Add Spec Section 23 21 13 Attachment A.pdf

Specifications Attachment A

COLMERY-O'NEIL VA MEDICAL CENTER

2200 SW Gage Blvd. | Topeka, KS 66622

EHRM Infrastructure Upgrades

VA Contract No. 367C77622C0043 Station Project No. 89A5-21-700 Bancroft-AE Project No. 21-116

Addendum#1

December 12th, 2024

Rev. May 2001 Page i

PERMA-PIPE, Inc. XTRU-Therm

Installation Manual

TABLE OF CONTENTS

PREFACE……………………………………………………………………………………………….….…….... i GENERAL PRECAUTIONS………………………………………………………………………………..……. i INTRODUCTION……………………………………………………………………………………………..…… ii FIELD TECHNICAL ASSISTANCE……………………………………………………….………………..…… ii NOTICE……………………………………………………………………………………………………..….….. ii Section 1 - RECEIVING, HANDLING, AND STORAGE…………..…………………,,………..….…….…. 1-1,2 Section 2 - EXCAVATION …………………………………………………………..…………………….….... 2-1,2 Section 3 - ASSEMBLY ………………………….. ………………………………………..………..…..…… 3-1 -- 5 Section 4 - ALTERATIONS AND REPAIRS…………………………………….…….……..…....….……… 4-1,2 Section 5 - TESTING AND INSPECTION …………………………………………….……..…....….……… 5-1 Section 6 - FIELD JOINT INSULATION AND JACKET …………………………..….…..…..…..………… 6-1 -- 7 Section 7 - BACKFILLING ……………………………………..……………,,,,,,…………………….…….... 7-1,2 Section 8 - OPERATION AND MAINTENANCE ……..……………………………….…………….…….... 8-1 WARRANTY……………………………………………………………………….………………………..……... Back

PREFACE

The objective of this Installation Manual is to provide the installer with recommended installation procedures for PERMA-PIPE’S XTRU-Therm piping system. This Installation Manual should be used in conjunction with all other applicable Installation Manual Supplements and engineering drawings and documentation supplied by PERMA-PIPE for the specific project. This Installation Manual addresses all common aspects of the installation process, from initial receiving and storage through final backfill and operation and maintenance.

If leak detection, heat tracing, and/or other ancillary equipment is included with your XTRU-Therm piping system, refer to the appropriate Installation Manual(s) in conjunction with this Installation Manual. If a particular procedure is not addressed in this Installation Manual, contact PERMA-PIPE for additional information, if needed.

The true operating success of the system is greatly dependent upon proper product application, installation, operation, and maintenance. PERMA- PIPE is committed to supporting the proper application and installation of a complete, high quality insulated piping system. This support includes clear and concise product data, and installation recommendations and expert applications engineering support and field technical assistance.

When installed, tested, operated, and maintained in accordance with these recommendations, a successful installation should be achieved and PERMA-PIPE’S XTRU-Therm piping system will provide excellent service, meeting or exceeding expectations.

GENERAL PRECAUTIONS

Due to the many possible variations in applications, use, installation conditions, and environment these installation recommendations can not address all possibilities. These recommendations are for general applicability, they are believed to be reasonably accurate and reliable. The installer is ultimately responsible for a proper installation. Trained and qualified personnel should be used for all phases of the installation. The importance of a proper installation cannot be overstated.

PERMA-PIPE cannot anticipate every circumstance that might involve hazard. The warnings in this Installation Manual are, therefore, not all-inclusive.

The installer must satisfy himself that each procedure, tool, work method or operating technique is safe.

If these recommendations conflict with the project contract specifications or drawings or PERMA- PIPE’S engineering drawings, the more stringent documents should take precedence. If in doubt, please contact your PERMA-PIPE Project Engineer, Project Manager or Field Technical Representative.

Any deviations from these recommendations or PERMA-PIPE’S engineering drawings should be reviewed with the appropriate PERMA-PIPE personnel.

Carefully plan and execute the installation sequence to avoid errors and expensive mistakes. Do Not skip steps.

For underground installations, Do Not complete trench backfilling until all testing and inspection is completed and accepted by the appropriate authority.

A Subsidiary of MFRI, Inc.

7720 North Lehigh Avenue Niles, Illinois 60714-3491 Phone (847) 966-2235 Fax (847) 470-1204 http://www.permapipe.com

Rev. May 2001 Page ii

Installation Manual

INTRODUCTION

XTRU-Therm is a versatile, pre-engineered, factory pre-fabricated insulated piping system for belowground or aboveground applications. XTRU- Therm is available in a wide variety of service pipe materials and for many different applications. The insulation is a low density, low thermal conductivity, rigid polyurethane insulation. The insulation jacket is a durable high density polyethylene (HDPE) material.

The customer is provided with the exact specifications of the XTRU-Therm product supplied for each project.. XTRU-Therm can be purchas ed in one of three different configurations wth varying degrees of factory prefabrication;

• XTRU-Therm Custom – Straight lengths of pipe and fittings are custom fabricated to field verified dimensions and angles. Field cutting of straight lengths of pipe is not required. All field joints are in straight lengths of pipe.

• XTRU-Therm Xpress – 20’ or 40’ insulated straight lengths of pipe. Fittings with standard tangent lengths and standard angles. Straight lengths of pipe are field cut to fit field dimensions. All field joints are in straight lengths of pipe.

• XTRU-Therm Economy – 20’ or 40’ insulated straight lengths of pipe, with field joint and fitting insulation kits. Fittings are field fabricated, insulated and jacketed. Materials are supplied in accordance with an agreed upon bill of material.

Service pipe fittings are supplied by the installer unless otherwise specified and purchased. Straight lengths of pipe are field cut to fit field dimensions.

