00-Master Catalog PDF

FAIL / SAFE CORROSION CONTROL COATINGS
FOR UNDERGROUND PIPE

FAIL/SAFE COATINGS
Polyguard Products believes that everyone concerned with the selection, specification,
installation, and use of corrosion control coatings on underground pipelines should understand
“fail/safe” coatings.
Most people know that underground pipelines use cathodic protection systems (CP) as part of
the corrosion prevention package. In almost all cases, the CP system is designed to act as a
backup corrosion protection system. The coating system is the primary corrosion control
system, and the CP system is designed to begin work whenever and wherever there is a
failure or defect in the coating system.
What many do not understand is that most coatings used around the world today have
properties of electrical resistance which, when coating adhesion is lost and water penetrates,
can block cathodic protection currents. In other words, if the coating fails, the pipeline is not
safe, because the cathodic protection system has effectively been disabled.
It follows that a “fail/safe” coating is one that, in the event there is a defect or failure area
where water has penetrated between the pipe and coating, will allow the passage of
protective electrical currents, and therefore will permit the CP system to keep the pipeline
safe.
This section, which is a printout of materials found on the Polyguard Products pipeline
coatings website, explains the fail/safe concept in more detail. Included are:
• Background information
• NACE definition of shielding
• NACE Standard Recommended Practice (RP0169) concerning shielding
• NACE training course which covers shielding
• Shielding behavior of corrosion control coating materials:
a. FBE
b. Shrink Sleeves
c. Polyguard RD 6
d. 2 and 3 layer Systems
e. Liquid Coatings
f. Polyethylene Backed Tapes
If you read this information and need more detail, further information can be found on the
website. w.xlp.FailSafe Coatings 01297
This Information is based on our best knowledge, but

POLYGUARD cannot guarantee the results to be obtained.
POLYGUARD PRODUCTS, INC • ENNIS, TEXAS 75120-0755

PH: 214-515-5000 • 800-541-4994 • FAX: 972-875-9425
Polyguard has been ISO 9000 certified
since 1996. Current certifications are:
- American Natl. Standards Institute
Web Site: www.polyguardproducts.com - Dutch Council for Certification
- Deutscher Akkreditierungs Rat
RD-6 COATING SYSTEM
For Line Pipe and Girth Welds
U.S. PATENT NOS. 4,983,449 AND 5,120,381 AND FOREIGN PATENTS
DESCRIPTION:
POLYGUARD RD-6 COATING SYSTEM consists of a geotextile backed protective pipeline coating applied over a companion
liquid adhesive and a slip-plane outerwrap. Corrosion protection comes from a rubberized bitumen coating. Bonded to the
outside surface of this coating is a strong, tightly woven, polypropylene geotextile, which provides fail/safe properties plus
exceptional strength.
The coating is supplied in rolls for easy application by manual or power operated machines. Since RD-6 is supplied with a
silicone coated separator sheet to keep the layers from sticking to each other, application machines have two spindles, one for
coating unwind and one to take up the separator sheet as coating is applied.
RD-6 can also be applied manually, without machine. However, it is important to recognize that much more tension can and
should be used during its application than is normal for other types of products.
Use of POLYGUARD SP6 OUTERWRAP is strongly recommended over the RD-6 COATING for diameters > 4”. This
inexpensive layer will further reduce the possibility of soil stress.
POLYGUARD 600 LIQUID ADHESIVE is fast drying, rubber based materials in a solvent solution. It is available in solvent
systems that will conform to most local air pollution requirements. Low VOC primer is also available.
PROPERTY DATA:
PROPERTY ASTM METHOD TYPICAL RESULTS TYPICAL RESULTS
(Metric) (English)
Total Thickness - Single layer of RD-6 Coating D 1000 1.27 mm 0.05 inches (50 mils)
Tensile Strength, Warp Direction D 4632 34 kN/m 200 lbf/inch width
Tensile Strength, PSI D 4632 27.6 MPa 4000 PSI
Elongation % at break (geotextile backing) D 4632 < 20% < 20%
Geotextile Backing–Temperature Resistance D 648 107 – 121° C 225 – 250° F
(Deflection temperature under 66 PSI flex load)
Water Vapor Transmission Rate E 96 Procedure B .006 g/h•m2 .009 grains/h•ft2
Puncture Resistance E 154 1379 kPa 200 PSI
Burst Strength D 751 2413 kPa 350 PSI
Cathodic 77°F (25°C), 30 days, 1.5v G8 < 5 mm < 5 mm (.197 in.)
Disbondment 150°F (66°C), 90 days, 3.0v G 42 < 10 mm < 10 mm (.4 in.)
“Fail/Safe” properties Internal Polyguard Pass (non-shielding) Pass (non-shielding)
(Does not shield cathodic protection currents)
Dielectric Strength (breakdown voltage, KV) D 149 > 12 KV > 12 KV
Adhesion to primed surface D 1000 Method A 3.5 kN/m 20 lbf/inch width
Adhesion to polyethylene D 1000 Method A 3.5 kN/m 20 lbf/inch width
Impact Resistance G 14 2.6 N/m 23.0 inch lb.

POLYGUARD PRODUCTS, INC • ENNIS, TEXAS 75120-0755 Polyguard has been ISO 9000 certified
PH: 214-515-5000 • 800-541-4994 • FAX: 972-875-9425 - American Natl. Standards Institute
- Dutch Council for Certification
Web Site: www.polyguardproducts.com - Deutscher Akkreditierungs Rat

ADVANTAGES:
• RD-6 is a “fail/safe” coating. This means that if the coating disbonds, cathodic protection currents will not
be shielded, and will be able to reach water underneath the coating.
• Has excellent resistance to cathodic disbondment, even if surface preparation is below standard, as often
happens in field application.
• Geotextile backing properties of high strength, low “stretchability” (elongation), and high temperature
resistance all contribute to resistance of soil stress.
• Fast and easy to apply, and can be backfilled immediately after coating.
• Woven construction of geotextile backing permits bitumen to bitumen contact at the overlaps.
• Has excellent resistance to water or vapor transmission.
• Is not subject to deterioration due to exposure to below ground acids and alkalis that are encountered in
normal soil.
• Provides uniform factory controlled thickness, compared to field applied liquid coatings.
• Elastomeric properties to accommodate normal expansion and contraction of the substrate.
PRECAUTIONS:
The liquid adhesive is an industrial coating and would be harmful or fatal if swallowed. It is marked as red label from
the standpoint of flash point. Prohibit flames, sparks, welding and smoking during application. Solvents could be
irritating to the eyes. In case of contact with eyes, flush with water and contact physician.
Avoid prolonged contact with skin and breathing of vapor or spray mist from liquid adhesive. In confined areas, use
adequate forced ventilation, fresh air masks, explosion proof equipment, and clean clothing.
This material is sold by Polyguard Products, Inc. only for the purposes described in this literature. Any other use of
the products is the responsibility of the purchaser and Polyguard Products does not warrant nor will be responsible
for any misuse of these products. Polyguard Products will replace material not meeting our published specifications
within one year from date of sale.
MATERIAL SAFETY DATA:
All Polyguard Products Material Safety Data Sheets (MSDS) and precautionary labels should be read and understood
by all user supervisory personnel and employees before using. Purchaser is responsible for complying with all
applicable federal, state or local laws and regulations covering use, health, safety, and disposal of the product.
MAINTENANCE:
None required.
Technical Service:
Polyguard Products Inc.

Ennis, Texas 75120-0755
PH: 214.515.5000
FAX: 972.875.9425
www.polyguardproducts.com
Share/lit/pipeline/rd6data 1/11/08
RD-6 APPLICATION SPECIFICATION
Manual Operated or Power Machine Application
U.S. PATENT NOS. 4,983,449 and 5,120,381. FOREIGN PATENTS
SPECIFICATION FOR HANDLING AND MACHINE APPLICATION OF

POLYGUARD RD-6 COATING FOR BELOW GROUND PIPING
1. MATERIALS:
1.1 COATING THICKNESS
1.1.1 RD-6 is 50 mils (1.27 mm)

nominal total thickness,
consisting of 10 mils
(.25mm) of woven mesh
geotextile fabric on the
outside laminated to 40 mils
(1.02 mm) of rubberized
bituminous compound. A
release sheet separates
layers in a roll.
1.2 ROLL WIDTH
1.2.1 Suggested roll widths for

various sized pipes as
follows: Application of RD-6 by machine is strongly recommended wherever possible.
The increased tension of machine application assists in resisting soil stress.
Diameter of Pipe Being Coated Width of RD-6 Roll suggested

4 inch to 6 inches (101.6 mm to 152.4 mm) 4 inch (101.6 mm)
6 inch to 48 inch (152.4 mm to 121.92 cm) 6 inch (152.4 mm)
1.2.2 Roll widths based upon:
Two-spindle application where one roll of coating and one roll of outerwrap are applied
simultaneously, or
One-spindle application where one roll of coating is applied. (A second machine can be used
to apply the outerwrap.)
1.3 OUTERWRAP
1.3.1 Unbonded type: POLYGUARD SP-6 OUTERWRAP
1.3.1.1 POLYGUARD SP-6 OUTERWRAP consists of a strong non woven, felt-like

polypropylene fabric.


PH: 214-515-5000 • 800-541-4994 • FAX: 972-875-9425 Polyguard has been ISO 9000 certified
Web Site: www.polyguardproducts.com - American Natl. Standards Institute
1.4 LONGITUDINAL MILL WELD SEAM STRIPPING MATERIAL (where required on DSAW pipe)
1.4.1 Polyguard RD-6 or
1.4.2 POLYGUARD 606 - A 60 mil (1.52 mm) thick, reinforced coating consisting of a rubberized
bituminous compound. It has no backing on either side of the compound. Release sheets
separate layers in a roll.
2. HANDLING OF COATING MATERIALS:

2.1 Coating and wrapping materials shall be hauled and stored in such a manner as to prevent injury
to packages. No packages shall be dropped from trucks or handled with hooks.
2.2 All coating and wrapping materials shall be protected from the elements. Wrapping materials shall
be transported only as needed during application of the coating, conveyed in a covered vehicle and
moved directly from the vehicle to the coating or wrapping machines as required.
2.3 Coating and liquid adhesive shall be maintained at a temperature of 45 deg. F. (7 deg. C) or higher
at time of application.
3. COATING APPLICATION:
3.1 PIPE
3.1.1 Surface Preparation
Surface preparation of the pipe shall include:
A. Removal of all visible oil and grease, by swabbing with a safety solvent that does not leave
residue.
B. Removal of splatter and slag from welds and pipe surface by filing, wire brushing or other
methods satisfactory to Company representative.
C. Minimum requirements: Pipe shall be cleaned to be free of all mill scale, loose rust, knurls,
frost, dust, moisture and other deleterious matter. If power brushes are used in the
cleaning process, a polished surface shall be avoided.
D. Blast Cleaning (if specified): It is required to obtain a commercial finish (minimum), as

described by NACE No. 3.
E. Cleaning to the satisfaction of Company representative. Bare pipe shall be considered clean
when all foreign matter has been removed, and a surface cleaned to the parent metal is
immediately available to the coating operation.
F. Protection of the cleaned pipe such that it will remain free from contamination and be
suitable for immediate coating application. In the event of surface contamination prior to
coating application, pipe shall be reprocessed through the necessary cleaning steps outlined
above.
3.1.2 Liquid Adhesive Application
All pipe shall be covered with POLYGUARD 600 LIQUID ADHESIVE after cleaning and
before coating application. LIQUID ADHESIVE shall be applied with a clean brush or roller
brush or other acceptable mechanical means to obtain uniform and complete coverage of
the pipe surface. Liquid Adhesive shall be applied at a rate of approximately 400 square
feet (10.0m2/Liter) per gallon and shall be dry or tacky/dry to touch prior to coating
application.
3.1.3 Weld Stripping Material (where required)
Where DSAW pipe is involved, the longitudinal mill weld seam shall be stripped with
POLYGUARD RD-6 preferably or POLYGUARD 606 - 6" wide stripping material after the
liquid adhesive has been applied to the pipe and before application of the coating. In
applying the stripping material, position the material over the weld so that when the roll is
unwound, half the width will rest on both sides of the weld. As the material is applied to the
weld, remove the inner separator sheet next to the weld. When completed, manually press
the stripping material into the weld crevices. When the 606 material is used, slowly remove
the outer separator sheet from the compound while pressing the material with a piece of the
release paper, to conform to the weld and pipe surface.
3.1.4 Coating (by machine)
A. The primary coating shall be spirally wrapped by an approved machine on pipe suitably cleaned,
and with liquid adhesive applied.
B. The machine used shall be equipped with take-up spindles to remove and wind the separator
sheet as the coating roll is applied to the pipe. The machine used shall be capable of applying the
primary coating with uniform tension across the width of the roll equal to 15 lbs. (6.8 Kgs/25.4
mm) per inch minimum width (dead weight). The machine shall be equipped with a constant
tension brake system to assure equalization of tension across the roll width and through out the
complete unwind of the roll, regardless of the roll size.
C. Operators shall make all necessary manual or machine adjustments to accomplish a uniform,
tightly adhered coating having a lap of at least 1" (25.44 mm) over the preceding spirals. Care
shall be taken that no wrinkles, puckers, voids, or breaks are left in the coating as a result of a
deficiency in application.
D. An unbonded outerwrap (if specified by the Company) shall be spirally applied. Operators shall
make necessary adjustments to achieve a uniform, outerwrap having a lap of at least 1" (25.44
mm) over preceding spirals.
E. Coated pipe shall be handled at all times with wide non-abrasive slings, belts or other equipment
designed and maintained to prevent damage to the coating. All skid supports shall be padded to
protect the coating. Equipment which the Company representative deems to be injurious to the
coating shall not be permitted. Walking on the coated pipe shall not be permitted.
4. INSPECTION AND REPAIR:

4.1 Where the coated pipe is above ground, the coated pipe shall be holiday detected and lowered into
the ditch with care. Coated pipe shall not be lowered into the ditch until it has been inspected and
approved by the Company representative.
4.2 The coating system shall be holiday detected with an adjustable electronic detector as follows:
The thickness of the RD-6 compound is 40 mils with a 10 mil mesh backing that will allow the current
from the holiday detector to easily penetrate if the compound is damaged. In a single layer of RD-6
set the detector at 4500 volts. Do not exceed 5500 volts. Excessive voltage can stress the coating
and cause burn through. If POLYGUARD OUTERWRAP is to be included with the coating in the
detection process, please consult the manufacturer for recommended voltage.
4.3 All holidays and defects shall be repaired by the Contractor to the satisfaction of the Company
representative. If any coated pipe is damaged upon lowering into the ditch, it shall be repaired in the
position deemed most practical by the Company representative.
4.4 All holidays and all damaged or defective coating shall be repaired immediately.
A. Small or pinhole type holidays can be repaired in the RD-6 by applying liquid adhesive over the
holiday area and when dry to touch, starting with RD-6, at the 2:00 o’clock position on the coated
pipe surface and while covering the repair area, a minimum of 1 inch (25.4 mm) on all sides of the
repair, make a complete wrap of 1-1/3 revolutions around the coated pipe surface, ending at the
10 o’clock position. This will make sure the tape laps on both sides are in a downward direction.
If outerwrap is being used apply a layer of unbonded outerwrap over the repair area and attach
with fiber reinforced strapping tape.
B. For larger holidays or where coating is damaged that exposes pipe, remove damaged coating and
smooth edges before repair is made. If a hole or large void area occurs, fill in the area with a
patch of RD-6 or 606 Filler tape to make sure bridging of the void does not occur. Finish repair as
in A. above. If the damaged area is large enough that it requires a material patch larger than 6"
(152.4 mm) x 12" (304.8 mm), then spiral wrap the pipe with RD-6, to include the damaged area.
Over this, apply an outerwrap as in A. above.
C. If an unbonded outerwrap was used, remove outerwrap and make repair as in A. or B. above.
4.5 All coating repairs shall be reinspected as outlined above.
5.0 PRECAUTIONS:
5.1 The liquid adhesive is an industrial coating and would be harmful or fatal if swallowed. It is marked
as red label from the standpoint of flash point. Prohibit flames, sparks, welding and smoking during
application. Solvents could be irritating to the eyes. In case of contact with eyes, flush with water
and contact physician.
5.2 Avoid prolonged contact with skin and breathing of vapor or spray mist from liquid adhesive. In
confined areas, use adequate forced ventilation, fresh air masks, explosion proof equipment, and
clean clothing.
5.3 This material is sold by Polyguard Products, Inc. only for the purposes described in this literature.
Any other use of the products is the responsibility of the purchaser and Polyguard Products does
not warrant nor will be responsible for any misuse of these products. Polyguard Products will
replace material not meeting our published specifications within one year from date of sale.
6.0 MATERIAL SAFETY DATA:

6.1 All Polyguard Products Material Safety Data Sheets (MSDS) and precautionary labels should be
read and understood by all user supervisory personnel and employees before using. Purchaser is
responsible for complying with all applicable federal, state or local laws and regulations covering
use, health, safety, and disposal of the product.
MAINTENANCE:
None required.
Technical Service:
PH: 214.515.5000
FAX: 972.875.9425
x.xl.RD6 Spec Mach Applic R.2-15-07

RD-6™ COATING APPLICATION SPECIFICATION - GENERAL
U.S. PATENT No. 4,983,449, U.S. PATENT No. 5,120,381 and FOREIGN PATENTS
COATING SYSTEM FOR GIRTH WELDS AND RECONDITIONING
DESCRIPTION:
POLYGUARD RD-6™ COATING SYSTEM consists of a
geotextile backed protective pipeline coating applied over a
companion liquid adhesive. Bonded to the outside surface
of this coating is a strong, tightly woven, polypropylene
geotextile, which provides fail/safe properties plus
The coating is supplied in rolls for easy application by

manual or power operated machines. The
RD-6™ is supplied with a silicone coated separator sheet to
keep the layers from sticking to each other.
Proper tension on the roll of the RD-6 coating as it is applied

to the cleaned and primed pipe surface is a major
contributing factor to the successful performance of the
coating system.
At minimum, the use of a manually operated wrapster is

recommended for application. It helps control tension with
its use. Application by machine permits the coating to be installed
under higher tensions. This aids resistance to soil stress.
In addition, depending upon the scope and size of the work,
application by “squirrel cage” type machine, either powered
or manually operated, is recommended.
Tension control of the RD-6 roll and adjustment of overlap
are advantages of this type machine. Also,
these machines, if equipped to do so, are capable of
applying a roll of RD-6 and a roll of SP-6 outerwrap,
simultaneously. Please refer to the separate procedure for
installation by squirrel cage machine.
RD-6™ can also be applied manually, without machine.

