cut and fit on the job using abrasive blades in carpenter saws. It is not necessary to
engineer or precut the panels. Field cut panels eliminate the need for drawings. Each
piece is cut to fit and no rework is required. Standard size panels are quickly fastened to
support beams with Hilti stud clips or with G clips. The cost of installation is far less
than for steel grating .

Safety Fewer injuries are incurred during installation because the product is lightweight
and does not cause pinch injuries. The non-slip surface of FRP grating prevents falls and
is better than steel in wet or dry conditions. FRP grating gives more on impact, so there is
lower probability of falls and lower probability of injury in the event of a fall. Composite
grating is more comfortable to walk on and to kneel on. In addition, FRP grating will not
get as hot as steel in the event of a nearby fire. Products with fire integrity ratings
provide improved performance for areas with high fire retardance and low smoke
emission requirements.

Low maintenance costs Steel grating requires extensive maintenance and will
probably have to be replaced two or more times during the life of an offshore platform.
FRP grating requires very little maintenance. Products with good UV resistance will last
the full life of the platform. The low maintenance characteristics of FRP results in a large
cost advantage over the life of a project as compared to steel.


Products

It is important to use the most suitable grating products. Both molded and pultruded
products can qualify, but the pultruded products are recommended. Typical properties for
molded, pultruded and pultruded fire integrity products are shown in Table 4.
6


Table 4 - Comparison of Typical Molded and Pultruded Products

Grating
Type
Series Span
1


(In.)
Resin

Max
Uniform
Load
2

(PSFU)
Grating
Weight
(PSF)
Product
Cost
3

($/SF)
Installed
Cost
3

($/SF)
Molded 1.5Th
x
1.5Sq
36 ISO PE 133 3.8 7.50 14.50
Pultruded


1.5
I Bar
48

ISO PE 225 3.3 8.50 12.00
Pultruded
Fire
Integrity

1.5
I bar
48 Phenolic 200 3.1 11.00 14.50
1 Center to center spacing for support beams
2 - 0.25 max deflection
3 - Typical project pricing direct from grating manufacturer





Fire integrity grating is available for areas with fire endurance requirements. Level 3 fire
endurance is required for walkways on open decks that may be used for escape, for fire
fighting or for emergency operations. Level 2 fire endurance is required for personnel
walkways, platforms or access areas in lifeboat embarkation zones or for temporary safe
refuge stations in open deck areas. Grating products must pass the prescribed fire tests
and have Coast Guard (USCG) Type Approval to qualify for offshore facilities under
USCG jurisdiction. Products that have USCG Type Approval are shown below. Shell
has used Duragrid phenolic products throughout several of their large projects. Duragrid
was used in the power module, the wellbay module, the drilling module and the process
module.
7

Engineering Considerations
Pultruded grating is recommended. Pultruded grating is lighter, stronger, stiffer and
installation costs are half that of molded grating.
Support beams should be on 48-inch centers for pultruded grating.
Iso polyester grating can be used in most areas in combination with phenolic grating
for the critical areas. Some use phenolic grating throughout the entire platform.
Grating should be ordered by lots in standard lengths, and cut to fit on the
construction site. Pre-engineering is not required.
Grating should be attached with G clips or with Hilti clips. Saddle clips are not
recommended.
Conductive coatings are not required on fiberglass grating for offshore applications.
Orthopolyester grating, a lower cost product, is not recommended for offshore
service. Premium grade vinyl ester products with increased chemical resistance are
also available, but are not normally required for offshore service.
Grating products for wave zone areas should be addressed separately. The
recommended products are not the same as those used on topsides.
Manufacturers
The U.S. Manufacturers of fiberglass grating are Strongwell, Fibergrate and Seasafe.


8

Secondary Fiberglass Structure

Pultrusion manufacturers offer additional fiberglass products that can be used for
walkways, access structure and cable support systems. Applications include cable tray,
cable tray support systems, handrails, stairs, ladders (including cages), access platforms
and well head platforms.



Advantages of FRP Secondary Structure

Low Weight Fiberglass products provide an opportunity to substantially reduce the
weight of topsides, typically 40 to 75% versus steel.
Low installation costs Installation costs are usually lower for the fiberglass products.
Low maintenance costs Maintenance costs are far less for fiberglass products than for
comparable steel products.

Engineering Considerations

FRP structure are low in stiffness as compared to steel. Designs are often governed by
deflection limits rather than strength limits.
UV resistant materials should be specified for offshore service.
The price of FRP structure ranges from 1.5 to 2.5 times the price of galvanized steel.
Skilled fabricators can achieve significant savings in installation costs as compared to
steel. FRP structure is usually cost effective for applications with service life
requirements greater than 15 years

Manufacturers/Fabricators

The US manufacturers for these products are Enduro, Strongwell, Fibergrate, Seasafe Inc.
and AIMS International, Inc. European manufacturers include Lionweld Kennedy, MITA
and Racolin.