Field joints are at all fittings and between straight lengths of pipe.

FIELD TECHNICAL ASSISTANCE

PERMA-PIPE Field Technical Assistance (FTA) is available for on site technical assistance. PERMA- PIPE recommends the use of FTA to support the proper installation of the XTRU-Therm piping system by the installer. Field Technical Assistance is provided when included as part of the customer’s purchase order or when purchased separately.

NOTICE

This Installation Manual and the recommendations it contains are reasonably believed to be accurate and reliable. However, due to variations in environment, application or installation, and because the conditions of use are beyond PERMA-PIPE’s control, the user of this Installation Manual assumes all risk connected with the use thereof. The installer of these piping products is ultimately responsible for his own work and, thus, the integrity of the system. PERMA-PIPE assumes no responsibility for the use of information presented herein and, hereby, expressly disclaims all liability in regard to such use.

Any technical recommendations, suggestions or advice with respect to storage, handling, installation or use of PERMA-PIPE’s materials, by, or on behalf of PERMA-PIPE is an accommodation to the Purchaser for which PERMA-PIPE shall have no responsibility, unless responsibility has been expressly assumed in writing by the President or a Vice-President of PERMA-PIPE.

jleise Rectangle

Rev. May 2001 Page 1-1

Receiving, Handling Installation Manual and Storage Section 1

RECEIVING

All materials have been factory inspected and carefully loaded and braced to prevent damage in shipment to the job site. However, even these efforts are sometimes not enough to prevent damage in transit. It is the carrier’s responsibility to deliver the shipment in good condition. It is the receiver’s responsibility to report any loss or damage upon receipt. PERMA-PIPE’s standard terms are F.O.B.

our factory, full freight allowed to job site.

When a shipment arrives at the job site, obtain the following documentation from the carrier before offloading;

• Packing List.

• Bill of Lading

• Material Safety Data Sheets (MSDS Sheets).

• PERMA-PIPE’s Part Drawing Layout (PDL), (if applicable)

• Quality Assurance Documentation as applicable

(x-ray film/reports, CMTR’s, pressure test reports, etc.)

Contact PERMA-PIPE for any missing documentation.

During off-loading, perform the following;

• Check all piping units, cartons, and pallets against the Packing List.

• Visually inspect the piping units, cartoons and pallet materials for damage.

• Review the Material Safely Data Sheets (MSDS) for safe handling and use procedures.

If there are any damaged or missing materials;

• Any shortage or damage must be noted on the Bill of Lading and Packing List.

• Do not dispose of any damaged materials until advised to do so by PERMA-PIPE.

• Immediately submit any claims to the carrier.

Failure to do so will result in loss of compensation for missing or damaged materials.

• Notify PERMA-PIPE of these claims if assistance is required.

• If replacement materials are required, they can be ordered from PERMA-PIPE. You will be advised of replacement purchase costs, which will also be required for your freight claim.

HANDLING

The means by which the piping units are unloaded and handled at the job site is the decision of the receiver. It is imperative that proper care and handling techniques are used to avoid damage.

Damaged piping units may require costly repairs, cause property damage, or worse, personal injury.

Safety and careful handling should be top priorities when handling any of the piping units.

PERMA-PIPE supplies two nylon slings with each shipment. If additional slings are required, they can be purchased from PERMA-PIPE.

The following procedures are recommended for handling the piping units;

• Support each piping unit with nylon slings during all phases of handling. The nylon slings prevent damage to the piping units.

• Do Not use hooks, steel cables or chains for handling any piping units.

• Do Not drag or drop piping units.

• Do Not strike the piping units against hard surfaces at any time.

• Do Not use forklifts for handling piping units.

• Do Not use a nylon sling that has been damaged or is fraying. Damaged slings should be cut in half and disposed of.

• If possible, use a spreader bar to maximize control of the piping units during handling.

PERMA-PIPE does not supply spreader bars.

Rev. May 2001 Page 1-2

Receiving, Handling Installation Manual and Storage (cont.) Section 1

HANDLING (cont.)

• Use two nylon slings where possible. The use of two nylon slings provides much more control of the load. A length of pipe suspended with a single nylon sling is more likely to swing out of control, potentially causing a safety hazard.

• Space the slings about 15 - 20 feet apart.

• If a piping unit is damaged during handling, refer to Section 4 for repair recommendations.

SAFETY CONSIDERATIONS

Safety should always be a primary consideration when unloading and handling piping units.

• Never lift more weight than your equipment can safely handle.

• Never lift more weight than the rating of the slings.

• Do Not use damaged slings, cut up and dispose of any damaged slings.

• PERMA-PIPE chocks only the outer piping units in each layer (or tier) on the truck. It is important to recognize that as you lift piping units off the truck, nearby piping units may become unstable and roll. Chock piping units that are not being unloaded.

STORAGE

Proper storage of piping units and loose shipped materials is very important. These materials can deteriorate or sustain damage if not properly stored.

Proper storage is the responsibility of the receiver.

The following procedures are recommended;

PIPING UNITS

• If possible, store the piping units in a warehouse or heated shelter. If this is not possible, store the piping units on high ground to avoid ingress of water into the pipe ends.

• When stacking, stack piping units in the same fashion they were received.

• Wooden shipping braces must be used as runners between layers of pipe.

• Do Not stack piping units more than three (3) tiers high.

• Use foam or other padding between layers.

THREE (3)

TIERS

MAX.

• If the ends of piping units were shipped with plastic covers and/or plastic pipe end caps, do not remove them when storing the piping units.

If any of the protective covers were damaged in shipping or handling, they must be restored by replacing the protective plastic cover where necessary.

• Use a light colored or opaque tarp to cover outdoor stored piping units to protect the piping units from weather and the Sun’s ultraviolet (UV) rays that can discolor or degrade the materials.

