ENGINEERED COMPOSITE PIPING SYSTEMS
Bonding Procedures
For FIBERBOND® Fiberglass Piping
Systems
June 2014 Edition
www.fiberbond.com
www.futurepipe.com
INTRODUCTION
The intent of this document is to provide reference information to those individuals involved in
field bonding FIBERBOND Engineered Composite Piping Systems. It is not the intention of
this document to provide the reader with full details for performing fiberglass bonding. In no
way should this information be used as a substitute for training. Personnel not properly trained
to work with fiberglass composites should not rely on the information contained in this manual
for specific instructions. Furthermore, any personnel working with fiberglass composites should
be properly supervised.
For training and certification contact:
Chipper Dawson
Field Services Manager
or
Jason Schexnayder
Project Manager
Specialty Plastics
Office
15915 Perkins Road (70810)
P.O. Box 83277
Fax No.
Baton Rouge, LA 70884-3277 E-mail:
+1 (225) 752-2705
(800) 752-PIPE(7473)
+1 (225) 225-2757
jason.s@fiberbond.com
chipper.dawson@fiberbond.com
Revision Log:
June 2014: Added information in the Typical Shelf Life table.
May 2013: Updated information on the gloves in the PPE section; added pictures
for continuous rovings and unidirectional fabrics.
April 2013: Updated email addresses.
November 2012: Clarified the assembly options as either the standard assembly
procedure or the procedure for the "20FR" products.
October 2012: Added table with typical shelf life for glasses and chemicals.
July 2012: Added details on the resins, additives, glass reinforcements & assembly
/ bonding tools.
March 2011: Updated PPE recommendations.
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January 2011: Updated contact information. Updated catalyzation table for putty.
Added notes to catalyzation table for resin.
October 2010: Added information on resins, promoters, catalysts, topcoats and
solvents. Added additional details throughout the document.
June 2009: Corrected CoNap ratios in Table 3. Updated contact info.
April 2008: Added photos of raw materials to assist in identification. Added
section on Assembly. Added details on promotion, other additives, accelerators,
and catalyzation in the bonding section.
October 2002: This is the first release of this document.
MATERIALS
The following is a general list of materials used for field bonding fiberglass-reinforced plastic. This list in
not necessarily a complete list nor is it typical for all FRP field bonding. Note: FRP and GRP are used
interchangeably in this document. The terms bonding and welding are also used interchangeably in this
document.
Glass Reinforcements
Glass fiber products should be carefully stored to prevent absorption of water and dirt. Use of dirty or wet
fibers can result in poor laminate quality, and therefore, should not be used.
Glass Reinforcements
Chopped Strand Mat – 1.5 oz/ft2 (450g/m2) or 0.75
oz/ft2 (225g/m2) chopped strand mat is matrix of short,
randomly oriented chopped E-glass fibers. Chopped
strand mat is used in combination with woven roving to
make up the structural cage of FRP welds.
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Glass Reinforcements
Woven Roving – 24 oz/yd2 (800g/m2) woven roving is
a matrix of bi-directional woven E-glass fibers used in
the structural cage of FRP welds.
Glass Kits – glass kits consist of pre-cut sequences of
chopped strand mat and woven roving. They are cut
based on the pipe size and product line. Typically, they
are packaged in brown paper wrapping and sometimes
enclosed in a water-resistance plastic seal.
Any required veil or unidirectional fabrics are normally
NOT included in the glass kit.
For large orders of glass kits, it is not uncommon for the
glass kits to be shipped in a steel drum. Do not confuse
these steel drums with acetone or other chemicals.
Veil – a synthetic veil, such as Nexus manufactured by
Burlington Industries, is a surfacing material used in the
external corrosion barrier of FRP welds.
Milled Fiber – a milled fiber can be added to putty for
better tacking properties.
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Glass Reinforcements
Continuous Rovings – Continuous rovings (individual
strands of filaments) are used as part of the fitup and
bonding process for certain product lines.
"Hoop" Unidirectional Fabrics – E-glass "hoop"
unidirectional fabrics are used as part of the bonding
process in certain sizes and certain product lines.
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Resins and Additives
Resins provide the corrosion resistance and act as the matrix material for the glass fibers in FRP welds.
Most resins for FIBERBOND® products are vinyl ester or polyester and thus do not require external heat
for proper curing. Instead, the promoter and catalyst react in the resin to generate the heat necessary to
cure the laminate. Other additives may be used depending upon the FIBERBOND® product and
application. The solvent for cleaning is also listed in this section.
Resins and Additives
Resins – The resin used in FRP welds varies according
to the FIBERBOND® product and application.
Typically, for field weld kits, there is only one resin
used, however, some products such as Series 20JF and
20JF-C, may use a "dual" laminate composed of two
different resins. Resins are Class 3 flammables.
When shipped in drums, resin drums are white in color
(to help reduce heat transfer from direct sunlight).
