Installation Instructions

**Installation Certification Required**

NOTE: These instructions are provided as a review to the certified technician installing this product. At no time shall untrained/uncertified personnel install this product. Certification will soon be available online.

1.0 Introduction to RhinoWrap®

The purpose of these instructions is to provide procedures for the installation of the RhinoWrap® Composite Repair System. Applied properly, this high-strength carbon fiber/fiberglass and epoxy system will restore strength to your pipe system without shutting down the operation (with exception in the case of active leaks). Installation of RhinoWrap® requires installer certification to meet industry standards (such as the ASME and the DOT). This certification may be obtained by taking our online test.

2.0 Description

The RhinoWrap® system includes a bi-directional weave of carbon fiber, fiberglass, and a 100% solids epoxy, forming a composite system that effectively repairs corroded or otherwise damaged pipe. The structural system forms a pipe around a pipe, and each successive wrap increases the pressure rating. Because of its low profile, RhinoWrap® can be installed on tees, elbows, straight runs of pipe, confined spaces and irregular surfaces that require structural reinforcement or leak containment. The adhesive properties of the epoxy allow it to be applied to most substrates. Each kit is designed to cover a specific square footage amount with 4 options on cloth width.

3.0 Safety

Resin and hardener compounds used with RhinoWrap® are non-hazardous materials and safe to use. However, certain people may exhibit allergies associated with epoxies. Material Safety Data Sheets are provided with every product kit shipped and may also be obtained by contacting the manufacturer directly.

3.1 Clothing and Equipment

Proper PPE and protective clothing is recommended during installation. Recommended clothing includes, but is not limited to: tyvek suit, coveralls, apron, rubber foot coverings, safety glasses or chemical splash goggles, and impervious gloves (vinyl, latex, or neoprene) to cover exposed areas of skin.

4.0 RhinoWrap® Installation

Each RhinoWrap® installation kit comes with enough material to effectively cover the area defined by the kit’s cloth and coverage specifications.

It is recommended that, if possible, all materials, tools and layout plastic should be stored at room temperature for at least 12 hours prior to use. Storing at cooler temperatures will make wet out mixing/application more difficult due to increased viscosity. Storing at higher temperature will reduce viscosity causing the material to drip during application and can cause the epoxies to set quicker than expected. With proper storage, shelf-life of the epoxies is given as two years.

4.1 Kit Contents

  1. Materials are pre-packaged containing all essential installation materials and tools required to cover the intended pipe surface.
  2. A two-part wet out system including one container of resin and one of hardener.
  3. Enough carbon/fiberglass hybrid cloth material to cover the surface area as specified by the kit’s cloth and coverage specifications.
  4. Vinyl, latex, or rubber gloves.
  5. Paper towels.
  6. Tubes for ease of installation.
  7. Roller and roller frames.

Lay out all of the materials and double check that the labels of the epoxy kits are matched.

For large voids, CMF-1 filler putty will be required to fill the void and properly transfer load to the wrap.

4.2 Surface Preparation

The pipe to be wrapped should be made as accessible as possible to facilitate ease of wrapping. All loose dirt, oil, grease, rust, or other build up should be removed.

The preferred method of surface preparation is sand blasting, but grinding, wire brushing, and water blasting may also be acceptable. SP-10 or SP11 (NACE 2) is the recommended blasting with a 2-3 mil surface anchor profile.

**DO NOT USE ANY METHODS OF SURFACE PREPARATION THAT WILL GIVE A SMOOTH OR GLASS LIKE SURFACE SUCH AS BY USING A BUFFER OR FLAPPER WHEEL.

You may tape off the area to be wrapped to demarkate the pipe to more clearly define your repair area. You may remove tape when wrap is complete.

4.3 Applying CMF-1 Filler Putty

(may not always be required)

  1. The filler putty evens out pits, rough spots, and smooths transitions for even load transfer.
  2. Mix all of the putty hardener into the putty resin container.
  3. Mix thoroughly using the stir stick provided.
  4. Mix for approximatley 1 to 2 minutes or until the color is even and no marbling is present. Make sure that all hardener is mixed thoroughly into the resin.
  5. Using the same stir stick, or a putty knife (not included), smooth the filler putty into the area required and return the pipe to as close to the original surface as possible.
  6. Pipe may be wrapped immediately, unless the filler putty was applied very thick. In this case, it may be best to allow the putty to set so as not to disturb or squeeze it out during wrapping.

4.4 Wetting the Hyrbrid Fabric

  1. Lay out the hyrbrid cloth on a clean, non-porous surface such as visqueen or a large trash bag.
  2. Pour the wetout hardener into the wetout resin container.
  3. Shake vigorously for a minimum of 1 to 2 minutes or until total mixing has occured.
  4. Pour equal amounts of the mixed wetout epoxy over the piece(s) of hybrid cloth.
  5. Using the roller provided, distribute the resin evenly over the entire hybrid cloth insuring that all areas are fully saturated.
  6. Flip the cloth over and brush again on the opposite side if needed.
  7. Fold the fabric like you would book wallpaper. This will insure that the fabric is completely and evenly wetted. You may also roll the hybrid fabric onto a cardboard tube (provided) to use as you unroll it onto the pipe.