LOOSE SHIPPED MATERIALS

• Store all field joint and ship loose materials indoors and in a dry area.

• Keep the materials in their original shipping containers. The recommended storage temperature range for chemicals is 60° - 85° F (18° -29°C).

• Refer to the Material Safety Data Sheets (MSDS Sheets) for proper handling, storage and use.

Some materials may be flammable or hazardous.

Extreme care must be taken so they are stored away from any open flames.

• Do Not allow chemicals to freeze as this may hinder effectiveness or render useless.

• Contact PERMA-PIPE if additional MSDS Sheets are needed.

Rev. May 2001 Page 2-1

Excavation Installation Manual

Section 2

EXCAVATION

GENERAL

All types of flexible pipe derive some of their strength from the passive soil resistance around the pipe.

Therefore, proper excavation and backfilling of the trench is very important to insure a structurally sound system.

XTRU-Therm piping is designed to handle normal soil and H-20 traffic loading when the recommendations in this Installation Manual are followed and a minimum of 2 feet of properly compacted backfill is provided. It should be noted that shallower burial depths will increase the piping system heat loss/gain slightly. See Section 7 for backfilling and compaction recommendations.

Special burial depths and compaction requirements may be required at taxiways, runways, railways, roadways, and other areas of high surface loading conditions. It is recommended that the customer contact both PERMA-PIPE and the local authority for more specific instructions.

NOTE: All federal, state and local regulations concerning jobsite safety should be observed.

TRENCH WIDTH – SINGLE PIPE

The minimum recommended trench width for a single pipe trench is the insulation jacket diameter plus 12 inches (6 inches between the pipe and trench wall).

4" MIN. BEDDING

6" MIN.

(TYP.)

TRENCH WIDTH

TRENCH WIDTH – MULTI-PIPE

For multi-pipe trenches, pipe centerline dimensions can usually be found on the layout drawings.

The minimum recommended trench width is the sum of all insulation jacket diameters, plus 6 inches between each pipe plus 12 inches (6” between pipes and 6 inches from the pipe to trench wall).

6" MIN. (TYP.)

TRENCH WIDTH

TRENCH DEPTH

The total trench depth should allow for a 4-inch bedding, the largest insulation jacket diameter and a minimum 24 inches cover above the largest insulation jacket diameter. See the contract specifications or drawings for specific burial depth requirements. For cover depths less than 24 inches, contact PERMA-PIPE. If special loading conditions, such as railroads, taxiways, runways are encountered contact PERMA-PIPE and the local authority.

24" MIN.

COVER

TRENCH BEDDING

The trench floor should be completely cleared of stones and rocks and then covered with 4-inches of compacted bedding. The bedding must be raked uniformly along the entire length of the trench and graded to a minimum slope of 1 inch per 40 feet to allow for gravity draining of the piping system.

Trench bedding material should be in accordance with the recommendations provided in Section 7.

BELL HOLES

Digging bell holes at field joint locations allows room for service pipe joining, testing, and field joint insulating and jacketing. A common way to dig bell holes is to cut across the trench with a backhoe.

The bell holes should be cut into the trench wall and between 1½ and 2 feet below the trench floor. Bell hole locations should be identified and dug before lowering piping units into the trench.

Rev. May 2001 Page 2-2

Excavation (cont.) Installation Manual

Section 2

ALTERNATE TRENCH BOTTOM

SAND OR DIRT BERMING

An alternate method to trench bedding is to sandbag or dirt berm the bottom of the excavated trench. If the berms elevate the bottom of the pipe above the trench bottom sufficiently, bell holes may not be required. However, the space under the pipe will require backfilling and compacting as described in Section 7.

EXCAVATED TRENCH BOTTOM

SAND OR DIRT BERM

INSULATED PIPE

4" MINIMUM

The material used for the berms should be in accordance with the recommendations provided in Section 7. If bags are used the bags should be cut open to allow proper compacting of the berm material. Do Not use wood or other degradable materials for berms.

The trench floor should be completely cleared of stones and rocks before placing the berms. The berms should be elevated to provide a minimum slope of 1 inch per 40 feet to allow for gravity draining of the piping system.

Berm spacing should be approximately 10 feet and berm width at least 6 inches. These values may need to be increased or decreased depending on the service pipe material, size, and weight but should be adequate enough to prevent the pipe from sagging between berms and to prevent the insulation and insulation jacket from being overloaded at the berms.

When ready to begin backfilling, refer to Section 7 for backfilling and compacting recommendations. It is critical that the space under the pipe be properly backfilled and compacted to provide a stable trench bed for the piping system.

SPECIAL SOIL CONDITIONS

UNSTABLE SOIL

During excavation, an unstable soil condition may be encountered, particularly in installations with deep burials. If this occurs, shore the trench walls before lowering the piping units into the trench. As the shoring is removed, replace it with compacted backfill material.

SHORING

Organic soils or plastic clays and silts with high liquid limits may be encountered that are incapable of supporting the pipe. Remove the poor soil, and replace it with proper bedding soil to a depth that will provide a firm stable foundation.

ROCK BOTTOM TRENCH

A rocky or uneven trench foundation should be covered with a firm soil or gravel before the trench bedding is placed.

BEDDING

FIRM SOIL ROCKY FOUNDATION

GRANULAR SOIL

In granular soil, the trench wall should be sloped at the natural angle of repose.

OVER EXCAVATION

Any accidental over-excavation should be filled with bedding material and compacted to 90-95% modified proctor.

Rev. May 2001 Page 3-1

Assembly Installation Manual

Section 3

ASSEMBLY

GENERAL

Assembly of the piping system should be in accordance with the engineering design of the piping system. Proper placement of end seals, anchors, expansion loops, expansion elbows, Z-bends, tees, external expansion pads, thrust blocks, and supports is critical to prevent overstressing of the piping system due to thermal expansion / contraction and other mechanical loads.

