PERMA-P IPE, Inc.

XTRU-Therm
A Subsidiary of MFRI, Inc.
7720 North Lehigh Avenue
Niles, Illinois 60714-3491
Phone (847) 966-2235
Fax (847) 470-1204
Installation Manual
http://www.permapipe.com

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 GENERAL PRECAUTIONS

The objective of this Installation Manual is to provide Due to the many possible variations in applications,
the installer with recommended installation use, installation conditions, and environment these
procedures for PERMA-PIPE’S XTRU-Therm piping installation recommendations can not address all
system. This Installation Manual should be used in possibilities. These recommendations are for general
conjunction with all other applicable Installation applicability, they are believed to be reasonably
Manual Supplements and engineering drawings and accurate and reliable. The installer is ultimately
documentation supplied by PERMA-PIPE for the responsible for a proper installation. Trained and
specific project. This Installation Manual addresses qualified personnel should be used for all phases of
all common aspects of the installation process, from the installation. The importance of a proper
initial receiving and storage through final backfill and installation cannot be overstated.
operation and maintenance.
PERMA-PIPE cannot anticipate every circumstance
If leak detection, heat tracing, and/or other ancillary that might involve hazard. The warnings in this
equipment is included with your XTRU-Therm piping Installation Manual are, therefore, not all-inclusive.
system, refer to the appropriate Installation Manual(s) The installer must satisfy himself that each
in conjunction with this Installation Manual. If a procedure, tool, work method or operating technique
particular procedure is not addressed in this is safe.
Installation Manual, contact PERMA-PIPE for
additional information, if needed. If these recommendations conflict with the project
contract specifications or drawings or PERMA-
The true operating success of the system is greatly PIPE’S engineering drawings, the more stringent
dependent upon proper product application, documents should take precedence. If in doubt,
installation, operation, and maintenance. PERMA- please contact your PERMA-PIPE Project Engineer,
PIPE is committed to supporting the proper Project Manager or Field Technical Representative.
application and installation of a complete, high quality Any deviations from these recommendations or
insulated piping system. This support includes clear PERMA-PIPE’S engineering drawings should be
and concise product data, and installation reviewed with the appropriate PERMA-PIPE
recommendations and expert applications personnel.
engineering support and field technical assistance.
Carefully plan and execute the installation sequence
When installed, tested, operated, and maintained in to avoid errors and expensive mistakes. Do Not skip
accordance with these recommendations, a steps.
successful installation should be achieved and
PERMA-PIPE’S XTRU-Therm piping system will For underground installations, Do Not complete
provide excellent service, meeting or exceeding trench backfilling until all testing and inspection is
expectations. completed and accepted by the appropriate authority.
Rev. May 2001 Page i
PERMA-P IPE, Inc. XTRU-Therm
Installation Manual
INTRODUCTION FIELD TECHNICAL ASSISTANCE
XTRU-Therm is a versatile, pre-engineered, factory PERMA-PIPE Field Technical Assistance (FTA) is
pre-fabricated insulated piping system for available for on site technical assistance. PERMA-
belowground or aboveground applications. XTRU- PIPE recommends the use of FTA to support the
Therm is available in a wide variety of service pipe proper installation of the XTRU-Therm piping system
materials and for many different applications. The by the installer. Field Technical Assistance is
insulation is a low density, low thermal conductivity, provided when included as part of the customer’s
rigid polyurethane insulation. The insulation jacket is purchase order or when purchased separately.
a durable high density polyethylene (HDPE) material.

The customer is provided with the exact

NOTICE
specifications of the XTRU-Therm product supplied
This Installation Manual and the recommendations it
for each project.. XTRU-Therm can be purchas ed in
contains are reasonably believed to be accurate and
one of three different configurations wth varying
reliable. However, due to variations in environment,
degrees of factory prefabrication;
application or installation, and because the conditions
• XTRU-Therm Custom – Straight lengths of pipe of use are beyond PERMA-PIPE’s control, the user of
and fittings are custom fabricated to field verified this Installation Manual assumes all risk connected
dimensions and angles. Field cutting of straight with the use thereof. The installer of these piping
lengths of pipe is not required. All field joints are in products is ultimately responsible for his own work
straight lengths of pipe. and, thus, the integrity of the system. PERMA-PIPE
• XTRU-Therm Xpress – 20’ or 40’ insulated straight assumes no responsibility for the use of information
lengths of pipe. Fittings with standard tangent presented herein and, hereby, expressly disclaims all
lengths and standard angles. Straight lengths of liability in regard to such use.
pipe are field cut to fit field dimensions. All field Any technical recommendations, suggestions or
joints are in straight lengths of pipe. advice with respect to storage, handling, installation
• XTRU-Therm Economy – 20’ or 40’ insulated or use of PERMA-PIPE’s materials, by, or on behalf
straight lengths of pipe, with field joint and fitting of PERMA-PIPE is an accommodation to the
insulation kits. Fittings are field fabricated, Purchaser for which PERMA-PIPE shall have no
insulated and jacketed. Materials are supplied in responsibility, unless responsibility has been
accordance with an agreed upon bill of material. expressly assumed in writing by the President or a
Service pipe fittings are supplied by the installer Vice-President of PERMA-PIPE.
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.

Rev. May 2001 Page ii

PERMA-P IPE, Inc. XTRU-Therm
Receiving, Handling Installation Manual
and Storage Section 1
RECEIVING HANDLING
All materials have been factory inspected and The means by which the piping units are unloaded
carefully loaded and braced to prevent damage in and handled at the job site is the decision of the
shipment to the job site. However, even these efforts receiver. It is imperative that proper care and
are sometimes not enough to prevent damage in handling techniques are used to avoid damage.
transit. It is the carrier’s responsibility to deliver the Damaged piping units may require costly repairs,
shipment in good condition. It is the receiver’s cause property damage, or worse, personal injury.
responsibility to report any loss or damage upon Safety and careful handling should be top priorities
receipt. PERMA-PIPE’s standard terms are F.O.B. when handling any of the piping units.
our factory, full freight allowed to job site.
PERMA-PIPE supplies two nylon slings with each
When a shipment arrives at the job site, obtain the shipment. If additional slings are required, they can
following documentation from the carrier before be purchased from PERMA-PIPE.
offloading;
The following procedures are recommended for
• Packing List. handling the piping units;
• Bill of Lading
• Support each piping unit with nylon slings during
• Material Safety Data Sheets (MSDS Sheets).
all phases of handling. The nylon slings prevent
• PERMA-PIPE’s Part Drawing Layout (PDL),
damage to the piping units.
(if applicable)
• Do Not use hooks, steel cables or chains for
• Quality Assurance Documentation as applicable
handling any piping units.
(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 • Do Not drag or drop piping units.
advised to do so by PERMA-PIPE. • Do Not strike the piping units against hard
• Immediately submit any claims to the carrier. surfaces at any time.
Failure to do so will result in loss of • Do Not use forklifts for handling piping units.
compensation for missing or damaged materials. • Do Not use a nylon sling that has been damaged
• Notify PERMA-PIPE of these claims if assistance or is fraying. Damaged slings should be cut in
is required. half and disposed of.
• If replacement materials are required, they can • If possible, use a spreader bar to maximize
be ordered from PERMA-PIPE. You will be control of the piping units during handling.
advised of replacement purchase costs, which PERMA-PIPE does not supply spreader bars.
will also be required for your freight claim.

Rev. May 2001 Page 1-1

PERMA-P IPE, Inc. XTRU-Therm
Receiving, Handling Installation Manual
and Storage (cont.) Section 1
HANDLING (cont.) • When stacking, stack piping units in the same
fashion they were received.
• Use two nylon slings where possible. The use of • Wooden shipping braces must be used as
two nylon slings provides much more control of runners between layers of pipe.
the load. A length of pipe suspended with a • Do Not stack piping units more than three (3)
single nylon sling is more likely to swing out of tiers high.
control, potentially causing a safety hazard. • Use foam or other padding between layers.

THREE (3)
TIERS
MAX.

• Space the slings about 15 - 20 feet apart.