Promoters – The promoter for the resins and adhesives
is Cobalt Napthenate, or CoNap, a 6% solution of active
cobalt in solvent. CoNap is a Class 3 flammable. The
promoter for the putty is N,N-Dimethylaniline (DMA).
DMA, instead of CoNap, may be used as a promoter for
the adhesive and/or resin. DMA is a Class 6.1 toxic.
(CoNap is a purplish liquid used to
promote resin.)
NOTE: Resin shipped to the jobsite for use in field weld kits
can be requested as pre-promoted (and does not require
additional promotion). However, the shelf-life of the resin is
reduced to 30 days or less once it is promoted. If not
specified, the resin is shipped unpromoted (and requires
additional promotion). The container of resin shall denote
whether or not the resin is pre-promoted. Putty may also be
shipped as pre-promoted or un-promoted. Adhesive is
normally always shipped as pre-promoted.
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Resins and Additives
Catalyst – MEKP – When promoted with CoNap, the
catalyst for the resins and adhesives is Methyl Ethyl
Ketone Peroxide (MEKP), a 9% active-oxygen solution
of MEKP and a plasiticizer.
MEKP is typically used in a catalyst “squeeze bottle”. It
is a clear liquid, but is sometimes pigmented red to
distinguish it from other chemicals.
MEKP is a Class 5.2 organic peroxide.
Catalyst – BPO – When promoted with DMA, the
catalyst for the putty is Benzoyl Peroxide (BPO). BPO
may also be used as a catalyst for the resin when it has
been promoted with DMA. Note that a DMA/BPO cure
typically provides for much shorter working times than
CoNap/MEKP, which is advantageous when working
with putty. BPO is sometimes referred to as BZQ.
BPO is a white paste and is a Class 5.2 organic
peroxide.
Accelerator – DMA – The accelerator is typically N, NDimethylaniline (DMA), an amine used to accelerate
MEKP, BPO, and CHP cures. With MEKP as the
catalyst, DMA is normally only required in cool
climates. At temperatures of 70F (21c) or higher, DMA
is rarely needed with an MEKP catalyst.
DMA is a yellowish liquid, normally dispensed from a
“wash bottle”. DMA is a Class 6.1 toxic.
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Resins and Additives
Top Coat – All FRP welds are finished with an external
corrosion barrier. One part of the external corrosion
barrier is the "top coat", sometimes referred to as a
"gelcoat". The topcoat is an epoxy that contains a wax
solution and UV absorbers. It is catalyzed with resin
and brushed onto the exterior surfaces of the weld to
seal all exposed glass. Topcoats are Class 3 flammables.
NOTE: In products with electrically conductive exteriors,
such as 20FR-EC and 20JF-C, the topcoat is a conductive
topcoat that is black in color. It is a two-part mix (Parts A
and B). Part A is a Class 3 flammable.
Thixotropies – A thixotropic material, such as Silica
Whacker (manufactured by Wacker-Chemie GmbH) is a
thickener used in the putty and/or adhesive for tacking
welds. Tween® 20, also known as Polysorbate 20, a
non-ionic surfactant manufactured by Croda Inc, is
another additive for making putty and/or adhesive.
UV Absorbers – Tinuvin 326 (manufactured by Geigy
Chemical) is used in the external corrosion barrier of
FRP welds. The UV absorber is normally included in
the topcoat.
Fire Retardant Additives – Certain FIBERBOND®
products, such as 20FR-E, 20FR16, 20FR20, 20JF and
20JF16, require an additive for fire retardancy.
Antimony pentoxide is a common additive that is used.
Series 20JF, 20JF-C, 20JF16 and 20JF16-C use two
different additives. The antimony pentoxide is used
with the 510C-350 resin and the alumina trihydrate
(ATH) is used with the 441-400 resin. Note: some
resins may be premixed with these additives.
Nyacol APE-1540 is a fire retardant additive that is
sometimes shipped in small “pony” drums when needed
in large amounts. Smaller amounts may be shipped in
pails.
Gel Time Retardants – In some cases, when the
temperature is above 90F (32c), a gel time retardant is
necessary. 2,4-Pentanedione (by Union Carbide) is
typically used.
NOTE: 2,4-P will not affect gel time when used with a
BPO/DMA cure system.
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Resins and Additives
Cleaning Solvents - Acetone is typically used to wash
brushes, rollers, and other equipment that has become
coated with resin or semi-gelled resin. Acetone is a
Class 3 flammable.
When shipped in drums, acetone drums are normally
black in color.
Typical Shelf Life
Glass Kits,
Chopped Strand
Mat, Woven
Roving
Typically 3 to 5 years. Glass kits must be kept dry at all times. Any glass
fabrics contaminated with water should be discarded. Glass fabrics that are
contaminated with water shall not be used even if they are allowed to dry.