9

Tanks and Vessels


Advantages of FRP Vessels

Lightweight Weight savings of 50% are
typical compared to stainless steel.
Low cost Lower installed cost,
particularly when replacing corrosion
resistant alloys. Maintenance and
operating costs should be substantially
lower.
Smooth internal surface - Facilitates
cleaning.


Engineering considerations

Low pressure FRP vessels and tanks are available for storage or process applications.
Low pressure vessels can be very large. Pressure ratings go up to 15 psig plus
hydrostatic head. Governing standards are ASME RTP-1 and BS 4994.
High pressure FRP vessels are also available. High pressure vessels must be qualified
to ASME Section X. Class I vessels may have pressure ratings to 150, 1500 or 3000
psig depending on the construction of the vessel. Class I vessels are qualified by test
of a prototype to destruction. Class II vessels may have pressure ratings ranging from
15 to 200 psi depending on the diameter and the design method. Class II vessels are
qualified by non-destructive testing.
Typical applications for FRP vessels include seawater filters, water storage, and
chemical storage. FRP vessels can be used to store hydrocarbons such as diesel fuel,
gasoline and lube oil when approved by the governing regulatory body.
Generally, the cost of FRP is between that
of carbon steel and stainless steel.
Design and fabrication of nozzles and
other attachments with good durability is
an engineering issue. Good procurement
specifications are important. The
fabrication QC plan and user inspections
are important considerations.

Manufacturers
Vessel manufacturers include Forbes,
Balmoral, Garlway, RL-Industries, Inc.,
Ershigs, Inc., and Lincoln Composites.
10

Other Applications

Small Modules, Panels and Fire Protection Cladding

Composites can be designed with the required fire, acoustic and thermal performance in a
single panel and have been used very effectively for the construction of small modules
and cladding. The lightweight facilitates the installation of pre-assembled units.

Applications include fire and blast enclosures for emergency shut down valves (ESDV),
actuators and riser end fittings; external cladding for thermal insulation and fire
protection of steel structure and wind walls. Blast relief panels and fire walls with
endurance ratings of H120, H60 and A60 are also available.

Major manufacturers include: SP Offshore Composites; Alderly Materials; Vosper
Thorneycroft; Mech-Tool; Fiberforce; Balmoral; Fiberglass Unlimited Inc; Hamon; MSP;
Coflexip; DML.

Caissons and Pull Tubes

Composite caissons by Ameron were evaluated in laboratory studies in the mid nineties.
Five installations were completed between 1994 and 1997. Composite caissons eliminate
the corrosion issues that often occur with steel caissons.

Pull tubes (J-tubes) are also candidates for composite construction. Hydro installed a
number of composite pull tubes on the Troll platform.

Potential manufacturers are Ameron, Hunting Engineering, DML, Plastillon Oy and
Balmoral.

Subsea Protection Structure
Fiberglass grating is used to construct lightweight, corrosion free impact protection
structure for subsea equipment such as well heads and piping manifolds.

Low Pressure Composite Valves

New composite valve products have been
developed in recent years. Potential
applications are for water and chemical
service lines.

The two principal manufacturers are
Dresser Industries and Advanced
Valve Technologies.
11

Engineering Documents and References
Pipe
"ABS Guide for Building and Classing Facilities on Offshore Installations", Appendix I, Plastic Pipe
Installations
IMO Resolution A.753 (18), "Guidelines for the Application of Plastic Pipe on Ships".
US Coast Guard "Policy File Memorandum on the Fire Performance Requirements for Plastic Pipe per
IMO Resolution A.753 (18)", PFM 1-98.
API Specification l5LR, Sixth Edition, 1990, "Specification for Low Pressure Fiberglass Line pipe"
ASTM Fl173 - 95 "Standard Specification for Thermosetting Resin Fiberglass Pipe and Fittings to be
Used in Marine Applications".
ISO DIS 14692 "Petroleum and natural gas industries - GRP piping"
"Specification and Recommended Practice for the use of GRP Piping Offshore", UKOOA, 1994
"Fiberglass Pipe Handbook", SPI Composites Institute, 1992
"Fiberglass Pipe Design", AWWA Manual of Water Supply Practices, AWWA M45, 1996
Grating and Secondary Structures
"Structural Design of Polymer Composites", EUROCOMP Design Code and Handbook
US Coast Guard "Policy File Memorandum on the Use of Fiber Reinforced Plastic (FRP) Grating and
Cable Trays", PFM 2-98
BS 4592: Part 4 -1992 "Industrial type flooring, walkways and stair treads: Specification for glass
reinforced plastic open bar gratings".
BS 5395: Part 3 "Code of Practice for the Design of Industrial Type Stairs, Permanent Ladders and
Walkways".
ASTM Fl092-87 "Standard Specification for Fiberglass (GRP) Open Weather Storm & Guard Square
Handrails"
Tanks and Vessels
BS 4994: 1987 "Design and Construction of Vessels and Tanks in Reinforced Plastics" ASME X: 1995
"Fiber-Reinforced Plastic Pressure Vessels".
ASTM 3299 Filament Wound, Corrosion Resistant FRP Tanks
ASME Section X Fiber-Reinforced Plastic Pressure Vessels
ASME RTP-1 Reinforced Thermoset Plastic Corrosion Resistant Equipment