• If a piping unit is damaged during handling, refer
• If the ends of piping units were shipped with
to Section 4 for repair recommendations.
plastic covers and/or plastic pipe end caps, do
SAFETY CONSIDERATIONS not remove them when storing the piping units.
Safety should always be a primary consideration If any of the protective covers were damaged in
when unloading and handling piping units. shipping or handling, they must be restored by
replacing the protective plastic cover where
• Never lift more weight than your equipment can
necessary.
safely handle.
• Use a light colored or opaque tarp to cover
• Never lift more weight than the rating of the
outdoor stored piping units to protect the piping
slings.
units from weather and the Sun’s ultraviolet (UV)
• Do Not use damaged slings, cut up and dispose rays that can discolor or degrade the materials.
of any damaged slings.
• PERMA-PIPE chocks only the outer piping units LOOSE SHIPPED MATERIALS
in each layer (or tier) on the truck. It is important
to recognize that as you lift piping units off the • Store all field joint and ship loose materials
truck, nearby piping units may become unstable indoors and in a dry area.
and roll. Chock piping units that are not being • Keep the materials in their original shipping
unloaded. containers. The recommended storage
temperature range for chemicals is 60° - 85° F
STORAGE (18° -29°C).
• Refer to the Material Safety Data Sheets (MSDS
Proper storage of piping units and loose shipped Sheets) for proper handling, storage and use.
materials is very important. These materials can Some materials may be flammable or hazardous.
deteriorate or sustain damage if not properly stored. Extreme care must be taken so they are stored
Proper storage is the responsibility of the receiver. away from any open flames.
The following procedures are recommended; • Do Not allow chemicals to freeze as this may
hinder effectiveness or render useless.
PIPING UNITS
• Contact PERMA-PIPE if additional MSDS Sheets
• If possible, store the piping units in a warehouse are needed.
or heated shelter. If this is not possible, store the
piping units on high ground to avoid ingress of
water into the pipe ends.

Rev. May 2001 Page 1-2

PERMA-P IPE, Inc. XTRU-Therm
Excavation Installation Manual
Section 2
EXCAVATION TRENCH WIDTH

GENERAL 6" MIN. (TYP.)

All types of flexible pipe derive some of their strength
from the passive soil resistance around t he pipe.
6" MIN.
Therefore, proper excavation and backfilling of the
trench is very important to insure a structurally sound
system.
4" MIN. BEDDING
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
TRENCH DEPTH
minimum of 2 feet of properly compacted backfill is
provided. It should be noted that shallower burial The total trench depth should allow for a 4-inch
depths will increase the piping system heat loss/gain bedding, the largest insulation jacket diameter and a
slightly. See Section 7 for backfilling and compaction minimum 24 inches cover above the largest
recommendations. insulation jacket diameter. See the contract
specifications or drawings for specific burial depth
Special burial depths and compaction requirements requirements. For cover depths less than 24 inches,
may be required at taxiways, runways, railways, contact PERMA-PIPE. If special loading conditions,
roadways, and other areas of high surface loading such as railroads, taxiways, runways are
conditions. It is recommended that the customer encountered contact PERMA-PIPE and the local
contact both PERMA-PIPE and the local authority for authority.
more specific instructions.
NOTE: All federal, state and local regulations 24" MIN.
concerning jobsite safety should be observed. COVER

TRENCH WIDTH – SINGLE PIPE

The minimum recommended trench width for a single
pipe trench is the insulation jacket diameter plus 12 4" MIN. BEDDING
inches (6 inches between the pipe and trench wall).
TRENCH BEDDING
The trench floor should be completely cleared of
TRENCH WIDTH
6" MIN.
stones and rocks and then covered with 4-inches of
(TYP.) 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.
4" MIN. BEDDING
BELL HOLES
Digging bell holes at field joint locations allows room
TRENCH WIDTH – MULTI-PIPE for service pipe joining, testing, and field joint
For multi-pipe trenches, pipe centerline dimensions insulating and jacketing. A common way to dig bell
can usually be found on the layout drawings. holes is to cut across the trench with a backhoe.
The minimum recommended trench width is the sum The bell holes should be cut into the trench wall and
of all insulation jacket diameters, plus 6 inches between 1½ and 2 feet below the trench floor. Bell
between each pipe plus 12 inches (6” between pipes hole locations should be identified and dug before
and 6 inches from the pipe to trench wall). lowering piping units into the trench.
Rev. May 2001 Page 2-1
PERMA-P IPE, Inc. XTRU-Therm
Excavation (cont.) Installation Manual
Section 2
ALTERNATE TRENCH BOTTOM SPECIAL SOIL CONDITIONS
SAND OR DIRT BERMING
An alternate method to trench bedding is to sandbag UNSTABLE SOIL
or dirt berm the bottom of the excavated trench. If During excavation, an unstable soil condition may be
the berms elevate the bottom of the pipe above the encountered, particularly in installations with deep
trench bottom sufficiently, bell holes may not be burials. If this occurs, shore the trench walls before
required. However, the space under the pipe will lowering the piping units into the trench. As the
require backfilling and compacting as described in shoring is removed, replace it with compacted backfill
Section 7. material.
INSULATED PIPE

SHORING

4" MINIMUM

SAND OR DIRT BERM

EXCAVATED TRENCH BOTTOM

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 Organic soils or plastic clays and silts with high liquid
open to allow proper compacting of the berm limits may be encountered that are incapable of
material. Do Not use wood or other degradable supporting the pipe. Remove the poor soil, and
materials for berms. replace it with proper bedding soil to a depth that will
The trench floor should be completely cleared of provide a firm stable foundation.
stones and rocks before placing the berms. The ROCK BOTTOM TRENCH
berms should be elevated to provide a minimum
slope of 1 inch per 40 feet to allow for gravity draining A rocky or uneven trench foundation should be
of the piping system. covered with a firm soil or gravel before the trench
bedding is placed.
Berm spacing should be approximately 10 feet and
berm width at least 6 inches. These values may BEDDING
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 FIRM SOIL ROCKY FOUNDATION
backfilling and compacting recommendations. It is
critical that the space under the pipe be properly GRANULAR SOIL
backfilled and compacted to provide a stable trench In granular soil, the trench wall should be sloped at
bed for the piping system. 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 2-2