Resins, Gelcoats,
Putty, Adhesive
In the unpromoted state, typically at least 4 months from date of
manufacture. Once promoted, shelf life is reduced to no more than 30
days. Unpromoted resin that is 30 days or less past the expiration date may
be used provided 1) an acceptable gel time is performed on the resin, 2) the
viscosity of the resin is acceptable and 3) visual inspection of the resin is
acceptable (i.e. there are no signs of gelling).
Conductive
Topcoat
Typically up to 2 years.
Promoters
Typically up to 5 years.
Catalysts,
accelerators
Typically 7 to 18 months.
Acetone
Typically 7 to 18 months.
Fire Retardant
Additives
Typically 7 to 18 months.
Items with a shelf life of 5 years or more can typically achieve an indefinite shelf life when
stored properly.
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TOOLS & PPE
The following is a general list of the tools & PPE used for field bonding fiberglass-reinforced plastic. This
list is not necessarily a complete list nor is it typical for all FRP field bonding.
Assembly and Bonding Tools
Assembly and Bonding Tools
Brushes – Typically 2” or 3” natural-hair brushes
used to wet-out the chopped strand mat and
woven roven with resin.
Serrated Rollers – Typically 1/2” x 3” metal
serrated aluminum rollers used to rollout the
trapped air pockets in the lamina.
Paint Roller Frame and Felt Sleeves – A simple
paint roller frame with felt sleeves are typically
used on large diameter bonds for placement and
applying resin.
Paint rollers are not to be used for rollout
purposes (use the aluminum serrated rollers for
rollout).
Bent Shears – A bent shears, typically 12” (300
mm) long, with a 6” (150 mm) length of cut, is
handy to have available in case any glass cutting
needs to be performed. The bent shears usually
has a very sharp knife edge.
A basic utility or razor knife may also come in
handy for the same purpose.
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Assembly and Bonding Tools
Buckets – One or two quart (0.95 to 1.9 L) plastic
buckets are used for mixing putty and resin.
Paper cups can be used for small mixtures.
Larger buckets (up to 5 gal – 19 L) may be used
for larger mixtures.
Note: some bonders may refer to bucket sizes by
the pound. This refers to the approximate weight
of the resin that the bucket holds:
1/2 quart (475 mL) = “1 pound” bucket
1 quart (0.95 L) = “2-pound” bucket
2 quart (0.5 gallons, 1.9 L) = “5-pound” bucket
1 gallon (3.8L) = “10-pound” bucket
Putty Sticks –Tongue depressors (aka “putty
sticks”) are used to mix putty and small amounts
of resin. Wooden or plastic sticks are acceptable.
Paint Paddle – A simple paint paddle is used for
manual mixing in buckets. Wooden or plastic
paint paddles are acceptable. 9” long paddles are
good for mixing in quart-size buckets. 12” to 14”
in gallon-size buckets. A 21” long paddle is
typically needed for 5-gallon-size buckets.
Catalyst Bottle – A “squeeze” measure beaker
used to accurately measure the proper amount of
catalyst. Typically a 16oz (473mL=473cc) or 8oz
(237mL=273cc) bottle is used for resin. Also
referred to as a Squeeze Bottle or Measuring
Dispenser.
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Assembly and Bonding Tools
Wash Bottle – A “squeeze” beaker used to
dispense very small amounts (a few cc’s) of
catalyst or accelerator. A wash bottle is used
when the amount to be dispensed is too little for a
catalyst bottle. Wash bottles are typically used to
catalyze putty and adhesive and to add DMA as
an accelerator to certain mixtures.
Grinder –Typically a 4 1/2” right angle grinder
used in surface preparation of field welds. A
larger grinder (7”) is often necessary when
working on larger diameter pipes.
Note: orbital sanders are typically ineffective
when performing surface preparation on pipes.
Grinding Discs – The grinding discs are usually
24-grit. Higher grit discs are usually ineffective
when grinding on FRP parts. Grinding discs need
to be sized to fit the grinder (e.g. a 5” disc for a
4.5” grinder, a 7” disc for a 7” grinder).
Backing Pads – If the grinder is not supplied
with a backing pad, one will be required. A disc
nut is normally included with the backing pad.
Compact Angle Grinder – Used for cutting ends
of pipe to the proper length for fitup and assembly
work. A compact angle grinder is used instead of
a sawzall or a circular saw because of its speed in
cutting.
Note: Metabo’s WEP14-150 (www.metabo.com)
is an example of a compact angle grinder.
Note: certain working environments, such as on
some offshore platforms, may require the use of
air-powered tools, not electric.
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Assembly and Bonding Tools
Thin Metal Cutoff Blade – Used on the compact
angle grinder. Typically aluminum oxide with an
A60T grit. The cutoff blade must be sized to fit
the compact angle grinder.
Sawzall (reciprocating saw) – Not the preferred
tool, but it may be needed for cutting pipes in
retrofit situations where there is little clearance
around the pipe to allow the use of the compact
angle grinder. A sawzall may also prove useful
when needed to cut “gusset” plates for olets.