The amount of factory pre-fabrication of the XTRU- Therm piping system depends on the configuration it was purchased – Custom, Xpress, or Economy. See the Introduction at the beginning of this Installation Manual for descriptions of each configuration.

XTRU-Therm piping ordered and supplied as a PERMA-PIPE pre-engineered system has been designed for the specified conditions and includes a Layout Drawing that indicates the designed routing and dimensions of the piping system. When the piping units have been fabricated to field dimensions, the Layout Drawing will include the part number of each piping unit and its designated location. Correct placement of the piping units is critical. Piping units installed out of order and/or with unapproved alterations may lead to operating hazards, system failure, and/or voiding of PERMA-PIPE’s warranty.

If the XTRU-Therm piping ordered and supplied is not a PERMA-PIPE pre-engineered system, the engineering design of the piping system is the responsibility of others and should be performed by a qualified piping system designer.

ANCILLARY EQUIPMENT

If the XTRU-Therm system being installed includes any ancillary equipment such as leak detection or heat trace, refer to the appropriate Installation Manual(s) and/or PERMA-PIPE documentation in conjunction with this Installation Manual.

PREPARATION AND SET -UP

Personnel performing any phase of installation should be trained and qualified in the procedures they will perform and be familiar with the appropriate sections of this Installation Manual, Installation Manual Supplements, and all engineering drawings and documentation supplied by PERMA-PIPE for the specific project.

Proper tools, equipment, and materials should be used for handling and installation of the piping units to prevent damage. All tools, equipment, and materials needed for a particular operation or procedure should be made readily available before starting. Refer to other sections of this Installation Manual for “specialty” tools that may be required.

COLD / WET WEATHER CONDITIONS

When installing pipe in temperatures below 60°F, or in rain or snow, refer to the Installation Manual Supplement for Cold / Wet Weather Conditions.

LAYOUT

Installation can be simplified by laying the piping units in the order they will be assembled. To avoid damaging the piping units they should not be laid out until trenching and bedding is completed for belowground systems or structural supports completed for aboveground systems.

ABOVEGROUND SYSTEMS - SUPPORTING

XTRU-Therm piping installed aboveground should be properly supported to prevent damage to the insulation or insulation jacket. Insulation shields or equivalent should be used at support locations to prevent overloading of the insulation or insulation jacket. Proper support type (fixed, guide, roller, etc.)

and spacing is required to prevent overstressing of the piping system and limit deflection between supports. Sloping, if required, must be provided for in the support system elevations.

CUTTING TO FIELD DIMENSIONS

Piping units may need to be cut to field dimensions.

All cuts should be made in straight sections of pipe in the manner described below.

Refer to the appropriate Installation Manual Supplement or PERMA-PIPE drawings for special service pipe end preparation requirements for bell & spigot PVC, ductile iron, FRP, or O-ring or gasketed coupling joints.

• Mark the location of the cut on the insulation jacket.

• Cut back the insulation jacket and insulation to the required dimension on each side of the cut mark. A knife, hand saw, or power saw can be used to cut the insulation jacket and insulation.

Be careful not to cut the service pipe.

• Remove all insulation in the cut back area. Clean to bare service pipe material.

• Cut the service pipe and restore the end preparation (weld bevel for steel pipe, shaved OD for FRP pipe, etc.).

Rev. May 2001 Page 3-2

Assembly (cont.) Installation Manual

SERVICE PIPE JOINING

If sufficient handling equipment is available, it may be easier to complete some field joints before lowering into the trench or lifting onto supports. This may require more than one crane and/or a spreader bar to lower or lift the joined piping units into place. Do Not allow the joined piping units to bow when handling.

Do Not join piping units with flexible joints such as gasketed bell & spigot or o-ring joints before lowering or lifting.

CAUTION: If your XTRU-Therm piping system has been supplied with the pressure testable field joint closure system, be sure to slide the pressure testable closure sleeve over the pipe ends at each field joint before joining the service pipes together.

All service pipe field joints should be completed in the following manner:

• If the piping unit has been supplied with end protection, remove all end protection materials.

• Properly align each field joint. Verify the legs of elbows and tees are perpendicular, and the legs of expansion loops are parallel to each other. If the legs of elbows, tees, and expansion loops are not positioned correctly, it will affect the overall length of the pipe run.

• Use the appropriate service pipe joining technique (weld, braze, adhesive, o-ring/gasketed coupling, etc.) for each field joint.

See the appropriate Installation Manual Supplement if required.

• Wrap the field joint area with plastic and seal with tape to keep moisture, rain, water, and dirt away from the service pipe and insulation ends.

• Perform all required service pipe testing and inspection and pressure test the service pipe as described in Section 5.

• After successful completion of all service pipe testing and inspection, insulate and jacket the field joints as described in Section 6.

LOWERING / LIFTING

Piping units should be moved into place in the following manner;

• Remove all free standing water from trenches and bell holes before lowering piping units. Bell holes and trench bedding must be dry during piping unit installation.

• Lower or lift the piping units into place. Do Not drop the piping units. Spreader bars or more than one crane may be required depending on the size of the piping unit being handled.

• If the piping units have been supplied with end protection, remove all end protection materials.

Do Not remove end protection materials until the service pipes are to be joined.

SERVICE PIPE ANCHORS

Service pipe anchors control the direction of movement caused by thermal expansion/contraction and the resulting service pipe stresses. Service pipe anchors must be properly placed to prevent overstressing of the piping system.