PERMA-P IPE, Inc. XTRU-Therm
Assembly Installation Manual
Section 3
ASSEMBLY to prevent damage. All tools, equipment, and
materials needed for a particular operation or
GENERAL procedure should be made readily available before
Assembly of the piping system should be in starting. Refer to other sections of this Installation
accordance with the engineering design of the piping Manual for “specialty” tools that may be required.
system. Proper placement of end seals, anchors,
expansion loops, expansion elbows, Z-bends, tees, COLD / WET WEATHER CONDITIONS
external expansion pads, thrust blocks, and supports When installing pipe in temperatures below 60°F, or
is critical to prevent overstressing of the piping in rain or snow, refer to the Installation Manual
system due to thermal expansion / contraction and Supplement for Cold / Wet Weather Conditions.
other mechanical loads.
The amount of factory pre-fabrication of the XTRU- LAYOUT
Therm piping system depends on the configuration it Installation can be simplified by laying the piping units
was purchased – Custom, Xpress, or Economy. See in the order they will be assembled. To avoid
the Introduction at the beginning of this Installation damaging the piping units they should not be laid out
Manual for descriptions of each configuration. until trenching and bedding is completed for
belowground systems or structural supports
XTRU-Therm piping ordered and supplied as a completed for aboveground systems.
PERMA-PIPE pre-engineered system has been
designed for the specified conditions and includes a ABOVEGROUND SYSTEMS - SUPPORTING
Layout Drawing that indicates the designed routing
XTRU-Therm piping installed aboveground should be
and dimensions of the piping system. When the
properly supported to prevent damage to the
piping units have been fabricated to field dimensions,
insulation or insulation jacket. Insulation shields or
the Layout Drawing will include the part number of
equivalent should be used at support locations to
each piping unit and its designated location. Correct
prevent overloading of the insulation or insulation
placement of the piping units is critical. Piping units
jacket. Proper support type (fixed, guide, roller, etc.)
installed out of order and/or with unapproved
and spacing is required to prevent overstressing of
alterations may lead to operating hazards, system
the piping system and limit deflection between
failure, and/or voiding of PERMA-PIPE’s warranty.
supports. Sloping, if required, must be provided for in
If the XTRU-Therm piping ordered and supplied is not the support system elevations.
a PERMA-PIPE pre-engineered system, the
engineering design of the piping system is the CUTTING TO FIELD DIMENSIONS
responsibility of others and should be performed by a Piping units may need to be cut to field dimensions.
qualified piping system designer. All cuts should be made in straight sections of pipe in
the manner described below.
ANCILLARY EQUIPMENT
If the XTRU-Therm system being installed includes Refer to the appropriate Installation Manual
Supplement or PERMA-PIPE drawings for special
any ancillary equipment such as leak detection or
service pipe end preparation requirements for bell &
heat trace, refer to the appropriate Installation
Manual(s) and/or PERMA-PIPE documentation in spigot PVC, ductile iron, FRP, or O-ring or gasketed
coupling joints.
conjunction with this Installation Manual.
• Mark the location of the cut on the insulation
PREPARATION AND SET -UP jacket.
Personnel performing any phase of installation • Cut back the insulation jacket and insulation to
should be trained and qualified in the procedures the required dimension on each side of the cut
they will perform and be familiar with the appropriate mark. A knife, hand saw, or power saw can be
sections of this Installation Manual, Installation used to cut the insulation jacket and insulation.
Manual Supplements, and all engineering drawings Be careful not to cut the service pipe.
and documentation supplied by PERMA-PIPE for the • Remove all insulation in the cut back area. Clean
specific project. to bare service pipe material.
• Cut the service pipe and restore the end
Proper tools, equipment, and materials should be preparation (weld bevel for steel pipe, shaved OD
used for handling and installation of the piping units for FRP pipe, etc.).
Rev. May 2001 Page 3-1
PERMA-P IPE, Inc. XTRU-Therm
Assembly (cont.) Installation Manual
Section 3
SERVICE PIPE JOINING • If the piping units have been supplied with end
If sufficient handling equipment is available, it may be protection, remove all end protection materials.
easier to complete some field joints before lowering Do Not remove end protection materials until the
into the trench or lifting onto supports. This may service pipes are to be joined.
require more than one crane and/or a spreader bar to
lower or lift the joined piping units into place. Do Not SERVICE PIPE ANCHORS
allow the joined piping units to bow when handling. Service pipe anchors control the direction of
Do Not join piping units with flexible joints such as movement caused by thermal expansion/contraction
gasketed bell & spigot or o-ring joints before lowering and the resulting service pipe stresses. Service pipe
or lifting. anchors must be properly placed to prevent
overstressing of the piping system.
CAUTION: If your XTRU-Therm piping system has
been supplied with the pressure testable field joint
XTRU-Therm anchors consist of a steel anchor plate
closure system, be sure to slide the pressure testable
rigidly attached to the service pipe. For underground
closure sleeve over the pipe ends at each field joint
piping systems the anchor plate should be encased
before joining the service pipes together.
in a concrete anchor block as described below. For
All service pipe field joints should be completed in the aboveground systems the anchor plate should be
following manner: welded to a structure capable of withstanding the
• If the piping unit has been supplied with end loads the anchor plate will apply to it.
protection, remove all end protection materials.
CONCRETE ANCHOR BLOCKS
• Properly align each field joint. Verify the legs of
elbows and tees are perpendicular, and the legs Concrete anchor blocks are used to transfer the
of expansion loops are parallel to each other. If service pipe anchor force to the soil. The anchor
the legs of elbows, tees, and expansion loops are block should be keyed into undisturbed earth to the
not positioned correctly, it will affect the overall maximum extent possible. The backfill around the
length of the pipe run. balance of the anchor block should be compacted as
• Use the appropriate service pipe joining described in Section 7. The resulting soil around the
technique (weld, braze, adhesive, o- anchor block should have a minimum bearing
2
ring/gasketed coupling, etc.) for each field joint. capacity of 2000 lbs./ft. . If the soil can not provide
See the appropriate Installation Manual this bearing capacity the anchor block size should be
Supplement if required. increased to increase its bearing surface area
• Wrap the field joint area with plastic and seal with enough to offset the lower soil bearing capacity.
tape to keep moisture, rain, water, and dirt away Contact PERMA-PIPE for assistance if needed.
from the service pipe and insulation ends. Anchor block concrete should be 2000 psi minimum
• Perform all required service pipe testing and rated concrete. Rebar is not required. Anchor blocks
inspection and pressure test the service pipe as for typical applications should be formed to the
described in Section 5. minimum dimensions shown on the details below.
• After successful completion of all service pipe
testing and inspection, insulate and jacket the 30" KEYHOLE TRENCH WALL
field joints as described in Section 6. INTO UNDISTURBED SOIL

LOWERING / LIFTING CONCRETE

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

• Remove all free standing water from trenches

and bell holes before lowering piping units. Bell
holes and trench bedding must be dry during
ANCHOR PLATE
piping unit installation.
9" TYP.
• Lower or lift the piping units into place. Do Not ALL AROUND
drop the piping units. Spreader bars or more
than one crane may be required depending on
the size of the piping unit being handled.
Rev. May 2001 Page 3-2
PERMA-P IPE, Inc. XTRU-Therm
Assembly (cont.) Installation Manual
Section 3
CONCRETE ANCHOR BLOCKS (cont.) expansion pad locations and thickness and length
If unusually high anchor forces will be encountered, requirements.
such as those resulting from expansion joint thrust If the XTRU-Therm piping ordered and supplied is not
forces, larger anchor block and specially designed a PERMA-PIPE pre-engineered system, the
anchor plates may be required. Contact PERMA- engineering design of the piping system, including
PIPE for assistance if needed. expansion pad requirements, is the responsibility of
For multiple pipe trenches, use the dimension in the others and should be performed by a qualified piping
figure above but increase the width by the additional system designer.
insulation jacket outside diameters plus the spacing
between insulation jackets (6 inches minimum). The total thickness of expansion pad material should
be greater than the expected expansion or
UNRESTRAINED JOINTS - CONCRETE THRUST contraction of the service pipe. The length should be
BLOCKS sufficient to allow enough service pipe movement to
prevent overstressing of the service pipe.
Concrete thrust blocks are required when the service
pipe joints are unrestrained, such as unrestrained Expansion pad material is supplied in bulk rolls. The
gasketed bell and spigot PVC or ductile iron, or o-ring material must be field cut to the width required to
or gasketed couplings, or FRP adhesive joints. wrap around the insulation jacket or previous layer of
Concrete thrust blocks are required for all changes in expansion pad material.
direction (elbows, tees), changes in size (reducers),
and dead ends (caps, plugs, valves). Expansion pads should be installed in the following
manner;
The size of the thrust block is dependent upon the • Determine required length and total thickness
test pressure, pipe size, type of fitting, number of from PERM -PIPE’s Layout Drawing (if a PERMA-
pipes, and soil conditions. Refer to the Installation PIPE pre-engineered system) or from the
Manual Supplement for Concrete Thrust Blocking for responsible engineer’s drawing.
thrust block sizing and installation recommendations. • Determine the required width from the measured
circumference of the insulation jacket or previous
UNRESTRAINED JOINTS – TIE-INS layer of expansion pad material. The expansion
Transitions from an unrestrained joint system to a pad must cover the top and sides as shown
restrained joint system are often made when an below.
underground piping system enters a building or • Cut the expansion pad material to the required
manhole or transitions to aboveground piping. width and length.
When tying in an unrestrained joint system to a • Install the required length and number of layers
restrained joint system an anchor is required in the of expansion pad as shown below. Exercise care
restrained joint system to resist the thrust load of the not to compress the expansion pad material
unrestrained joint system. This anchor should be during installation.
LENGTH AS REQUIRED
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 LENGTH

AS REQUIRED INSULATED PIPE
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- EXPANSION PADS TOTAL
THICKNESS AS REQ'D.
INSULATED PIPE
PIPE. PLACE BACKFILL MATERIAL BOTH
SIDES TO HOLD IN PLACE
DURING INSTALLATION
XTRU-Therm piping ordered and supplied as a
PERMA-PIPE pre-engineered system includes a
Layout Drawing that indicates the necessary
TRENCH BEDDING

Rev. May 2001 Page 3-3

PERMA-P IPE, Inc. XTRU-Therm
Assembly (cont.) Installation Manual
Section 3
WALL OR FLOOR ENTRIES • Apply a heat shrink end seal to the front side of
PERMA-PIPE recommends that all building or the FRP reinforcement sleeve. Follow the heat
manhole entries be sleeved and the annular space shrink end seal recommendations below.
between the insulation jacket and sleeve sealed by a
INSULATION JACKET
mechanical rubber seal or waterproof sealant. Wall 6" WIDE HEAT SHRINK SLEEVE FRP SLEEVE, TRIM TO THE
sleeves and mechanical rubber seals are available 24" LONG FRP SLEEVE
CORRECT CIRCUMFERENCE
AND FILL LONGITUDINAL SEAM
from PERMA-PIPE. A WITH FRP ADHESIVE