Note: certain working environments, such as on
some offshore platforms, may require the use of
air-powered tools, not electric.
Sawzall Blades - Carbide-tipped or Diamondtipped blades are required for cutting fiberglass
pipe. Standard steel blades are not suitable for
cutting fiberglass.
Circular Saw – Only used when cutting very
large pipes (20”NB, 500 DN and larger).
Note: certain working environments, such as on
some offshore platforms, may require the use of
air-powered tools, not electric.
Circular Saw Blades - Carbide-tipped or DryCut Diamond-tipped blades are required for
cutting fiberglass pipe. Standard steel blades are
not suitable for cutting fiberglass.
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Assembly and Bonding Tools
Cardboard – Typically used as a disposable
material for protection when wetting out plies of
mat and woven roven prior to lay-up. It is also
used for mixing putty with catalyst.
Level – A carpenter’s level is required for fit-up
of joints. It also needed when aligning flange
holes. Levels can range from “torpedo level” size
to 2-feet (600 mm) or longer. Digital levels, up to
4-feet (1.2 m) in length, are handy for complex
angles.
Tape Measure – Used for measuring field trim to
be removed for fit-up of joints.
Pipe Stands – Used when spools are fabricated in
the field. Pipe stands are when piping needs
additional support during the assembly process.
Bung Mounted Agitator (Drum Mixer) – When
promoting 55-gallon (208 L) drums of resin, a
drum mixer is required to properly mix the
promoter and any other additives into the resin.
Note: 55-gallon refers to the nominal size of the
drum.
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Assembly and Bonding Tools
Brass Drum Gate Valve – When dispensing
material from drums, a gate valve is needed. 2” is
the typical size to fit a 55-gallon (208 L) drum of
resin or acetone.
Note: 55-gallon refers to the nominal size of the
drum.
4-Wheel Drum Dolly – Can assist with moving
drums of resin and acetone. For a typical 55gallon (208 L) drum, the drum O.D. is about 23”
(584 mm).
Note: 55-gallon refers to the nominal size of the
drum.
Drum Cradle Truck – Used to position drums
horizontally, allowing for dispensing of material
via gravity flow. A tipping lever may be a
separate attachment that is required.
A drum cradle truck should not be confused with
a “manual drum upender” or a “manual drum
tipper”. An upender or tipper is a simple tool that
provides leverage to allow a drum to moved from
the vertical to the horizontal position (and vice
versa).
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Assembly and Bonding Tools
Drill – Required to mix chemicals in mediumsize pails (1 to 5 gallon – 3.8 to 19 L). A 3/8”
drill is normally sufficient. If you are going to
use the drill with the hole saw cutter attachment,
it is best if the drill comes with an auxiliary
handle.
Note: certain working environments, such as on
some offshore platforms, may require the use of
air-powered tools, not electric.
Jiffy Mixer – Attachment used with the drill to
mix chemicals in medium-size pails.
Hole Saw Cutter – If you have to install a small
diameter “olet” (also called a saddle), a hole saw
cutter (along with a drill) is needed to the cut the
hole in the header pipe. The hole saw cutter must
be carbide-tipped or diamond-tipped. The hole
saw cutter must be sized to fit the pipe size. Olets
are typically fitted to the I.D. of the header pipe,
so the hole saw needs to cut a hole to fit the O.D.
of the olet.
Pencil Grinder w/ burr bits – Used for touch up
work and hard to reach areas. An example is a
bonded connection made between a flange and
another fitting or a pipe. After the bond is made,
it may be necessary to touch up around the bolt
holes of the flange. A pencil grinder may also be
needed when making “saddles” (or olets).
Burr bits can be straight or tapered.
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Assembly and Bonding Tools
Other tools that may be required, include but are
not limited to: speed square, framing square, pipe
wraps (for marking straight lines around the pipe),
flange aligners, centering head and china markers
(for marking the pipe).
For bolting up flanges, a torque wrench, set of
mechanical sockets and a set of box wrenches are
required.
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Personal Protective Equipment
Personal Protective Equipment (PPE)
Gloves – Neoprene (or other suitable material)
gloves may be required by bonders to prevent
skin exposure to chemicals. When used as a
disposable glove, natural latex gloves offer
good short-term protection along with
maximum dexterity.
Leather Work Gloves – A heavy duty leather
work glove is normally recommended when
working with power tools. Other types of cloth
gloves may be suitable.
Filtering Facepiece – An N95 filtering
facepiece (sometimes referred to as a dust
mask) may be required during grinding
procedures to prevent irritation.
Eye protection glasses – Safety glasses with
side shields should be worn at all times for
impact protection. If splashing or spraying
from chemicals is a concern, goggles should be
used instead. If protection of the entire facial
area is needed, a faceshield should be used as
well.
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Personal Protective Equipment (PPE)
Other safety supplies that may be required
include, but are not limited to: hard hats, safety
shoes and a flame retardant Nomex coverall.