However, it is important to recognize that MUCH MORE
TENSION can and should be used during its application than
is normal for other types of coatings.
Use of POLYGUARD SP6 OUTERWRAP is strongly

recommended over the RD-6™ COATING for diameters >
4”. This inexpensive layer will further reduce the possibility
of soil stress.
The use of POLYGUARD SP6 OUTERWRAP is also advised
POLYGUARD 600 LIQUID ADHESIVE is fast drying, for resistance to soil stress.
rubber based materials in a solvent solution. It is available
in solvent systems that will conform to most local air
pollution requirements.


PH: 214-515-5000 • 800-541-4994 • FAX: 972-875-9425
APPLICATION SPECIFICATIONS:
HANDLING MATERIALS: RD-6™ COATING and LIQUID ADHESIVE should be hauled and stored in such a manner as to prevent
injury to the packages. No packages should be dropped or thrown from trucks. Packages shall not be handled with hooks. Containers
and rolls should be stored in a dry place, kept from contact with earth, and protected from weather at all times. It is recommended
that the coating and liquid adhesive be transported in warmed vehicles and stored in heated buildings in cold weather.
Although the coating can be applied at lower temperatures, to maximize the quality, it is recommended that the coating and liquid
adhesives be maintained at a temperature of 45 deg. F (7 deg. C) or higher at time of application.
SURFACE PREPARATION: At the minimum, the pipe shall be cleaned of all paints, oil and grease, mill scale, loose rust, welding
residue, knurls, frost, dust, moisture, weeds, and other foreign matter. Where feasible and practical, the surface can be blast cleaned
to a commercial finish, such as described in NACE No. 3. Where mill coated pipe is involved, the LIQUID ADHESIVE and coating should
be applied to the girth weld, starting on top of the mill coating, at least 2" back from the edges of the mill coating. The liquid adhesive
should extend 1” out from the RD-6 Coating.
Neither liquid adhesive nor coating should be applied to pipe surfaces where there is the presence of visual moisture. POLYGUARD
RD-6™ COATING SYSTEMS will not properly adhere to pipes with moisture. Condensation happens on a metal surface when the
temperature of the pipe is at or below the dew point temperature. Relative humidity is the measure of how much moisture is in the
air. Dew point is the combination of temperature and relative humidity where moisture condensates on a surface. The ASTM E 337,
AStandard Method for Measuring Humidity with Psychrometer: is the recommended method for measuring dew point temperature.
When condensation is a problem, the pipe surfaces should be heated to at least 5°F above the dew point temperature before the
coating is applied. Condensation is usually not a problem unless the relative humidity is 85% or more.
LIQUID ADHESIVE APPLICATION: POLYGUARD 600 LIQUID ADHESIVE should be applied at an average rate of 400 ft2 / gallon
(10.0m2/liter). Stir before using. Apply liquid adhesive with brush or roller to clean and dry substrate. Do not thin liquid adhesive.
APPLICATION: POLYGUARD RD-6™ can be spirally wrapped by hand or power operated machine. Coating is spirally wrapped with
bitumen side next to the dry or tacky/dry liquid adhesive. As coating is unwound from its spindle, the separator sheet is rewound
simultaneously onto the other spindle and discarded after roll is completely applied. Enough brake tension should be used to obtain
good overlap confirmation and a smooth, tight, air pocket free condition on pipe surface. Coating overlap should be minimum 1"
(25.4mm) unless otherwise specified. Where DSAW pipe is being coated, prior to coating, 6” (152.4mm) wide RD-6™ material must
be used for stripping purposes over the mill weld. The material is applied over the LIQUID ADHESIVE surface before the RD-6™
coating is applied. Centering the middle of the product over the weld, the roll is unwound normally, removing the separator sheet as it
is unwound. If the coated pipe in hot weather remains in either an open ditch or on skids for an extended period, overwrap coating
with kraft paper or other suitable temporary material.
Use of POLYGUARD SP6 OUTERWRAP is strongly recommended over the RD-6™ for diameters > 4”. This inexpensive layer will
further assist RD-6 and provide a major contribution to the mitigation of soil stress forces.
LOWERING IN: The coated pipe should be inspected before lowering-in with a holiday detector. The thickness of the RD-6™
compound is nominal 40 mils with a nominal 10 mil mesh backing that will allow the current from the holiday detector to easily
penetrate if the compound is damaged. For this reason Polyguard recommends setting the holiday detector at maximum of 4000
volts. Significant testing has proven that when the compound is not damaged, the voltage could be set at higher voltages, but doing
so can penetrate thin spots that may be perfectly good coating otherwise.
BACKFILLING: Care shall be taken in backfilling to avoid sharp rocks or other material in the backfill which would damage and
penetrate the coating. In areas of rough backfill, suitable rock shield shall be provided to protect the coating from backfill damage.
PRECAUTIONS:
The liquid adhesive is an industrial coating and would be harmful or fatal if swallowed. It is marked as red label from the standpoint of
flash point. Prohibit flames, sparks, welding and smoking during application. Solvents could be irritating to the eyes. In case of contact
with eyes, flush with water and contact physician.
Avoid prolonged contact with skin and breathing of vapor or spray mist from liquid adhesive. In confined areas, use adequate forced
ventilation, fresh air masks, explosion proof equipment, and clean clothing.
This material is sold by Polyguard Products, Inc. only for the purposes described in this literature. Any other use of the products is the
responsibility of the purchaser and Polyguard Products does not warrant nor will be responsible for any misuse of these products.
Polyguard Products will replace material not meeting our published specifications within one year from date of sale.
All Polyguard Products Material Safety Data Sheets (MSDS) and precautionary labels should be read and understood by all user
supervisory personnel and employees before using. Purchaser is responsible for complying with all applicable federal, state or local
laws and regulations covering use, health, safety, and disposal of the product.
MAINTENANCE:
None required.
Technical Service:

PH: 214.515-5000
FAX: 972.875.9425
x.lit/pipeline/rd6 application spec genl R 11-15-07
Coverage Table for 50’ Rolls
With Spiral Wrap Application
(Normal rolls for RD-6 are 50 ft in length. However, for large projects, custom roll widths or lengths can be produced. Additional lead times and
minimum quantities are required. In some instances additional charges will apply)
Rolls of Coating Required to Coat 100 LF of Pipe

**Note: figures shown are theoretical, no loss or any field contingency included**
2" x 50’ Rolls 4" x 50’ Rolls 6" x 50’ Rolls
Nominal Surface Area: Ft2
Pipe Diam per 100 LF of Pipe
1" Overlap 1" Overlap 50% Overlap 1" Overlap 50% Overlap
1/2" 22.0 5.3

3/4" 27.5 6.6
1" 34.4 8.3
1 1/4" 43.5 10.4 3.5 5.2
1 1/2" 49.7 12.0 4.0 6.0
2" 62.2 15.0 5.0 7.5
2 1/2" 75.3 18.1 5.3 9.0
3" 91.6 22.0 7.4 11.0
4" 117.8 9.5 14.2 5.7 9.5
5" 145.6 11.7 17.5 7.0 11.7
6" 173.4 13.9 20.8 8.4 13.9
8" 225.8 18.0 27.1 10.9 18.0
10" 281.4 22.5 33.8 13.5 22.5
12" 333.8 26.7 40.0 16.0 26.7
14" 366.5 17.6 29.3
16" 418.9 20.1 33.5
18" 471.3 22.6 37.7
20" 523.6 25.1 41.9
22" 576.0 27.6 46.1
24" 628.3 30.2 50.3
26" 680.7 32.7 54.5
28" 733.0 35.2 58.6
30" 785.4 37.7 62.8
32" 837.8 40.2 67.0
34" 890.1 42.7 71.2
36" 942.5 45.2 75.4
38" 993.8 47.8 79.6
40" 1046.7 50.3 83.8
42" 1099.0 52.8 88.0
44" 1150.8 55.3 92.2
48" 1256.0 60.3 100.5
w.xlp.Spiral Wrap Coverage Table 01307


PH: 214-515-5000 • 800-541-4994 • FAX: 972-875-9425
600 Quick Dry Liquid Adhesive
DESCRIPTION:
POLYGUARD 600 QUICK DRY LIQUID ADHESIVE is a fast drying, rubber based adhesive in solvent
solution which is used in conjunction with Polyguard pipeline coatings and tapes. It is available in
solvent systems that will conform to most local VOC requirements.
PHYSICAL PROPERTIES TYPICAL RESULTS

Color Black
Solids Content 19%
Flash Point 50°F TOC
Viscosity 300-500 cps @ 77°F
Shelf Life 1 Year *
At Application 25°F. to 130°F (-4° to 54° C)
Temperature Ranges: In Service -25°F to 150°F (-32° to 66° C)
APPLICATION:
600 QUICK DRY LIQUID ADHESIVE may be applied with roller or brush to clean and dry pipe
surface. It should be applied at an average rate of 400 ft2 per gallon (10m2/liter). DO NOT THIN
LIQUID ADHESIVE. In the event of cold weather, store inside prior to use.
PRECAUTIONS:
The liquid adhesive is an industrial coating and would be harmful or fatal if swallowed. It is marked as
red label from the standpoint of flash point. Prohibit flames, sparks, welding and smoking during
application. Solvents could be irritating to the eyes. In case of contact with eyes, flush with water and
contact physician.
Avoid prolonged contact with skin and breathing of vapor or spray mist from liquid adhesive. In
confined areas, use adequate forced ventilation, fresh air masks, explosion proof equipment, and clean
clothing.
This material is sold by Polyguard Products, Inc. only for the purposes described in this literature. Any
other use of the products is the responsibility of the purchaser and Polyguard Products does not
warrant nor will be responsible for any misuse of these products. Polyguard Products will replace
material not meeting our published specifications within one year from date of sale.


PH: 214-515-5000 • 800-541-4994 • FAX: 972-875-9425
All Polyguard Products Material Safety Data Sheets (MSDS) and precautionary labels should be
read and understood by all user supervisory personnel and employees before using. Purchaser is
responsible for complying with all applicable federal, state or local laws and regulations covering
MAINTENANCE:
None required.
Technical Service:

PH: 214.515-5000
FAX: 972.875.9425
w.xlp.600 Quick Dry Primer 3-1-07

606 FILLER TAPE
FABRIC REINFORCED COATING FOR MOLDING IRREGULAR SURFACES
606 Filler Tape can fill irregular transition areas, thus avoiding This photo illustrates how the corrosion control coating
DESCRIPTION:
gaps and voids under the coating. used in 606 Filler Tape conforms and fills voids.
POLYGUARD 606 FILLER TAPE is a cold applied protective coating. Within the rubberized bitumen
coating is a continuous filament thermoplastic fiber for reinforcement. The fiber adds tensile strength
and provides resistance to tear. The continuous filament fiber used to reinforce the coating is randomly
arranged and highly dispersed within the compound. The fiber can be stretched within its break level
so as not to restrict conformability and to assure exceptionally good molding characteristics. The coat-
ing is supplied in rolls and utilizes both paper and plastic film release sheets which are removed prior to
application.
606 FILLER TAPE is formulated for use with POLYGUARD RD-6 and 600 SERIES COATINGS. It also is
applied over a companion 600 LIQUID ADHESIVE.
USES:
606 FILLER TAPE is designed for hand application. It is primarily designed for use over weld seams,
but also finds use as a filler material under the coating and wrapping of station piping, irregular shapes
such as valve bodies, flange bolts, and compression fittings.
ADVANTAGES:
Following are the advantages of 606 FILLER TAPE.
! Easily applied and provides excellent conformation and molding properties.
! Has excellent resistance to water or vapor transmission.
! Not subject to deterioration from below ground acids and alkalis that are encountered in normal soil.
! Has excellent ability to resist infiltration of moisture.
! Has elastomeric properties to accommodate normal expansion and contraction of the substrate.
! Includes as the basic corrosion coating a polymer modified bitumen.
PROPERTY ASTM Test English Metric

Color Black Black
Thickness D 1000 0.06” 1.5 mm
Moisture Absorption D 570 0.2% 0.2 %


PH: 214-515-5000 • 800-541-4994 • FAX: 972-875-9425
GUIDE SPECIFICATION:
Handling Materials: 606 FILLER TAPE and LIQUID ADHESIVE should be hauled and stored in such a
manner as to prevent injury to the packages. All packages and rolls of wrapping materials should be
transported in warmed vehicles and stored in a warm dry place and kept from contact with earth and
protected from weather at all times.
Although the filler tape can be utilized at lower temperatures, to maximize the quality application
characteristics of the tape, it is recommended that the tape and liquid adhesive be maintained at a
temperature of 60EF (16EC) or higher at all times.
Surface Preparation: The pipe shall be cleaned of all paint, oil, grease, mill scale, loose rust, welding
residue, knurls, frost, dust, moisture, weeds and other foreign matter.
Applying Liquid Adhesive: Polyguard Liquid Adhesive should be applied at an average rate of 400 sq. ft.
per gallon (10.0m2/liter). Stir before using. Apply with brush or roller to clean and dry substrate. DO
NOT THIN POLYGUARD LIQUID ADHESIVES.
Wrapping: 606 FILLER TAPE can be applied by spiral wrapping or by cigarette wrapping. The release
sheet is to be removed immediately prior to the time of application. Remove the paper release liner and
apply coating to the substrate. Remove the remaining plastic film liner and press filler coating into all
voids, using a piece of release paper to do this.
The coating should be applied with enough tension to eliminate any air pockets and to conform to the
surface area.
Lowering-in and Backfilling: Normally, filler material is used under coating systems such as RD-6 and
the 600 Series Systems. In these circumstances, the recommendations made for lowering-in, inspection
and backfilling for these specific coating systems should be followed.
Where filler material is to be used alone or in combination with materials other than mentioned above,
please consult POLYGUARD.
PRECAUTIONS:
contact physician.
Avoid prolonged contact with skin and breathing of vapor or spray mist from liquid adhesive. In confined
areas, use adequate forced ventilation, fresh air masks, explosion proof equipment, and clean clothing.
other use of the products is the responsibility of the purchaser and Polyguard Products does not warrant
nor will be responsible for any misuse of these products. Polyguard Products will replace material not
meeting our published specifications within one year from date of sale.
All Polyguard Products Material Safety Data Sheets (MSDS) and precautionary labels should be read and
understood by all user supervisory personnel and employees before using. Purchaser is responsible for
complying with all applicable federal, state or local laws and regulations covering use, health, safety, and
disposal of the product.
MAINTENANCE:
None required.
Technical Service:

PH: 214.515.5000
FAX: 972.875.9425
w.xlp.606 Filler Tape R. 11-15-07

SP-6 Unbonded Outerwrap
“Fail / Safe” Outerwrap for Soil Stress Resistance
DESCRIPTION:
POLYGUARD SP-6 UNBONDED
OUTERWRAP is an integral part
of the RD-6 Coating System. It
consists of a strong non woven,
felt-like polypropylene fabric. The
product is engineered to provide
high bursting strength and low
tensile and elongation properties.
The result is an outerwrap with
improved soil stress resistance.
SP-6 will reduce the deformation of corrosion coating systems
caused by soil stress. It acts as a slip plane to relieve soil stress.
SP-6 UNBONDED OUTERWRAP provides the following performance properties:

Design Feature Engineering Purpose
There is no adhesive on For years, the pipeline coating industry relied upon bonded outerwraps.
the surfaces of either side
of the fabric. However, permanent adhesion of the outerwrap to the corrosion coating
underneath is not desired. Quite the opposite. The fabric when unbonded has
the freedom to be moved by the forces of soil stress, independently of the
coating over which it has been applied. If the fabric of the outerwrap had been
bonded to the coating underneath, the soil stresses would be transferred to the
corrosion coating underneath, and could cause deformation of the corrosion
coating.
The fabric permits water This porous property keeps the outerwrap from contributing to the cathodic
and cathodic protection protection shielding problem. Solid film back corrosion coatings and
currents to pass through outerwraps have been proven to shield (block) the passage of protective
it. currents.