XTRU-Therm anchors consist of a steel anchor plate rigidly attached to the service pipe. For underground piping systems the anchor plate should be encased in a concrete anchor block as described below. For aboveground systems the anchor plate should be welded to a structure capable of withstanding the loads the anchor plate will apply to it.

CONCRETE ANCHOR BLOCKS

Concrete anchor blocks are used to transfer the service pipe anchor force to the soil. The anchor block should be keyed into undisturbed earth to the maximum extent possible. The backfill around the balance of the anchor block should be compacted as described in Section 7. The resulting soil around the anchor block should have a minimum bearing capacity of 2000 lbs./ft.2. If the soil can not provide this bearing capacity the anchor block size should be increased to increase its bearing surface area enough to offset the lower soil bearing capacity.

Contact PERMA-PIPE for assistance if needed.

Anchor block concrete should be 2000 psi minimum rated concrete. Rebar is not required. Anchor blocks for typical applications should be formed to the minimum dimensions shown on the details below.

KEYHOLE TRENCH WALL

INTO UNDISTURBED SOIL

ANCHOR PLATE

30"

9" TYP.

ALL AROUND

CONCRETE

ANCHOR

BLOCK

CONCRETE

ANCHOR

BLOCK

Rev. May 2001 Page 3-3

Assembly (cont.) Installation Manual

CONCRETE ANCHOR BLOCKS (cont.)

If unusually high anchor forces will be encountered, such as those resulting from expansion joint thrust forces, larger anchor block and specially designed anchor plates may be required. Contact PERMA- PIPE for assistance if needed.

For multiple pipe trenches, use the dimension in the figure above but increase the width by the additional insulation jacket outside diameters plus the spacing between insulation jackets (6 inches minimum).

UNRESTRAINED JOINTS - CONCRETE THRUST

BLOCKS

Concrete thrust blocks are required when the service pipe joints are unrestrained, such as unrestrained gasketed bell and spigot PVC or ductile iron, or o-ring or gasketed couplings, or FRP adhesive joints.

Concrete thrust blocks are required for all changes in direction (elbows, tees), changes in size (reducers), and dead ends (caps, plugs, valves).

The size of the thrust block is dependent upon the test pressure, pipe size, type of fitting, number of pipes, and soil conditions. Refer to the Installation Manual Supplement for Concrete Thrust Blocking for thrust block sizing and installation recommendations.

UNRESTRAINED JOINTS – TIE-INS

Transitions from an unrestrained joint system to a restrained joint system are often made when an underground piping system enters a building or manhole or transitions to aboveground piping.

When tying in an unrestrained joint system to a restrained joint system an anchor is required in the restrained joint system to resist the thrust load of the unrestrained joint system. This anchor should be within 5 feet of the end of the unrestrained joint system. The anchor should be designed to withstand the same load as if it were a concrete thrust block, as described above.

EXTERNAL EXANSION PADS

External expansion pads installed around elbows, expansion loops, z-bends, and tees are used to allow thermal expansion/contraction in underground piping systems to prevent overstressing of the service pipe.

Expansion pad material is available from PERMA-

PIPE.

XTRU-Therm piping ordered and supplied as a PERMA-PIPE pre-engineered system includes a Layout Drawing that indicates the necessary expansion pad locations and thickness and length requirements.

If the XTRU-Therm piping ordered and supplied is not a PERMA-PIPE pre-engineered system, the engineering design of the piping system, including expansion pad requirements, is the responsibility of others and should be performed by a qualified piping system designer.

The total thickness of expansion pad material should be greater than the expected expansion or contraction of the service pipe. The length should be sufficient to allow enough service pipe movement to prevent overstressing of the service pipe.

Expansion pad material is supplied in bulk rolls. The material must be field cut to the width required to wrap around the insulation jacket or previous layer of expansion pad material.

Expansion pads should be installed in the following manner;

• Determine required length and total thickness from PERM -PIPE’s Layout Drawing (if a PERMA- PIPE pre-engineered system) or from the responsible engineer’s drawing.

• Determine the required width from the measured circumference of the insulation jacket or previous layer of expansion pad material. The expansion pad must cover the top and sides as shown below.

• Cut the expansion pad material to the required width and length.

• Install the required length and number of layers of expansion pad as shown below. Exercise care not to compress the expansion pad material during installation.

LENGTH

AS REQUIRED INSULATED PIPE

LENGTH AS REQUIRED

PLACE BACKFILL MATERIAL BOTH

EXPANSION PADS TOTAL

INSULATED PIPE

SIDES TO HOLD IN PLACE

DURING INSTALLATION

THICKNESS AS REQ'D.

TRENCH BEDDING

Issue 1 3/22/01 Page 3-4

Assembly (cont.) Installation Manual

WALL OR FLOOR ENTRIES

PERMA-PIPE recommends that all building or manhole entries be sleeved and the annular space between the insulation jacket and sleeve sealed by a mechanical rubber seal or waterproof sealant. Wall sleeves and mechanical rubber seals are available from PERMA-PIPE.

Mechanical rubber seals function by compressing onto the insulation jacket and wall sleeve. If a mechanical rubber seal is used, an XTRU-Therm wall/floor entry end seal assembly must be used to prevent the mechanical rubber seal from damaging the insulation and jacket. The XTRU-Therm wall/floor entry end seal assembly provides mechanical reinforcement to the insulation jacket and a water tight seal between this reinforcement and insulation jacket. XTRU-Therm Custom and Xpress wall/floor entry end seals are factory fabricated. XTRU-Therm Economy wall/floor entry end seals are field assembled.

XTRU-Therm ECONOMY WALL/FLOOR ENTRY

END SEAL ASSEMBLIES

XTRU-Therm Economy floor/wall entry end seal assemblies consist of an FRP reinforcement sleeve, adhesive, heat shrink sleeve, and heat shrink end seal all supplied by PERM -PIPE for field assembly.