For special conditions, such as working at
heights or working in a confined space, refer to
the safety program for the location where the
work is being conducted.
As a precaution, a portable fire extinguisher
may be required when working with some of
the flammable chemicals. A portable eye wash
bottle may also be required.
FIELD BONDING
NOTE: The steps in the assembly and bonding sections are for reference purposes only. It is not the
intention of this document to provide the reader with full details for performing fiberglass bonding. In no
way should this information be used as a substitute for training. Personnel not properly trained in
working with fiberglass composites should not rely on this information or this manual alone for specific
instructions. Furthermore, any personnel working with fiberglass composites should be properly
supervised.
Surface Preparation
All contamination must be removed from the surfaces to be joined. This includes dirt, dust,
moisture, and all other foreign materials.
The surface to be welded must be completely sanded and roughened (there should be no glossy
resin finish). The roughened surface should extend at least 1inch (25mm) beyond the area where
the glass/resin will be applied.
The bonding should be performed as soon as possible following grinding. Under no
circumstances shall the bonding be performed if the area has been contaminated or the grinded
surface is older than 12 hours.
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Putty Mixing
A typical mixture of putty consists of 4.5 gallons of Silica Whacker, 2.5 gallons of resin, 25-35
cc of Tween® 20, and 0.5 gallons of milled fiber. Note: the milled fiber is optional in the putty
mix. This mixture will produce approximately 5 gallons of “unpromoted” putty. An electric
drill with a jiffy mixer is suitable for mixing. The amount of Silica Whacker can be adjusted to
produce the desired thickness. The Silica Whacker only acts as a thickener, it does not affect the
mechanical properties of the putty.
Putty mixture (unpromoted)
BPO (Luperox AFR40)
DMA
For puttying a field weld, measure the needed portion of the
putty mixture and place onto a small strip of cardboard
(approximately 4in x 4in) with a putty stick. Mix the
appropriate amount of catalyst thoroughly into the putty (see
Table 1). The working time will vary according to resin used,
amount of catalyst, and temperature. Typically, BPOpromoted putty is catalyzed with 1cc of DMA per pound of
putty. CoNap-promoted putty is catalyzed with 8.0cc of
MEKP per pound of putty.
Putty mixture (promoted)
After the putty is mixed with the catalyst, it is applied to the joint will a putty stick. Be sure to
cover all crevasses evenly with putty. When the putty has hardened, the excess putty needs to be
removed with a grinder. Before bonding continues the joint must be inspected for removal of
glossy surfaces and regions with excess putty.
Table 1. Recommended Catalyzation - Putty
Temperature
Working Time
5 minutes
Cool 50s to Hot 90s
(10 to 35c)
10 - 20 minutes
20 - 30 minutes
N/A
Use BPO-putty.
Use MEKP-putty.
Catalyze with 1cc of
DMA per pound (454
grams) of putty.
Catalyze with 8cc of
MEKP per pound (454
grams) of putty.
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Adhesive Mixing
Adhesive is similar to putty except that it uses an elastomer-modified epoxy vinyl ester resin for
the resin and requires the use of milled fiber. Adhesive is typically promoted with CoNap and
catalyzed with MEKP.
Assembly
All cut pipe lengths must be square and butted together as close as possible. All surfaces must
be dry. Do not contaminate the grinding area with your hands. Wear cloth gloves, if needed,
when handling.
Standard Assembly Procedure:
Roughen all cut edges, then coat with resin. Butt together the pieces of pipe/fittings/flanges to be
joined. Apply putty to the joint from the exterior to fill any gaps and irregularities in the joint.
After the putty hardens, it must be ground for a good anchor pattern prior to any bonding work.
All putty, except that required to fill any cracks or crevices, must be removed.
It is not necessary, however, it is acceptable to bevel the edges of the two pieces to be joined to
allow more putty to be applied and thus hold the joint better prior to layup. However, the putty
(after grinding) shall not be wider than 1/4" (6mm) nor thicker than 1/4" (6mm) to fill the gaps.
Series 20FR-E, 20FR-EC, 20FR16, 20FR16-C, 20FR20, 20FR20-C:
When used in firewater applications that require IMO A.753(18) Level 3 fire endurance, these
products have a slight modification to the assembly procedure:
A 1:1 bevel is required at the center of the joint where the two parts are butted together. After
beveling, butt together the pieces of pipe/fittings/flanges to be joined. Apply catalyzed resin to
the beveled area. A very light application of putty may be used to tack the pieces together, but
the putty should not be used to fill the beveled area. Hoop wrap 10 strands of filaments to fill the
1:1 bevel. The strands of filament should be “wetted out” with catalyzed resin prior to hoop
wrapping. Once filaments have cured, re-grind the entire area with a grinder and then with
36grit sandpaper. Any “hump” from the filaments that extends beyond the bevel may be ground
evenly with the pipe, but it is not required.