PH: 214-515-5000 • 800-541-4994 • FAX: 972-875-9425
USES:
POLYGUARD SP-6 is the outerwrap for use over POLYGUARD RD-6. It is an integral part of the
“fail/safe” and soil stress resistant RD-6 Coating system. It can of course be used over any other coating
to provide non-shielding soil stress resistance.
TECHNICAL DATA:
Typical properties of the SP-6 non-woven fabric are:
Property ASTM Test Method Results - English Results – Metric

Weight D 5261 4.1 oz / yd2 140 g/m2
Tensile Strength – Grab D 4632 102 lbs. 0.45 KN
Elongation D 4632 50% 50%
Burst Strength – Mullen D 3786 200 PSI 1378 kPa
Thickness D 1000 .027” .69mm
Permittivity D 4491 2.5 sec. -1 2.5 sec. -1
PRECAUTIONS:
MAINTENANCE:
None required.
TECHNICAL SERVICE:

PH: 214.515.5000
FAX: 972.875.9425
w.xlp.SP-6 Data Sheet 11-15-07

Polyguard RD-6 Pipeline Coating System
RD-6 HAS BEEN USED OVER 19 YEARS ON THOUSANDS OF PROJECTS. TO OUR
KNOWLEDGE, NEITHER EXTERNAL CORROSION NOR SCC HAS BEEN A PROBLEM
UNDER RD-6 OR FBE. WHY?
The Advantages of RD-6
Advantage # 1:
RD-6 and FBE are both “fail / safe” coatings.
This means that if the coating ever fails (disbonds and water penetrates the area), the pipeline is safe because
cathodic protection currents can reach the disbonded area. Once there, the CP current will raise the pH of the
water underneath the disbonded area to 9 or higher – a level that significantly reduces the corrosion of steel.
Additionally, the geotextile backing of RD-6 does not shield cathodic protection currents.
Advantage # 2: (applies to RD-6 only, not FBE)

RD-6 is less likely to fail (to become disbonded) because:
2a: RD-6 resists disbondment from the pipe, even if surface preparation is less than perfect.
2b: RD-6 is highly resistant to soil stress, a major cause of coating disbondment.
2c: RD-6 installs faster than almost any other coating, and requires no cure. This means that the system
will not fail because it was backfilled before cure.
Advantage # 3:
RD-6 is not a tape.
North American pipeline operators have virtually banished solid film backed tapes and shrink sleeves. RD-6
is quite different.
Advantage # 4:
RD-6 has a very long record of successful installations in the field.
The first installations of RD-6 were in 1988. By 1992, the product was being widely used in North America.
Today there are thousands of installations.
These advantages are explained in more detail in the following pages, as well as on our website:
www.polyguardproducts.com/failsafecoating.htm.
w.xl.RD 6 Adv Introduction
Web Site:www.polyguardproducts.com/failsafecoating.htm
PH: 214-515-5000
Polyguard Products' has been certified to

these quality systems requirements:
Polyguard RD-6TM Pipeline Coating System
Advantage #1
RD-6 is a ‘Fail/Safe’ coating system
‘Fail/Safe’ coatings are coatings which do not shield (block) cathodic protection currents.
The subject of shielding is a complex and technical one, which not many understand in
detail. However, as it relates to the subject of underground exterior pipeline corrosion
coatings, some general concepts can be explained which do not require detailed training.
It is important for anyone with pipeline responsibilities to understand cathodic shielding.

That is because the latest NACE standard, as well as government regulations (CFR
§192.461 and §195.559) require that external corrosion coating materials have non-
shielding properties.
Here is the NACE definition of shielding:
“Shielding: Preventing or diverting the cathodic protection current from its intended
path.” NACE Standard RPO169-2002, Control of External Corrosion on Underground or Submerged Metallic Piping Systems, page 3
Here is what the NACE standard says about corrosion coatings which shield:
“Materials and construction practices that create electrical shielding should not be used
on the pipeline.”
NACE Standard RPO169-2002, Control of External Corrosion on Underground or Submerged Metallic Piping Systems
Here is what CFR §192.461 says about allowable corrosion coatings:
“(a) Each external protective coating, whether conductive or insulating, applied for the
purposes of external corrosion control must--...............(5) Have properties compatible
with any supplemental cathodic protection.”
49 CFR Part 192-Transportation of Natural and Other Gas by Pipeline: Minimum Federal Safety Standards, Subpart I – Requirements for Corrosion Control
Coatings with solid film backing have been proven to shield. Solid film backings have a
property of high resistivity, which is not compatible with supplemental cathodic protection.
This is why shrink sleeves and solid film backed tapes have lost favor with North American
pipeline operators. The high resistivity property of these film backings resists the passage
of electricity; thus these coatings can “hide” areas of corrosion from cathodic protection
currents.
As early as the late 1980’s, the Pipeline Research Council reported(1) that both corrosion and
SCC were; “..enhanced by cathodic shielding at the disbonded areas..” by solid
polyethylene film backed tapes installed on natural gas pipelines. In the mid 1990’s,
PH: 214-515-5000

Canada’s National Energy Board concluded that solid film back tapes contributed to an
outbreak of SCC failures because of shielding.
Although usage of solid film back tapes and shrink sleeves has greatly declined in North
America, both types of products continue to be broadly used in other areas of the world. In
addition, 2 layer and 3 layer systems using solid film coatings of polyethylene or
polypropylene are in wide use. All of these coatings have proven shielding characteristics.
The graphic below gives some idea how “fail / safe” coatings differ from shielding
coatings.
FBE and Polyguard RD-6 are both “fail /

safe” coatings. This means that they have
been proven to allow passage of protective
currents to disbonded areas with corrosion
potential. Once the protective current has
penetrated underneath the coating, the
current raises the pH of the water to 9 or
more, a level which significantly reduces
corrosion.
We don’t have space here to show you the

evidence, but we invite you to our website
to review both external and internal pH check indicates a high pH (9 to 10) in water under this improperly applied
testing. On the website is also a RD-6. High pH confirms “Fail/Safe” properties.
PowerPoint presentation which illustrates

the concept more fully.
(1) A Review of Gas Industry Pipeline Coating Practices, July 1988,
Corrosion Supervisory Committee, Pipeline Research Committee, Catalog
L51586, Technical Toolboxes, Inc, Houston, TX 77098
w.xlp.RD6 Adv Fail Safe R. 2-26-07

Advantage #2a:
RD-6 resists disbondment,
whether surface preparation quality is minimal, medium, or high
Polyguard recommends a NACE 3 Minimum Prep - RD-6 had 8 mm Disbondment
Polyguard RD-6 (7)
blast finish whenever possible, but we Shrink Sleeve (9)
Hand Tool Surface Prep

also realize that surface preparation Cold A pplied Tape (5)
Hot A pplied Tape (8)
quality of field applied coatings is a Shrink Sleeve (11)
Liquid Epoxy (3)
major problem. Cold A pplied Tape (6)
Liquid Epoxy (2)
Shrink Sleeve (10)
Liquid Epoxy (1)

Several years ago, a joint industry Liquid Epoxy (4)
project (1) sponsored by US and 0 20 40 60 80 100

Cathodic Dis bondm e nt Radius - m m
120
Canadian pipeline companies was Medium Quality Prep- RD-6 had 7mm Disbondment
designed to address the problem that Ho t A pp lied Tape (8)
most external corrosion occurs at the Power Tool Surface Prep

Po lyguard RD-6 (7)
Shrink Sleeve (9)
girth weld, where coatings are field Liq uid Ep o xy (3)
Cold A pp lied Tape (5)
applied and subject to application Shrink Sleeve (11)
Cold A pp lied Tape (6)
quality problems. Liq uid Ep o xy (2)
Liq uid Epo xy (1)
Liq uid Ep o xy (4)
A main objective of the study was to see Shrink Sleeve (10)
0 20 40 60 80 100 120
how a group of 11 representative Cathodic Dis bondm e nt Radius - m m
coatings performed under different High Quality Prep - RD-6 had Zero Disbondment
levels of surface preparation quality. Polyguard RD-6 (7)
Shrink Sleeve (9)

Abrasive Blast Surface Prep
Liquid Epoxy (3)
The 11 coatings were applied using Shrink Sleeve (10)
Liquid Epoxy (1)
three different quality levels of surface Liquid Epoxy (4)
preparation (abrasive blast, power tool, Cold A pplied Tape (5)
Liquid Epoxy (2)
and hand tool). Shrink Sleeve (11)
Cold A pplied Tape (6)
Hot A pplied Tape (8)
Cathodic disbondment results showed 0 5 10 15

Cathodic Disbondm ent Radius - m m
20
that RD-6 gave top performance, at all

levels of surface preparation quality.
(1)
Joint Industry Project Field Applied
External Pipeline Coatings, June 1997,
Charter Coating Service, Ltd, Calgary
Alberta Canada.
Study details(1) are on our website

www.polyguardproducts.com/failsafecoating.htm
w.xl.RD 6 Adv Prep
Web Site: www.polyguardproducts.com/failsafecoating.htm

PH: 214-515-5000

Advantage #2b
RD-6 has very high resistance to soil stress
Soil stress usually comes from backfill pressure as it Tensile Strength in PSI
settles around a pipeline. Typical result is a “bag and
sag” at the 4 and 8 o’clock positions.
RD-6
TYPICAL SOIL STRESS DAMAGE TO SHRINK

SLEEVES OR SOLID FILM BACK TAPES Shrink Sleeves
Tape
0 1000 2000 3000 4000 5000

Source: Manufacturers' Literature - Typical Product
"Stretchiness" (Elongation at Break - %)
RD-6
Shrink Sleeves
Tape
The RD-6 soil stress advantage comes from its backing. 0% 100% 200% 300% 400% 500% 600% 700%
The RD-6 backing is a high strength, low elongation Source: Manufacturers' Literature - Typical Product
polypropylene geotextile mesh. The RD-6 backing helps

with soil stress three ways: Temperatures (Deg.F) Where Strength Loss Begins
Deflection Temperature (Deg.F) Under Flex Load
A. Higher Tensile Strength:
RD-6 - PP
Somewhat stronger than HDPE shrink sleeves. Ten
times stronger than typical tapes. Sleeves-HDPE
Tape LDPE/MDPE
B. Less Stretchable:
- 50 100 150 200 250
th Source: Handbook of Plastics, Elastom ers, and Com posites (1)
A critical difference. 1/20 as stretchable as shrink
sleeves or tapes. (1) 2ND edition. Published by McGraw Hill, Inc.
1992. pp C32-C37.
C. More Resistant to Weakening from High Heat:
If your pipeline operates above ambient, polymers relax

(begin to stretch) as you heat them. Polypropylene (used
in RD-6) has 75°F higher resistance to this weakening w.xl.RD 6 Adv Soil
than polyethylenes.
PH: 214-515-5000

Advantage #2c:
RD-6 can be installed quickly and backfilled immediately
Hours From Start to Backfill -
Several years ago a joint industry Field Applied External Coatings
project(1) sponsored by US and Canadian
pipeline companies tracked 11 coatings Hot Applie d Tape (8) 0.75
for speed of installation from start to Cold Applie d Tape (5) 0.75
1.00
Polyguard RD-6 (7)
backfill. “Tapes” and RD-6 as a group
1.50
Cold Applie d Tape (6)
won this race by a big margin – twice as 1.75
Shrink Sle e ve (11)
fast as shrink sleeves, four times faster Shrink Sle e ve (10) 2.50
than liquid epoxies. Shrink Sle e ve (9) 2.75
3.50
Liquid Epoxy (3)
Polyguard prefers you to think of Liquid Epoxy (4) 4.50
RD-6 as different from “tape”, since the Liquid Epoxy (1) 5.00
RD-6 geotextile backing is many times Liquid Epoxy (2) 5.50
stronger and far less stretchable than 0.00 1.00 2.00 3.00 4.00 5.00 6.00
solid film back sleeves and tape. Source: Joint Industry Project-Field Applied External Pipeline Coatings
Another difference is that RD-6 won’t

shield cathodic protection currents as do
solid film back sleeves and tape.
However, like “tape”, RD-6 is supplied

in roll form and needs no cure before
backfill.
(1) Joint Industry Project Field Applied External Pipeline

Coatings, June 1997, Charter Coating Service, Ltd, Calgary
Alberta Canada
w.xl.RD 6 Adv Fast

PH: 214-515-5000

Advantage #3
RD-6 Is Not a Tape. (Or is it?)
Many pipeline operators have experienced problems with tapes. For these people, the word “tape”
brings a very negative reaction. In North America, operators have largely banished tapes and shrink
sleeves.
Bob Nee invented Polyguard RD-6. When Bob took early retirement from Surfcote/3M/Bredero Price
in 1988 to rejoin Polyguard(1), the first thing he said was; “Tape is on the way out.” This news was not
greeted with applause, since most of what Polyguard sold was tape. But we couldn’t argue when Bob
showed us a study by the Pipeline Research Council(1) showing that gas transmission users were
condemning solid film backed coatings due to corrosion and SCC failures from cathodic shielding, soil
stress, and related problems.
Part of the secret is the

In the RD-6 invention, Bob replaced solid film geotextile backing - strong and
backing with high strength geotextile backing. non-shielding to cathodic
protection current
The result is not a tape in the traditional pipeline
coating sense. Read below and decide yourself.
RD-6 is Not a Tape, because… RD-6 is a Tape, because…

RD-6 has a woven geotextile backing, proven not to shield RD-6 is a long strip with coating
cathodic protection currents compound wound on a roll
RD-6 is far stronger and less stretchable than solid poly- RD-6 has all the traditional tape
ethylene backings. Soil stress vulnerability is much lower advantages of easy, rapid installation
Our purpose with this ad is to address those who have lumped RD-6 into the dreaded “tape” category.
The intent of the RD-6 invention was to eliminate the problems being caused by stretchable, solid film
backings while maintaining the benefits of tape application.
(1) For details of Bob Nee’s story, the Pipeline Research Council study, and technical backup, see www.polyguardproducts.com/failsafecoating.htm
w.xl.RD 6 Adv Not a Tape
PH: 214-515-5000

Advantage #4:
RD-6 has a very long record of successful installations in the field
Polyguard installed its first RD-6 project
in October, 1988, on a 26” products line
in Beaumont, Texas. This particular
project was in a high soil stress area.
The project was excavated in April,
1989. It was in perfect condition except
for a small wrinkled area where no
outerwrap had been used over the RD-6.
The base of RD-6 projects grew steadily. Installation of the first RD-6 project – October 1988
Corrosion engineers who understood the on a products line in Beaumont, Texas
mechanics of the shielding problem

recognized that the RD-6 backing would
not shield cathodic protection currents.
By 1992, RD-6 was well recognized and

growing. The magazine cover to the
right featured the use of RD-6.
Over the years since 1988, usage of RD-6

has grown almost every year, with an
average annual unit sales growth of
35%. Virtually every pipeline operator
who has used RD-6 on their line has By 1992, RD-6 had become a recognize
product with a growing user base.
continued to use the product.
Polyguard RD-6 Installed Base
14
12.46
Today, some of the world’s biggest 11.15
Millions of Square Feet
12
operators utilize RD-6 as their standard 9.91
10 9.04
coating. The base of installed projects is 7.97
8 7.05
in the thousands, both large and small. 6.15
5.27
6
The total square footage of installed RD- 4.48
3.75
4 3.10
6 at the end of 2006 exceeded 12 million. 2.50
1.95
1.44
2 0.97
0.50
0.010.020.05
-
88
90
92
94
96
98
00
02
04
06
19
19
19
19
19
19
20
20
20
20
Year
RD6 Adv #4 - Long Track rcd
Total installed square footage of RD-6 now exceeds 12 million

PH: 214-515-5000

PGJ Home Permission to Copy Order Reprints
Is Your Pipeline Coating ‘Fail Safe’?

By Richard Norsworthy, Polyguard Products, Inc.
hen selecting a pipeline coating, poor application techniques and selection of is resistant to soil stress effects, especially
the “Fail Safe” characteristics the wrong coating are why pipeline coatings when the complete system includes the use of
may be more important than other disbond during service. When a coating system unbonded (slip plane type) outer wrap.
issues that are normally considered. fails, the question one must ask is, will the coat- 5. Less stringent surface preparation, ease
A “Fail Safe” coating system is defined as one ing shield CP if the bond fails (Moore, 2000)? of application, easy cleanup, mixing or off
that will allow cathodic protection (CP) current ratio concerns and no cure time (no sophisti-
to pass through it to protect the substrate - not cated equipment needed).
shield it - should the coating bond fail and ade- 6. No heat required for application which
quate CP is available (Norsworthy, June 2004). is much safer for applicators and removes the
Therefore, “Fail Safe” coatings will reduce or problems with over- or under-heating.
eliminate corrosion, including stress corrosion 7. The compound is compatible with most
cracking (SCC), on the pipe under the coating other pipeline coatings.
if a bond failure occurs, water penetrates and 8. Because current can penetrate at the areas
cathodic protection is adequate. of disbondment, these areas can be located by
Fusion bonded epoxy (FBE) coatings are the use of Direct Current Voltage Gradient
known to be “Fail Safe.” Polyguard RD-6 is (DCVG) surveys.
a pipeline coating system that provides “Fail 9. Since the coating is “Fail Safe,” the end
Safe” properties incorporated with reduced user does not have to be as concerned about
soil stress problems and shielding problems. replacing the coating immediately.
It has been used for more than 15 years, but 10. Compatible with CP (over 15 years of
the “Fail Safe” technology is just now being test data and in-service life).
understood by many in the pipeline industry. 11. Resistant to microbiological attack.
12. There are no known failures after over
Why Fail Safe Coatings? 15 years of service when proper surface prepa-
Several corrosion technical papers refer to Soil stress caused wrinkles in shrink sleeve ration and application were used.
this characteristic which may be called “Fail on 10-inch pipe which allowed water and SS 13. The two occasions water has been found
Safe,” “CP Compatible,” or “CP Friendly.” shielded CP, resulting in significant corrosion under this coating (once was an application
When these CP-compatible coatings degrade after eight years. problem and the other was the intentional
or groundwater contacts the pipe, the surface application to a wet pipe) the pH was 10 to 11,
is still protected from corrosion and SCC Typically, if the bond (adhesion to pipe) is indicating adequate CP for protection is being
because the CP current can pass through the good, there is no water buildup between the achieved under the disbonded area.
permeable coating (King et al., 2004). It is coating and the pipe, therefore neither corro-
believed that the high permeability of FBE sion nor SCC is usually a problem. Even when
coating to water is the reason for the appar- water permeable coatings absorb water or allow
ently “transparent” nature of FBE coating to water to penetrate by other methods, the water
the cathodic protection (Ruschau, 2006). SCC does not present a problem as long as the coat-
has been studied extensively and has never ing is well bonded to the pipe surface. The type
been observed on FBE-coated pipelines in of coating chosen can lead to potential pipe-
over 30 years (Neal, 2000). line corrosion and failure if water penetrates
between the coating and the pipe and the coat-
ing does not have “Fail Safe” characteristics.
One “Fail Safe” Coating