Fiberglass-Composite Pipe Group/Europe
P.O.Box 6 4191 CA Geldermalsen Holland
tel. +31 345 587 587 fax +31 345 587 561
Introduction in to glass
reinforced plastics
General statement A general definition of a composite is a synergistic combination of
two or more materials. More specifically, the composites referred
to here comprise a high strength reinforcement in fibrous form,
incorporated into and bonded together by a matrix, usually a
thermosetting polymer. The term fiber reinforced plastics (FRP) is
widely used to describe such materials with glass reinforced
plastic (GRP) when the reinforcement is glass fiber. Glass
reinforced epoxy (GRE) is used when, as in the case of much
composite pipework, epoxy resin is the matrix
The nature of E-glass Most glass fibers consist of E-glass, a term which once stood
fibers for electrical grade glass, as used in insulators and capacitors.
This glass, which is transparent and brittle, but of high strength, is
a super-cooled mixture of metallic oxides. Glasses in bulk form
tend to have relatively low strength levels, because of the
presence of microscopic surface flaws which act at site for crack
propagation. Glass in fibrous form can be much stronger provided
that the surface of the fibers is protected at all times against
damage. Glass is produced in a furnace about 1200C and spun
into fibers by allowing it to drain under its own weight through
many heated bushings. Molten glass is quite corrosive, and the
bushings must be made from platinum to avoid damage, and to
protect the glass from contamination. Each bushing contains
many hundreds of holes through which the molten glass must
pass before forming fibers of approximately 10 microns in
diameter.
The secret of the strength of glass fibers, and of their ability to
bond to polymeric matrices is the size which is applied to the
surface of the fiber's in the form of an aqueous solution shortly
after the fiber's emerge from the bushings. The size contains a
polymeric binder which coats the glass surface to protect it and
lightly binds together the individual fiber's in each fiber tow to
prevent them rubbing against one another during subsequent
handling and processing. The size also contains a coupling agent
- 1 - a reactive component, usually an organosilane, which is a
multi-functional molecule. The silane part of the molecule bonds
tightly to the surface of the glass while the organic part is
designed to attach itself to the polymer matrix. When purchasing
glass fiber it is necessary to stipulate the type of resin matrix to be
used, since some coupling agents are specifically chosen to be
compatible with particular resins. The size also contains a film
former to enable it to spread over the glass surface and lubricants
to facilitate processing without damage.
Technical Bulletin 1
May 1998
2
Despite the presence of the size, every processing or handling
operation introduces flaws and reduces the strength of the
glass. By the time it has been incorporated into the composite, the
effective tensile strength is generally about 1700 Mpa, which is
many times tower than its strength immediately after leaving the
bushing.
After spinning, the glass fiber tows, referred to as rovings
1

