Armor Plate® Pipe Wrap (APPW) is a composite structural pipeline repair system. APPW is designed to repair pipelines while in service without depressurizing or lowering the Maximum Allowable Operating Pressure (MAOP). APPW is a 3-part system (Resin, Putty and Armor Fiber®) specially designed for repairing straight pipe, elbows, tees, risers, reducers, wrinkle bends and most any pipe configuration with external corrosion or mechanical damage. Once cured, the AP 360 HT System has been tested and designed for operating temperatures ranging from -60ºF to 350º F (-51º C to 177º C). The AP 360 HT Pipe Wrap System may be applied in world-wide environments with ambient temperature and/or operating temperature ranging from 195° F to 350°F (91° C to 177° C). The AP 360 HT System contains pre-mixed Resin, pre-mixed Putty, Armor Fiber® and all necessary equipment for application in the field. The APPW System is recognized by DOT as a permanent repair product and as the model for composite repairs. When a buried pipeline has been exposed and the repair is complete, the area may be backfilled the same day. For complete curing, the AP 360 HT System requires a constant heat source of 250º F (122º C) or above, continuous for approximately 3 to 4 hours.

 

Armor Plate® 360 HT Pipe Wrap is user-friendly and is applied by certified installers.

 

 

Prepare the repair area surface by grit blasting, power tool cleaning or hand tool cleaning. For grit blasting, the best surface is a near white metal (NACE 2, Swedish Sa 2½ or SSPC SP10) finish with a 2 to 3 mil anchor pattern. For power tool and hand tool cleaning, remove all loose dirt and debris, rust, and other contaminants that reduce adhesion. A roughened, clean surface is necessary to properly install the APPW System. The area prepared for the APPW Installation must extend 2 inches (5 centimeters) or more beyond both edges/sides of the anomaly/anomalies. The area to be wrapped should be thoroughly wiped with Acetone, MEK, Xylene or equivalent, if possible.

 

 

1.) On external corrosion, the required number of wraps of Armor Plate® Pipe Wrap is determined by using ARMOR CALC^TM. ARMOR CALC^TM is an engineered and tested program that uses the pipe size, nominal pipe wall thickness, pipe grade, corrosion depth and corrosion length. The ARMOR CALC^TM will then determine how many wraps to apply to bring the pipe back to greater than the MAOP.

 

2.) The Armor Plate® Pipe Wrap System is designed to repair almost any external corrosion depth or pipe wall loss up to 80 per cent of the nominal wall thickness. The APPW system prohibits the repair of pipes containing 80 per cent or more wall loss as a safety factor.

 

3.) On a dent, gouge, manufactured defect or wrinkle bend (mechanical damage), the pipe wall thickness is multiplied by 1.5, then divided by the thickness of the Armor Fiber® (.0625 inches) to determine how many wraps to apply to bring the pipe back to greater than the MAOP. This formula is not shown on the ARMOR CALC^TM Program. For “Wrinkle Bend Repairs” refer to Installation Guidance / Application Procedure for “Armor Plate® 360 MP (Multi-Purpose) Pipe Wrap for Wrinkle Bends”, Sections III and IV. Any sharp edges should be removed and an inspection should be performed to identify cracks. Cracks must be removed before installing the APPW Product.

 

*Note: The Armor Plate® Pipe Wrap System is installed with the required number of wraps for each repair area. Two wraps is the minimum number of wraps to apply. A typical repair using APPW is normally 5, 6 or 7 wraps. However, if the pipe wall or damage is severe, the number of wraps may be higher based on the pipe data.

 

 

1.) Measure the circumference of the pipe and add 2 inches (5 centimeters) or more, to provide an overlap of the trailing end over the leading end of the Armor Fiber®. Cut the Armor Fiber® for the required number of wraps, as per the measurement in the circumferential direction. If the “required number of wraps” is more than 4 wraps, add 2 inches (5 centimeters) or more to the cut length of the Armor Fiber® in order to accommodate the increase in the outside diameter. This should be done for each additional 4 wraps.

 

Example: If the circumference of the pipe is 25 inches (63½ centimeters) around, the Armor Fiber® should be cut 27 inches or more (68½ centimeters or more) long for a 2 inch (5 centimeter) or more overlap at the trailing end on each wrap of Armor Fiber®.

 

2.) Once the surface of the pipe repair area is ready, it is now time to stir the pre-mixed AP 360 HT Resin for approximately 3 to 5 minutes, so that the pre-mixed resin will blend evenly before priming and saturating the Armor Fiber®. Heat is used as the cure rather than a separate “B” side resin (curing agent).

 

3.) With a roller, completely saturate the Armor Fiber® on the rough side (chopped strand) first, then turn the Armor Fiber® over and completely saturate the smooth side using the pre-mixed AP 360 HT Resin. Completely saturate the Armor Fiber® with resin until both surfaces are gray in color before applying to the pipe surface.