The advantages of selecting a “Fail Safe”
coating system are many. Here are the advan-
tages for the woven geo-textile mesh-backed
wrap system:
1. When adequate CP is present, corrosion, RD-6 applied for three years on partially
including SCC, is significantly reduced or elim- sweating pipe in severe soil stress area. No
inated if water penetrates under the coating. bond to area where pipe was sweating at
2. Field- and lab-proven “Fail Safe” proper- installation, but pH was 11 on water under
ties similar to FBE (Norsworthy 2004). There the coating proving “Fail Safe”. Notice wrin-
typically is a change in the pH to between 10 kles on white tape, but no wrinkles on RD-6.
and 13 under the disbondment proving that the
“Fail Safe” FBE coating in central U.S. with
pipe is getting adequate CP. Summary
3. This coating system provides an excel- By selecting “Fail Safe” pipeline-coating
blisters. Water pH was 12 with no corrosion lent choice for rehabilitation, girth welds systems, the likelihood of reoccurring corro-
under FBE. and repairing pipeline coatings to provide sion under disbonded coatings is significant-
What happens if the coating is not “Fail improved pipeline integrity and safety. ly reduced or eliminated with adequate CP.
Safe”? Soil stress, poor surface preparation, 4. The woven geo-textile mesh backing “Fail Safe” coatings are also less susceptible
62 Pipeline & Gas Journal / October 2006 / www.pgjonline.com

present. Therefore, the chance of significant NACE committees and is a NACE instructor
corrosion or SCC is less likely. for CP, Basic Corrosion and Coatings Used
Since FBE is not easily applied in the with Cathodic Protection.
field except to girth welds, it is not con-
LITERATURE:
sidered a rehabilitation coating. The alter-
J. Beaver and N.G. Thompson, “Corrosion Beneath
?
native is to use another coating that has
Disbonded Pipeline Coatings,” Materials Performance,
been proven to be “Fail Safe” through
April 1997, Pg.. 13.
field observations and laboratory testing.
T. Fore, K. Varughese, “First Generation of Fusion
The “Fail Safe” choices are limited. At
Bonded Epoxy Coatings Performance After 30 Years
this time, few pipeline coatings have actu-
of Service--A Case Study,” CORROSION 2006, Paper
ally been tested for these characteristics.
Therefore the question to ask the coating 06045, pg. 3.
vendor should be: “Has your pipeline coat- F. King, T. Jack, M. Kolar, and R. Worthingham,
RD-6 coating system condition shown is after “A Permeable Coating Model for Predicting the
ing been proven to be Fail Safe?” P&GJ
one year in severe soil stress area. Use of Environment at the Pipe Surface Under CP-Compatible
“Slip Plane” non-shielding, non-bonded outer ACKNOWLEDGMENT: Coatings,” CORROSION 2004, Paper 04158, pg. 1.
wrap enhances soil stress resistance. Based on a presentation at NACE CORROSION 2006. G. Koch, “A Test of Stress,” Oil Week, Oct. 17, 1994,
Pg. 16.
f to SCC. Most of the intergranular failures
have been on pipes coated with a coal tar Author: Richard Norsworthy graduated from D. P. Moore, “Cathodic Shielding Can Be A Major
primer and coal tar enamel reinforced with Problem After a Coatings Fails,” MP39, 4, 2000,
Stephen F.Austin State University, Nacogdoches,
felt or fiber glass, although some failures Pg. 44.
TX with a degree in Mathematics. In 1980, he
have occurred with asphalt or tape-coated D. Neal, “Pipeline Coatings Failure – Not Always
started working for Tennessee Gas Pipeline as What You Think It Is,” CORROSION 2000, Paper
systems, but none with thin film (FBE) coat-
a corrosion technician. From 1984-88 he 00755, Pg. 5.
t ings (Parkins, 1996).
There have been other documented cases taught the Corrosion Technology program at R. Norsworthy, “Fail Safe Tape System Used in
of corrosion under solid film-backed tape, Kilgore College, Kilgore, TX, then worked as Conjunction with Cathodic Protection,” Materials
shrink sleeves and other very high dielec- a Corrosion Specialist for Amoco Pipeline Co. Performance, June 2004, Pg. 34.
tric strength coatings (Ruschau, 2006, from 1988-90. He was with Mobil Pipeline R. Norsworthy, “Select Effective Pipeline Coatings,”
t
Norsworthy, 1997, Koch, 1994, Beavers & Hart’s Pipeline Digest, Feb. 1997, Pg. 17.
as Corrosion Control Manager from 1991-
Thompson, 1997). The ability of coatings R. N. Parkins, “Stress Corrosion Cracking of
d 95. From 1995-2005 he was an independent
t such as FBE or the geo-textile mesh strands Pipelines- Its Control or Prevention,” CCORROSION
corrosion consultant and then a Corrosion
of the RD-6 to permit CP current to penetrate 96, Paper 249.
to the pipe surface if disbondment occurs Specialist for Tepsco. On June 1, 2006, he G. R. Ruschau, “Determining the CP Shielding
f
accounts for the higher potential and subse- started in technical sales for Polyguard Behavior of Pipeline Coatings in the Laboratory,”
quent change in pH of any water that may be Products, Inc. He is a member of several CORROSION 2006, Paper 06043, pg.2.
r
Pipeline & Gas Journal / October 2006 / www.pgjonline.com 63

OUTSIDE TESTING OF RD–6 COATING
Joint Industry Project - Field Applied Pipeline Coatings

The stated purpose of this project, which was conducted by Charter Coating Service, Ltd., of Calgary,
Alberta, Canada, was to evaluate how field applied joint coating systems performed under three levels of
surface preparation quality (abrasive blast, power tool, and hand tool). The Background on page 1 states:
“The main site of external corrosion on pipelines is the joint area

which is coated in the field.”
In field application, job site conditions can be quite variable, and installation methods are sometimes done by
untrained and/or unsupervised personnel.
Eleven manufacturers of field applied coatings were invited to submit a product for testing. The types of
coatings were grouped as follows:\
• Liquid coatings, 100% solids

• Cold Applied Tapes (1)
• Torch Applied Tape
• Heat Shrinkable Sleeves
(1) Polyguard RD-6 was categorized by the laboratory as a Cold Applied Tape for purposes of this test. For a summary of the differences between
Polyguard RD-6 and “Tapes”, see the separate note discussing the differences.
The most important finding of this test for Polyguard RD-6 is a demonstration that, even with less than the
best surface preparation, RD-6 performed best for overall cathodic disbondment at 21° C/ 70° F:
RD-6 Cathodic Disbondment

Surface Preparation Method (Radius in mm @ 21°C/ 70°F)
Abrasive Blast Cleaning 0 mm
Power Tool Cleaning 7 mm
Hand Tool Cleaning 8 mm
A secondary RD-6 advantage was also demonstrated by this test, as shown in the measure of total application
time to backfill. RD-6 had an elapsed time of one hour total.
In accordance with an initial agreement, only the Polyguard RD-6 corrosion coating is identified by
name in the condensed report which follows. The other coatings are identified only generically.
w.xlp.RD6 outside test sum


PH: 214-515-5000 • 800-541-4994 • FAX: 972-875-9425
FIELD APPLIED PIPELINE COATINGS - SUMMARY OF TEST RESULTS
Coating No./ Cathodic Disbondment (radius in mm) Impact Resistance (in-lbs) Hot Water Soak Coating Manufacturers
Coating Name (adhesion rating,
21°C / 70°F Hot1 (°C) 1=best, 5=worst Coating No., Manufacturer
Blast Power Hand Blast Power 21°C 0°C -30°C Blast Power Hand tool 1 Liquid Epoxy
tool tool Tool 70°F 32°F -22°F tool 2 Liquid Epoxy
3 Liquid Epoxy
LIQUIDS 4 Liquid Epoxy
5 Tape Cold Applied
1/ Liquid Epoxy 100% Solids 4 27 37 33 90 27 48 43 40 2 5 5 6 Tape Cold Applied
7 Polyguard Products
2/ Liquid Epoxy 100% Solids 6 18 28 22 65 15 48 79 58 1 2 5
8 Tape Torch Applied
3/ Liquid Epoxy 100% Solids 3 8 19 23 Total 35 38 20 2 3 5 9 Shrink Sleeve
90
10 Shrink Sleeve
4/ Liquid Epoxy 100% Solids 5 38 Total 45 90 Total 27 18 16 4 5 5 11 Shrink Sleeve
Coating No./ Cathodic Disbondment (radius in mm) Impact Resistance (in-lbs) Shear Resistance Peel Rate at 2 kg weight
Coating Name (hrs. to fail) (mm/min)
21°C / 70°F Hot1 (°C)
Blast Power Hand Blast Power 21°C 0°C -30°C 21°C Hot1 (°C) 21°C Hot1 (°C) YJI FBE
tool tool Tool 70°F 32°F -22°F 70°F 70°F
TAPES (Cold Applied)
5/ Tape with Primer 5 10 14 Mastic Flow 60 123 137 158 0.1 instant 60 2.9 360 60 3.1 2.1
6/ Tape with Primer 11 14 21 Mastic Flow 75 171 166 139 2.7 instant 75 2.1 instant 75 5.9 4.5
7/ Polyguard RD-6 Tape 0 7 8 Mastic Flow 65 92 130 134 22.1 instant 66 <1 64 66 <1 <1
with Primer
TAPES (Hot Applied)

8/ Tape with Primer 15 6 16 33 43 34 48 43 40 >50 0.4 43 <1 30 43 <1 <1
SHRINK SLEEVES
9/ Sleeve with Primer 0 8 12 32 65 60%2 >180 >180 116 >50 2.3 65 <1 53 65 <1 <1
2
10/ Sleeve with Primer 3 40% 33 18 80 Total >180 >180 >180 >50 >50 80 <1 11 80 <1 <1
11/ Sleeve 8 11 18 16 80 85%2 124 143 81 36.25 instant 80 2.2 87 80 2.7 2.4
1 2
“Hot temperatures are shown in shaded areas for each test. Proportion of test area disbonded, these areas were extensive.
ii
FIELD APPLIED PIPELINE COATINGS - EXECUTIVE SUMMARY
A joint industry project was conducted by Charter Coating Service to examine the performance of a series of
external pipeline coatings that can be applied under field conditions. The eleven participants in this project
included both end user companies and coating suppliers. Eleven pipeline coatings were selected including:
four liquid coatings; three cold applied tapes; one hot applied tape; and three shrink sleeves. Coatings were
examined for application characteristics and for performance in a number of tests that simulate stresses
imposed on pipeline coatings in service. The coatings were examined over different substrates including
different standards of steel cleanliness and different main line coatings.
Application Characteristics:
All the coatings were applied with simple equipment that could be readily transported and used in the field.
A notable difference between the coatings is the requirement for preheat of the pipe in the application of the
shrink sleeves. Pre-heating is not typically possible on pipelines that are in service and so this requirement
restricts the use of shrink sleeves in rehabilitation work.
The liquid coatings were the fastest to apply but required the longest time to set-up to a point where the line
could be backfilled. This set-up time can be reduced by preheat of the pipe. The liquid coatings were the easiest
to examine for quality of application.
Application of the cold applied tapes was faster and easier using a wrapster. The hot applied tape required
careful use of a torch but was more simple to apply than the shrink sleeves. The shrink sleeves required the
most skill to apply well.
Performance Characteristics:
The coatings tested and their performance are shown in the table on the following page. The coatings were
examined for resistance to: cathodic disbondment; impact damage; adhesive failure of liquid applied coatings
(hot water soak, pull-off adhesion); and soil stress damage of tapes and sleeves (shear and peel resistance).
Tests were conducted at varying temperatures to simulate the effects of application and service under different
ambient and pipeline service conditions. Pull-off adhesion data has not been included in the Table because the
preponderance of failures were between the coatings and the pull-off load fixtures. Failures of this type do not
give true adhesion value and can be misleading.
The following notes summarize the main differences noted in the performance of the coatings in this study.
C Performance was improved by better substrate preparation in the order: abrasive blasted better than power
tool cleaned better than hand tool cleaned.
C The coatings that had the least tolerance for poorer surface preparation were those that included a two-
component epoxy (the liquid coatings plus). These coatings would not typically be suited for application
where the substrate can only be power tool cleaned.
C Higher temperatures worsened performance characteristics of all coatings. Performance in these tests
indicates that most of the coatings would not be expected to give long term protection to pipelines running
continuously at or near their maximum rated temperature. In selecting a coating for high temperature
service it is important to examine the performance characteristics of the candidate coatings at the service
temperature.
C The tapes and sleeves had higher impact resistance than the liquid coatings which would be expected since
tapes and sleeves have a deformable outer wrap. Most coatings had lower resistance to impact under cold
conditions.
C Adhesion of the test products to main line coatings varied. Coatings selection should include consideration
of the compatibility of the candidate coatings with the existing coatings on the pipeline.
Charter Coating Service Ltd.
0300-96-01-T(Main) i
BACKGROUND
The failure of pipelines by external corrosion has caused both financial and environmental
consequences and is also a safety hazard. Corrosion protection of pipelines is accomplished by a
combination of cathodic protection and protective coatings. The coatings provide a barrier to the
environment and the cathodic protection protects holiday or damage sites in the he coating.
The main site of external corrosion on pipelines is the joint area which is coated in the field. The steel
at the junction between different pipe sections is more susceptible to corrosion because of the heat
affected zone near the weld or because of the complexity of the joint system. Nevertheless, the joint
area has historically received the least amount of attention when it comes to coating application.
Corrosion can occur at the joint area despite the cathodic protection because the pipe may be shielded
from flow of current between the coating failure and the anode. Cathodic shielding, as it is called, is
most commonly attributed to the electrical insulating properties of disbonded coating.
A problem often associated with external corrosion is stress corrosion cracking (SCC). A December
1996 report by the National Energy Board (NEB) of Canada has reviewed the SCC on Canada’s
pipelines. The NEB report recommends a comprehensive approach to the SCC problem including the
implementation by each pipeline company of an SCC management program. The report notes that
most of the 22 SCC related pipeline failures occurred on pipelines that were coated with polyethylene
tape, a common joint coating.
Interviews with a number of companies identified a desire for a test program to evaluate field applied
external pipeline coatings. This study was designed to bring in a number of industry participants, both
end users and coating suppliers, in a cooperative venture. Based on a test plan developed by Charter
Coating, a number of interested companies met to discuss the details of the project. Further to this
meeting a final test plan was developed. Companies that elected to participate in this project all
contributed the same amount to the project and were considered equal participants in all respects.
The test plan that was developed for this project examines characteristics of the coatings that have a
bearing on their long term performance in service. These characteristics include both performance and
application characteristics since poor performance is often a result of improper application procedures.
The performance tests were selected to simulate stresses encountered on buried pipelines. Tests were
conducted at both 21°C/70°F to represent cold and ambient running lines and at the maximum rated
temperature of the selected coating systems to determine changes in performance as a result of
temperature and to evaluate the acceptability of the suppliers temperature ratings on buried lines.
The joint industry project that was developed included one coating per participant. Coatings were
selected by the participants as detailed in the Coating Selection section of this report. All tests and test
conditions were specified at the introductory meeting. Products and product information were supplied
free of charge by the coating suppliers. This study was limited to application and testing of the selected
coating systems.

0300-96-01-T(Main) 1
TEST PROGRAM OBJECTIVES
C Select and source a representative range of field applied external pipeline coatings.
C Identify substrates commonly encountered in pipeline joint and rehabilitation coating.
C Evaluate the application characteristics of the selected coating systems.
C Record the different temperature requirements for application of the coatings.
C Compare performance of coatings applied to different surface preparations of steel pipe.
C Determine performance of the coatings at both 21°C/70°F and at the maximum rated
temperatures for the coatings.
C Measure impact resistance of the coatings at varying temperatures.
C Examine and compare adhesion of the coatings to the different substrates.
C Evaluate shear resistance of tape and sleeve coatings.
COATING SELECTION
Coating selection was based on discussion between the participants that were present at the introductory
meeting so as to result in the desired mix of coating systems. Each participant selected one coating for
the study. The final decision as to the coatings used was at the discretion of the participant that
sponsored the selected product. The coatings selected represent a broad range of tried and tested or
recently introduced products from a number of generic coating types.

0300-96-01-T(Main) 3
SUMMARY OF TEST PROGRAM
Application Characteristics
The different generic types of coating were compared to determine the strengths of each of the systems.
Application characteristics of the coating systems were evaluated for:
- ease of application
- equipment requirements
- required temperatures
- speed of application
- speed of set-up (time to backfill)
- safety aspects of the applications
- ease of inspection (can defects be easily detected?)
- tendency of tent over welds
- likelihood of channelling within the coating
The components within each coating system are noted together with any preheating that was used. All
coatings were applied either by or in the presence of representatives of the coating suppliers.
The coatings were applied to a variety of substrates. These substrates included prepared pipe and main
line coatings to simulate the environments at joints, tie-ins, risors and repair areas. Surface preparation
methods included hand tool, power tool, and abrasive blasting.
Details of application characteristics are in the Application Section of this report.

