PH KLAMBON STEEL PIPING

PH.1 PROTECTIVE COATINGS

PH.1.1 EXTERNAL COATING TO STEEL PIPES

1.1.1 Steel pipes of nominal bore less than 2000mm shall be hot dip galvanised.
Galvanising shall be heavy duty to SABS EN 10240. All pipes are to be
wrapped at the factory. The specification is as follows :

Pipe barrel shall be cleaned to remove dirt, be solvent wiped and then
primed all in accordance with Clauses PSLT3.2 and PSLT5.2.
Denso Ultraflex 750 shall be applied at a 55% overlap in accordance with
Clause PSLT5.2.6.
The tape wrap shall be stopped 50mm of the rolled groove. Wrapped pipes
shall be supported on appropriate dunnage that will not damage the tape
wrapping during handling , transportation or storage on site.

PH.1.2 INTERNAL LINING OF STEEL PIPES

1.2.1 Steel pipes of nominal bore less than 200mm shall be hot dip galvanised to
SABS EN 10240 heavy duty.

PH.2 GALVANISED MILD STEEL PIPES - SPECIFICATIONS

PH.2.1 PIPES AND COATING

2.1.1 All pipes to be roll grooved before galvanising.

2.1.2 Klambon couplings shall be manufactures as SP CAST IRON couplings.

2.1.3 Klambon couplings shall be hot dip galvanised to SABS EN 10240. The bolts
of all be cuphend oval neck with UNC tread and all nuts and bolts shall be hot
dip galvanised.

2.1.4 The coupling gaskets shall be EPDM rubber suitable for use in potable water
applications. Bolts and nuts for coupling shall be to UNC standards.

The coupling shall be capable of withstanding hydraulic pressures of one and a

half times the maximum working pressures in the pipeline (i.e. maximum
working pressure in pipeline is 3.3 mPA). Coupling shall allow a lateral
movement of up to 5mm and shall allow deflection of at least 2,8 degrees.

Pipe rolled grove seats and rubber seals to be free of all weld spatter and
galvanising residue.

Remedial grinding and application of cold galvanising to affected areas will not
be permitted.
 Ten percent of all pipes and couplings to be factory hydro-tested to 5 Mpa
pressure for a 2 hour period with no visual leaks present at the end of the test
period.

PH.3 TAPE WRAPPING SYSTEM FOR COATING OF STEEL PIPES

PH.3.1 TAPE WRAPPING SYSTEM FOR STRAIGHT PIPE LENGTHS

PH.3.1.1 General

All material shall conform to either SABS or IS09001 Quality Assurance

Standards and to SABS 1117-1977 Type C and Type D - Plastic Wrapping for
the Protection of Steel Pipelines.

Tenders shall provide with their tenders details of case histories of not less
than 5 years duration in South African conditions inclusive of a full set of test
results of the proposed tape system together with a full set of technical back up
literature giving the physical properties and cathodic disbondment test which
have been carried out.

The engineer reserves the right to request test samples or to conduct test
procedures to verify the physical or electrical properties of the tape system at
any stage and to reject the coating if the system fails to comply with any or all
the requirements of this specification.

Maximum tape widths for wrapping straight lengths of steel pipe shall not
exceed 200mm in width. All polyethylene films shall be pre-treated to provide a
barrier layer between the film and the bituminous adhesive compound. All
polyethylene films shall also be key coated to avoid disborning of the backing
film from the adhesive compounds.

PH.3.1.2 Primer

The primer shall be a polymer modified bituminous primer (i.e. Denso Primer
D) suitable for application using a brush or spray gun, and shall be in
accordance with the requirements of SABS 1117 Type 1 Pipeline Primer.

PH.4 TAPE WRAPPING PROCEDURE FOR STRAIGHT PIPE LENGTHS

PH.4.1 SURFACE PREPARATION

Prior to treatment all steel surfaces shall be cleaned and dirt and grease
removed. Degreasing shall be effected by the use of a water rinseable solvent
degreaser such as that complying with SABS 1244 or, for use in enclosed
systems , with SABS 1365.
After complete removal of oil or grease contamination the pipe shall be
washed with clean potable water to remove all residues including all white
oxide. The surface shall be water break free. The pipe shall then be allowed
to dry.
PH.4.2 HANDLING OF CLEANED PIPE

After the surface preparation described above, the pipe surface shall not be
contaminated in any way.