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 SECTION A - A
A
the insulation and jacket. The XTRU-Therm wall/floor
HEAT SHRINK END SEAL
entry end seal assembly provides mechanical
reinforcement to the insulation jacket and a water
tight seal between this reinforcement and insulation
HEAT SHRINK END SEALS
jacket. XTRU-Therm Custom and Xpress wall/floor
entry end seals are factory fabricated. XTRU-Therm Heat shrink end seals form a water tight seal
Economy wall/floor entry end seals are field between the insulation jacket and service pipe.
assembled. Heating the heat shrink end seal causes the adhesive
to soften and the heat shrink end seal to shrink
XTRU-Therm ECONOMY WALL/FLOOR ENTRY compressing the adhesive and forming a seal
END SEAL ASSEMBLIES between the heat shrink end seal and insulation
XTRU-Therm Economy floor/wall entry end seal jacket and service pipe.
assemblies consist of an FRP reinforcement sleeve,
Heat shrink end seals should be used at all
adhesive, heat shrink sleeve, and heat shrink end
termination ends and open ends of the XTRU-Therm
seal all supplied by PERM -PIPE for field assembly.
piping system to prevent ingress of water or moisture.
Wall/floor entry end seal assemblies should be
assembled in the following manner; Depending on the configuration of XTRU-Therm
• Measure the circumference of the outside purchased – Custom, Xpress, or Economy, some
diameter of the insulation jacket. heat shrink end seals may require field installation.
• Trim the FRP reinforcement sleeve When field installation of heat shrink end seals is
circumference about 1/8 to 1/4 inch smaller than required, refer to the Installation Manual Supplement
the insulation jacket. for Heat Shrink End Seals.
• Abrade and clean the inside diameter of the FRP
reinforcement sleeve.
INSULATION JACKET HEAT SHRINK END SEAL
• Abrade and clean the insulation jacket area that
SERVICE PIPE
will be under the FRP reinforcement sleeve.
• Apply adhesive to the FRP reinforcement sleeve
inside diameter. ADHESIVE/MASTIC
SEALANT
• 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 XTRU-Therm ECONOMY FITTINGS
FRP reinforcement sleeve.
XTRU-Therm Economy service pipe elbows, tees,
• Allow the adhesive to cure. and reducers are typically supplied by the installer
• Apply a heat shrink sleeve to the back side of the unless otherwise specified and purchased. These
FRP reinforcement sleeve. Follow the heat fittings should be joined to the service pipe as
shrink sleeve recommendations in Section 6. described above.

Issue 1 3/22/01 Page 3-4

PERMA-P IPE, Inc. XTRU-Therm
Assembly (cont.) Installation Manual
Section 3
XTRU-Therm ECONOMY ANCHORS -BELOW GROUND XTRU-Therm ECONOMY ANCHORS -ABOVEGROUND
XTRU-Therm Economy belowground anchors are XTRU-Therm Economy aboveground anchors are
field assembled, insulated, and jacketed. PERMA- field assembled, insulated, and jacketed. PERMA-
PIPE supplies the steel anchor plate and steel PIPE supplies the galvanized steel anchor plate and
sleeves. The anchor should be installed in the galvanized steel sleeves. The anchor should be
following manner; installed in the following manner;
• Mark the anchor location on the insulation jacket. • Mark the anchor location on the insulation jacket.
• Strip 8 inches of insulation jacket and insulation • Strip 8 inches of insulation jacket and insulation
on each side of the marked location. Clean to on each side of the marked location. Clean to
bare service pipe material. bare service pipe material.
• If required to fit over the service pipe, cut the • If required to fit over the service pipe, cut the
anchor plate in two halves. anchor plate in two halves.
• Weld (or braze if copper service pipe) the anchor • Weld (or braze if copper service pipe) the anchor
assembly to the service pipe as shown on assembly to the service pipe as shown on
PERMA-PIPE’s engineering drawings and the PERMA-PIPE’s engineering drawings and the
figure below. figure below.
• Seal weld the anchor plate split seams if the • Seal weld the anchor plate split seams if the
anchor plate was cut in two halves. Grind the anchor plate was cut in two halves. Grind the
seal welds flush and smooth. seal welds flush.
• Weld the steel sleeves to both sides of the • Weld the steel sleeves to both sides of the
anchor plate. anchor plate.
• Seal weld the longitudinal seams of the steel • Seal weld the longitudinal seams of the steel
sleeves. Grind the outside surface of the welds sleeves. Grind the outside surface of the welds
flush and smooth. flush and smooth.
• Grind a minimum 1/16 inch chamfer on all • Apply a zinc rich paint to the exposed weld areas
outside edges of the anchor plate. to prevent corrosion.

FILLET WELD SIZE FILLET WELD SIZE

EQUAL TO PIPE EQUAL TO PIPE
TYP. IF REQ'D. GALVANIZED TYP. IF REQ'D.
WALL THICKNESS STEEL SLEEVE WALL THICKNESS STEEL SLEEVE

8" 8"

BELOW GROUND STEEL SERVICE PIPE ANCHOR ABOVEGROUND STEEL SERVICE PIPE ANCHOR

FLARED COPPER FLARED COPPER

COUPLINGS COUPLINGS
SILVER BRAZED TO SILVER BRAZED TYP. IF REQ'D.
TYP. IF REQ'D. GALVANIZED
SERVICE PIPE STEEL SLEEVE TO SERVICE PIPE
STEEL SLEEVE

8" 8"

BELOW GROUND COPPER SERVICE PIPE ANCHOR ABOVEGROUND COPPER SERVICE PIPE ANCHOR

Rev. May 2001 Page 3-5

PERMA-P IPE, Inc. XTRU-Therm
Alterations and Installation Manual
Repairs Section 4
ALTERATIONS REPAIRS

When alterations to an XTRU-Therm piping system INSULATION JACKET

are necessary, the considerations herein are Remove all damaged insulation jacket material up to
recommended. Alterations should be performed the point where the insulation jacket is no longer
using the appropriate installation recommendations damaged.
described in other sections of this Installation Manual.
Small areas of damaged insulation jacket, up to 3/8
PERMA-PIPE or the responsible piping system inch x 3/8 inch, can be repaired using an adhesive
designer should be consulted to properly design the melt stick. Adhesive melt sticks are available from
alteration and ensure the alteration will not adversely PERMA-PIPE. Adhesive melt stick repairs can be
effect the design and operation of the piping system. made in the following manner;
In all cases it is critical that the insulation, insulation • Remove the damaged insulation jacket material.
jacket, and insulation jacket integrity be fully restored. • Abrade the edges of the jacket around the repair
area. Clean this area with a clean cloth.
PIPE LENGTH • Gently warm the repair area with a propane
The change in the piping system layout and effect on torch.
the piping system stresses must be considered when • Melt the adhesive melt stick onto the repair area
the piping system dimensions are changed. Even with a propane torch.
relatively small changes in dimensions can cause
overstressing of the piping system if these changes
• Smooth and blend the surface and edges of the
are made in areas, such as expansion elbows or z- adhesive into the existing jacket.
bends, where dimensional changes could cause
ADHESIVE MELT STICK
overstressing of the piping system due to the
reduction in flexibility or increase in thermal
expansion /contraction displacements. DAMAGED JACKET
AREA
Pipe cutting should be performed as recommended in
Section 3.

FITTINGS OR COMPONENTS
The change in the piping system layout and effect on Small or large areas of damaged insulation jacket
the piping system stresses must be considered for can be repaired using a heat shrink sleeve. The
alterations that add or delete fittings, or other piping width of the heat shrink sleeve should extend a
system components. minimum of 6 inches past each edge of the damaged
The addition or deletion of anchors, elbows, tees, or jacket area. See Section 6 of this Installation Manual
other piping system components can have serious for heat shrink sleeve installation recommendations.
detrimental effects on the piping system design and
operation. 6" MINIMUM OVERLAP
DAMAGED JACKET
AREA
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.
HEAT SHRINK SLEEVE

Rev. May 2001 Page 4-1

PERMA-P IPE, Inc. XTRU-Therm
Alterations and Installation Manual
Repairs (cont.) Section 4

REPAIRS (cont.) SERVICE PIPE

Do Not operate a service pipe that has damage to its
INSULATION pressure retaining capability.
Remove all damaged insulation material up to the Service pipe damage such as gouges, dents, cracks,
point where the insulation is no longer damaged. bending, or flattening require repair or replacement of
Damaged insulation includes insulation that is wet. the service pipe.
Small or large areas of damaged insulation can be If the service pipe is repaired, the repair method must
repaired using pour foam polyurethane. See Section restore the full pressure retaining capability to the
6 of this Installation Manual for installation service pipe.
recommendations.
If the service pipe is replaced, an equivalent section
Large areas of damaged insulation can be repaired of XTRU-Therm piping should be installed with field
using pre-form polyurethane insulation. See the joints at the connections to the existing system.
Installation Manual Supplement for Pre-Formed
Polyurethane Insulation for installation
recommendations.
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.