Resin Mixing
Promotion: Before use, the resin must first be promoted. This is normally done in 55-gallon
drums (approximately 450 lbs) prior to shipment to the field, however, some resins may be
shipped unpromoted to extend their shelf life (promoted resins normally have a shelf life of one
month; unpromoted resins have a shelf life of 3 months or more). A drum mixer should be used
to thoroughly mix the appropriate amount of promoter in to the resin. Smaller portions of resin
can be promoted with a jiffy mixer. Any additives or accelerators, if needed, should be added
after the promoter is completely mixed into the resin.
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1. 510C-350 Resin (unpromoted)
3. CoNap (purple)
2. 510C-350 Resin (promoted)
Under no circumstances should the promoter (CoNap) be mixed
directly with a peroxide catalyst (MEKP, BPO, and CHP). This
could cause a fire or explosion.
Other Additives: Series 20FR-E, 20FR-EC, 20FR16, 20FR16-C,
20FR20, and 20FR20-C require an antimony pentoxide additive
that is normally mixed after promotion. The antimony
pentoxide, typically labeled as Nyacol APE-1540, is added at a
rate of 3.75% by resin weight (e.g., for each 10lbs of resin, add
0.375lbs of Nyacol APE-1540).
4. Nyacol APE-1540
Series 20JF, 20JF-C, 20JF16 and 20JF16-C use two different resins and each resin has its own
additive. The 1st resin, which is typically labeled as 510C or 510C-350, requires the antimony
pentoxide additive to be added at a rate of 3.75% by resin weight. The 2nd resin, which is
typically labeled as 441 or 441-400, requires an alumina trihydrate (ATH) additive. The ATH
additive is typically labeled as Solem SB-336 or Solem SB-432 in 50lb (23kg) bags. Note: the
labeling of the resin and additives may vary depending on the material supplied. Materials
supplied by Specialty Plastics, Inc. or one of its licensees are in accordance with the internal
quality assurance requirements of the product line. Please contact Specialty Plastics, Inc. or the
licensee from which the materials were purchased for assistance.
Accelerators: In colder temperatures, it can become necessary to add dimethylaniline (DMA) as
an accelerator to help assist with the cure of the resin. DMA is a liquid, clear to somewhat
yellowish in color that has a very strong, pungent odor. You will not see a color change when
DMA is added as an accelerator. Typically, if DMA is being added to a drum of resin, it should
be mixed for 45 minutes.
Catalyzation: When you are ready to begin field bonding, use a one-pound cup (about 1 pint or
473mL) to measure the amount of resin you wish to catalyze. Then add the appropriate amount
of catalyst using a catalyst bottle. Thoroughly mix the catalyst
with the resin and scrape the sides and bottom while mixing. It
is important to never use a brush to mix catalyst with the resin,
because it will absorb the uncatalyzed resin changing the ratio of
catalyst to resin.
Once the resin has been catalyzed the working time will be
reduced to 10-40 minutes (see Table 3). Be sure to catalyze only
the amount of resin needed within the given time. Because
conditions vary greatly from day to night, it can be very difficult
5. MEKP (Luperox DDM-9)
FIBERBOND®
Engineered Composite Piping Systems
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June 2014 Edition
to catalyze resin at night. It is strongly recommending that bonding be carried out during the
day.
Important Note: It is not the intention of this manual to provide specific formulating information for
proper curing of fiberglass laminates. Characteristics of resins vary from manufacturer to manufacturer,
working conditions fluctuate during the day, weather conditions vary from jobsite to jobsite, and desired
gel times vary from one fabricator to another. It is not uncommon for actual catalyzation levels to vary
from 50 to 150% of the values in these tables. The resin manufacturer's literature can be referenced for
general information; however, personnel not properly trained in working with fiberglass composites
should not rely on this information or this manual alone for specific instructions. Furthermore, any
personnel working with fiberglass composites should be properly supervised.
FIBERBOND®
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June 2014 Edition
Table 3. Recommended Promotion & Catalyzation - Resin
Temp.
< 50F (10c)
At temperatures below 50F (10c), for optimum performance, it may be
necessary to provide some source of heat to the resin and the surfaces being
bonded in order to ensure a satisfactory degree of cure. Changes in promotion
and catalyzation are at the discretion of the bonder.