are
wound at high speed onto cylindrical packages, or cheeses, and
placed in a drying oven where the water in the size coating is
removed. These cylindrical packages are the basic intermediate
from which a wide variety of glass reinforcing products are
manufactured. Examples of such products are described in figure
1 and are given in table 1 and 2.
The tex of a fiber tow or roving is its weight in g per km.
Undirectional rovings can be used directly in composite
manufacture, or they can be converted to other intermediate
products. Direct applications include the uni-directional rovings
used in process such as spray lay up, filament winding and
pultrusion. Alternatively, the glass strands may be chopped,
usually to a length of 50 mm, and sprinkled onto a moving belt to
make chopped strand mat (CSM), the most widely used
reinforcing product for boat building and other general purpose
GRP products. CSM contains randomly orientated glass strands,
held together by the application of a small amount of polymeric
binder. In purchasing CSM, it is important to specify the type of
binder: some are soluble in liquid resin, some are not.
More importantly, some binders are unsuitable for use in
laminates to be continuously immersed in water. CSM is widely
used in contact moulding, resin transfer moulding and other
processes.
Continuous strand mat or swirl mat is similar in some respects to
CSM, except that the fiber's are continuous. Swirl mat is used in
pultrusion, where the reinforcement is required to have sufficient
integrity to allow it to be pulled through the process under tension.
Technical Bulletin 1
May 1998
3
Glass fibre manufacture
intermediate products Figure 1.
and process
Properties of fibres and
typical composite Table 1. Fibers and metals
materials
Density Modulus Tensile Specific Specific
10
3
-kg/m
3
(Gpa) strength stiffness strength
Mpa (GPa)* (MPa)*
E-glass 2.5 70 1700 28 680
carbon 1.8 230 to 820 2000 to 820 128 to 1111 to
7000 455 3900
Ararnid 1.4 130 3000 98 2140
Polyethylene 0.97 170 3000 175 3090
HT steel 7.8 210 750 27 96
Aluminium 2.7 75 260 28 96
*Stiffness or strength divided by Specific Gravity
Table 2: Material properties
Resin Reinforcement Possible applications Density Tensile Tensile comp. Approx.
(g/cm
3
) strength Modulus strength cost
(Mpa) (Gpa) (Mpa)* ( /kg)
Polyester E-Glass CSM 1.44 80-180 7.3.9.3 140-150 1.6
E-Glass WR General Hand lay-up 1.63 210-300 12-21 150-270 1.8
E-Glass uni 1.80 410-1180 1241 210480 1.8
S-Glass WR Increased stiffness 1.64 440 20 210 5.6
amid WR 1.31 430 26 115 17.1
vinylester E-Glass WR General RTM lay up 1.89 342 25 355 2,4
Glass WR 1.90 =520 =45 -- 5.8
Aramid WR Increased & high stiffness 1.35 =500 =40 -- 20.2
Carbon WR 1.50 =600 =85 -- 18.0
Epoxy E-GIass WR Higher strength, durability 1.92 360 17 240 3.0
E-Glass Uni Fatigue loading 1.92 1190 39 1001 3.2
Aramid WR High stiffness 1.33 517 31 172 20.9
1.38 1379 76 276 21.0
High strength & stiffness 1.53 625 73 500 48.3
1.57 2040 134 1000 18.5
Phenolic E-Glass CSM Non/semi structural, fire 1.50 85-150 5-7.5 -- 2.1
E-Glass WR high temperature resist. 1.65 220-330 13-17 -- 2.2
Acrylic E-Glass WR Structural, Fire/high 170 308 21 292 2.3
temperature resistance
Note: these figures are for guidance only
Technical Bulletin 1
May 1998
4
Glass fiber rovings may also be woven by standard textile
processes into a range of reinforcing fabrics. Such woven rovings
can have various types of weave, such as plain, satin or twill, plain
being the most common. Woven rovings can be used in
processes such as contact moulding, resin transfer moulding and
pre-preg manufacture. In their most common form, woven rovings
have equal quantities of fiber in the warp and weft directions,
giving orthotropic laminates with roughly similar properties in
these two directions. It is also possible to produce biased fabrics
with different quantities of fiber in the two directions, the extreme
case being "unidirectional" fabric, where almost all the
reinforcement is the in the warp direction, with lust sufficient
stitching in the transverse direction to maintain integrity during
processing
Recently, there has been interest in "non-crimp" fabrics, where
uni-directional rovings are stitched together in layers. These
fabrics produce somewhat stronger, stiffer laminates than woven
fabrics, because the rovings do not undulate as they would in a
conventional fabric. It is also possible to stitch together layers or
plies with different fiber orientation, including 45 plies, as well
as 90 ones.
C-glass C-glass is chemically resistant glass, used as a protective layer in
the manufacture of pipes and other GAP
components exposed to aggressive environments. Unlike E-glass,
C-glass, which is manufactured by a different process, is not
available in the form of continuos rovings. It is supplied as a non-
woven mat, known as surface veil. The use of C-glass is intended
to provide a resin rich barrier layer between a particular fluid
environment and the main stress-bearing part of the laminate.
Other special glass and In addition to E-glass, there is range of glassy
ceramic fibers reinforcements of alternative composition, designed to give
either superior mechanical performance or resistance to certain
types of environment. These types of glass reinforcement are
more expensive than E-glass, by a factor of 5 to 30, depending
upon the material. S-glass, S2-glass and A-glass offer substantial
strength and small stiffness improvements over E-glass, while
ECR- glass offers enhanced resistance to certain types of
corrosive environment. The use of these special glasses offshore
is not currently significant, but could grow.
Silica and aluminia fiber's have much better high temperature
performance than E-glass, which softens well below 1000
0
C.
Benefits can therefore be achieved by combining small amounts
of these fiber's with E-glass when hydrocarbon fire resistance is
needed.
Technical Bulletin 1
May 1998
5
The nature of Polymers consist of long organic chain molecules. They are
thermosetting resins held together by two types of bond: the strong covalent
bonds joining the atoms within the chains and the weak Van der
Waals bonds which are between adjacent chains. If the chains are
linear, the polymer can be melted or softened to allow it to be
shaped, then cooled again.
Resins of this type are known as thermoplastics. If, on the other
hand, the chains are bridged or cross-linked to form a molecular
network, a polymer is obtained which cannot be melted and