Rev. May 2001 Page 4-2

PERMA-P IPE, Inc. XTRU-Therm
Testing and Installation Manual
Inspection Section 5
TESTING PRESSURE TESTABLE FIELD JOINTS
If your XTRU-Therm piping system has been
SERVICE PIPE PRESSURE TESTING supplied with the pressure testable field joint closure
Prior to field joint insulating and jacketing and system, refer to the Installation Manual Supplement
backfilling (for underground systems), all service pipe for Pressure Testable Field Joints.
joints should be pressure tested in accordance with
the applicable ASME B31 piping code and any other OTHER TESTING AND INSPECTION
contract specifications. In the event of conflict the Other tests and inspections, such as water hammer
more stringent requirement should be used. testing, field joint weld radiography, dye penetrant or
Prior to pressure testing, all anchors, concrete anchor magnetic particle may be required by the contract
blocks, concrete thrust blocks and any other piping specifications. It is the installer’s responsibility to
system thrust restraint devices must be in place. perform these test and inspections, as required, for
full contract compliance.
PERMA-PIPE recommends hydrostatic pressure
testing (hydrotesting). Pneumatic testing is not INSPECTION
recommended due to the safety hazards associated
with a large volume of high pressure gas. VISUAL INSPECTION
The following steps are recommended to be part of After the piping system has successfully passed the
the hydrotest procedure; hydrotest and all field joint insulation and insulation
jacketing is completed, and prior to backfilling of
• After all service pipes are joined, and before field underground systems, a final visual inspection of the
joint insulating, connect pipe test caps at the piping system should be made.
ends of the pipe run. Pipe test caps, including
flanges and blind flanges for testing purposes, • Walk the pipe lines and carefully inspect the
are not supplied by PERMA-PIPE. piping for any damage and to ensure all work has
been completed. For underground systems, this
• Use a pressure gauge sized properly, and close
step should be performed just prior to backfilling.
to, the test pressure.
• Remove all anchor block forms, construction
• Set all valves so the section of piping to be tested
materials, soil or any other work that may have
will be pressurized. In most cases, it is preferred
caused damage or may cover damaged areas.
not to test directly against a valve, because they
are sometimes the source of a “leak”, especially • Any damage should be repaired as described in
Section 4.
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.

Rev. May 2001 Page 5-1

PERMA-P IPE, Inc. XTRU-Therm
Field Joint Insulation Installation Manual
And Jacket Section 6
FIELD JOINTS PREPARATION
All materials, equipment, and tools should be made
After completion of all tests and inspections as
readily available before starting.
described in Section 5, each field joint requires
application of insulation and insulation jacket to Do Not attempt insulating field joints in wet bell
properly complete the field joint. holes. If the bell hole is wet, pump it dry before
Field joints are made in straight sections of pipe only insulating the field joint.
for XTRU-Therm Xpress and Custom configurations. PERMA-PIPE provides the following materials for
Field joints are made in straight sections of pipe and field joint insulating;
at fittings (elbows, tees, and anchors) for XTRU-
• Polyurethane pour foam insulation, A and B
Therm Economy.
components, in bulk liquid form
The standard XTRU-Therm straight field joint • Metal pour foam mold for straight field joints
consists of a temporary metal mold, polyurethane • Transition sleeves, PVC fitting cover, and
pour foam insulation and a heat shrink sleeve. sealing tape for fitting field joints (XTRU-Therm
The standard fitting field joint consists of Economy)
polyurethane pour foam insulation, transition sleeves, NOTE: Insulation components A and B must be
a flexible PVC fitting cover, and sealing tape. stored between 60°F to 85°F before use. Insulation
If your XTRU-Therm piping system has been stored below 60°F will not react properly. Insulation
supplied with a different type of field joint insulation or stored above 85°F may result in spoiling.
jacket refer to the appropriate PERMA-PIPE
The metal molds provided by PERMA-PIPE can be
Installation Manual Supplement and / or engineering
used to insulate at least 10 field joints when properly
documentation.
maintained.
If your XTRU-Therm piping system has been
The installer will need to furnish the following;
supplied with the pressure testable field joint closure
system, refer to the Installation Manual Supplement • Disposable paper mixing pails
for Pressure Testable Field Joints. • Measuring containers
• Heavy duty gloves
When cold or wet weather conditions are present,
• Dry rags
tenting and heating may be required to enable the
• Banding wire, rope, or tape
proper application of the field joint materials. Refer to
the Installation Manual Supplement for Cold / Wet • Mold release
Weather Conditions. • Safety clothing
• Tin snips
SERVICE PIPE INSULATION • Wood rasp
• Stir sticks and/or cordless drill and paint agitator
The standard XTRU-Therm service pipe field joint • Denatured alcohol or equivalent solvent
insulation is polyurethane pour foam insulation. This
insulation is supplied as two components, A and B, in PREPARING THE MOLD – STRAIGHT JOINTS
bulk liquid form. PERMA-PIPE supplies bulk roll sheet metal material
The installer must prepare the insulation molds for temporary metal molds for field joints in straight
around the field joints, measure the proper amounts sections of pipe. The metal molds should be cut and
of insulation components, mix the liquids to initiate a prepared in the following manner;
chemical reaction, and pour the insulation into the • Measure the circumference of the outside
mold formed around the field joint. When properly diameter of the insulation jacket at both ends of
measured and mixed the liquids will react and rise to the field joint. It is normal for there to be
produce a low density (approximately 2.5 – 3.0 differences in the insulation jacket outside
3
lbs./ft. ) rigid polyurethane insulation around the field diameter at fittings and special components. A
joint. slight taper in the field joint insulation will
compensate this for.
The following paragraphs describe PERMA-PIPE’s
recommendations for applying pour foam insulation
to XTRU-Therm field joints.
Rev. May 2001 Page 6-1
PERMA-P IPE, Inc. XTRU-Therm
Field Joint Insulation Installation Manual
And Jacket (cont.) Section 6
PREPARING THE MOLD – STRAIGHT JOINTS (cont.) • One side of the metal mold will wrap around the
• Cut the sheet metal length to 1.25 times the steel sleeve welded to the anchor plate. The
largest measured circumference of the insulation other side will wrap around the insulation jacket.
jacket outside diameter. • Cut only one 2 – 3 inch diameter pour and vent
(Length = 1.25 x Maximum Circumference) hole.
• Prior to each use, coat the entire inside surface ANCHOR PLATE W/SLEEVES
of the metal mold with a mold release. Mold BANDING
POUR/VENT HOLE
release is commonly found in fiberglass supply MOLD
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. PREPARING THE MOLD - FITTING KITS
• Wrap the metal mold around the field joint area Elbow and tee fittings for XTRU-Therm Economy are
as shown below. Center it so the ends extend at field assembled, insulated, and jacketed.
least 4 inches past the edge of each insulation
jacket. The mold for a fitting kit consists of transition sleeves,
a flexible PVC fitting cover, and sealing tape. The
• Band the metal mold with wire, rope or tape 2
molds for fittings should be prepared in the following
inches from each edge. Use two more bands in
manner;
the middle, evenly spacing all four.
• Place the transition sleeves on the ends of the
NOTE: It is important to fasten the metal mold straight pipe insulation jacket. Seal the
tightly around the insulation jacket. Gaps longitudinal and circumferential seams with
between the metal mold and insulation jacket will sealing tape.
allow some of the rising pour foam insulation to • Wrap the flexible PVC fitting cover over the fitting
escape. This could result in an incomplete pour and onto the transition sleeves. Seal the
and require mixing another small batch of circumferential and longitudinal seams with
insulation to complete the field joint. sealing tape.
• Cut two 2-3 inches diameter pour and vent holes • Cut two 2 – 3 inch diameter pour and vent holes
in the top of the metal mold between the bands. in the top of the mold.
BANDING FLEXIBLE PVC FITTING COVER
TRANSITION
MOLD POUR/VENT HOLE SLEEVE (TYP.)

POUR/VENT HOLE

PREPARING THE MOLD – ANCHOR KITS

4" WIDE SEALING TAPE TO
Anchors for XTRU-Therm Economy are field HOLD THE PVC FITTING
assembled, insulated, and jacketed. The insulating COVER AND TRANSITION
SLEEVE IN PLACE
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 NOTE: It is important to tightly seal all seams with
that required for a straight field joint. The actual sealing tape. Gaps between the mold and insulation
width will depend on the amount of insulation and jacket will allow some of the rising pour foam
jacket cutback made to install the anchor. It insulation to escape. This could result in an
should be wide enough to overlap at least 4 incomplete pour and require mixing another small
inches on each side. batch of insulation to complete the joint.