Cold - 50s
(10-15c)
0.40% CoNap
2.5% MEKP
0.05 to 0.10% DMA
16.4cc per gallon
11.4cc per pound
0.2 to 0.5cc per pound
4.3cc per liter
25.0cc per kg
0.5 to 1.0cc per kg
Cool - 60s
(15-20c)
0.30% CoNap
2.5% MEKP
0.0 to 0.10% DMA
12.3cc per gallon
11.4cc per pound
0.0 to 0.5cc per pound
3.2cc per liter
25.0cc per kg
0.0 to 1.0cc per kg
0.40% CoNap
2.0 to 2.5% MEKP
0.0 to 0.05% DMA
16.4cc per gallon
9.1 to 11.4cc per pound
0.0 to 0.2cc per pound
4.3cc per liter
20.0 to 22.5cc per kg
0.0 to 0.5cc per kg
0.20% CoNap
1.0 to 1.75% MEKP
0.05% DMA
8.2cc per gallon
4.5 to 7.9cc per pound
0.2cc per pound
2.2cc per liter
10.0 to 17.5cc per kg
0.5cc per kg
0.30% CoNap
1.75% MEKP
12.3cc per gallon
7.9cc per pound
3.2cc per liter
17.5cc per kg
0.40% CoNap
2.25% MEKP
16.4cc per gallon
10.2cc per pound
4.3cc per liter
22.5cc per kg
0.20% CoNap
1.25% MEKP
0.0 to 0.035% 2,4-P
8.2cc per gallon
5.7cc per pound
0 to 0.16cc per pound
2.2cc per liter
12.5cc per kg
0 to 0.35cc per kg
0.30% CoNap
1.5 to 1.75% MEKP
12.3cc per gallon
6.8 to 7.9cc per pound
3.2cc per liter
15.0 to 17.5cc per kg
0.40% CoNap
2.0 to 2.25% MEKP
16.4cc per gallon
9.1 to 10.2cc per pound
4.3cc per liter
20.0 to 22.5cc per kg
0.20% CoNap
1.0 to 1.5% MEKP
0.0 to 0.05% 2,4-P
8.2cc per gallon
4.5 to 6.8cc per pound
0 to 0.2cc per pound
2.2cc per liter
10.0 to 15.0cc per kg
0 to 0.5cc per kg
0.30% CoNap
1.25 to 1.75% MEKP
12.3cc per gallon
5.0 to 7.0cc per pound
3.2cc per liter
11 to 15.4cc per kg
0.40% CoNap
1.75 to 2.25% MEKP
16.4cc per gallon
7.0 to 9.0cc per pound
4.3cc per liter
15.4 to 19.8cc per kg
Mild - 70s
(20-25c)
Warm - 80s
(25-30c)
Hot - 90s
(30-35c)
See Important Note preceding this table.
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June 2014 Edition
Table 2. Recommended Catalyzation - Gelcoats (Promoted)
Temperature
Working Time
10 - 20 minutes
< 50F (10c)
55 - 65F
(12-18c)
65 - 75F
(18-24c)
75 - 85F
(24-29c)
20 - 30 minutes
30 - 40 minutes
At temperatures below 50F (10c), for optimum performance, it may be
necessary to provide some source of heat to the resin and the surfaces being
bonded in order to ensure a satisfactory degree of cure. Changes in
promotion and catalyzation are at the discretion of the bonder.
4.4% MEKP
3.6% MEKP
2.2% MEKP
(20.0cc per pound)
(16.4cc per pound)
(10.0cc per pound)
(44.2cc per kg)
(36.1cc per kg)
(22.1cc per kg)
3.6% MEKP
3.0% MEKP
1.8% MEKP
(16.4cc per pound)
(13.7cc per pound)
(8.2cc per pound)
(36.1cc per kg)
(30.1cc per kg)
(18.1cc per kg)
3.0% MEKP
2.2% MEKP
(13.7cc per pound)
(10.0cc per pound)
(30.1cc per kg)
(22.1cc per kg)
See Important Note preceding this table. This table does not apply to conductive topcoats.
Batch Conversion Factors
Weight %
cc per
pound
cc per
kilogram
cc per
gallon
cc per
liter
fluiz oz per drum
cc per drum
(452lb, 50gal,
190L)
0.10%
0.5
1.0
4.1
1.1
7.7
204
0.20%
0.9
2.0
8.2
2.2
15.5
409
0.30%
1.4
3.0
12.3
3.2
23.2
613
0.40%
1.8
4.0
16.4
4.3
31.0
818
0.50%
2.3
5.0
20.4
5.4
38.7
1022
0.60%
2.7
6.0
24.5
6.5
46.4
1226
0.70%
3.2
7.0
28.6
7.6
54.2
1431
0.80%
3.6
8.0
32.7
8.7
61.9
1635
0.90%
4.1
9.0
36.8
9.7
69.7
1840
1.00%
4.5
10.0
40.9
10.8
77.4
2044
1.25%
5.7
12.5
51.1
13.5
96.8
2555
1.50%
6.8
15.0
61.3
16.2
116.1
3066
1.75%
7.9
17.5
71.5
18.9
135.5
3577
2.00%
9.1
20.0
81.8
21.6
154.8
4088
2.25%
10.2
22.5
92.0
24.3
174.2
4599
2.50%
11.4
25.0
102.2
27.0
193.5
5110
(1) gallon = (4) quarts = (3.8) liters; (1) quart = (2) pints; (1) pint = (2) cups; (1) cup = (8) ounces; (1) ounce = 29.57cc
Based on cured resin weight (cured resin S.G. of 1.08, liquid resin S.G. of 1.15, liquid additive density of 1.00).