cannot be easily deformed without either fracture or
decomposition taking place. This type of polymer is known as a
thermoset.
Although there is interest in using thermoplastic polymers as the
basis for composites, thermoplastics matrix composites are still at
an early stage of development, and hence are unsuitable for large
structures. All the resins of current interest for offshore use are of
the thermosetting type.
Typical characteristics of thermosetting polymers are that they
usually have stiffness values in the range 2-4 GPa, depending on
the degree of cross linking, with strength values around 40-70
MPa and, being bound together chemically, they are capable of
relatively little plastic deformation. Hence they cannot be shaped
by flow or plastics deformation. It follows that when fabricating
composite parts. from thermosetting polymers the shaping
operation must be carried out at the same time as the chemical
reaction that establishes the cross linked network. The cross-
linking process, known as curing, can be carried out in two
different ways. In the case of cold curing, the cross-linking
reaction is started by mixing together components which react. In
hot curing, the sequence of reactions which produces cross-
linking is initiated by raising the temperature.
The cure reaction often fails to go to completion initially. In
C most cases, the properties of the composites are
considerably improved if a post-curing operation is carried
out. This is usually done by placing the component in an oven for
several hours at elevated temperature. Sometimes, however, the
size or shape of the component may prevent this.
Thermosets become softer as temperature is increased, but do
not melt in the way that thermoplastics do. At an elevated
temperature, large segments of the molecules eventually become
mobile and the Modulus falls to a low value. The
temperature where the Modulus drops most sharply is called the
glass transition temperature or Tg. This temperature is often
taken as an approximate indication of the maximum service
temperature of the resin. Eventually, at some temperature in
excess of the glass transition temperature, the resin will begin to
decompose.
Technical Bulletin 1
May 1998
6
Polyesters These are the resins most commonly used in the manufacture of
thermosetting composites in the uncured state they consist of a
polymer, an unsaturated polyester resin. Unsaturated means that
the backbone chain contains some carbon-carbon double bonds.
The polyester is dissolved in a reactive monomor, usually styrene.
To cure the resin, a peroxide initiator must be added, which
decomposes to produce free radicals which act on the styrene
monomor, causing it to polymerise. The polymerisation takes
place by the opening up of the double bonds in the styrene and
the double bonds in the polyester chain are also involved in this
reactions, leading to a molecular network where the polyester
chains are cross-linked by polystyrene ones, as shown
schematically in figure
2.
Scheme of the filament
winding process Figure 2. Schematic representation of the cure mechanism of
polyester resins
In cold -cured polyesters, the decomposition of the peroxide
initiator is catalysed by adding an accelerator, usually a cobalt
salt. In hot-cured resins the peroxide decomposition is triggered
simply by increasing the temperature.
The constituents of the polyester chain can be varied to confer the
desired properties on the final polymer. For instance, the density
of the cross-links can be controlled by varying the number of
double bonds in the chain, known as the reactivity of the resin.
Resins with high reactivity produce highly cross-linked products
which have a high glass transition temperature and good chemical
resistance, but which are somewhat brittle at room temperature.
Low reactivity resins give a lower level of cross-linking, a lower Tg
and less chemical resistance, but are tougher at room
temperature.
Technical Bulletin 1
May 1998
7
The advantage of the free radical cure mechanism is its ease of
control. The uncured resins are fairly stable and have a long shelf
life but when they are required to cure, the reaction may be
brought about rapidly and controllably. The period of time for
which the resins remain processable after the curing system has
been added is known as the pot life. Different pot lives are
required according to the size of the laminating operation and the
process used. The rate of cure can be varied by changing the
amount of curing agent added, and additionally, a delay in the
onset of curing, which may be needed for instance when
laminating large structures, can be achieved by adding an
inhibitor. The polyesters also have some disadvantages. The cure
reaction is temperature sensitive, so the environmental
temperature must be held within certain limits. The resins also
tend to emit styrene vapour during processing, which is
undesirable from a health and safety viewpoint. Good ventilation
is required when laminating large areas.
Epoxy Vinylesters These resins are, to a certain extent, a chemical
compromise between epoxies and polyesters. The
unsaturated polyester is replaced by an epoxy-like one,
which is much more chemically and thermally resistant.
Moreover, the styrene content is decreased. The curing
mechanism is similar to that of the polyesters, although more
accurate control of the quantities of curing agent added is
essential, as the cure reaction is less tolerant of
compositional variations than in the case of polyesters.
Epoxy vinylesters, or simply vinylesters or variants of this
system are used in place of polyester when improved
toughness and chemical resistance is needed.
Epoxies Epoxy resin systems generally consist of two separate
ingredients which must be mixed immediately prior to
processing. One of these is the epoxide or resin part of the
system. Although the constituents of the molecule may be
varied to achieve certain final properties, the key
characteristic is the epoxide or ring like structure at each end
of the molecule, and the fact that there are a number of -OH
groups present on the chain. The cross-linking reaction may
involve both the end groups and the hydroxyl (-OH) groups.
The second ingredient of the resin is the hardener, which is
frequently a primary or secondary amine or an acid anhydride. For
wet laminating and filament winding, the main offshore uses,
amine cured epoxies are preferred. Two different types of amine
may be used; aliphatic amines or aromatic amines.
Aromatic amines give the highest T
a