OPTIONAL WETOUT PROCEDURE: You may also wet out the pieces of hybrid fabric by placing them in the plastic bag provided. Then pour the mixed wetout epoxy into the bag and knead the bag and fabric until the fabric is completely saturated. This option may be easier when working with the narrower width fabrics.

4.5 Wrapping the Pipe

If you are not familiar with spiral wrapping pipe, elbows, or tees, we strongly recommend that you make a test wrap on the subject pipe or one similar, so that you are able to wrap the pipe section without leaving air pockets, creases or wrinkles in the wrap. This can be done using cloth that has not yet been saturated by the resin (dry cloth).

**DO NOT MIX EPOXY UNTIL YOU ARE READY TO USE IT.

4.5.1 Wrapping Weld Style

  1. Center the hybrid cloth over the area to be wrapped. Using your gloved hand, press the end of the cloth onto the pipe where the wrap will begin.
  2. Unroll the cloth and wrap it around the pipe keeping it centered over the defect and overlapping at the end. After the first wrap, pull gently to insure that the wrap is tight.
  3. Using your gloved hand, smooth the cloth out, removing all air bubbles and smoothing out the edges. Take this time to feel all the way around the wrap to insure it is securely adhered to the pipe with no air pockets.
  4. Repeat steps 1 thru 3 for each piece of cloth or as many times around the pipe as required.
  5. Smooth out all of the edges, wrinkles, and bubbles to minimize any sharp edges when the epoxy hardens.
  6. You may use any remaining wet out epoxy as a glaze coat if so desired by pouring it directly onto the wrap and smoothing it on with your hands.
  7. The normal set time for the wrap is approximately 2 hours. All set times will vary with ambient conditions. Set time may be accelerated by using an outside heat source such as a heater or a lamp.

4.5.2 Wrapping Spiral Style

  1. Begin by making one complete wrap around the pipe with the hybrid fabric at the end point of the repair section.
  2. Repeat Step 3 in procedure for weld wraps to insure the wrap is secure on the pipe.
  3. With the next wrap, begin spiraling the fabric by overlapping the previous wrap by 50% of the width of the fabric.
  4. Continue wrapping in this manner until you reach the end of the repair section, all the while insuring there is no air pockets or wrinkles in the wrap as you go.
  5. Once at the end of the repair section, repeat the procedure by starting on the end you finished at and going back over your first layer of wrap.
  6. Repeat Step 5 until the total number of layers over the pipe is sufficient for the repair.

4.5.3 Wrapping an Elbow Wrap

For elbows, make one complete wrap and then follow the instructions for spiral wrapping above. On the radius of the elbow, the overlap on the inside of the radius will increase to 75 – 80% and will remain 50% on the outside of the radius. This will insure the fabric is continually being wrapped perpendicular to the tangent of the pipe.

4.5.4 Wrapping a Tee

Tees will need to have specially cut pieces to fit around the main branch of the tee to insure the entire joint is covered.

Begin with the wider piece(s) of cloth (diapers) that is about 3 to 4 times as long as the pipe’s diameter. Center this cloth(s) on the straight side of the tee and the wrap both ends around the body of the tee and up the sides of the side outlet of the tee. (You will have to notch the cloth at the base of the side outlet, so that this section can be laid smooth.)

Next you will be making a spiral wrap on each leg of the Tee working toward the middle. Begin by spiral wrapping as you would in the instructions for a spiral wrap above. When you reach the tee, the last wrap should allow you to make one wrap around the opposite side of the tee. At this time, there should be no bare pipe showing. Repeat procedure starting with “diaper” then spiral wrap each leg until the total required layers have been applied.

5.0 Applying the Blue Film

(optional)

The application of the blue film may serve several purposes for the wrap. It will contain all epoxy as the wrap cures. It will keep the wrap clean from debris that may land in the wrap and stick. It will also help to insure that there are no wrinkles or air trapped within the wrap as it may be pulled taught while applying.

Begin the film in the same location as you did with the wrap itself. Wrap in the same manner and in the same direction putting tension on the film so that it tightens onto the wrap, but do not overpull as this will simply cause the film to slide around the wrap.

Once the wrap has cured, the film may be removed if desired, or left in place depending on your preference.

6.0 UV Protection

UV protection is recommended for any wrap that may be subjected to high levels of UV radiation.

SLS-300 may be used as a UV resistant topcoat where the wrap will be exposed to high levels of UV radiation (direct sunlight). Another option is to use a topcoat of epoxy or urethane paint.

SLS-300 can be applied as soon as the wrap is complete. There is no need to wait for the wrap to set as long as you do not cause the fabric to slip while you are applying the topcoat.

For the use of other topcoats of epoxy or urethane, let the wrap set and become tack-free before applying. You do not need to wait until the wrap is fully cured.