FIBERBOND®
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June 2014 Edition
Bonding (also called Welding)
Refer to the field weld kit packages for the laminate sequence. The glass reinforcement materials are
already cut to the proper length and width for field bonding.
1. On a piece of thick paper or cardboard apply a layer of
catalyzed resin with a 2in. or 3in. natural hair brush. The
cardboard should be completely saturated with resin (no
dry spots). Apply the widest ply of the weld sequence to
this layer of resin and add more resin to this ply of glass.
Note:

The widest ply of the weld sequence is not necessarily the widest ply of the weld kit. The weld kit may
have to be divided into more than one "sequence" because of thickness. A typical sequence consists of 5
plies of material. Therefore, a weld kit with 8 plies of material will normally be divided into 2 sequences.
You should separate the weld sequences in the kit when wetting out the glass. The last and first ply of each
sequence should always be a chopped strand mat.

Be sure the mat is wet out thoroughly. There should be no white strands showing.
2. Continue adding the following plies to the sequence one at
a time. Completely saturate each with resin.
Note:

When adding the glass plies to the sequence, stagger each about 1/2in. from the previous ply.
3. Lift the mat from the cardboard and place one end over the
puttied joint (The narrowest ply should be placed to the
inside.). The weld should be centered on the joint. While
holding one end of the wetted sequence, start rolling
(circumferentially around the pipe) the sequence on the
joint. Continue rolling until 180degrees of the joint is
covered.
Note:

When you first begin rolling, it is important to hold the other end of the sequence in your hand to prevent
stretching.
FIBERBOND®
Engineered Composite Piping Systems
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June 2014 Edition
4. Form the remainder of the weld around the joint and
continue rolling in the direction of the wrap until all the air
is removed.
Note:



Keep the roller going in one direction. If all the air has not been removed, continue rolling in the same
direction for another pass around the joint. It is important that all visible air pockets are completely
removed before proceeding with the next step.
If the roller is picking up strands of mat or causing more air bubbles, clean the roller. Shake all the cleaner
off of the roller and dip the roller in catalyzed resin and continue rolling.
Direct sunlight may cause burns and should not make contact with the weld. Shade the joint with
cardboard or other suitable protection.
5. Once rolling is completed, the first sequence needs to
harden and cool down (part of its curing process). During
curing, do not let the joint be moved, impacted, or
contaminated with water, dirt, etc.
For the second and remaining sequences, repeat steps 1
through 4. Note that in the remaining sequences, there are
normally more than 3 plies, depending upon the resin.
Also note that normally there are woven plies in these
sequences.
Note:


After the first sequence has hardened and cooled down, it should be lightly sanded to smooth any glass that
may be sticking up that can cause air entrapment in the second sequence.
If the first sequence cures for more than 12 hours, it must be reground with a 24-grit disc on an electric
sander before applying the second sequence.
6. Once the final structural sequence has cured, visual
inspection should be performed. Visually look for air
entrapment, burns, drains, and contamination. Also ensure
that the weld is properly positioned over the joint.
FIBERBOND®
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June 2014 Edition
7. Once the final sequence is applied, a veil layer is applied.
Please note that the veil layer is applied before the final
sequence has hardened. It is usually necessary to brush a
thin layer of resin onto the final sequence before applying
the veil. Continue applying the veil until the entire joint is
covered. The veil should be applied tightly to the joint to
help remove excess air and resin.
8. Once the veil is applied, it should be brushed with resin. It
is important to cover the entire veil layer with resin until
saturated. Before applying the external coat (which may
be a natural color waxcoat, pigmented topcoat, or
conductive topcoat), the veil layer (which has now
hardened and cooled) needs to be ground lightly.
Once the surfacing veil has hardened and cooled down, the
external coat is applied (not shown). Apply the external
coat to the exterior surface with a brush being sure to
cover the entire surface.
Note:

At temperatures below 50F (10c), for optimum performance, it may be necessary to provide some source of
heat to the resin and the surfaces being bonded in order to ensure a satisfactory degree of cure. The use of
an enclosure, such as tenting, may provide assistance in maintaining satisfactory temperatures. An external
heat source may be in the form of electric heater blankets, space heater units with the hot air ducted to the
work area or other suitable method.
FIBERBOND®
Engineered Composite Piping Systems
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June 2014 Edition
OVER 40 YEARS EXPERIENCE IN SUCCESSFUL
APPLICATIONS OF FIBERGLASS PIPE SYSTEMS.
Phone
+1 (225) 7522705
Toll Free
(U.S.A.)
(800-752-7473)
June 2014 Edition
Future Pipe Industries, Inc.
15915 Perkins Road
Baton Rouge, LA 70810 U.S.A.
www fiberbond com
ISO 9001
Certified