values, and the best
mechanical and chemical properties at high temperature, but they
are most expensive. Aliphatic amines are less expensive and
below 100C their cured resin properties are at least as good as
those of aromatic amines. They do, however, require careful post
curing.
Technical Bulletin 1
May 1998
8
Unlike the polyester resins, epoxies lake longer to cure during
processing. Anhydride cured epoxies have excellent properties
and are used in prepeg systems for aerospace and also in large
quantities in piping Systems.
In the case of epoxy prepregs, the reinforcement is impregnated
with resin and cure allowed to progress to an intermediate B-stage
where it is halted. The prepeg is then kept at low temperature until
it is needed for moulding. Prepreg systems are much more
expensive than composites produced by the "wet resin route", but
they do produce products with excellent properties. Some
companies with in-house pre-pregging facilities are beginning to
use prepeg systems for marine construction.
Phenolics These are the oldest class of synthetic polymers. Recently, many
improvements have taken place in the chemistry of
these resins, which have rendered them suitable for use in
composites. There are two main types of phenolic resin which am
distinguished by the type of curing agent used.
The majority of the liquid resins processed by cold cure are
hardened by the addition of a strong acid catalyst. The catalyst
can cause problems with corrosion of mould tooling and there can
also be difficulties with the alkali content of glass fiber
reinforcements from certain sources, which can interfere with the
action of the curing agent. Most phenolic resins contain a certain
amount of water, and further water is evolved during the cure
reaction. Although most of the water can be removed by a high
temperature post cure, this usually leaves the matrix with a
number of microvoids. Despite this, and despite the fact that the
matrix is relatively brittle in the un-reinforced state, phenolic resin
composites have good mechanical properties, which at room
temperature are comparable to those of composites based on
isophtalic polyester. Because of the presence of the microvoids,
phenolics show a higher level of water absorption than the other
resins but there is little evidence as yet that this causes any long
term deterioration of properties.
The outstanding feature of phenolic resins, which has proved the
driving force behind the development of more easily processed
grades, is their fire performance. They possess relatively good
levels of integrity at high temperatures, have low smoke and
toxicity as well as low levels of heat release. For these reasons,
they may well be the only resin systems which can be tolerated in
laminates facing in critical area's such as accommodation
modules and safe havens. The reason for the good performance
of these resins in tire is that instead of decomposing and
volatilising at high temperatures, the aromatic ring structure in
phenolics condenses progressively, eventually producing a
carbonaceous char, which persists for some time. However, a
disadvantage of phenolics in fire is that any water present in the
laminate can sometimes lead to violent delamination when it
volatiles.
Technical Bulletin 1
May 1998
9
Because of their generally attractive attributes in fire, there have
been attempts recently to develop grades or resin that can be
processed by pultrusion. These have met with some limited
success, and there are now two manufacturers in Europe offering
phenolic matrix pultrusions.
Phenolic resins are also used as the basis for foams, which have
excellent insulating properties, combined with low
toxicity. They are unfortunately very friable, which greatly restricts
their feasibility for use as a core for sandwich
panels.
There are, however, a number of phenolic based syntactic core
materials which contain various lightweight mineral
fillers bonded together in a phenolic matrix. Some of these
materials have exceptionally good burn-through
characteristics are therefore viable core materials for heat and
blast protections panels.
In addition to the acid-cured phenolics, there is another class,
known as novolacs, which are cured by alkaline agents. These
resins are favoured for hot cure processes such as press and
prepeg moulding. Recently, to overcome the problems of both
acid and base cured resins, new "neutral