Wall/floor entry end seal assemblies should be assembled in the following manner;

• Measure the circumference of the outside diameter of the insulation jacket.

• Trim the FRP reinforcement sleeve circumference about 1/8 to 1/4 inch smaller than the insulation jacket.

• Abrade and clean the inside diameter of the FRP reinforcement sleeve.

• Abrade and clean the insulation jacket area that will be under the FRP reinforcement sleeve.

• Apply adhesive to the FRP reinforcement sleeve inside diameter.

• Slide the FRP reinforcement sleeve over the insulation jacket. Secure it down tightly to the insulation jacket with steel bands.

• Seal the longitudinal seam with adhesive. Form the seam smooth to the outside surface of the FRP reinforcement sleeve.

• Allow the adhesive to cure.

• Apply a heat shrink sleeve to the back side of the

FRP reinforcement sleeve. Follow the heat shrink sleeve recommendations in Section 6.

• Apply a heat shrink end seal to the front side of the FRP reinforcement sleeve. Follow the heat shrink end seal recommendations below.

FRP SLEEVE, TRIM TO THE

CORRECT CIRCUMFERENCE

AND FILL LONGITUDINAL SEAM

WITH FRP ADHESIVE

SECTION A - A

6" WIDE HEAT SHRINK SLEEVE

24" LONG FRP SLEEVE

HEAT SHRINK END SEAL

A

INSULATION JACKET

A

HEAT SHRINK END SEALS

Heat shrink end seals form a water tight seal between the insulation jacket and service pipe.

Heating the heat shrink end seal causes the adhesive to soften and the heat shrink end seal to shrink compressing the adhesive and forming a seal between the heat shrink end seal and insulation jacket and service pipe.

Heat shrink end seals should be used at all termination ends and open ends of the XTRU-Therm piping system to prevent ingress of water or moisture.

Depending on the configuration of XTRU-Therm purchased – Custom, Xpress, or Economy, some heat shrink end seals may require field installation.

When field installation of heat shrink end seals is required, refer to the Installation Manual Supplement for Heat Shrink End Seals.

HEAT SHRINK END SEALINSULATION JACKET

SERVICE PIPE

ADHESIVE/MASTIC

SEALANT

XTRU-Therm ECONOMY FITTINGS

XTRU-Therm Economy service pipe elbows, tees, and reducers are typically supplied by the installer unless otherwise specified and purchased. These fittings should be joined to the service pipe as described above.

Rev. May 2001 Page 3-5

Assembly (cont.) Installation Manual

XTRU-Therm ECONOMY ANCHORS -BELOW GROUND

XTRU-Therm Economy belowground anchors are field assembled, insulated, and jacketed. PERMA- PIPE supplies the steel anchor plate and steel sleeves. The anchor should be installed in the

• Mark the anchor location on the insulation jacket.

• Strip 8 inches of insulation jacket and insulation on each side of the marked location. Clean to bare service pipe material.

• If required to fit over the service pipe, cut the anchor plate in two halves.

• Weld (or braze if copper service pipe) the anchor assembly to the service pipe as shown on PERMA-PIPE’s engineering drawings and the figure below.

• Seal weld the anchor plate split seams if the anchor plate was cut in two halves. Grind the seal welds flush and smooth.

• Weld the steel sleeves to both sides of the anchor plate.

• Seal weld the longitudinal seams of the steel sleeves. Grind the outside surface of the welds flush and smooth.

• Grind a minimum 1/16 inch chamfer on all outside edges of the anchor plate.

TYP. IF REQ'D.STEEL SLEEVE

FILLET WELD SIZE

EQUAL TO PIPE

WALL THICKNESS

8"

8"

FLARED COPPER

COUPLINGS

SILVER BRAZED TO

SERVICE PIPE STEEL SLEEVE TYP. IF REQ'D.

BELOW GROUND STEEL SERVICE PIPE ANCHOR

BELOW GROUND COPPER SERVICE PIPE ANCHOR

XTRU-Therm ECONOMY ANCHORS -ABOVEGROUND

XTRU-Therm Economy aboveground anchors are field assembled, insulated, and jacketed. PERMA- PIPE supplies the galvanized steel anchor plate and galvanized steel sleeves. The anchor should be installed in the following manner;

• Mark the anchor location on the insulation jacket.

• Strip 8 inches of insulation jacket and insulation on each side of the marked location. Clean to bare service pipe material.

• If required to fit over the service pipe, cut the anchor plate in two halves.

• Weld (or braze if copper service pipe) the anchor assembly to the service pipe as shown on PERMA-PIPE’s engineering drawings and the figure below.

• Seal weld the anchor plate split seams if the anchor plate was cut in two halves. Grind the seal welds flush.

• Weld the steel sleeves to both sides of the anchor plate.

• Seal weld the longitudinal seams of the steel sleeves. Grind the outside surface of the welds flush and smooth.

• Apply a zinc rich paint to the exposed weld areas to prevent corrosion.

TYP. IF REQ'D.GALVANIZED

STEEL SLEEVE

FILLET WELD SIZE

EQUAL TO PIPE

WALL THICKNESS

8"

8"

ABOVEGROUND STEEL SERVICE PIPE ANCHOR

ABOVEGROUND COPPER SERVICE PIPE ANCHOR

FLARED COPPER

COUPLINGS

SILVER BRAZED

TO SERVICE PIPE GALVANIZED

STEEL SLEEVE

TYP. IF REQ'D.

Rev. May 2001 Page 4-1

Alterations and Installation Manual Repairs Section 4

ALTERATIONS

When alterations to an XTRU-Therm piping system are necessary, the considerations herein are recommended. Alterations should be performed using the appropriate installation recommendations described in other sections of this Installation Manual.