 

4.) Once the Armor Fiber® is saturated, with the rough side down and the smooth side exposed, roll the Armor Fiber® onto the 2 inch x 2 inch wide x 15 inch long wooden applicator. The Armor Fiber® is now ready to be applied over the pipe repair area.

 

5.) Stir the pre-mixed Putty. Apply the Putty to the pit and/or irregular surface and smooth over the area in order to produce a smooth, uniform and transitional surface.

 

6.) Using a brush or roller provided, apply a primer coat of the AP 360 HT Resin to the entire pipe surface and over the putty in the repair area.

 

7.) With the rough side facing the pipe surface, position the leading end of the saturated Armor Fiber® onto the pipe surface (near the top center of the pipe surface on a horizontal pipeline). Hand tension the Armor Fiber® and wrap the Armor Fiber® around the circumference of the pipe. As you wrap the circumference of the pipe, smooth out the wrap, in the circumferential direction, using gloved hands to prevent air pockets, voids or wrinkles. You should now have one wrap and one linear foot of pipe covered. The wrap should be straight and even around the pipe. Each additional wrap should always be applied in the same circumferential direction as the previous wrap.

 

8.) Continue wrapping the pipe until the desired number of wraps is obtained for each linear foot section. If you are installing more than a one linear foot section, stagger each wrap by half an inch or more to cover the circumferential seam on the previous layer. Make sure multiple wraps in a single layer are adjacent but not overlapping.

 

9.) After the “required number of wraps” is installed, apply the AP 360 HT Putty to each exposed circumferential seam, to both edges and at the trailing end of the Armor Fiber®. These areas should be covered with approximately one inch (2½ centimeters) in width of putty to insure the wrap is properly sealed, thus completing the repair.

 

*Note: It is recommended that the Installation Crew or a Crewmember remain on site until there is satisfaction that the progression of the curing is acceptable.

 

 

Kit sizes are based on square footage (12.5, 25, 50, or 100 square foot kits). Each kit will repair any variation of pipe diameters. For example: The same 100 square foot kit may repair 8 inch pipe, 14 inch pipe or a 36 inch pipe all at the same time, depending on the number of wraps and the linear feet of the repair.

 

Armor Plate® 360 HT Pre-Mixed Resin (gray in color)

 

Armor Plate® 360 HT Pre-Mixed Putty (gray in color)

 

Armor Fiber® (The length of the Armor Fiber® is determined by the square footage size of each kit - for example, a 25 square foot kit contains a roll of Armor Fiber® that is 25 foot in length.)

 

*Note: See the respective Material Safety Data Sheets for additional information on the above materials.

 

1.) The AP 360 HT Pipe Wrap System is user-friendly.

 

2.) Mix ratio: NONE, the Armor Plate® 360 HT Resin and Putty are pre-mixed. Heat cures both the resin and putty.

 

3.) Once cured, the AP 360 HT Pipe Wrap System has been tested and designed for operating temperatures ranging from -60° F to 350° F (-51° C to 177° C).

 

4.) The AP 360 HT Pipe Wrap System is designed to work in areas where pipelines are running at temperatures from 195º F to 350° F (91° C to 177° C).

 

5.) The AP 360 HT Pipe Wrap System can usually be applied by two field crewmembers. On larger repairs a crew of four field crewmembers is required. They can usually apply between 75 and 125 square feet of material per hour, depending on the severity of weather conditions and/or access to the repair area.

 

6.) Estimating Coverage: One gallon of Armor Plate® Pipe Wrap 360 HT Resin will saturate approximately 25 square feet of Armor Fiber®.

 

 

1.) System will cure on damp and wet pipe. Primer coat of Armor Plate® 360 HT Resin will displace moisture.

 

2.) Heat applied at temperatures below 50º F makes the system apply easier.

 

3.) For complete curing, the AP 360 HT System requires a constant heat source of 250º F (122º C) or above, continuous for approximately 3 to 4 hours.

 

 

1.) The AP 360 HT Pipe Wrap components must be kept dry. The Epoxy Resin, Epoxy Putty and Armor Fiber® must be stored in a dry area, or covered in order for the application equipment and Armor Fiber® to perform properly.

 

2.) The Armor Fiber® must be completely dry at the time of mixing to achieve proper saturation.

 

3.) The Shelf Life on the Pre-Mixed Resin and Putty – minimum six (6) months.

 

 

1.) AP 360 HT Pipe Wrap is a safe system, but we recommend usage of the safety equipment: rubber gloves, Tyvek suit, proper eye wear, etc.

 

2.) Use AP 360 HT Pipe Wrap in well-ventilated areas and avoid directly breathing fumes while mixing and saturating the Armor Fiber®.

 

3.) Avoid skin contact if possible. Gloves and safety glasses are recommended.

 

4.) Use soap and water to thoroughly clean contaminated areas of the body.

 

5.) In case of eye contact, thoroughly flush the eye with water and seek immediate medical attention.