Operators shall wear clean gloves and all surfaces in contact with the pipe
surface shall be clean and free from oil, grease, grit, dirt and other
contamination.

PH.4.3 CUT BACK OF COATING

The blast cleaned surface shall be stopped off or cut back by suitable masking
which shall not contaminate the cleaned surface as follows:

All pipes up to and including 200mm diameter - 300mm from both ends of
the pipe.

PH.4.4 PRIMING OF SURFACE

Cleaned pipe shall be primed the same day and prior to any recontamination to
the pipe. Any flash rusting, surface oxidation, or other foreign agents shall be
removed by reprocessing through the necessary cleaning steps described
above.

The primer shall be applied in a uniformly thin film, free of runs and snags
covering the entire surface of the pipe. The flow primer shall be regulated so
that the pipe surface is entirely covered and so that a rate of application of 6 to
8m squared per litre is attained.

The solvent shall be allowed to flash off until finger touch dry before application
of tape or mastic.

Uncoated, flooded or arcas primed over improperly cleaned pipe, shall be

cleaned to the satisfaction of the Engineer and re-coated.

PH.4.5 SEALING OF WELD BEAD ( APPLICABLE TO PIPE SPECIALS)

Sealing tape shall be centred over the weld beads. After application the
release paper shall be removed and finger pressure shall be applied to the
tape to seal all void areas. End overlap between consecutive tapes shall not
be less that 25mm.

PH.4.6 APPLICATION OF TAPE WRAP SYSTEM

A constant tension shall be maintained at all times to the inner and outer wrap
to ensure a tightly adhered coating , free of wrinkles, voids and thermals. At
no time shall the narrowing of the tape under tension be greater than 2% of the
total width of the tape.
 The tape wrap shall be applied with a minimum 55% overlap to ensure double
thickness throughout.

After application the tape wrap shall average 1,5mm in thickness at both ends
of the pipe length the outer wrap shall be applied 50mm short of the pipe rolled
grove pipe.

Sealed tape as specified for sealing the weld beads shall be applied at each
end of the tape wrap system to secure the tape wrap and outer wrap ends. the
sealing tape shall be applied spiral by hand for a distance of 300mm from the
tape ends of each pipe. Sufficient tension shall be applied to maintain a tightly
adhered coating free of wrinkles.

PH.4.7 DENSO WRAPPING OF KLAMBON JOINTS & SPECIALS

TO BE UNDERTAKEN BY CONTRACTOR ON SITE

All Klambon joints and specials in contact with the ground to be wrapped on
site as follows :

Apply Denso priming at 9m squared / litre.

Apply where required self supporting Denso Profiling Masticround all irregular shaped
fittings to provide suitable profile for the application of anti-corrosion tapes.
Apply one layer Denso Petrolatum Tape.
Apply 4 layers Denso Cling Wrap.

NOTE : One layer of Denso S105 paste primer to be utilised where pipe
special will be in high water table areas. Rate of application
0,5m squared/kg

PH.4.8 PRODUCT SPECIFICATIONS

DENSO PRIMER D :

Composition : Polymer Bitumen Solution

Flash Point : + 23 degree C minimum
Covering capacity for steel : 6m squared/ litre nominal
Drying Period : 15 minutes average @ 20 degree C.

DENSO ULTRAFLEX 750 :

Base Layer : Polymer Modified Polyethylene

Base Layer Thickness : 0.3mm
Adhesive : Polymer Modified Bitumen.
Adhesive Thickness : 0.45mm
Overall Thickness : 0.75mm
Impact Strength : >5N/mm
 Elongation at break : 250%
Adhesion to Primer D : 2N/mm minimum
Adhesion to self : 2N/mm minimum
Dielectric Strength : 15Kv Minimum
Insulation resistance : 10 Megohm
Service temperature : -20 to + 70 degrees C

DENSO PETROLATUM TAPE :

Tensile Strength : 100N/25mm width average.

Thickness : 1.15 average
Mass : 1.44 kg/m squared average

DENSO CLING WRAP

Minimum Overlap : 55%

Film Thickness : 40 micron