PERMA-PIPE or the responsible piping system designer should be consulted to properly design the alteration and ensure the alteration will not adversely effect the design and operation of the piping system.

In all cases it is critical that the insulation, insulation jacket, and insulation jacket integrity be fully restored.

PIPE LENGTH

The change in the piping system layout and effect on the piping system stresses must be considered when the piping system dimensions are changed. Even relatively small changes in dimensions can cause overstressing of the piping system if these changes are made in areas, such as expansion elbows or z-bends, where dimensional changes could cause overstressing of the piping system due to the reduction in flexibility or increase in thermal expansion /contraction displacements.

Pipe cutting should be performed as recommended in Section 3.

FITTINGS OR COMPONENTS

The change in the piping system layout and effect on the piping system stresses must be considered for alterations that add or delete fittings, or other piping system components.

The addition or deletion of anchors, elbows, tees, or other piping system components can have serious detrimental effects on the piping system design and operation.

DESIGN TEMPERATURE OR PRESSURE

An increase in design temperature or pressure can cause overstressing of the piping system. The piping system design should be re-evaluated for any changes in design conditions.

REPAIRS

Remove all damaged insulation jacket material up to the point where the insulation jacket is no longer damaged.

Small areas of damaged insulation jacket, up to 3/8 inch x 3/8 inch, can be repaired using an adhesive melt stick. Adhesive melt sticks are available from PERMA-PIPE. Adhesive melt stick repairs can be made in the following manner;

• Remove the damaged insulation jacket material.

• Abrade the edges of the jacket around the repair area. Clean this area with a clean cloth.

• Gently warm the repair area with a propane torch.

• Melt the adhesive melt stick onto the repair area with a propane torch.

• Smooth and blend the surface and edges of the adhesive into the existing jacket.

ADHESIVE MELT STICK

DAMAGED JACKET

AREA

Small or large areas of damaged insulation jacket can be repaired using a heat shrink sleeve. The width of the heat shrink sleeve should extend a minimum of 6 inches past each edge of the damaged jacket area. See Section 6 of this Installation Manual for heat shrink sleeve installation recommendations.

DAMAGED JACKET

AREA

6" MINIMUM OVERLAP

HEAT SHRINK SLEEVE

Rev. May 2001 Page 4-2

Alterations and Installation Manual Repairs (cont.) Section 4

REPAIRS (cont.)

INSULATION

Remove all damaged insulation material up to the point where the insulation is no longer damaged.

Damaged insulation includes insulation that is wet.

Small or large areas of damaged insulation can be repaired using pour foam polyurethane. See Section 6 of this Installation Manual for installation

Large areas of damaged insulation can be repaired using pre-form polyurethane insulation. See the Installation Manual Supplement for Pre-Formed Polyurethane Insulation for installation

The surface of the repair area should be trimmed to be flush and smooth with the adjacent insulation and insulation jacket.

The insulation jacket must be restored to all insulation repair areas.

SERVICE PIPE

Do Not operate a service pipe that has damage to its pressure retaining capability.

Service pipe damage such as gouges, dents, cracks, bending, or flattening require repair or replacement of the service pipe.

If the service pipe is repaired, the repair method must restore the full pressure retaining capability to the service pipe.

If the service pipe is replaced, an equivalent section of XTRU-Therm piping should be installed with field joints at the connections to the existing system.

Rev. May 2001 Page 5-1

Testing and Installation Manual Inspection Section 5

TESTING

SERVICE PIPE PRESSURE TESTING

Prior to field joint insulating and jacketing and backfilling (for underground systems), all service pipe joints should be pressure tested in accordance with the applicable ASME B31 piping code and any other contract specifications. In the event of conflict the more stringent requirement should be used.

Prior to pressure testing, all anchors, concrete anchor blocks, concrete thrust blocks and any other piping system thrust restraint devices must be in place.

PERMA-PIPE recommends hydrostatic pressure testing (hydrotesting). Pneumatic testing is not recommended due to the safety hazards associated with a large volume of high pressure gas.

The following steps are recommended to be part of the hydrotest procedure;

• After all service pipes are joined, and before field joint insulating, connect pipe test caps at the ends of the pipe run. Pipe test caps, including flanges and blind flanges for testing purposes, are not supplied by PERMA-PIPE.

• Use a pressure gauge sized properly, and close to, the test pressure.

• Set all valves so the section of piping to be tested will be pressurized. In most cases, it is preferred not to test directly against a valve, because they are sometimes the source of a “leak”, especially during standing or timed tests.

• Fill the service pipe completely with water. Vent the service pipe of all air. Trapped air is a common cause of unexplained pressure drops during a standing hydrotest.

• Slowly pressurize the service pipe to test pressure (typically 1½ times the design pressure).

CAUTION: under no circumstance should the system be tested at a pressure greater than the maximum pressure rating of any component in the system.

• Maintain the pressure for two hours, allowing for corrections due to temperature changes.

• Visually inspect all exposed joints for signs of leakage.

• Repair and retest any leaking joints.

PRESSURE TESTABLE FIELD JOINTS

If your XTRU-Therm piping system has been supplied with the pressure testable field joint closure system, refer to the Installation Manual Supplement for Pressure Testable Field Joints.

OTHER TESTING AND INSPECTION

Other tests and inspections, such as water hammer testing, field joint weld radiography, dye penetrant or magnetic particle may be required by the contract specifications. It is the installer’s responsibility to perform these test and inspections, as required, for full contract compliance.

INSPECTION

VISUAL INSPECTION

After the piping system has successfully passed the hydrotest and all field joint insulation and insulation jacketing is completed, and prior to backfilling of underground systems, a final visual inspection of the piping system should be made.