curing systems have
been introduced.
Filament-Winding This is the process by which composite pipework is manufactured,
but which has also the potential to be used for large complex
structures. There are several configurations, but in the most
common one, shown in Figure 3, continuous tows of
reinforcement are drawn through a resin bath to wet them and
then applied, via a transversing feed eye, to a rotating mandrel.
The speed of the feed eye relative to that of the mandrel
determines the winding angle. For pressure piping, a winding
angle of t 550 is normally used. Modern winding machines are
numerically controlled to lay down a precisely controlled number
of covers of reinforcement. For chemical resistance, pipes are
usually provided with a resin rich inner linen This is applied
to the mandrel in the form of a non-woven scrim, soaked in resin.
The reinforcement in the scrim may be either C-glass of non-
woven polyester fabric.
Filament winding is not limited to simple cylindrical shapes:
pipes with bell ends may be wound, as may pressure vessels or
storage tanks with wound in ends. Large structures such as
storage tanks and silos may also be produced by filament
winding. In some cases as with large tanks, the process may be
simplified to one of hoop winding, to minimise the rate at which
the feed eye must transverse the mandrel. When this is done,
spray lay-up of randomly oriented fiber's is often employed in
addition to the hoop winding to give the structure the necessary
transverse strength.
Technical Bulletin 1
May 1998
10
The process is not limited to axi-symmetric structures:
prismatic shapes and more complex parts, such as tee-joints may
be wound on machines equipped with the appropriate number of
degrees of freedom. Complex shapes which have been
successfully filament wound include rocket motor casings
1
aircraft
fuselages and railroad hopper cars.
In the introduction of pipework, impregnated lows are wound onto
waxed, preheated steel mandrels. After winding these are
removed from the machine to an oven for curing and post curing,
during which the mandrel is continuously rotated to maintain
uniformity or resin content around the circumference. After curing,
the pipe is removed from the mandrel, either by a hydraulic
extractor or by the application of internal pressure. Although most
filament winding operations are batch processes, it is possible to
filament wind continuous pipework.
Figure 3. Scheme of the filament winding process
RECIPROCAL FILAMENT WINDING PROCESS
Source 1994 Marinetech Research, Project CP 275, General Principals
and Guidance for the Application of Glass Reinforced Composites
Offshore.
Edited by : D.A. Spagni and A.G. Gibson.
Contributors: M.J. Cowling, T. Hodgkiess, T.Y. Reddy.
Fiberglass-Composite Pipe Group division Europe
P.O. Box 6 - 4191 CA Geldermalsen - Holland
tel. +31 345 587 587 - fax +31 345 587 561
email: info@ameron-fpg.nl
Ameron Calculation Manual for
Bondstrand GRE Pipe Systems
INDEX
1. Introduction
2. Pipewall Thickness based on internal pressure
2.1 Wall thickness
2.2 Diameter
2.3 Dimensional pipe properties
3. Trust force due to temperature and variation in length
3.1 Length Change
3.2 Thrust
4. Support and guide spacing
5. Pipe bending radius
6. Collapse resistance for liquid
7. Pipe-ring stiffness
8. Waterhammer and surge
9. Headloss or pressure drop for liquid flow
10. Literature
11. Legenda
Calculation Manual for Bondstrand GRE Pipe Systems
Technical Bulletin 3
July 1997
2
1. Introduction In this Technical Bulletin an overview is given of commonly
used formulas in relation with Glassfibre Reinforced Epoxy
piping.
2. Pipe wall thickness The minimum required wallthickness of the pipe is based on
design codes as ASME and ANSI. To most products an inferior
liner is added, consisting of C-veil and resin.
3. Trust forces due to
temperature, pressure
and variation in length
On many occasions the pipe is fabricated to pressure as well as
a varying temperature of the medium. Pressure variation will
cause a length change if the product is unrestrained and due to
the Poisson effect an increase in pressure will shorten the pipe.
This is alos mathematically explained. Expension and
contraction due to temperature variations and internal pressure
will either combined or individual result in thrust forces on the
anchoring points
4. Support and Guide
spacing
The formulas for the calculation of the optimal distance between
two supports or guide spacings for single, partial and
continuous spans are given. The calculations take into account
density of the liquid and the weight of the pipe.
5. Bending radius A slight gradual change in direction or deviation of the pipe may
be obtained by using the flexibility of the pipe. In that case the
allowable bending radius of the glass reinforced epoxy pipe can
be calculated
6. Collapse resistance for
liquid
When the external pressure on the pipe may exceed the
internal pressure one has to take into account the collapse
resistance of the pipe. This is ruled by equations which differs
from those for internal pressure.
7. Pipe-ring stiffness To make calculations for earth and wheel-loads on buried pipe,
values have to be used like STIS (= Specific Tangential Initial
Stiffness), STES (= Specific Tangential End Stiffness) and other
values, as used in the U.S.A., Stiffness Factor and Pipe
Stiffness.
8. Waterhammer and
surge
Changes in velocity of fluids cause changes in pressure.
Especially when these velocity changes are sudden, they can
result in high forces, which may harm the piping system
9. Head loss or pressure
drop for liquid flow
Head loss or pressure drop can be calculated by using the
Hazen-Williams equation for water and the Darcy-Weisbach for
laminar flows, e.g. for oil. Head loss in fittings are calculated by
defining a corresponding pipe length.
Calculation Manual for Bondstrand GRE Pipe Systems
Technical Bulletin 3
July 1997
3
1. INTRODUCTION
This manual presents the calculations, used by Ameron to
calculate the various aspects related to glass reinforced epoxy
(= GRE) pipe.
This will help the reader to understand the equations which
govern certain common engineering cases of GRE
pipesystems. Also these equations can be used to make the
required calculations.
When making these calculations the input data should be
based on the physical mechanical properties, diameter and
wallthickness of Ameron products by: The spreadsheet
presented by Ameron in its documentation gives these values.
2. PIPEWALL THICKNESS BASED ON INTERNAL PRESSURE
2.1 Wall Thickness The minimum pipewall thickness is calculated with the formula
according to
ASME / ANSI B31.3 [1] (Paragraph A304.1.2):
t
Dp
2sF
s
=
+ p
(1)
ASTM D-2992 [2] uses the same type of formula to calculate
the hoop stress as follows:
= p
(D - t )
2t
a s
s
(2)
The above mentioned formula has been rearranged to induce
the internal liner and is used by Ameron to calculate the
minimum reinforced wall thickness of Bondstrand pipe as
follows:
Minimum reinforced wall thickness in [m]:
t
p(d 2t )
2 s p
p
2
d t 2t
s
l s
s l
=
+