0300-96-01-T(Main) 4
Performance Characteristics
The performance tests in this project are shown in the following table. Details of the performance of
the coatings are included in the different test sections of this report.
TEST TEST PROCEDURE SUBSTRATE TYPE TEST CONDITIONS
TEMPERATURE OTHER
Cathodic ASTM G8-90 Abrasive blasted - SP6(1) 70°F/21°C 30 days

Disbondment Power tool cleaned - SP3 -1.5V
Wire brushed - SP2
Abrasive blasted Maximum service

Power tool cleaned rating(2)
Peel Resistance CSA Z245.21-M92 Abrasive blasted 70°F/21°C 0.3,2.0 and

(Only tape and Hanging Weight FBE 15.3 kg per
sleeve products) Polyethylene system inch width
Tar and fiberglass wrap
Power tool cleaned Maximum service

rating(2)
Pull-off adhesion ASTM D4541-89 All six substrate types 70°F/21°C --

(Liquid products)
Impact resistance ASTM G14-88 Power tool cleaned 70°F/21°C --
70°F/21°C
70°F/21°C
Shear resistance Aramco 09-AMSS- Power tool cleaned 70°F/21°C 50 hours

(Only tape and 96
sleeve products) “Alyeska Shear Test” Maximum service
rating(2)
Hot water soak CSA Z245.20-M92 Abrasive blasted 203°F/95°C 24 hours

(Only liquid Power tool cleaned
products) Wire brushed
(1)
2.0-3.0 mil profile
(2)
Manufacturer’s maximum continuous temperature rating

0300-96-01-T(Main) 5
1 APPLICATION CHARACTERISTICS
INTRODUCTION
Improper application of field applied pipeline coatings has been the source of many coating failures.
Problems in the application may be attributed to one or more of the following factors:
- Application specifications either don’t exist or have poor detail

- Quality control of the application work is limited and often performed by individuals with
minimal knowledge of the coating system
- Training of the field applicators is insufficient
In planning a particular project, it is important to understand that there may be restrictions on the
equipment and personnel that can be used to apply the coatings. In this study coatings were selected that
were relatively easy to apply and required quite simple equipment since these products can be used more
widely than complex systems. For example we did not examine fusion bond epoxy(FBE) or plural
component spray applied coatings even though these systems are used for field application to new
pipelines.
The application of all the coatings was observed by Charter Coating and was conducted either by
or in the presence of representatives of the coating suppliers. This allowed for continuity of analysis of
the application characteristics while ensuring that the suppliers standard application procedures
were being properly adhered to. All applications were conducted at 2 °C/70°F with an initial pipe
temperature of 18-19°C/64-66°F.
All coatings were applied to six substrates. These were:
Abrasive blasted steel (SSPC-SP6, commercial blast to 2.0-3.0 mil profile)

Power tool cleaned steel (SSPC-SP3)
Hand tool cleaned steel (SSPC-SP2)
Polyethylene coated pipe (YJI)
Fusion bond epoxy (FBE) coated pipe
Tar and wrap coated pipe
The objective of this work was to identify application characteristics and equipment requirements
that might impact on the desirability of the coatings for specific projects.

0300-96-01-T(1 Application) 1
COATINGS IN STUDY
The generic components of the coatings are shown in the following table. All tapes were applied
with a 50% overlap resulting in a double layer of tape over the surface of the pipe (see Figure 2 in
Photographic Section). The average film thickness shown in the table is the film thickness measured
over the power tool cleaned steel substrate.
Coating Type Coating Name Base Hardener Mix Ratio2 Av. DFT
(mils)
Liquid No. 1 Epoxy resin Amine 1:1 55
Coatings
No. 2 Epoxy resin Amine 3:1 39
Coating Type Coating Name Primer Adhesive Backing Av.DFT
(mils)
Cold Applied No. 5 Primer Bitumen based, PVC 110
Tapes Bitumen based fabric
reinforced
No. 6 Primer Bitumen based PVC 100
Bitumen based
Polyguard RD-6 Polyguard #600 Bitumen based Woven 95
No. 7 Bitumen based geotextile
Hot Applied No. 8 Bitumen based Coal tar, Thin plastic 105
Tape reinforced film
Shrink No. 9 2-component1 Copolymer hot Expanded 105
Sleeves epoxy melt polyethylene
No. 10 2-component1 Copolymer hot Expanded 60
epoxy melt polyethylene
No. 11 None Mastic Expanded 70
polyethylene
1
All 2-component epoxies were 100% solids products
2
Mix ratios are by volume

SUMMARY OF APPLICATION PARAMETERS
Coating Equipment Time to Time to TEMPERATURES USED Final Film Holidays
Requirements Apply1 Backfill2 Thickness
Range
Preheat Preheat of Heat Post Heat (Avg.)
of Product Pipe Applied to mils3
Primer
No. 1 stirrer (power stirrer 30 min 5 hrs None None None None 12-77(55) None
preferred and an
No. 2 applicator (brush, 30 min 5½ hrs 25°C/77°F None None None 15-75(39) 5 pinholes
roller, or trowel),
No. 3 30 min 3½ hrs 25°C/77°F 32°C/90°F None None 13-66(23) 2 pinholes
No. 4 30 min4 4½ hrs None None None None 16-80(23) 6 pinholes
No. 5 stirrer, brush, and 45 min ¾ hrs None None None None (110) None
wrapster (wrapster
No. 6 optional) 90 min 1½ hrs None None None None (100) None
Polyguard RD-6 60 min 1 hr None None None None (95) None
No. 7
No. 8 stirrer, applicator, 40 min ¾ hr Propane None None None (105) None
and torch torch
No. 9 stirrer, applicator, 50 min 2.¾ hrs None 45°C/113°F 90°C/194°F Heat from (105) None
and torch propane
No. 10 90 min 2½ hrs None 70°C/158°F None torch to (60) None
shrink
No. 11 torch 50 min 1¾ hrs None 100°C/212°F None sleeve (70) None
1
Time to apply was recorded during application of each coating to 11 foot of 4" diameter power tooled pipe and includes mixing time and,
where appropriate, time to set-up of primer
2
Time to backfill includes time to apply plus time required for the coating to develop properties that will withstand backfilling
3
Only an average film thickness is given for the tapes and sleeves because there was little variation for each product
4
Due to dripping of the coating the applicator continued to go back to the pipe to brush out the drips, thereby extending the time to apply
THIS REPORT HAS BEEN REPRODUCED, IN ITS ENTIRETY, (WORD FOR WORD) FOR THE PURPOSE OF
HIGHLIGHTING. ORIGINAL COPIES ARE AVAILABLE.
Testing of Pipeline Maintenance and Rehabilitation

Coatings
by R. Norsworthy
Mobil Asset Services, Dallas, Texas
The International Pipeline Monitoring & Rehabilitation Seminar
Twenty-Nine (29) different pipeline coat-

ings were tested, evaluated and then The Doubletree Hotel/Post Oak
ranked, based upon the results. Houston, Texas
Tapes, shrink sleeves and brushable coat-
ings were included. All Known manufac-
turers were invited to submit the coating’s
February 6-9, 1995
of their choice.
Highlighted here is what we consider

pertinent information. However, reading Organized by
the complete paper provides interesting
and unbiased information for those in-
volved in Coating Selection.
Systems Integrity
and
The Polyguard RD-6 Coating System
was ranked number one. Pipeline & Gas Journal
TESTING OF PIPELINE MAINTENANCE
AND REHABILITATION COATINGS
By Richard Norsworthy
February 1995
In an effort to provide information needed to determine which coatings are best suited for use in repairing or
replacing pipeline coatings during normal maintenance or rehabilitation, a test program was developed and
implemented. This testing program was designed to give specific information that is
important for determining the best coating in the different categories tested as well as the
best types to be used in different conditions.
Many of the tests are adaptations of standard tests. Changes in these test procedures
were usually made by changing the length of the test, voltages and temperatures. When
there was not a suitable standard to test for parameters that were important, new tests
were developed. Most of these tests were developed by using the expertise of Paul
Partridge (Technical Inspection Services, Inc.) and Gary Cox (ITI Anti-Corrosion, Inc.).
Paul and Gary helped to take the needs and ideas for different test parameters and
adapt these into a very good test program.
One of the new cathodic disbondment (CD) test parameters involved determining how the coating performs at
longitudinal and girth welds. Each sample had a longitudinal weld and one girth weld. As
seen in some of the results, many of the failures did occur at the weld areas. Three
eights (3/8) inch holidays (larger than usual) were intentionally placed at the intersection
of the longitudinal and girth welds. Some of the tape and shrink sleeve coatings allowed water
penetration along the weld seams. Some of the brushable coatings developed problems along the welds and
not in other areas.
Another test was developed to determine the peel resistance a coating may have when compared to other
coatings of the same type. This test could only be performed on the tape and shrink sleeve
coatings. The particular test involves determining the differences of peel strength at
cathodic disbondment and impact areas to find out what kind of peel strength is lost (if
any) at areas of damage. Many tape and shrink sleeve manufacturers make claims that
their products “self heal” when minor damage occurs, but is the integrity of the coating
bond in these areas as good as before the damage? This condition will be referred to
as the “weakened bond radius” and will be determined by comparison to the average
peel strength on the original coating. The average “weakened bond radius” was
considered to be cathodic disbondment or water permeation.
128
Pull off tests were performed on all the brushable coatings to determine the extent of
adhesion. Most results were good with one or two being exceptional. The cathodic
disbondment area was easier to identify with these coatings. A problem did develop on
some of the mor brittle coatings that kept chipping past the CD ring. However since
there was good adhesion, no metal corrosion or water penetration in these areas, this
was not considered to be further failure.
The tensile and tear properties of the tapes and shrink sleeves were compared before and after approximately
3000 hours in the prohesion exposure equipment. This test was to determine what changes are seen in these
coatings after they have been exposed to burial conditions. The break strength and percent
elongation at break were also used to determine what coatings would perform best in soil stress
situations. The best ratings were given to those coatings that had a high break strength and the least amount
of elongation. Some coatings actually showed an improvement in these properties after the
prohesion exposure.
The attached information will give the basic information for the test program and an
example of how the results were distributed. All participating company names have been
deleted and generic descriptions used for each coating type. Of course for Mobil’s use,
this information was included.
Plans are to continue this test program on an annual basis or at least at times when there
are enough new or different coatings to test. By reusing the same testing labs and test
parameters, a continual updating process will exist. This gives the opportunity to look
at existing coating technology as well as new coating systems that are being developed.
After comparing the results, pipeline repair and rehabilitation coatings can be selected
on a basis of tests and performance, not just cost or popularity.
I would like to thank each participating company, both testing labs and each of you for
support and help during this program
.
129
TESTING OF PIPELINE REPAIR AND REHABILITATION
COATINGS
Page 1 of 11
The purpose of this testing is to have the information needed to recommend a variety of
the best coatings to be used for repair and rehabilitation of pipeline coatings. Selected
independent testing lab(s) are to be used for each type of testing. Each coating supplier
will be given the rest results of each coating they supplied for the test, but not the overall
test results.
I. TYPES OF COATINGS TO BE TESTED

A. Tapes
1. Cold applied
2. Hot applied
B. Shrink Sleeves
C. Brushable* Coatings
1. Epoxies
2. Mastics
3. Wax or petroleum based coatings
4. Other coatings not classed as a tape or shrink sleeve.
* Brushable may be applied with rollers, mits, etc. Spray applied coatings will
be considered if process does not require considerable investment in
specialized equipment.
II. SAMPLES TO BE TESTED
A. All coatings to be applied by testing lab personnel or coating supplier

representative at the lab site. Each supplier may be present to direct and assist
in the application of their particular coatings. The coating application procedure
will be videotaped by lab personnel. Photographs and videotapes of the results
and testing in progress may also be made.
B. Each coating will be applied to a 3 or 4 inch diameter hot rolled pipe, ten feet in
length, blasted to a commercial finish. Blast medium to be medium grit coal
slag, with a 2 to 4 mil profile. Maintain the pipe at 70°F ± 5° and less than or
equal to 75% relative humidity between blasting and coating. Each pipe to have
simulated longitudinal and girth welds conforming to API 5L and API 1104
specifications. Coatings to be applied within one hour of blasting.
130
COATINGS
Page 2 of 11
C. Each coating will be given the manufacturer recommended time to cure before
any testint or cutting of samples.
1. Each coating must be applied holiday free.
2. Each coating must be applied at the manufacturer’s suggest thickness.
3. Each coating will be tested for holidays at the manufacturer’s suggested DC

voltage.
D. Samples will be cut from these ten foot pieces of pipe as needed for testing.
Each sample shall have a girth weld and a continuous longitudinal weld seam.
E. Each supplier will furnish to the testing lab all manufacturer’s data on each
coating regarding:
1. Generic type
2. Recommended service conditions
3. Chemical and physical characteristics
4. Safety related precautions
5. MSDS sheets
6. Application information
7. The temperature range at which the coating should be tested; ranges are
150 or 200°F.
F. Each supplier must furnish to the testing lab:
1. Enough of each coating material to be tested so each piece of pipe can be

properly coated.
2. Enough primer to properly prime each pipe for that particular coating.
3. Enough thinner to properly thin and clean up after applying coatings.
4. Any special tools needed for properly applying each coating, such as, hand
wrapping machines, special torches, propane bottles, etc.
G. Selected testing lab(s) will furnish all pipe, equipment, and personnel for testing.
H. The Corrosion Specialist or designee will have free access to observe any of the
testing, application, and evaluation of the coatings tested in this program.
I. The Corrosion Specialist will receive all videotapes, photographs, reports and
results of all coatings tested in this program and will be responsible for sending
results to the coating suppliers.
131
COATINGS
Page 3 of 11
J. The Corrosion Specialist will make all decisions about which coatings will be
tested and recommended for use on their pipeline systems. The results of these
tests will be used as part of that decision making process.
III. TESTS TO BE PERFORMED
A. Cathodic Disbondment/Moisture Permeation (The moisture permeation will be

done to test the effect of cathodic protection on the moisture permeation of the
coating.)
1. Test conditions:
a. Electrolyte: NaCl, 3%
b. Potential: -3.0 VDC
c. Temperatures:
(Coating suppliers will decide at what temperature(s) their coating will be
tested.) 150 or 200°F ± 5°
d. Holiday diameter: 3/8" (three per sample) One will be drilled at the
intersection of the girth and lingitudinal weld seams, one in the overlap of
tape coatings away from the weld and one in the regular thickness of the
coating away from the weld.
e. Ends will be sealed to prevent moisture from entering the inside of the
sample.
2. Duration of tests
a. Begin with three samples per coating system.
b. Evaluate one sample per coating system at 30 days.
c. Discontinue CD testing on any coating system that disbonds enough to

require a significant increase in amperage to maintin the test voltage.
d. Evaluate one sample per remaining coating system at 60 days.
e. Discontinue CD testing on any coating system that disbonds enough to

require a significant increase in amperage to maintain the test voltage.
f. Evaluate the remaining coating systems after 90 days.
g. If all of the one type of coating system fails at the 30 or 60 day interval,
the samples will be evaluated to determine which coating of that type will
perform the best.
132
COATINGS
Page 4 of 11
3. Evaluate criteria for cathodic disbondment
a. Using a utility knife, make eight radial cuts through the brushable coatings
to the substrate, with the holiday being in the center. Radial cuts shall be
at least 1" in each direction.
b. Cool the samples to room temperature. For tapes and shrink sleeves, a
1" strip will be cut, beginning wt the holiday, circumferentially, completely
around the sample. This strip will be cut 180° from the holiday and
peeled back enough to be gripped by the peel adhesion machine.
c. For brushable coatings insert knife blade under the coating and use a
lever action to chip off or remove the coating.
d. For tape coatings and shrink sleeves, the coating must have the same
characteristic and strength of bond at the holiday as it did in peel tests
performed on the original samples of the coating. The average weakend
bond radius* will be considered to be cathodic disbondment. Tape
coatings (such as hot applied coal tar tapes) on which peel tests cannot
be performed because they are brittle and do not have the tensile
strength needed for a peel test, will be evaluated the same as brushable
coatings.
* The weakened bond radius will be that point at which the peel strength of th4e
coating is the same as the average peel strength of the original samples. This
strength will be determined by a peel test comparable to the one taken on the
original sample.
e. Average CD radius will be measured from the holiday edge.
4. Evaluation for moisture permeation from CD testing:
a. Brushable coatings will be tested by cutting 1" scribes (insuring that cuts
penetrate to the substrate) crosswise at 45° angles at three areas 180°
from the holidays.
b. Air cool the samples to room temperature, but not longer than two hours.
For tapes and shrink sleeves, prepare samples as in part III.A.3.b.
above.
c. For brushable coatings, insert the knife blade under the coating at the
junction of the cuts and flip upwards. Note any chipping or peeling of the
coating.
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d. Tape coatings on which peel test cannot be performed will be evaluated

the same as brushable coatings.
e. All coatings will be checked in the first ten minutes after removal for
blistering, swelling, and change in color and texture.
f. Rating:
Excessive blistering or swelling may be cause for rejection. Change in
color or texture will be recorded. For brushable coatings there may be
chipping but no peeling of the coating. For tape and shrink sleeve
coatings the peel strength should be comparable to that of the original
peel strength.
B. Moisture Permeation/Impact
1. Test conditions
a. Electrolyte - Tap water
b. Temperatures - 150 or 200°F ± 5°.
c. Three impacts will be made on each sample and marked. Impacts will be
at least four inches from each other and from the end of the sample.
Impacts will be one each at 40 inch-pounds, 60 inch-pounds and 100
inch-pounds. Each impact will be tested for holidays at manufacturer’s
recommended voltage for the coating thickness and type. Holidays,
cracking, and other damage from the impacts will be evaluated and
recorded before immersion.
d. Ends of pipe will be sealed to prevent moisture from entering the inside
of the pipe.
2. Duration of tests
a. Begin with two samples per coating system.
b. Evaluate one sample after 30 days.
c. Discontinue testing on any failed coating system.
d. Evaluate remaining samples after 60 days.
e. If all of one type of coating system fails at the 30 day interval, the testing
lab will evaluate the rate the performance of these coatings.
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3. Evaluation criteria
a. Brushable coatings wll be tested by cutting 1" scribes (insuring that cuts
penetrate to the substrate) at 45° angles across the impacted areas and
at three areas 180° away from the impacted areas.
b. Air cool the samples to room temperature, but not longer than 2 hours.
For tapes and shrink sleeves, 1" wide strips will be cut circumferentially
around the pipe with the impact area being in the center of the cut. These
areas will be tested for peel strength by cutting the coating 180° from the
impact areas and peeling the coating back enough to insert it in the peel
strength test machine. The piece will be peeled around the pipe and at
least 1" past the impact area.
c. For brushable coatings, insert the knife blade under the coating at the
junction of the cuts and flip upwards. Note any chipping or peeling of the
coating.
d. For tapes and shrink sleeves, the peel strength will be evaluated and
compared to the original peel strength values (refer to part III.C). tape
coatings (such as hot applied coal tar tapes) on which peel tests cannot
be performed will be evaluated the same as brushable coatings.
e. All coatings will be checked in the first ten minutes for blistering, swelling
and change in color and texture.
f. Rating:
Any blistering or swelling may be cause for rejection of the coating.
Change in color or texture will be recorded. Moisture permeation or lack
of adhesion around weld seams (girth or longitudinal) will be cause for
rejection. For brushable coatings there may be chipping but no peeling*
of the coating. For tape coatings and shrink sleeves the peel strength
should be comparable** to that of the original peel strength.
* Some peeling may occur at the impact area, but should not extend beyond the
size of the area when compared to the earlier impacts at these same values.
** Comparable means no more than a 10% loss in peel strength when compared
to the original peel test of that coating.
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C. Peel Test - Tape Coatings and Shrink Sleeves
1. Test conditions
a. Cured coatings
b. Temperature of sample - all samples tested at ambient (room