Rev. May 2001 Page 6-2

PERMA-P IPE, Inc. XTRU-Therm
Field Joint Insulation Installation Manual
And Jacket (cont.) Section 6
MEASURING THE POUR FOAM
Polyurethane foam insulation A and B components Pour Foam Insulation
1
are mixed in a 1:1 ratio. The amount of pour foam A and B Component Quantities (oz.)
required for a field joint depends on the volume of the Nominal Insulation Thickness
field joint and the density of the polyurethane Pipe Size 1” 1.5” 2” 2.5” 3”
insulation after it has completely reacted and risen. 1” 2 3 4 6 7½
The density of the field joint insulation is highly 1 ¼” 2½ 3½ 4½ 6½ 8
dependent on the ambient temperature and service 1 ½” 2½ 3½ 5 6½ 8½
pipe temperature. Cold conditions increase the 2” 3 4 5½ 7 9
density of the field joint insulation, which will result in 2 ½” 3 4½ 6 8 10
the need for more pour foam to complete a joint. 3” 3½ 5 6½ 8½ 11
4” 4 6 7½ 10 12½
PERMA-PIPE provides sufficient pour foam materials
to do the field joints for each order under typical 5” 4½ 6½ 9 11 14
conditions. If you are experiencing higher pour foam 6” 5 7½ 10 13 17
use than would be expected, as outlined herein, 8” 6 9 12 16 19
monitor your pour foam inventory to avoid running 10” 7 10½ 14 18 23
out. Additional pour foam materials are available 12” 8 12 17 21 26
from PERMA-PIPE. 14” 9 13 18 23 28
16” 10 14½ 20 25 31
Below are recommendations for determining the 18” 11 16 22 28 34
initial pour foam insulation A and B component 20” 12 18 24 30 37
quantities. The actual quantity used will depend on 24” 14 21 28 35 43
the factors described above. After a field joint is 30” 17 26 34 43 52
poured, adjust the pour foam quantity used for
subsequent field joints based on the results of the (1) Table values based on a standard 12 inch long field
joint. For different field joint lengths adjust the table
previously poured field joint(s).
values by multiplying by the factor – (actual field joint
Initial pour foam insulation A and B component length (inches) / 12).
quantities can be found using the table on this page.
This table is based on a standard 12 inch long field For pipe sizes or insulation thickness not in the table,
joint. For different field joint lengths the values in the the following equation can be used to determine the
table can be adjusted by multiplying by the factor – initial pour foam insulation A and B component
(actual field joint length (inches) / 12). For elbow, quantities;
tee, and anchor fittings, approximate the field joint
OZA = OZ B = 1.0 + (ODpipe + t insul. ) x tinsul. x L
length by measuring along the centerline length of
the fitting field joint. 23

Example: 6 “ pipe (6 5/8” OD) Where; OZA = ounces of component A

1.5” insulation OZB = ounces of component B
16” long field joint ODpipe = outside diameter of service pipe (in.)
tinsul. = thickness of insulation (in.)
Table è 7 ½ oz. Component A
L = length of field joint (in.) (for elbows
7 ½ oz. Component B
and tees, approximate by measuring
factor = 16 / 12 = 1.33 the length along the centerline)
Component A = 1.33 x 7 ½ = 10 oz.
Component B = 1.33 x 7 ½ = 10 oz. Example: 6 “ pipe (6 5/8” OD)
1.5” insulation
16” long field joint
Calculation è OZA = 9.5 oz.
OZB = 9.5 oz.

Rev. May 2001 Page 6-3

PERMA-P IPE, Inc. XTRU-Therm
Field Joint Insulation Installation Manual
And Jacket (cont.) Section 6
MIXING AND POURING THE POUR FOAM REMOVING TEMPORARY METAL MOLDS
Do Not mix the A and B components until the mold is The temporary metal molds should be removed in the
prepared and you are ready to begin insulating the following manner;
field joint. Once mixed, the components will begin a • Remove the banding and carefully peel the metal
chemical reaction and rise increasing in volume and mold off the insulation. Tearing the metal mold
decreasing in density by a factor of approximately 20.
]
off may damage the insulation or mold.
CAUTION: The chemical reaction will generate heat,
If the mold sticks repeatedly, use additional mold
causing the mold and insulation to become hot for a release on the mold.
short period of time.
• After each use, clean the inside of the mold with
Before opening a container of pour foam A or B denatured alcohol or an equivalent cleaning
component, turn the container upside down for about solvent to remove any dirt or insulation.
15 minutes to ensure it is properly mixed prior to • Patch any voids in the surface of the insulation by
being used. mixing another small batch of pour foam. As
Mix and pour the pour foam in the following manner; soon as the pour foam begins to rise in the
mixing pail, apply it to the void area(s).
CAUTION: Wear eye protection when mixing and
pouring the pour foam A and B components. • After the insulation has cooled, trim it flush with
the surrounding insulation.
• Use two measuring containers, each large
• If the heat shrink sleeve is not being applied
enough to hold the required quantity. Mark one
immediately after removal of the metal mold, use
of the containers “A” and the other “B”. Do Not
plastic sheet and tape to seal around the
use the containers interchangeably.
exposed insulation to prevent exposure to water
• Pour the required amount of component A into and moisture.
the “A” container. Pour an equal amount of
Insulation that becomes wet must be removed and
component B into the “B” container.
replaced.
• Combine the contents of both into a paper mixing
pail and immediately begin stirring. Use a stirring INSULATION JACKET
stick in hot weather and a cordless drill and paint
agitator in cool weather. Stir vigorously for about The field joint insulation jacket is designed to keep
15 seconds. The insulation begins to react and water and moisture from the insulation and service
rise in 15-30 seconds. pipe. The integrity of the insulation jacket is critical
• After 15 seconds of stirring, pour the mixture to the long life of the XTRU-Therm piping system.
through the pour and vent hole(s) into the mold.
The mixture will begin to react and rise filling the The standard XTRU-Therm straight field joint
mold. insulation jacket is a heat shrink sleeve. The
insulation jacket for elbow and tee fittings for XTRU-
• Discard the paper mixing pail, do not reuse.
Therm Economy is sealing tape over the transition
• If sufficient pour foam was used, excess sleeves and flexible PVC cover. The insulation jacket
insulation will push out through the pour and vent for XTRU-Therm Economy belowground anchors is a
hole(s). high shrink ratio heat shrink sleeve.
• If the mold does not fill completely, estimate how
much more insulation will be required. Mix the A HEAT SHRINK SLEEVES - GENERAL
and B components and pour again into the pour Heat shrink sleeves form a water tight seal between
hole(s). the sleeve and the insulation jacket and insulation.
• After the pour stops rising, allow the mold and Heating causes the adhesive backing to soften and
insulation to cool for approximately 10 minutes the sleeve to shrink, compressing the adhesive and
then cut and trim flush any excess insulation. forming a seal between the sleeve and insulation
jacket and insulation.
The amount of pour foam used for subsequent field
joints of similar size and type, assuming there are no
volume, field joint length, or temperature changes
should be adjusted based on the results of previously
poured field joint(s).
Rev. May 2001 Page 6-4
 PERMA-P IPE, Inc. XTRU-Therm
Field Joint Insulation Installation Manual
And Jacket (cont.) Section 6
HEAT SHRINK SLEEVES – PREPARATION • Wear heat resistant gloves whenever working
All materials, equipment, and tools should be made with the propane torch.
readily available before starting. • The propane torch flame should be kept at least
6 inches away from the shrink sleeve and at an
Do Not attempt applying heat shrink sleeves in wet angle to the surface. Holding the propane torch
bell holes. If the bell hole is wet, pump it dry before at an angle allows the flame to bounce off the
insulating the field joint. shrink sleeve and decreases the local intensity of
the heat. If the flame is held too close to the
PERMA-PIPE provides the following materials for surface, the shrink sleeve will burn and may tear
heat shrink sleeve application; around the burned areas.
• Heat shrink sleeve bulk roll material • Use your body as a shield to protect the flame
• Propane torch head - high capacity flame nozzle from the wind. Keep the propane torch at an
(For outside diameters less than 18 inches, the angle to the sleeve and pointed in the direction
minimum, torch size is 150,000 BTU/hr. For the wind is blowing to maintain a fairly even
outside diameters greater than 18 inches, the flame. Do Not increase the size of the flame, this
minimum torch size is 300,000 BTU/hr.) could overheat and burn the shrink sleeve.
Only use the torch provided or one that is • Keep the propane torch in constant motion. Do
equivalent. Not burn the surface.
• Refer to the Installation Guide that is included
The installer will need to furnish the following; with the heat shrink sleeve material for additional
• Propane tank, hose, fittings, valves, and information.
regulators.
• Hand roller HEAT SHRINK SLEEVE – APPLICATION
• Heat resistant gloves Apply the heat shrink sleeve in the following manner;
• Roughen the surface of the insulation jacket with
HEAT SHRINK SLEEVE - SIZING sandpaper in the areas when the heat shrink
PERMA-PIPE provides heat shrink sleeve material in sleeve will cover.
bulk roll. For each field joint, measure the field joint • Wipe the field joint area clean with a clean cloth.
and cut the heat shrink sleeve length in the following Use solvent if needed.
manner; • Measure the width of the field joint area and the
• Measure the circumference of the outside heat shrink sleeve. Use chalk to mark guidelines
diameter of the insulation jacket at both ends of on the insulation jacket for the edges of the heat
the field joint. It is normal for there to be shrink sleeve. The heat shrink sleeve should be
differences in the insulation jacket outside centered on the field joint area with a minimum
diameter at fittings and special components. A overlap onto the insulation jacket of 4 inches on
slight taper in the field joint will compensate this each end.
for. • Remove the first 6-10 inches of backing material
• Depending on the maximum circumference from the heat shrink sleeve.
measured, add the following for heat shrink • Hold the heat shrink sleeve up. Press the top
edge of the heat shrink sleeve just below the top
sleeve overlap and slack;
of the field joint and centered between the chalk
Overlap Slack lines.
Max. Circ < 27” 4” 2” • Heat the top 2 inches of the sleeve with the
27” < Max. Circ < 57” 4” 3” propane torch until it becomes soft and adheres
Max. Circ. > 57” 6” 3” to the polyurethane insulation and insulation
• Cut the heat shrink sleeve length to the jacket.
dimension determined above. CHALK LINES
CUT 1/2" TRIANGLE
• Cut a ½ inch triangle from each corner of the ON THE HEAT SHRINK
SLEEVE CORNERS
heat shrink sleeve to prevent the corners from
peeling up after application.