=
+ +
st
(3)
Minimum total wall thickness in [m]:
t t t t
s l a
= + + (4)
2.2 Diameter Minimum outside diameter of pipe in [m]:
D d 2t = + (5)
Mean pipe wall diameter in [m]:

D d t
m
= + (6)
Calculation Manual for Bondstrand GRE Pipe Systems
Technical Bulletin 3
July 1997
4
2.3 Dimensional pipe
properties
Cross section area of minimum pipe wall in [m
2
] :
( )
A d t
w
= + t (7)
Area of pipe bore in [m
2
]:
2
b
d 0,25 A = (8)
Cross section area of min. structural wall in [m
2
]:
( ) ( ) A d 2t t t
s l s s
= + + (9)
Cross section area of inner liner in [m
2
]:
( ) A d t t
l l l
= + , (10)
Weight of pipe per unit length in [kg/m
2
]:
w A A
p s s l l
= + (11)
Weight of fluid per unit pipe length in [kg/m
1
]:
f
2
f
d 0,25 w = (12)
Linear moment of inertia of the pipe [3] in [m
4
]:
I I I
l s lin
= + (13)
Linear moment of inertia of the structural wall in [m
4
]:
( ) ( ) ( )
4
l
4
s l s
2t d 2t 2t d
64
I + + + =

(14)
Linear moment of inertia of the inner liner in [m
4
]:
( ) ( )
4
4
l lin
d 2t d
64
I + =

(15)
Note! In case of calculating with the moment of inertia of the
total wall thickness and the elasticity modulus of structural wall,
the moment of inertia may be multiplied by 0,25, which is the
approximate ratio between the modulus of elasticity of the liner
and the structural wall. The stiffness factor IE = I
s
E
s
+ I
lin
E
l
= I
s
E
s
+ I
lin
E
s
0,25 so I = I
s
+ I
lin
0,25.
3. TRUST FORCE DUE TO TEMPERATURE AND VARIATION IN LENGTH
3.1 Length change Like in other types of pipe material, in unrestrained condition,
Bondstrand fiberglass reinforced pipe changes its length with
temperature change. Tests have shown that the amount of
expansion varies linearly with temperature, in other words the
coefficient of thermal expansion of Bondstrand pipe is constant
[4, 5, 6].
Calculation Manual for Bondstrand GRE Pipe Systems
Technical Bulletin 3
July 1997
5
Change in length due to thermal expansion in [m]:
L L T
T
= (16)
Subjected to an internal pressure, a free Bondstrand pipeline
will expand its length due to thrust force at the ends of the
pipeline.
The amount of change in the pipeline is a function of pressure,
pipe wall thickness, diameter, Poisson's ratio and the effective
moduli of elasticity in both, axial and circumferential direction at
the operating temperature.
Change in length due to pressure in [m]:
L L
pd
4tD E
pd
2tD E
L
pd
4tD E
(1 2
E
E
)
p
2
m l
c
2
m c
2
m l
c
l
c
=


(17)
The total length change is the sum of the change due to
temperature and due to pressure.
The above shown equation for length change due to pressure,
compared to the general equation:
L L
P