temperature).
c. The 200°F test samples will also be peel tested at a substrate

temperature of no less than 170°F.
d. Same apparatus to be used for all peel tests including CD and moisture
permeation tests.
2. Test procedure
a. Cut two 1" wide strips circumferentially around the pipe.
b. Cut the strip and peel the coating back enough to attach it to the peel test
apparatus.
c. Attach peel test apparatus.
d. The strips will all be pulled at the same rate of inches per minute (to be
determined by the testing lab).
3. Rating/Evaluation
a. These test results will be used for comparison values for the CD and
moisture permeation tests.
b. The results will be given in a value that can be used for ranking each
coating according to peel strength.
D. Impact Testing
1. Test conditions
a. Cured coatings
b. Temperature of sample - all samples tested at ambient (room

temperature).
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c. The 200°F test samples will also be impact tested at a substrate

temperature of no less than 170°F.
d. Same apparatus used for moisture permeation/impact testing.
2. Test procedure
a. Perform impact tests beginning at 20 inch-pounds and increasing by 10

inch-pounds per test on each sample until the impact causes the area to
fail a holiday detection test. Each impact will be performed on the coating
at an area at least one inch from previous impacts and from the end of the
sample.
b. Perform impact tests of 40, 60 and 100 inch-pounds on each sample,

whether failure occurs or not. These three impacts will be evaluated for
use on the moisture permeation/impact testing results.
a. Record the impact value in inch-pounds at which each sample fails

holiday detection.
b. Evaluate each sample at 40, 60, and 100 inch-pounds of impact to

determine the amount and type of damage done to the coating (such as
disbonding, cracking, etc.)
c. Record results.
E. Tensile Properties of Tapes and Shrink Sleeves
1. Test conditions
a. Tapes and shrink sleeves only
b. Performed on each coating in applied form (This may require shrink

sleeves to be heated, tapes to be stretched, etc.)
c. To be performed on original coating before exposure.
d. To be performed after 3,000 hours of prohesion exposure.
2. Test procedure
a. Evaluate break strength and percent elongation at break.
b. Evaluate tear strength.
c. Tape to tape peel strength (adhesion at overlaps).
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a. Each coating will be rated as to break strength and percent elongation.
b. Each coating will be rated as to tear strength.
c. Each coating will be rated as to peel strength or adhesion strength at

overlaps.
F. Pull-off Test for Brushable Coatings
1. Test conditions
a. Roughen surface of coating with 60-grit sandpaper or approved method.
b. Roughen surface of an Elcometer adhesion dolly.
c. Mix and apply adhesive in thin film to both the pipe surface and dolly
surface.
d. Sprinkle #4 sand on the epoxy on both surfaces.
e. Apply dolly to coating and press firmly, avoid trapping air.
f. Allow to cure 12 hours at 100°F to 150°F.
g. Cool to room temperature (approx. 72°F).
h. Attach to tensile machine and pull off at a rate of one inch per minute.
a. Record maximum load at failure.
b. Note type and location of failure.
c. Rate each coating as to pull-off strength.
*** For 200°F coatings, an attempt will be made to perform the adhesion test
when the substrate is no less than 170°F.
Any changes or deviations in this testing program shall be approved by the Corrosion
Specialist shown below. In some cases, equpment or procedures may have to be
changed or may not be available as described in the above specifications. Any changes
or deviations shall be made before testing begins.
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The testing lab must furnish an evaluation report for each coating that includes, but is not
limited to the following:
1. Comments on eacse of application.

2. Procedure followed for each application.
3. Procedure for surface preparation.
4. Manufacturer’s datea for each coating.
5. List of materials supplied by each coating supplier.
6. Results and procedure of each test performed.
7. Additional comments about each coating and test parameters that may help with
future testing programs or proper use of the coating.
8. All results shall be sent to the Corrosion Specialist listed below by an agreed
upon date.
All reports, additional information or questions should be directed to:
(Corrosion Specialist Name and address)
TESTING LABS AND COSTS
As indicated by the previous test procedures, this testing may be more stringent than
some testing that has been done in the past. Please review these procedures, costs and
requirements before submitting any coating for testing. This information will be used to
select field applied repair and rehabilitation pipeline coatings for the future.
The following indepedent testing lab has been chosen for testing all tape coatngs (hot
and cold applied) and all shrink sleeves:
ITI Anti-Corrosion, Inc.

10175 Harwin
Suite 110
Houston, TX. 77036
Telephone (713) 771-0688
Fax: (713) 776-9634
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The following indepedent testing lab has been chosen for testing all brushable coatings,
wax type coatings and coatings that can not be tested as described for tapes and shrinks
sleeves:
TECHNICAL INSPECTION SERVICES, INC.

5202 South Shaver
Houston, TX. 77034
Telephone (713) 947-6630
Fax: (713) 947-7796
Please contact “Corrosion Specialist - Phone Number” if your company wants to

participate in this program.
END
140
TEST RESULTS OF PIPE LINE REPAIR & REHABILITATION COATINGS
December, 1994
AUTHOR: R. Norsworthy Page 1 of 9
INTRODUCTION
The purpose of this testing was to have the information needed to recommend a variety of the best
coatings to be used for repairs and rehabilitation of pipeline coatings. These coatings are for normal
temperature (-20 to 150°F) underground or submersed pipelines, must be compatible with cathodic
protection, be simple to apply and withstand the environment in which they are used.
A variety of pipeline coatings have been used by industry in the past. Some of these coatings have
been successful, others have not. A testing program evaluates the coatings that are available and
eliminates those that do not meet the company standards for coatings of this type.
Twenty-nine coatings were tested as shown in the following report. A discussion about the ranking and test results of each
coating will be latter in this report.
Since this will be an ongoing test program in which the vendors of the products pay for the cost of
the testing, the recommended coatings should be used for repair or replacement of coatings on all
buried or submerged pipelines in the organization. Other coatings that are being used should be
tested for comparisons to the tested coatings. Any company that promotes a coating should be
encouraged to participate in future testing programs. The purpose of the continuing program is to
evaluate coatings that come on the market or existing coatings that have not been tested or used.
The recommended list will change and be updated after each set of tests are completed.
All referrals for testing should be made through the Corrosion Specialist. The Corrosion Specialist
will oversee the testing programs and make recommendations from the results of the tests,
comparisons with other coatings that have been tested and past experiences with particular coating
sytems. Field input and experiences with particular coatings systems will be very valuable
information in determining the recommended coatings for the future.
The generic types of coatings tested were cold and hot applied tapes, shrink sleeves, brushable
(liquid) types and petrolatum tape systems.
RANKING
(Ranking - Number 1 represents the best product from the group and will be highly recommended for use in the areas indicated
in the discussion. The larger the number the lower the ranking. Those not ranked should not be used for any reason.)
COLD AND HOT APPLIED TAPES
RANKING TEST # DESCRIPTION

1 12 Primer/Outer Wrap
2 13 Primer/Weld Seam Tape
3 1 Primer/Weld Seam Tape/Inner Wrap/Outer Wrap
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December, 1994
Page 2 of 9 AUTHOR: R. Norsworthy
4 8 Outer Wrap over 2-Part Epoxy Primer

5 15 Primer/Inner/Outer
6 6 Primer/Outer Wrap
7 14 Primer/Inner/Outer
NOT RANKED BECAUSE OF MASSIVE CD FAILURE.
5 Primer/Tape
SHRINK SLEEVES
RANKING TEST # SYSTEM

1 3 Shrink Sleeve
2 2 Primer/Shrink Sleeve
3 4 Primer/Shrink Sleeve
NOT RANKED BECAUSE OF MASSIVE CD FAILURES.
7 Shrink Sleeve
9 Shrink Sleeve
10 Shrink Sleeve
11 Experimental Shrink Sleeve
BRUSHABLE COATINGS

1 V1 Brushable Amine Adduct Cured 100% Solid Epoxy
2 C2 Coal Tar Epoxy Mastic (2 Coats)
3 N1 Epoxy Amine Adduct with Reinforced Wrap
4 C5 Epoxy Amine
5 P1 Epoxy/Polymer
6 V2 Modified Ureathane Polymer
7 A2 Pentaglycidalether of Cyclosilicon
8 C3 Epoxy Amine Adduct
9 C4 Epoxy Phenolic
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December, 1994
NOT RANKED BECAUSE OF MASSIVE CD FAILURES

C1 Zinc Rich Moisture Cured Ureathane
W1 Coal Tar Moisture Cured Ureathane
5 Primer/Tape
PETROLATUM TAPE SYSTEMS

1 TR Primer/Wax Tape
2 S1 Primer/Wrap
3 TA Primer/Wrap
DISCUSSIONS OF EACH COATING SYSTEM
COLD APPLIED TAPES.
#12 COLD APPLIED TAPE
This coating system was ranked number 1 because of its cathodic disbondment results, overall performance, ease of
application and the design of the coating.
#12 had the best results in the cathodic disbondment test of all the coatings tested. This is the most stringent test for a coating.
The overall test performance was also excellent for this coating. The peel and adhesion tests were difficult to perform on this
coating because of the fiber mesh make up of the coating. The most important result from the moisture permeation/impact test
was the fact that no moisture or rust was seen under the coating. This coating can be pulled extremely hard when applying
to a structure, therefore it can be pulled down tight during application. The fabric backing (mesh) will not cause the same CP
shielding problems as other tapes or shrink sleeves that have solid plastic backings. This has been a major problem with many
tapes in the past. The application of #12 involves preparing the surface, applying the primer and then
wrapping the tape by machine or by hand. An advantage is that #12 can be backfilled immediately after coating.
(See data sheets for specific application and information.)
USUES:
#12 system should be used on all pipelines that require a cold applied tape wrap. This coating is recommended to be used
as the number one choice because of the excellent test results, ease of application and the use of the mesh filber to help
eliminate the shielding problem of other tapes.
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December, 1994
#13 - PRIMER/WELD TAPE/INNER/OUTER
This coating had very good results in the cathodic disbondment tests and good overall results on
the other tests. The major disadvantage is the application because of the requirements of the seqm
tape and double wrapping.
The #13 coating did very good in the CD testing. #13 also did very good in the moisture
permeation/impact testing with no moisture or rust detected under the tape. The use of the weld
seam tape probably helped to prevent water penetration around the weld seams. The double
wrapping also helps from an impact standpoint. The coating can be backfilled immediately after
application. The coating can be applied by hand or machine, but machine would be recommended
for large areas. The tested system involved using a primer, weld seam tape, an inner and outer
wrap which could be labor intensive and provide more opportunity for error of application. The time
required and the amount of coating used could also be more expensive.
USES:
This #13 system will be an excellent choice for areas that may have severe environmental stress
and require the use of a tape wrap. This #13 system should be considered as a second choice and
is recommended for use on all underground or submerged systems. This system requires use of
a primer, seam tape, and inner and outer wraps and amy be more expensive and time consuming
to install.
#1 - PRIMER/WELD SEAM TAPE/INNER WRAP/OUTER WRAP
This coating system had good results on the cathodic disbondment test and good overall results on
the other tests. The major disadvantage is the application because of the requirements for seam
tape and double wrapping.
The #1 tape did good in the CD test, but not as good others. The moisture permeation/impact
results were also good. The peel strength results actually improved over the 90 days, which may
indicate an improvement in peel strength with ageing. Once again the use of the weld seam tape
may have helped with the water penetration at the welds. The coating can be backfilled immediately
after coating. The coating can be applied by hand or machine. The tested system consisted of
using a primer, weld seam tape, an inner wrap and an outer wrap which could be labor intensive and
provide more opportunity for error of application. The time required and the amount of coating used
could also cause the coating to be more expensive.
USES:
This #1 system would be an alternative to the #13 system, but the test results were not as good
overall, therefore it is not recommended to use except when the #12 or #13 systems are not
available. Once again it requires the use of four different steps and products to complete the coating
system.
#8-PRIMER/OUTER WRAP
This coating had very good results on the cathodic disbondment test and good overall results on the
other tests. The major disadvantage of this coating is the use of the primer which requires
144
December, 1994
considerable curing time, especially on cool damp days or cold pipe.
This #8 system did very good in the CD test and very good in the moisture permeation/impact
with no water penetration. This is a two coat system that is fairly simple to apply. The primer is
brushed on and the tape can be applied by hand or machine. The major problem with this
coating is the cure time of the primer. During a demonstration in January, the day was rainy and
cool. The primer took between one to two hours to cure enough the #8 Representatives could
apply the tape. If there is plenty of tie for curing the primer this could be a second choice to the
#12.
USES:
This #8 system is recommended to be used only when there is sufficient time to allow the primer
to cure properly. The application is similar to the #12 (two coats), but the test resultsd were not
as good and the primer takes a long time to cure (especially on cold days or cold pipe).
THE FOLLOWING COATINGS WILL NOT BE RECOMMENDED FOR USE UNDER ANY
CIRCUMSTANCES. THESE COATINGS ALL HAD POOR RESULTS ON THE CATHODIC
DISBONDMENT TESTS AND OVERALL LOWER RATINGS ON THE OTHER TESTS.
#15 - PRIMER/INNER WRAP/OUTER WRAP
#06 - PRIMER/OUTER WRAP
#14 - PRIMER/INNER WRAP/OUTER WRAP
THE FOLLOWING COATINGS HAD MASSIVE FAILURE IN THE CD TESTING AND WOULD NOT
BE RECOMMENDED FOR ANY PURPOSE.
#5 - PRIMER/TAPE
SHRINK SLEEVES -
#3 - SHRINK SLEEVE - NO PRIMER
This shrink sleeve had excellent results on the cathodic disbondment tests and very good overall
results on the other tests. This sleeve does not require a primer and is fairly easy to apply.
The #3 shrink sleeve had excellent CD results and very good results on the other tests. The
moisture/impact results were very good with no moisture penetration or rust. Shrink sleeves are
applied with an open flame torch, require training and use of the proper equipment. The sleeve
needs to cool a few minutes before backfilling. The open flame torch can be a safety problem
and requires training and use of the proper torch. Shrink sleeves may not bond well to cold
pipes or inservice pipes that have cold (under 50°F) product.
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December, 1994
USES:
The #3 sleeve will be excellent to use on out of service or new construction pipe when the proper
surface preparation and preheat can be applied to the pipe steel. The test results were excellent and this
could be an overall second choice to the #12 tape wrap coating and may be first choice on new or out-of-service pipes.
This will depend on cost and application cocnerns.
THE FOLLOWING SHRINK SLEEVES ARE NOT RECOMMENDED FOR USE BECAUSE OF
MOISTURE PERMEATION PROBLEMS AND POOR CD RESULTS.
#2 - Primer/Shrink Sleeve
#4 - Primer/Shrink Sleeve
THE FOLLOWING SHRINK SLEEVES ARE NOT RECOMMENDED FOR USE UNDER ANY
CIRCUMSTANCES BECAUSE OF MASSIVE CD FAILURES.
#7 - Shrink Sleeve
#9 - Shrink Sleeve
#10 - Shrink Sleeve
#11 - EXPERIMENTAL Shrink Sleeve
BRUSHABLE COATINGS -
V1 - BRUSHABLE AMINE ADDUCT CURED 100% SOLIDS EPOXY
This two part epoxy coating has very good cathodic disbondment results, overall perforamnce
and is easy to apply. This coating has been used for field joints and patching on FBE and
FBE/polyolefin coated pipelines for approximately two years with good results.
The CD results for this coating may be hard to evaluate because of the formulation used in the
test tended to chip easily from the steel. This may have lead the testing lab to assume this
chipping was caused from CD. As the photo indicates, the CD discoloration rings are much
smaller than those indicated in the test results. The supplier has also reformulated slightly to
decrease the chipping. Moisture permeation/impact testing results were very good with no
moisture or rust under the coating. This coating had the best adhesive test results of any of the
coatings. This coating is a two part epoxy that is mixed in correct proportions and applied
directly to the pipe steel after surface preparation. The supplier can supply this coating in
different size containers that will eliminate the need for measuring and waste. Curing has to take
place before backfilling. Curing time is dependent on the temperature of the pipe and air. An
advantage of this coating over tape coating is the fact that it will not have the same shielding
characteristics as tapes or shrink sleeves, can be applied to irregular shapes and is ery
compatible with FBE coatings.
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December, 1994
USES:
The V1 Brushable Epoxy should be first choice for repairs, field joints and rehabilitation of FBE
or FBE/polyolefin coated pipelines. This product is easy to apply and requires only one coat
without a primer. The coating must cure before backfilling, but there are some ways to possibly
speed up the cure or protect the uncured coating during backfilling. The time for curing will be
determined by the pipe temperature and the air temperature. This coating could also be used for
valves and irregular shapes, especially if mostly coated ahead of time in the shop.
C2-COAL TAR EPOXY MASTIC
This coating had good results in the cathodic disbondment test and performed good in most of
the other test. The test coating was applied in a two coat system, but could be applied in a one
coat if given enough time to cure priperly.
The results were good on the CD tests. Moisture permeation/impact test were very good with no
blisters or holidays. The adhesion test results were good and impact resistance only fair. The
curing time will be a factor in the field, but using one coat will speed up the time to backfill. This
coating is simple to apply in either a one coat or two coat system.
USES:
The C-2 Black Mastic will be a very good coating for use on valves and other irregular shaped
components. This coating should be very compatible with coal tar and asphalt coatings. This
coating will not cause shielding like many tape coatings. The C-2 would be a second choice to
the V1 Brushable Epoxy coating.
N1 - EPOXY AMINE ADDUCT WITH REINFORCED WRAP
N1 had very good results in nearly all the testing and might be the number one coating
recommended if it were not for the application problems. The application is basically a three
step operation.
This coating had very good CD results and very good moisture permeation/impact results. The
N1 is a very thick coating and has the potential for causing shielding problems similar to heavy
tape coatings. Impact resistance is excellent because of the thickness. Adhesion is also very
good. This coating is very labor intensive and messy to apply.
USES:
N1 has potential for very agreesive environments where other coatings may have difficulties. If
the application problems with this coating are not a concern for a particular application this is a
very good coating. When conditions allow for proper application and cure times N1 would be
recommended.
C5 - EPOXY AMINE
The C5 had good results in all the tests. This system requires a primer and top coat system.
147
December, 1994
The results of this system were similar to the V1 Brushable Epoxy. It had good CD and moisture
permeation/impact results and very good adhesion results. The major difference in the two
coatings is that the C5 requires a primer that must cure before the top coat is applied. If the
application allowed for time to cure the primer and the top coat before backfilling this coating
could possibly be used in the place of the V1 Brushable Epoxy.
USES:
C5 does not have the past experience with Mobil that the V1 Brushable Epoxy has at this time,
therefore it will not be recommended for use except when the V1 Brushable Epoxy is not
available.
P1 - EPOXY POLYMER
P1 IS STILL AN EXPERIMENTAL COATING, BUT HAS PROMISE FOR THE FUTURE. AT THIS
TIME P1 IS NOT RECOMMENDED FOR USE AS A PIPELINE COATING.
THE FOLLOWING COATINGS ARE NOT RECOMMENDED FOR USE A A PIPELINE COATING
BECAUSE OF THEIR POOR TEST RESULTS.
V2 - MODIFIED UREATHANE POLYMER
A2 - PENTAGLYCIDALETHER OF CYCLOSILICON
C3 - EPOXY AMINE ADDUCT
C4 - EPOXY PHENOLIC
C1 - ZINC RICH MOISTURE CURED UREATHANE
W1 - COAL TAR MOISTURE CURED UREATHANE
PETROLATUM TAPE SYSTEMS.
TR - WAX TAPE
TR had very good results in most of the tests. As with all petrolatum based coatings, the impact
resistance was poor. The petrolatum coatings were tested at lower temperatures (75°F) than the
other coatings (150°F).
TR did very good in the cathodic disbondment and mositure permeation/impact testing with no
water penetration to the pipe steel. This coating is very easy to apply and will conform well
around irregular shapes. The prime coat of TR primer is very effective in stopping water after it
is top coated with the wax tape. These type coatings do not handle heat or impacts very well.
Petrolatum coatings are more forgiving than most coatings to a poor surface preparation.
USES:
TR coating is recommended for use in special cases where other coatings may not work be-
cause of pipe or weather conditions (cold, wet, etc.). The wax tape can be used to coat valves
and other irregular shaped components. This coating is very easy to apply. Limitations
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December, 1994
USES:
on mechanical strength and temperature must be considered before using this coating. This
would also be an excellent coating for short term projects and old gathering lines where coating
requirements are not as stringent. This coating would be good to use in areas where poor
coditions exist for coating at the time, but the hole needs to be backfilled. In this case the
recommended procedure would be to coat with the wax tape then return and recoat with other
coating at a time when the conditions are right.
S1 - PRIMER/WRAP
S1 also did very good in the testing and has many of the same characteristics as the TR. The
one exception is in the make up of the coatings.
S1 had very good resulsts in the cathodic disbondment and moisture permeation/impact testing
with poor results on the impact test. The main difference in the coatings is that the S1 tape has
an inert filler material that may leach out and mix with backfill materials, therefore causing
deterioration of the coating. This is probably not a major problem but is one that has been
reported by others.
USES:
S1 could be used as a substitute for the TR when it is not available.
TA
TA is not recommended for use at this time because of its poor performance in the cathodic
disbondment testing program.
!!!!! CAUTION !!!!!
DO NOT USE PRODUCTS OTHER THAN THOSE SPECIFICALLY LISTED UNTIL THEY ARE
TESTED AND RECOMMENDED! THERE ARE MANY VARIETIES OF COATINGS AND SIMILAR
PRODUCTS BY THE SAME COMPANIES OR COMPETITORS THAT HAVE NOT BEEN TESTED
AND MAY NOT PEFORM UP TO THE STANDARDS RECOMMENDED.
DO NOT USE OUTER WRAPS ON THESE OR OTHER COATINGS THAT WILL CAUSE SHIELD-
ING OF CATHODIC PROTECTION CURRENTS! THE USE OF ANY ROCK SHIELD OR OTHER
PROTECTIVE LAYERS SHOULD BE APPROVED BY CORROSION PERSONNEL.
APPLY THESE PRODUCTS AS SPECIFIED BY THE MANUFACTURER! USE ONLY THOSE