HEAT SHRINK SLEEVE–HEAT SHRINKING TECHNIQUE

Before starting heat shrink sleeve application,
become familiar with the following technique for
shrinking a heat shrink sleeve;
Rev. May 2001 Page 6-5
PERMA-P IPE, Inc. XTRU-Therm
Field Joint Insulation Installation Manual
And Jacket (cont.) Section 6
HEAT SHRINK SLEEVE – APPLICATION (CONT.) • When the center of the heat shrink sleeve has
• Wrap the heat shrink sleeve around the field joint shrunk, begin to move the propane torch with an
so the lower portion forms a loose gap that hangs up-and –down spiral motion around the sleeve
about 1 inch from the bottom of the insulation toward the left edge.
jacket. This gives the sleeve room to shrink
properly. If the sleeve is wrapped snugly, without
a gap, it may pull apart or tear during heating.
• Stay within the chalk guidelines. Reheat the top
2 inches of the heat shrink sleeve before
overlapping. Be sure to overlap downward.

OVERLAP
DOWNWARD

• When the left side has shrunk, heat the right side
in the same up-and-down spiral manner.
• Reduce the flame slightly and shrink the edges of
LOOSE GAP the sleeve onto the insulation jacket. Black
adhesive escaping at the edges of the heat
• Cut a ½ inch triangle from each corner of the shrink sleeve indicates a good bond and
closure strip to prevent the corners from peeling up shrinkage.
after application.
• Heat the closure strip with the propane torch until
• Peel the backing strip off the closure strip and it sticks to the heat shrink sleeve. Use a wooden
preheat the closure strip for approximately 5
wallpaper roller to apply pressure to the closure
seconds until it becomes soft.
strip. Sufficient heat and pressure, is required to
• Attach the closure strip directly over the seam of the
shrink sleeve. Overlap and press down firmly. Do completely fuse the closure strip to the heat
not try to smooth the closure strip at this time. shrink sleeve seam.
• If the heat shrink sleeve edge raises up, reheat
and press down firmly.
• While the heat shrink sleeve is still hot and soft,
use a hand roller to gently roll the sleeve surface
and push any trapped air up and out of the
sleeve. Reheat, if necessary.

CUT 1/2" TRIANGLES

ON CLOSURE STRIP
CORNERS

• Heat the center section of the heat shrink sleeve

all the way around until it shrinks.

Rev. May 2001 Page 6-6

PERMA-P IPE, Inc. XTRU-Therm
Field Joint Insulation Installation Manual
And Jacket (cont.) Section 6
SEALING TAPE – XTRU-Therm ECONOMY FITTINGS XTRU-Therm ECONOMY ANCHORS - BELOWGROUND
The insulation jacket for XTRU-Therm Economy XTRU-Therm Economy belowground anchors are
elbow and tee fittings is 4 inch wide sealing tape over field assembled, insulated, and jacketed. The entire
the transition sleeves and flexible PVC cover that are anchor assembly is jacketed with a high shrink ratio
used for the insulation mold. heat shrink sleeve. The heat shrink sleeve
application recommendations above should be used
CAUTION: PERMA-PIPE’s standard sealing tape is for the installation of these heat shrink sleeves with
for belowground applications and is not resistant to the following modification;
the Sun’s ultraviolet (UV) rays. Aboveground, UV
• The maximum circumference used to determine
resistant sealing tape is available from PERMA-PIPE
the length to cut the shrink sleeve should be the
when specified and ordered for aboveground service.
circumference of the outside diameter of the
Verify that the correct sealing tape has been
anchor plate.
purchased and received prior to use.
CAUTION: Verify the heat shrink sleeves being
The sealing tape should be applied in the following
used for the anchors are high ratio heat shrink
manner;
sleeves, do not mix or confuse them with the heat
• Roughen the surface of the insulation jacket, shrink sleeves for straight field joints.
transition sleeves, and flexible PVC cover with
sandpaper in the areas that will be covered with HEAT SHRINK SLEEVE
(HIGH SHRINK RATIO)
sealing tape.
• Wipe the area clean with a clean cloth. Use
solvent if needed.
• Spirally wrap the sealing tape, with at least ½
inch overlap between layers, starting and
finishing on the insulation jacket and completely
covering the transition sleeves and flexible PVC
cover. XTRU-Therm ECONOMY ANCHORS - ABOVEGROUND
• Apply the sealing tape smooth and without air XTRU-Therm Economy aboveground anchors are
bubbles or open seams. field assembled, insulated, and jacketed. The
aboveground anchors have welded steel sleeve
extensions for sealing a standard heat shrink sleeve
onto. The heat shrink sleeve application
recommendations above should be used for the
installation of these heat shrink sleeves.

HEAT
SHRINK SLEEVE
4" WIDE SEALING TAPE

Rev. May 2001 Page 6-7

PERMA-P IPE, Inc. XTRU-Therm
Backfilling Installation Manual
Section 7
BACKFILLING caution when using flowable fill due to the potential
difficulty that may exist if re-excavation is required for
GENERAL repairs, modifications, or replacement.
All types of flexible pipe derive some of their strength
from the passive soil resistance around the pipe. EQUIPMENT AND TOOLS
Therefore, proper backfilling of the trench is very
The critical part of the backfill process is the
important to insure a structurally sound system. compaction of the soil underneath, alongside, and up
XTRU-Therm piping is designed to handle normal soil to 6” above the piping. Hand tamping tools can be
and H20 traffic loading when these recommendations constructed using small diameter pipe and plate
are followed and a minimum of 2 feet of properly materials. These tools will compact the soil firmly
compacted backfill is provided. It should be noted and evenly around the pipe and should be used
that shallower burial depths will increase the piping instead of mechanical tampers to prevent damage to
system heat loss/gain slightly. the insulation or insulation jacket.

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.

HIGH SURFACE LOADING CONDITIONS Mechanical compactors or wheeled or tracked

Special burial depths and compaction requirements vehicles can be used for the trench bed and after a
may be required at taxiways, runways, railways, minimum of 12 inches of compacted soil is above the
roadways, and other areas of high surface loading top of the insulation jacket.
conditions. It is recommended that the customer
contact both PERMA-PIPE and the local authority for TRENCH BEDDING AND INITIAL BACKFILL
more specific instructions. Material used for the trench bedding and initial
backfill must be in accordance with the specifications
TRENCH BED AND INITIAL BACKFILL MATERIALS above. Place the trench bed and initial backfill
The following specifications should be used for the material in the following manner;
backfill material used for the trench bedding and • Prior to backfilling, remove any foreign materials
initial backfill. Local geo-technical or soil testing such as shoring, braces and support blocks.
laboratories can test backfill materials for compliance • Under normal conditions, place trench bedding
with these requirements. and initial backfill material in 6 inch lifts and
• Sand or a sand-gravel mixture in which the gravel compact to 90% modified proctor.
is either pea gravel or crushed stone without • Water can be added to the backfill material to
sharp edges. achieve the optimum moisture content. Less
• No unstable soil, such as plant or vegetable compaction effort is required when the backfill
residue, clay or silt lumps, or frozen earth. material is at the optimum moisture content.
• Particles not larger than ¾ inch in diameter. Local geo-technical or soil testing laboratories
• 90% minimum passing a No. 4 sieve. can provide soil testing to determine the optimum
• 90% minimum retained by a No.200 sieve. moisture content and the soil density required to
meet the proctor / compaction requirements.
Flowable fills can be used if they meet the above
requirements. However, PERMA-PIPE advises

Rev. May 2001 Page 7-1

PERMA-P IPE, Inc. XTRU-Therm
Backfilling (cont.) Installation Manual
Section 7
INITIAL BACKFILL (continued) FINAL BACKFILL
• Proper compaction of the haunching materials, The final backfill material can be native soil but
that section of the backfill extending from the should free of rocks larger than 3 inches in diameter,
bottom of the pipe to the centerline, should be frozen earth, organic material, plant or vegetable
performed using the hand tamping tool described residue, or foreign matter.
above. Place the final backfill material to grade in 1 foot lifts
and compact to 85% modified proctor.
Use of mechanical compaction equipment to
complete the final backfill is suggested, but Do Not
use mechanical compactors until a minimum of 12
inches of compacted soil is above the top of the
insulation jacket.

