Protecto | Test Results
Standard Specification For Lining
Sewer Service Ductile Iron Pipe
Procedures For Sealing Cut Ends
And Repairing Field Damaged Areas Of PROTECTO 401 Lined Pipe And Fittings.
PROTECTO 401 Joint Compound
STANDARD SPECIFICATION FOR
LINING SEWER SERVICE DUCTILE IRON PIPE
I. Condition of Ductile Iron Prior to Surface
All ductile pipe and fittings shall be
delivered to the application facility without asphalt, cement lining or any other lining
on the interior surface. The removal of old linings may not be possible, the intent of
this specification is that the entire interior of the ductile iron pipe and fittings shall
not be lined with any substance prior to the application of the specified lining material
and no coating shall have been applied to the first six inches of the exterior of the
II. Lining Material
The standard of quality is Protecto 401 Ceramic
Epoxy. The material shall be an amine cured novalac epoxy containing at least 20% of
volume of ceramic quartz pigment. Any request for substitution must be accompanied by a
successful history of lining pipe and fittings for sewer service, a test report verifying
the following properties, and a certification of the results.
A. A permeability rating of 0.00 when tested
according to Method A of ASTM E-96-66, Procedure A with a test duration of 30 days.
B. The following tests must be run on coupons from
factory lined ductile iron pipe:
- 1. ASTM B-117 Salt spray (scribed panel) - Results to
equal 0.0 undercutting after two years.
- 2. ASTM G-95 Cathodic Disbondment 1.5 volts @ 77 ° F.
Results to equal no more than 0.5 mm undercutting after 30 days.
- 3. Immersion testing rated using ASTM D-714-87.
- a. 20% Sulfuric Acid-No effect after two years.
- b. 25% Sodium Hydroxide-No effect after two years.
- c. 160 ° F Distilled Water-No effect after two years.
- d. 140 ° F Tap Water (scribed panel)- No undercutting
two years with no effect.
C. An abrasion resistance of no more than 4 mils
(.10mm) loss after one million cycles European Standard EN598:1994 section 7.8 Abrasion
The lining shall he applied by a competent firm with
a successful history of applying linings to the interior of ductile iron pipe and
B. Surface Preparation
Prior to abrasive blasting, the entire area to
receive the protective compound shall be inspected for oil, grease, etc. Any areas where
oil, grease, or any substance which can be removed by solvent is present shall be solvent
cleaned using the guidelines outlined in DIPRA-1 Solvent Cleaning. After the surface has
been made free of grease, oil or other substances, all areas to receive the protective
compounds shall be abrasive blasted using compressed air nozzles with sand or grit
abrasive media. The entire surface to be lined shall be struck with the blast media so
that all rust, loose oxides, etc. are removed from the surface. Only slight stains and
tightly adhearing annealing oxide may be left on the surface. Any area where rust appears
before lining must be reblasted
After the surface preparation and within 8 hours of
surface preparation the interior of the pipe shall receive 40 mils nominal dry film
thickness of Protecto 401. No lining shall take place when the substrate or ambient
temperature is below 40 ° Fahrenheit. The surface also must be dry and dust free if
flange pipe or fittings are included in the project the lining shall not be used on the
face of the flange
D. Coating of Bell Sockets and Spigot Ends
Due to the tolerances involved, the gasket area and
spigot end up to 6 inches back from the end of the spigot end must be coated with 6 mils
nominal, 10 mils maximum Protecto Joint Compound. The Joint Compound shall be applied by
brush to ensure coverage. Care should be taken that the Joint Compound is smooth without
excess buildup in the gasket seat or on the spigot ends. Coating of the gasket seat and
spigot ends shall done after the application of the lining.
E. Number of Coats
The number of coats of lining material applied shall
be as recommended by the lining manufacturer. However, in no case shall this material be
applied above the dry thickness per coat recommended by the lining manufacturer in printed
literature. The maximum or minimum time between coats shall be that time recommended by
the lining material manufacturer. No material shall be used for lining which is not
indefinitely recoatable with itself without roughening of the surface.
F. Touch-Up & Repair
Protecto Joint Compound shall be used for touch-up or
repair in accordance with manufacturer recommendations.
IV. Inspection and certification
1. All ductile iron pipe and fitting linings shall he
checked for thickness using a magnetic film thickness gauge. The thickness testing shall
he done using the method outlined in SSPC-PA-2 Film Thickness Rating.
2. The interior lining of all pipe and fittings shall
be tested for pinholes with a nondestructive 2,500 volt test. Any defects found shall be
repaired prior to shipment.
3. Each pipe joint and fitting shall be marked with
the date of application of the lining system along with its numerical sequence of
application on that date and records maintained by the applicator of his work.
The pipe or fitting manufacturer must supply a
certificate attesting to the fact that the applicator met the requirements of this
specification, and that the material used was as specified.
Protecto 401 lined pipe and fittings must be handled
only from the outside of the pipe and fittings. No forks, chains, straps, hooks, etc.
shall be placed inside the pipe and fittings for lifting, positioning, or laying.
PROCEDURES FOR SEALING CUT
ENDS AND REPAIRING FIELD DAMAGED AREAS OF PROTECTO 401 LINED PIPE AND FITTINGS.
I. Remove burrs caused by field cutting of ends or
handling damage and smooth out the edge of the lining if rough.
II. Remove all traces of oil, grease, asphalt, dust,
III. Remove any damaged lining caused by field
cutting operations or handling and clean any exposed metal by sanding or scraping.
Sandblasting or power tool cleaning roughening is also acceptable. It is recommended that
any loose lining be removed by chiseling, cutting, or scraping into well adhered lined
area before patching. Be sure to overlap at least 1" of lining in the area to be
IV. With the area to be sealed or repaired absolutely
clean and suitably roughened, apply a coat of Protecto Joint Compound using the following
a. Mixing Procedure - The repair kit for Protecto 401
contains two small cans of Protecto Joint Compound. Protecto Joint Compound is a two
component epoxy and the contents of the small container shall be mixed with the contents
of the large container. If less than the full contents of each can is to be mixed, the
material may be mixed using the mixing ratio printed on the labels. After Part B is added
to Part A, the mixture shall be thoroughly agitated. All activated material must be used
within one hour of mixing.
b. Application of Material - After the material
has been thoroughly mixed, it can be applied to the prepared surface by brush. Brushing is
usually best due to the fact that the areas to be repaired are usually small. Practices
conducive to a good coating are contained in the technical data sheet for Protecto Joint
V. It is important to coat the entire freshly cut
exposed metal surface of the cut pipe end. To ensure proper sealing, overlap at least one
inch of the lining with this repair material.
PROTECTO 401 JOINT COMPOUND
A brushable novalac epoxy designed for sealing cut
ends and repairs when pipes are lined with Protecto 401 Ceramic Epoxy.
This material should be used on spigots and in bell
sockets only after the pipe or fitting is lined with Protecto 401 Ceramic Epoxy. Protecto
Joint Compound can be used over Protecto 401 or on bare substrate Note: Do not apply
Protecto 401 over Protecto Joint Compound.
The surface preparation shall be equal to the
specifications for the project or as outlined in the touch-up procedure. Do not apply
Protecto Joint Compound over wet or frozen surfaces.
Dry Film Thickness:
As outlined in specifications.
Brush, roll, or airless spray.
Thin or clean up with Methyl Ethyl Ketone.
Volatile Organic Contents:
< 1.40 lbs. per gal. mixed unthinned
See individual product label for safety and health
data information. Individual Material Safety Data Sheets are available upon request.