PRODUCTS SPECIFIED TO BE COMPATABLE WIEN MORE THAN ONE COMPONENT IS USED
IN A COATING SYSTEM!
149
SECURITY CLEARANCE REQUIRED W E A P O N S Y S T E M S R E V I E W
®
RG-2400
THE POWER TO STOP A KILLER
ADVANCED COMPOUND NEUTRALIZES

THREAT OF CORROSION UNDER INSULATION (CUI)
The most potent weapon in the arsenal of the Corrosion Intervention Agency (CIA) is RG-2400®. A blue, non-skinning,
corrosion-control compound that, when applied to a metal surface, forms a mineral barrier to effectively prohibit and
inhibit the development of corrosion. RG-2400 not only prevents CUI on new systems, but it stops existing corrosion in
its tracks. RG-2400 even prevents stainless steel or copper stress-crack corrosion. With minimal surface preparation, the
reservoir of gel provides resistance to minor mechanical damage and undiminished corrosion protection in the presence
of moisture. All this makes RG-2400 the ideal choice for a range of application requirements and installation environments.
Its proven success in extreme testing conditions and in customer operations demonstrates a cost-efficient ability to
eliminate lost time, productivity and profit that result from corrosion-related repair, replacement and plant shutdowns.
RG-2400® ELIMINATES CORROSION FOR GOOD

SECURITY CLEARANCE REQUIRED W E A P O N S Y S T E M S R E V I E W
RG-2400® CORROSION-CONTROL COMPOUND

RANGE OF APPLICATION: RG-2400® is designed for use in insulated pipes, valves, strainers, tanks,
vessels, fixtures and equipment with a temperature range between -200°F and +200°F (-128.9°C
to +110°C). It provides the same protective benefits on new construction as it provides on repairs
and retrofits, whether used for interior or exterior applications.
PROTECTION TECHNOLOGY: The reason RG-2400 provides such significant corrosion protection is
its use of surface conversion technology or mineralization to grow a thin mineral coating which
bonds to the surface of the metal. This allows certain oxides to anchor to this adhesion layer and
polymerize into a three-dimensional, inorganic structure 50-200 angstroms thick. The result is an
effective barrier between the corrosion-forming elements in the metal and typical electrolytes, such
The results of a 365-day test in as moisture, which initiates the corrosion process. RG-2400 has the unique ability to self-heal from
a highly corrosive environment minor mechanical damage and to chemically alter water into a non-corrosive solution, even if it
dramatically demonstrates the comes in contact with the metal surface.
effectiveness of RG-2400.
PROVEN EFFECTIVENESS: RG-2400 successfully passed the standard ASTM G43 T304 stainless
RG-2400 steel pitting test and ASTM G48 T304 stainless steel stress-crack test with no evidence of corrosion
(pitting or cracking). In addition, a worst-case test was developed and run on pipe submerged in a
vat containing an aerated 5% salt solution for 365 days. The result of this test was that no corrosion
formed on the protected surfaces. Actual customer installations in applications within the food and
petrochemical processing, energy generation, refrigeration, military, automotive and other industries
Metal support the validity of RG-2400’s test results and protection claims.
Mineral Formation
RG-2400 creates a mineralization

APPLICATION SIMPLICITY: For corrosion remediation (using RG-2400 on systems which are already
barrier between metal ions and corroded), minimal surface preparation is required. In most cases, the use of a wire brush to
electrolytes that initiate corrosion. remove loose scale or a water-soluble solvent, such as alcohol, to remove oil or contaminants
is sufficient. RG-2400 is typically bead-applied to the insulation bore and then twisted onto pipes
to evenly distribute protection. RG-2400 can also be spray-, brush-, paint mitt- or glove-applied.
SAFETY/ENVIRONMENTAL: Testing reveals no known hazards or toxicity to animals or the

environment, but RG-2400 is chemical hygiene classified as an irritant, so hand and eye
protection is recommended during application. RG-2400 has a mild paint-like odor.
PACKAGING/AVAILABILITY: RG-2400 is available in 10- and 30-ounce caulk tubes as well as 1-,
5-, 10- and 55-gallon containers. For large tank applications, 300-gallon totes can be supplied.
For more information including MSDS, application instructions, SqFt per LF bead charts,
coverage, or to ask specific technical questions, visit www.rg2400.com or call 972.875.8421.
RG-2400® ELIMINATES CORROSION FOR GOOD
©2004 Polyguard Products, Inc. RG-2400 is a registered trademark of Polyguard Products, Inc. CS 1784
POLYGUARD PRODUCTS, INC.
SELF ADHESIVE PROTECTIVE COATINGS FOR ENGINEERING AND CONSTRUCTION
Additional Technical Papers and Tests
96 Hour Salt Water Toxicity Test
ASTM G43 T-304 Stainless Steel Pitting
ASTM G48 T-304 Stainless Steel Stress Crack Corrosion
Closed Bottle Test for Salt Water Wildlife Toxicity
Long Term Salt Fog Exposure
Measurement of CUI
Long Term Salt Water Immersion Exposure (1 year)
ENNIS, TEXAS 75120-0755

PH: 214-515-5000 • 800-541-4994 • FAX: 972-875-9425
E-Mail: polyguard@polyguardproducts.com
Web Site: www.polyguardproducts.com
Metal surface:
Mineralization Technology Oxides
Metal carbonates
Metal hydroxides
METAL
Surface conversion technology, also known as
mineralization, or the science of minetics, is the
ability to grow very thin minerals on metal
surfaces for useful purposes. Engineered Metal surface
surfaces form when mineral-forming reactants are
delivered to the surface of a metal or metal
containing article via novel modifications of known
base formulations (e.g., paint, gel, grease, METAL
aqueous suspension). Substrates contribute
donor ions to react and/or interact with delivered
reactants, forming a very thin layer of mineral, Polymerized
which chemically bonds to the surface of the metal silicate
lattice
substrate and has been measured to be only a METAL
few monolayers thick. In many applications,
lattice-forming oxides anchor to this surface-
adhesion layer and polymerize into a three- Protected surface
dimensional inorganic framework structure until Extended surface
the final coating thickness is 50-200 Angstroms. Mineral formation
(a piece of paper is approx. 1,000,000 angstroms METAL
thick)
Engineered Mineralization products have been
developed to deliver the mineral-forming reactants
in a wide variety of formulations including paints,
coatings, synthetic gels, greases, thread dressing,
sealants, adhesives, and water gels. Patents and
patent applications cover the delivery of novel
formulations as well as the mineralized layer that
is formed as a result of an interaction between the
applied coating and the underlying substrate. The
presence and uniqueness of the mineralized layer
can be confirmed by conventional analytical
surface methods such as x-ray Photoelectron
Spectroscopy (XPS) or Atomic Force Microscope
(AFM) Mineralization
Layer
Microscopic
Benefits of Engineered Surfaces: Detail
¾ Outstanding Corrosion Prevention
¾ Direct application on rusted surfaces
¾ Fast and efficient mineralization, including
¾ A unique self-healing mechanism R.2-27-07
¾ Environmentally friendly
RG Series products are protected by US and foreign patents.

PH: 214-515-5000 • 800-541-4994 • FAX: 972-875-9425

Coverage Chart by Pipe Size
20 MILS THICK 30 MILS THICK 40 MILS THICK

Iron Copper Pipe Square Feet of Pipe Feet of Pipe Feet of Pipe
Pipe Tube Outside Foot 1 Gallon 1 Gallon 1 Gallon
Size Size Diameter Per LF Covers Covers Covers
1/4" 5/8" 0.625 0.164 489 327 246
1/2" 7/8" 0.875 0.229 349 234 175
3/4" 1-1/8" 1.05 0.275 291 195 146
1" 1-3/8" 1.375 0.360 222 149 112
1-1/4" 1-5/8" 1.625 0.425 188 126 94
1-1/2" 2-1/8" 1.9 0.497 161 108 81
2" 2-5/8" 2.375 0.622 129 86 65
2-1/2" 3-1/8" 2.875 0.753 106 71 53
3" 3-5/8" 3.5 0.916 87 58 44
3-1/2" 4-1/8" 4.0 1.047 76 51 38
4" 4.5 1.178 68 45 34
4-1/2" 5-1/8" 5.0 1.309 61 41 31
5" 6-1/8" 5.563 1.456 55 37 28
6" 6.625 1.734 46 31 23
8" 8.625 2.258 35 24 18
10" 10.75 2.814 28 19 14
12" 12.75 3.338 24 16 12
14" 14.0 3.665 22 15 11
16" 16.0 4.189 19 13 10
18" 18.0 4.713 17 11 9
20" 20.0 5.236 15 10 8
22" 22.0 5.760 14 9 7
24" 24.0 6.283 13 9 6
Pipe Outside Diameters Based on Industry Standards

http://www.rg2400.com
R. 2-15-07
Polyguard Products, Inc.
PO Box 755, Ennis, TX 75120
214-515-5000
CLEANER
RG-2400® Cleaner is a low V.O.C., fast-acting, readily biodegradable cleaner which
lifts heavy grease, oil, synthetic oil, and preservatives. Cleans accumulated cutting
fluids and petroleum residues. Developed to remove and clean up the RG-2400®
corrosion gels. Biodegradable, non-petroleum, high flash point, low V.O.C., maximum
strength formulation is ready-to-use. Clean up any residue with soap and water.
TEST METHOD DESCRIPTION RESULTS
ASTM E-659 Autoignition Temperature 253°C

Ignition Delay Time 136.5 seconds
Barometric Pressure 757 mm Hg
ASTM D-92 Flash Point & Fire Point 245°F*
*occurred simultaneously
ASTM D-93 Flash Point 184°F
ASTM D-1218 Refractive Index 1.45775@ 25°C
ASTM D-1120 Boiling Point 528°F @ 761 mm Hg
ASTM D-1177 Freezing Point No Distinct Inflections
ASTM D-2879 Vapor Pressure @ 25°C 1.8 mm Hg
ASTM D-1298 Specific Gravity 29.2 @ 60°F
Ingredients are E.P.A. listed as approved replacement chemical for solvent usage.
DISPOSE OF CLEANING RESIDUES IN ACCORDANCE WITH LOCAL, STATE, AND

FEDERAL LAWS AND REGULATIONS.
PO Box 755, Ennis, TX 75120

TELE: (214)515-5000 FAX (972) 875-9425
www.rg2400.com
The information given here is considered to be correct and is offered for your consideration, investigation and verification. No
warranties are expressed or implied since the use of our products is beyond our control. Statements concerning the use of
Polyguard Products are not to be construed as recommending the infringement of any patent Revision Date: 2-15-07
600 Series Coating Systems
Cold Applied Pipeline Coating for Hand Application
DESCRIPTION:
POLYGUARD 600 SERIES COATING SYSTEMS are
laminated protective coatings. The primary corrosion
coating material is a rubberized bitumen coating, bonded
to a white polyethylene film. For products that conform
easily, Polyguard coatings have exceptional adhesion
and mechanical strength. The coatings are supplied in
rolls for easy application on all sizes of pipe.
POLYGUARD 600 LIQUID ADHESIVE is a fast drying,
rubber based materials in a solvent solution. It is
available in solvent systems that will conform to most
local VOC requirements.
USES:
POLYGUARD 600 SERIES COATING SYSTEMS are for
hand application for coating and wrapping of station
piping, field joints, repairs on mill coated pipe, gas distri- 600 Series Coating applied on a rehabilitation project.
bution, and for reconditioning of older lines.
ADVANTAGES:
! Excellent cathodic disbondment resistance.
! Uniform factory controlled thickness.
! Damaged coating areas can be repaired quickly and easily.
! Excellent resistance to water or vapor transmission.
! Resistant to deterioration from acids and alkalis encountered in normal soil.
! Excellent ability at the lap to resist infiltration of moisture.
! Elastomeric properties to accommodate normal expansion and contraction of the substrate.
! Easy to apply.
! Excellent peel adhesion.
PROPERTY TEST METHODS 600/634P COATINGS 610/CP50P COATINGS

Nominal Coating Thickness ASTM D 1000 35 mils (.89 mm) 50 mils (1.27mm)
Nominal Film Thickness ASTM D 1000 10 mils (.25mm) 10 mils (.25mm)
Tensile Strength ASTM D 882-B 22.5 lb./in/width (4.0 kg./cm.width) 22.5 lb./in/width (4.0 kg./cm.width)
Elongation at Break ASTM D 882-B 400% 400%
Dielectric Strength ASTM D 149 >12 KV >12 KV
Low Temperature Flex at 0EF. (-17.8EC) ASTM D 146 No Cracking No Cracking
Adhesion to Primed Steel ASTM D 1000 17.0 lb./in. width (3.0 kg./cm. width) 17.0 lb./in.width (3.0 kg./cm. width)
Adhesion to Overlap ASTM D 1000 14.0 lb./in. width (2.4 kg./cm. width) 14.0 lb./in. width (2.4 kg./cm. width)
Cathodic Disbondment ASTM G 8 < 5.0 mm avg. < 5.0 mm avg.
2 2 2 2
Water Vapor Transmission Rate ASTM E 96 .032 grains/hr/ft (.036 g/h-m ) .032 grains/hr/ft (.036 g/h-m )
Water Absorption ASTM D 570 <.1% <.1%
Temperature Ranges: ! At Application 25EF. to 110EF (-4E to 43E C)
! In Service -25EF. to 130EF (-32E to 54E C)