• Walk the pipe lines and carefully inspect the piping for any damage and to ensure all work has been completed. For underground systems, this step should be performed just prior to backfilling.

• Remove all anchor block forms, construction materials, soil or any other work that may have caused damage or may cover damaged areas.

• Any damage should be repaired as described in Section 4.

Rev. May 2001 Page 6-1

Field Joint Insulation Installation Manual And Jacket Section 6

FIELD JOINTS

After completion of all tests and inspections as described in Section 5, each field joint requires application of insulation and insulation jacket to properly complete the field joint.

Field joints are made in straight sections of pipe only for XTRU-Therm Xpress and Custom configurations.

Field joints are made in straight sections of pipe and at fittings (elbows, tees, and anchors) for XTRU- Therm Economy.

The standard XTRU-Therm straight field joint consists of a temporary metal mold, polyurethane pour foam insulation and a heat shrink sleeve.

The standard fitting field joint consists of polyurethane pour foam insulation, transition sleeves, a flexible PVC fitting cover, and sealing tape.

supplied with a different type of field joint insulation or jacket refer to the appropriate PERMA-PIPE Installation Manual Supplement and / or engineering documentation.

supplied with the pressure testable field joint closure system, refer to the Installation Manual Supplement for Pressure Testable Field Joints.

When cold or wet weather conditions are present, tenting and heating may be required to enable the proper application of the field joint materials. Refer to the Installation Manual Supplement for Cold / Wet Weather Conditions.

SERVICE PIPE INSULATION

The standard XTRU-Therm service pipe field joint insulation is polyurethane pour foam insulation. This insulation is supplied as two components, A and B, in bulk liquid form.

The installer must prepare the insulation molds around the field joints, measure the proper amounts of insulation components, mix the liquids to initiate a chemical reaction, and pour the insulation into the mold formed around the field joint. When properly measured and mixed the liquids will react and rise to produce a low density (approximately 2.5 – 3.0 lbs./ft.3) rigid polyurethane insulation around the field joint.

The following paragraphs describe PERMA-PIPE’s recommendations for applying pour foam insulation to XTRU-Therm field joints.

PREPARATION

All materials, equipment, and tools should be made readily available before starting.

Do Not attempt insulating field joints in wet bell holes. If the bell hole is wet, pump it dry before insulating the field joint.

PERMA-PIPE provides the following materials for field joint insulating;

• Polyurethane pour foam insulation, A and B components, in bulk liquid form

• Metal pour foam mold for straight field joints

• Transition sleeves, PVC fitting cover, and sealing tape for fitting field joints (XTRU-Therm Economy)

NOTE: Insulation components A and B must be stored between 60°F to 85°F before use. Insulation stored below 60°F will not react properly. Insulation stored above 85°F may result in spoiling.

The metal molds provided by PERMA-PIPE can be used to insulate at least 10 field joints when properly maintained.

The installer will need to furnish the following;

• Disposable paper mixing pails

• Measuring containers

• Heavy duty gloves

• Dry rags

• Banding wire, rope, or tape

• Mold release

• Safety clothing

• Tin snips

• Wood rasp

• Stir sticks and/or cordless drill and paint agitator

• Denatured alcohol or equivalent solvent

PREPARING THE MOLD – STRAIGHT JOINTS

PERMA-PIPE supplies bulk roll sheet metal material for temporary metal molds for field joints in straight sections of pipe. The metal molds should be cut and prepared in the following manner;

• Measure the circumference of the outside diameter of the insulation jacket at both ends of the field joint. It is normal for there to be differences in the insulation jacket outside diameter at fittings and special components. A slight taper in the field joint insulation will compensate this for.

Rev. May 2001 Page 6-2

Field Joint Insulation Installation Manual And Jacket (cont.) Section 6

PREPARING THE MOLD – STRAIGHT JOINTS (cont.)

• Cut the sheet metal length to 1.25 times the largest measured circumference of the insulation jacket outside diameter.

(Length = 1.25 x Maximum Circumference)

• Prior to each use, coat the entire inside surface of the metal mold with a mold release. Mold release is commonly found in fiberglass supply houses. Non-stick coating sprays, such as PAM , can also be used. Without mold release, insulation may stick to uncoated portions of the metal mold and cause damage to both the insulation and the mold when the mold is removed from the field joint area.

• Wrap the metal mold around the field joint area as shown below. Center it so the ends extend at least 4 inches past the edge of each insulation jacket.

• Band the metal mold with wire, rope or tape 2 inches from each edge. Use two more bands in the middle, evenly spacing all four.

NOTE: It is important to fasten the metal mold tightly around the insulation jacket. Gaps between the metal mold and insulation jacket will allow some of the rising pour foam insulation to escape. This could result in an incomplete pour and require mixing another small batch of insulation to complete the field joint.

• Cut two 2-3 inches diameter pour and vent holes in the top of the metal mold between the bands.

BANDING

MOLD

POUR/VENT HOLE

PREPARING THE MOLD – ANCHOR KITS

Anchors for XTRU-Therm Economy are field assembled, insulated, and jacketed. The insulating mold should be prepared in a manner similar to that for a typical straight field joint as described above but with the following modifications;

• The metal mold for an anchor is not as wide as that required for a straight field joint. The actual width will depend on the amount of insulation and jacket cutback made to install the anchor. It should be wide enough to overlap at least 4 inches on each side.

• One side of the metal mold will wrap around the steel sleeve welded to the anchor plate. The other side will wrap around the insulation jacket.

• Cut only one 2 – 3 inch diameter pour and vent hole.

ANCHOR PLATE W/SLEEVES

BANDING

MOLD

PREPARING THE MOLD - FITTING KITS

Elbow and tee fittings for XTRU-Therm Economy are field assembled, insulated, and…