4" MIN. BEDDING NATIVE BACKFILL

85% PROCTOR

• Place and compact the initial backfill from the

bottom of the trench to 6 inches above the top of
the pipe. 6" MIN.

4" MIN. BEDDING

6" MIN.

4" MIN. BEDDING

• Do Not use mechanical compactors or wheel or

tracked vehicles for compaction until a minimum
of 12 inches of compacted soil is above the top
the insulation jacket.

Rev. May 2001 Page 7-2

PERMA-P IPE, Inc. XTRU-Therm
Operation Installation Manual
And Maintenance Section 8
GENERAL inspecting and maintaining your piping system.
Contact PERMA-PIPE for additional information.
PERMA-PIPE’s XTRU-Therm piping system is An inspection and maintenance log should be set up
designed for long, reliable service when properly with all inspections and maintenance recorded. The
installed, operated, and maintained. inspection and maintenance log can be helpful for
If heat trace, leak detection, and/or other ancillary identify trends, providing documentation of inspection
equipment is included with your XTRU-Therm piping and maintenance activities, and troubleshooting.
system, refer to the appropriate Installation Manual
for operation and maintenance instructions. UNDERGROUND SYSTEMS
• Inspect all insulation termination ends, building
OPERATION entries, manhole entries, and valve pits. Under
no circumstances should water be allowed to
The piping system should be operated within the cover insulation termination ends. Accumulating
temperature and pressure limits designed for to water should be immediately removed.
prevent overstressing of the piping, damage to the • On all wall and floor entries, inspect the link
insulation, or other related problems. seals, packings, or other sealing devices being
used to assure proper sealing of ground water.
During start up, operation, and shut down the piping • Inspect all exposed piping.
system should be heated and cooled slowly to
prevent thermal shock and avoid slug flow conditions. • Investigate any signs of excessive heat loss or
heat gain.
Abrupt changes in flowrate should be avoided to • Observe the landscape for signs of fluid leakage
prevent water hammer and surge effects. or excessive heat loss or gain. Grass browning
For corrosive fluid services, fluid treatment and / or or snow melting above the piping are signs of
de-aeration should be performed to prevent or retard excessive heat loss or gain.
interior corrosion of the service pipe. • Inspect for signs of other excavations or
constructions that could interfere with the piping.
MAINTENANCE Any signs of damage, degradation, or deterioration
should be identified, evaluated, and repaired.
Periodic maintenance should be performed to ensure
the XTRU-Therm piping system is in good condition ABOVEGROUND SYSTEMS
and to maximize its service life. Any signs of
damage, degradation, or deterioration should be • Inspect all insulation termination ends.
identified, evaluated, and repaired. • Inspect all insulation jacket, and field joint
closures.
It is critical that the insulation jacket integrity is
maintained and the insulation is kept dry to prevent • Inspect the insulation jacket and insulation at all
degradation to the insulation and corrosion of the support points.
service pipe. • Inspect all exposed piping.

At least twice a year the piping system should be

• Investigate any signs of excessive heat loss or
heat gain.
inspected so any problems that may arise can be
detected early. The actual frequency of inspection Any signs of damage, degradation, or deterioration
should be adjusted to account for service and should be identified, evaluated, and repaired.
operating conditions, climate, and/or ground
conditions.
PERMA-PIPE INSPECTION SERVICES can provide
infrared leak detection and energy evaluation
surveys, sonic leak detection, ultrasonic pipe wall
thickness testing and evaluation, and tracer gas leak
detection services. These service can be useful for

Rev. May 2001 Page 8-1

PERMA-P IPE, Inc. XTRU-Therm
A Subsidiary of MFRI, Inc.
7720 North Lehigh Avenue
Niles, Illinois 60714-3491
Phone (847) 966-2235
Fax (847) 470-1204
Installation Manual
http://www.permapipe.com

WARRANTY
Seller warrants to the original Buyer only that the products sold hereunder will substantially comply with the above referenced
technical specifications for the products and that no product will have any defect in Seller’s design, workmanship or material.
Seller shall not be responsible for and does not warrant the installation of the products. Seller agrees to provide field services as
provided herein and warrants only that the information provided to Seller during such field service visits will be consistent with
Seller’s recommendations for installation. Seller specifically rejects all other warranties in the contract documents for the project,
which may apply to Seller’s products. The foregoing warranty shall be in effect with respect to each product sold hereunder only
for a period of fifteen (15) months from the date of completion of testing of such product, but in no event more than eighteen (18)
months from the date of shipment by Seller of such product; provided, however, no claim shall be permitted under the warranties
contained herein unless Buyer shall give to Seller written notice of all respects in which Buyer claims the product to be defective
or at a variance with specifications within ten (10) days from the date Buyer discovers or should have discovered a defect or
variance from specifications, but in no event later than eighteen (18) months after shipment of such product, and unless Buyer
shall afford Seller a reasonable opportunity to inspect such product after notice has been given. The foregoing warranties shall
not apply to any products or components thereof, which have been subject to abnormal or improper use, negligence or accident
or which have been altered or repaired by someone other than Seller or Seller’s authorized representative. No product shall be
returned without Seller’s prior written consent. Buyer shall accept minor variations in dimensions or other variance from
specifications provided that there is no impairment of function or useful life of the product. Seller warrants that its title to the
product sold hereunder is good, and that the transfer thereof to Buyer is rightful.

Seller’s obligations under the warranties contained herein and any other provision of the Agreement determined to constitute a
warranty by the Seller of the products to be sold pursuant hereto, and Buyer’s remedies for any defective or non-conforming
products shall be limited solely to the repair or replacement, as elected by Seller of defective or non-conforming materials.

To the maximum extent permitted by law, Buyer irrevocably waives all claims against Seller for money damages relating to the
condition, use and performance of the goods sold pursuant hereto, including claims based upon tort, strict liability, negligence
and product liability. Notwithstanding the provisions of the preceding sentence, if money damages are assessed against the
Seller, in no event shall Seller’s liability for such damages exceed the purchase price of products sold by Seller.

IN NO EVENT, WHETHER BECAUSE OF A BREACH OF WARRANTY OR REPRESENTATION OR ANY OTHER CAUSE,

WHETHER BASED UPON CONTRACT, TORT, WARRANTY OR OTHERWISE, ARISING OUT OF PERFORMANCE OR NON-
PERFORMANCE BY SELLER OF IT’S OBLIGATIONS UNDER THIS AGREEMENT OR WITH RESPECT TO THE PRODUCTS
SOLD PURSUANT HERETO SHALL SELLER BE LIABLE FOR LOST EARNINGS, INCOME OR PROFITS OR INDIRECT,
INCIDENTAL OR CONSEQUENTIAL DAMAGES.

THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND, EXCEPT AS
SPECIFICALLY SET FORTH HEREIN, ALL OTHER WARRANTIES AND REPRESENTATIONS, EXPRESS OR IMPLIED, ARE
HEREBY DISCLAIMED AND EXCLUDED. NOTHING SHALL BE CONSTRUED AS AN ADDITIONAL WARRANTY UNLESS
SPECIFICALLY DESIGNATED AS SUCH IN WRITING AND SIGNED BY THE SELLER, IN WHICH CASE SUCH ADDITIONAL
WARRANTY SHALL BE SUBJECT TO THE PROVISIONS HERIN AS TO THE DURATION AND LIMITATION OF REMEDY
UNLESS SUCH ADDITIONAL WARRANTY EXPRESSLY VARIES SUCH PROVISIONS.

Rev. May 2001