POLYGUARD PRODUCTS, INC • ENNIS, TEXAS 75120-0755 - American Natl. Standards Institute
PH: 214-515-5000 • 800-541-4994 • FAX: 972-875-9425

Web Site: www.polyguardproducts.com

Handling Materials: Polyguard coatings and liquid adhesives should be hauled and stored in such a manner as to prevent injury to the packages.
All packages and rolls should be stored in a dry place, kept from contact with earth and protected from weather. It is recommended that the tape and
liquid adhesive be transported in warmed vehicles and stored in heated buildings during cold weather. Although the coating can be utilized at lower
temperatures, to maximize the quality application characteristics of the coating system, coating and liquid adhesives should be maintained at a tem-
perature of 45EF (7EC) or higher at times of application.
Surface Preparation: The pipe shall be cleaned of all paint, oil and grease, mill scale, loose rust, welding residue, knurls, frost, dust, moisture,
weeds, and other foreign matter. Where feasible and practical, the surface can be blast cleaned to a NACE No. 3 finish. Where mill coated pipe is
involved, the liquid adhesive and coating should be applied to the girth weld, starting on top of the mill coating, at least 1" back from the edges of the
mill coating.
2
Liquid Adhesive Application: Polyguard liquid adhesive should be applied at an average rate of 400 sq. ft. per gallon (10m /liter). Stir liquid
adhesive before using. Apply with brush or roller to clean and dry pipe surface. DO NOT THIN POLYGUARD LIQUID ADHESIVE. In cold weather,
store inside prior to use.
Wrapping: Polyguard coating systems can be applied by spiral wrapping. The release sheet is to be removed immediately prior to the application.
The bitumen surface of the coating shall be applied to the dry liquid adhesive. In spiral wrapping, a minimum of 1" (25.44 mm) lap shall be maintained.
In areas designated by the owner as critical, overlap may be increased to 50%. Critical areas are determined by pipe diameter, weight of the pipe,
type of backfill soil and the severity of soil stress conditions.
Where larger diameter pipe is involved or where soil stress conditions exist, it is advisable to over wrap the applied coating systems with Polyguard
SP6 Outerwrap or other suitable outerwrap material.
Polyguard 600 Series Coatings should be applied with enough tension to eliminate any air pockets and also to conform to the weld bead area and
beveled cut back. DO NOT STRETCH EXCESSIVELY.
Coating Repairs: The pipe and mill coating surface shall be clean and dry. Remove all loose or damaged coating around the holiday with a draw
knife or other sharp hand tool. Feather edge the mill coating. Prime the pipe and adjacent coating area 2" wider than the repair coating. Either
cigarette wrap or spiral wrap the repair coating to cover the entire holiday area, plus at least 2" of mill coating on either side of the damage area.
Small pinholes may be patched by a single cigarette wrap over the coated pipe surface. The end laps should be at least 4". A postage stamp patch
may be substituted for the complete cigarette wrap around the pipe when dry sandy or loam soil is used as backfill material. Patches are not
recommended when backfill consists of large wet or dry dirt clods that could dislodge the patch from the pipe surface as the backfill settles.
Lowering-in: The pipe should be inspected immediately before lowering in. Polyguard 600 Series Coating Systems shall be holiday detected with an
adjustable electronic detector at a maximum voltage in accord with the following formula:
V = /T x 1250, where V = Voltage, and T = Coating thickness, in mils
Excess voltage will break down the dielectric strength of the coating. Care should be taken to use the minimum voltage setting to locate defects in the
coating system. Follow instructions of holiday equipment manufacturer.
Backfilling: Take care in backfilling to avoid sharp rocks or other material in backfill that would damage and penetrate the coating. In areas of rough
backfill, suitable rock shielding shall be provided to protect the coating from backfill damage.
PRECAUTIONS:
The liquid adhesive is an industrial coating and would be harmful or fatal if swallowed. It is marked as red label from the standpoint of flash point.
Prohibit flames, sparks, welding and smoking during application. Solvents could be irritating to the eyes. In case of contact with eyes, flush with water
and contact physician.
Avoid prolonged contact with skin and breathing of vapor or spray mist from liquid adhesive. In confined areas, use adequate forced ventilation, fresh
air masks, explosion proof equipment, and clean clothing.
This material is sold by Polyguard Products, Inc. only for the purposes described in this literature. Any other use of the products is the responsibility of
the purchaser and Polyguard Products does not warrant nor will be responsible for any misuse of these products. Polyguard Products will replace
material not meeting our published specifications within one year from date of sale.
All Polyguard Products Material Safety Data Sheets (MSDS) and precautionary labels should be read and understood by all user supervisory
personnel and employees before using. Purchaser is responsible for complying with all applicable federal, state or local laws and regulations covering
MAINTENANCE:
None required.
Technical Service:

PH: 214.515.5000
FAX: 972.875.9425
x.xl.pipeline.600 Series Data R. 1-10-08
600 UV 350 Corrosion Coating System
Weather Resistant 50 mil Pipeline Coating for Hand Application
DESCRIPTION
POLYGUARD 600 UV 350 COATING SYSTEM is a laminated protective coating which is applied over
its companion liquid adhesive. The primary corrosion coating material is a rubberized bitumen coating,
bonded to an organic ethylene polymer film, which provides UV resistance. For a product that
conforms easily, 600 UV 350 has exceptional adhesion. The coating is supplied in rolls for easy
application on all sizes of pipe. 600 UV 350 is manufactured with a disposable release sheet.
POLYGUARD 600 LIQUID ADHESIVE is a fast drying, rubber based material in a solvent solution. It
will conform to most local air pollution requirements.
USES:
600 UV 350 COATING is used as a hand applied coating and wrapping for steel pipe that is exposed
above and below ground whenever resistance to ultra violet is a consideration.
No other use of these materials is to be made without prior approval of Polyguard Products as to ser-
vice and method of application.
ADVANTAGES:
Following are the advantages of 600 UV 350:
! The organic ethylene polymer film backing is more resistant to UV rays than most other types of films.
! The film backing is resistant to a variety of chemical environments, including acids, salts, and bases, without
significant property loss. Consult Polyguard for more information on these properties.
! Provides uniform coating thickness.
! Has excellent ability at the lap to resist infiltration of moisture.
! Has elastomeric properties to accommodate normal expansion and contraction of the substrate.
! Included as the corrosion coating element is a rubberized bitumen coating.
600 UV 350 Corrosion Coating – Typical Properties

Property ASTM Method English Metric
Color Black Black
Coating Thickness D 1000 .050” 1.19 mm
Film Weatherability @ 300 hours exposure D 3361 No cracking or No cracking or
(Test results reported by manufacturer of film) delamination delamination
Tensile Strength D 1000 400 PSI 2.8 N/mm
Cathodic Disbondment G8 < 5.0 mm avg. < 5.0 mm avg.
Dielectric Strength D 149 > 12 KV > 12 KV
Bacterial Resistance G 22 Excellent Excellent
Elongation at Break D 1000 250% 250%
Water Vapor Transmission E 96 .039 grains/hr/ft2 .026 grains/hr/m2
Peel Adhesion D 1000 20 lb./inch width 3.5 N/mm
Handling Materials: Polyguard coatings and liquid adhesives should be hauled and stored in such a
manner as to prevent injury to the packages. No packages should be dropped or thrown from trucks.
All packages and rolls of wrapping materials should be stored in a dry place, kept from contact with
earth, and protected from weather. Materials may be applied between 0 F (-18 C) and 120 F (49 C).
It is recommended that the tape and liquid adhesive be transported in warmed vehicles and stored in

PH: 214-515-5000 • 800-541-4994 • FAX: 972-875-9425 - American Natl. Standards Institute

heated buildings during cold weather. Although the coating can be utilized at lower temperatures, to
maximize the quality application characteristics of the coating system, it is recommended that the
coating and liquid adhesive be maintained at a temperature of 45EF (7EC) or higher at times of
application.
Surface Preparation: As a minimum, pipe should be cleaned of all paint, oil and grease, mill scale,
loose rust, welding residue, knurls, frost, dust, moisture, weeds, and other deleterious matter. Where
feasible and practical, the surface can be blast cleaned to a commercial finish, as described in NACE No.
3. In cold weather, where safety regulations permit, pipe surface may be warmed to 100EF. (38EC)
approximately, prior to application of liquid adhesive to accelerate adhesion.
Priming: Polyguard liquid adhesive should be applied at an average rate of 400 sq. ft. per gallon
(10m2/liter). Stir before each use. Apply with brush or roller to clean and dry pipe surface. Do not thin
the liquid adhesive.
Wrapping: 600 UV 350 can be applied by spiral wrapping. The release sheet is to be removed
immediately prior to the time of application. The bitumen surface of the coating shall be applied to the
dry liquid adhesive. In spiral wrapping, a minimum of 1" (25.4 mm) lap should be maintained. In areas
designated by the owner as critical, the overlap may be increased to 50%. Critical areas would be
determined by the severity of conditions in a particular area.
600 UV 350 should be applied with just enough tension to eliminate any air pockets, to conform to the
shape of the object being coated and to make complete contact with the covered pipe surface.
If 600 UV 350 is required to tie into a coating below ground, clean surface of below ground coating of
any deleterious contamination before overlapping. Overlap existing coating a minimum of 2" (50.8 mm).
If any questions of compatibility of coatings should occur, contact Polyguard Products. When applied on
risers, the coating system should be applied starting at grade or below grade level and continue upward
to provide a shingle effect at the overlap area.
PRECAUTIONS:
contact physician.
Avoid prolonged contact with skin and breathing of vapor or spray mist from liquid adhesive. In confined
areas, use adequate forced ventilation, fresh air masks, explosion proof equipment, and clean clothing.
MAINTENANCE:
None required.
Technical Service:

PH: 214.515.5000
FAX: 972.875.9425
x.xl.pipeline600 UV 350 Data R.11-15-07
ALUMAGUARD™
AN ALUMINUM THEFT DETERRENT FOR EXPOSED REMOTE PIPELINES
Alumaguard™ is a rubberized bitumen membrane

used worldwide for installation over insulated piping
and ductwork in petrochemical, industrial, and
commercial applications. Alumaguard™ is self-
adhesive, self-healing if punctured, UV stable and
will expand and contract with the mechanical
system. See www.polyguardproducts.com for
details of current applications.
An emerging use for Alumaguard is to replace

aluminum jacketing on remote insulated pipelines
which might experience an aluminum theft problem.
If aluminum jacketing has been replaced with Alumaguard, thieves have nothing of value, since the
aluminum on Alumaguard is a thin foil. Membrane is adhered to the insulation, which increases the
difficulty of removal.
Overall project costs can often be reduced by the use of Alumaguard, since the expensive
fabricated aluminum jacketing is no longer used. Alumaguard has replaced exterior aluminum
jacketing for insulated ductwork in thousands of North American projects over the last 10 years.
A further benefit will be obtained: since the primary function of Alumaguard, in its established
applications, is to waterproof the insulated system, the user will find the pipeline protected from
moisture and corrosion to a degree never possible with aluminum jacketing alone. Properties
which enhance moisture protection include:
• Self heals around mechanical fasteners and small punctures

• Will not suffer metal fatigue from expansion/contraction cycles
• Self healing in case of punctures, may be patched for larger damage areas
• Very low vapor transmission
Alumaguard™ is not, and should not be used, as a mechanical fastener to secure the insulation.
Band or pin insulation following the insulation manufacturer’s instructions.
LIMITATION: NOT compatible for use with CP systems.
Alumaguard™ Properties
Property ASTM # Typical - English Typical – Metric
Thickness D 1000 .055” 1.4 mm
Water Vapor Transmission (grains/hour/ft2) E 96 .01 1.48 x 10-9
Peel Adhesion to Primed Steel D 1000 > 12 lb/inch width 2.1 N/mm
Tensile Strength D 882 5000 PSI 34.6 N/mm2
Elongation at Break - % (compound only) D 882 > 600 > 600
Puncture Resistance - Backing E 154 > 40 lb 145 N
Fungus Resistance G 21 - 90 0 growth 0 growth
Softening Point - Compound D 36 > 200 deg F > 93 deg C
This information is based on our best knowledge, but

Web Site:www.polyguardproducts.com
PH: 214-515-5000
ALUMAGUARD is an excellent piping jacketing system. Its properties facilitate installation on systems without
the need for slip joints, eliminating a potential vapor breach. ALUMAGUARD will expand and contract with the
piping system without rupture; minimal wrinkling may occur.
Piping systems jacketed with ALUMAGUARD should be installed in the following manner; the “stretch out” for
each piece should be cut to allow a 6” lap over the circumferential lap. Install tightly around the pipe
insulation, rolling with a laminate roller or other firm “rolling pin” type roller to insure contact with the
substrate. Each piece should be within 1-1/2” of the previous piece and a 4” wide butt lap placed over the joint
and rolled with a roller. The butt lap should start where the circumferential lap ends, wrapping around the
pipe, and then lapping over 6” past the starting point. Installation can also be a cigarette wrap method using a
3” longitudinal lap and the same 6” circumferential lap.
NOTE: Care should be taken when using ALUMAGUARD on hot systems to insure that the surface
temperatures after insulation do not exceed our upper temperature use limitations. It is important to note that
heat transfer through single layer joint seams could result in the softening or melting of the rubberized asphalt
compound.
Install the first ALUMAGUARD piece over the insulation with a 6” lap terminated at the 4 o'clock position. Install
the second piece of ALUMAGUARD with 3” overlapped onto the previous piece of ALUMAGUARD. The
circumferential laps should all line up at the 4 o’clock position to shed water. Roll the surface with a laminate
roller or other firm “rolling pin” type roller to insure contact with the substrate. Insulated piping exceeding 12”
outside diameter requires the use of banding.
Fittings, 90’s, tees, valves, and 45’s can be laid out using standard sheet metal methods, modified to allow for
overlap. This can be accomplished by adding 1-1/2”-2” to the throat of the bottom half of the fitting and
adding 1-1/2” to the heel of the top half of the fitting. The bottom piece is installed first, and then the top
piece lapped over the bottom piece to permit water shedding over the lap. Tees, valves and other fittings can
be fabricated just like you would use standard layout procedures, adding 1-1/2” to 2” for the required laps.
Fittings can also be ‘gored’, over sizing each gore piece to allow for a lap onto the preceding piece. The two
piece method makes a better looking fitting, however, as with metal work, larger fittings must be gored due to
material constraints and ease of application. Installers can also use standard metal fitting covers with the
Alumaguard products. Care must be used to insure that the fittings are vapor sealed.
X:/Lit/Pipeline/Alumaguard_Theft_Deterrent_R. 02-26-07
MASTICS FOR CORROSION PROTECTION
CA-9 Mastic [Oil Resistant]

CA-14 Mastics [General Maintenance]
DESCRIPTION:
POLYGUARD CA-9 MASTIC is a cold applied, solvent release, corrosion resistant protective coating for
waterproofing underground metal surfaces. This single component bitumen coating has high film building
characteristics and provides dry film thickness up to 12 mils per coat. The solvent-resin combination obtains
good substrate wetting, consequently a primer is not required for CA-9 MASTIC.
CA-9 MASTIC is a solution of coal tar and vinyl resin. The combination of the tar and the vinyl provides
enhanced resistance to crude oil and aliphatic petroleum products.
POLYGUARD CA-14 MASTIC is a general maintenance coating of excellent quality for use on buried steel. It is
a solution of bitumen with mineral filler. It is self priming.
POLYGUARD 400 WRAP is a reinforcing fabric of spun bonded continuous thermoplastic filaments in mat form.
The wrap is supplied in rolls of 4" (.101m), 6" (.152m), 9" (.228m) and 12" (.305m) on 3" (.076m) cores.
USES:
CA-9 MASTIC is recommended where a corrosive environment is encountered, including crude oil saturated soil.
It is used for below ground corrosion protection of pipe, tanks, valves, mechanical couplings and other irregular
shaped steel structures.
CA-14 MASTIC is used for below ground corrosion protection of pipe, tanks, valves, mechanical couplings and
other irregular shaped steel structures. CA-14 coating is satisfactory as a protective coating for sewer piping and
below-grade concrete structures.
400 WRAP is used to reinforce and protect POLYGUARD MASTICS.
ADVANTAGES:
Here are some advantages of POLYGUARD MASTICS and 400 WRAP:
• High solids content.
• Low cost per mil durable coating for underground substances.
• Excellent resistance to water and moisture vapor transmission.
• Resistant to deterioration from acids and alkalis encountered in normal soil.
• Easily applied to irregular and complex shapes such as valves, flanges, tees, elbows and mechanical couplings.
• Vinyl component enhances the resistance of CA-9 MASTIC to most crude oil and aliphatic hydrocarbons.
• No priming required.
• 400 WRAP is not affected by the solvents or solids of the mastic. It provides excellent reinforcement and mechanical
exterior protection for the mastic, as well as a good platform for a second coat of mastic.
• 400 WRAP causes no irritation in handling. The fiber does not float off in the air during unwind and does not cause skin
irritation or inhalation irritations.
GUIDE SPECIFICATIONS:
Handling Materials: POLYGUARD MASTICS should be handled in such a manner as to prevent injury to the
materials. All containers should be protected from weather and lids securely fastened. In cold weather, materials
shall be stored in heated buildings and transported in warmed vehicles. Store above 60°F (16°C).
SURFACE PREPARATION: Steel surfaces should be cleaned of all paint, oils, grease, mill scale, loose welding
residue, burrs, dust, dirt, frost, moisture and other foreign matter. Where feasible and practical the surface can
be blasted to a NACE No. 3 finish. Otherwise hand wire brush cleaning method may be used providing all above
foreign matter is removed. No priming is required.
This information is based on our best knowledge, but

Web Site:www.polyguardproducts.com
PH: 214-515-5000 Polyguard Products' has been certified to
APPLICATION: POLYGUARD MASTICS should be brush applied for best adhesion to the substrate. They are
normally applied in a two coat system. The first coat should be dry before the second coat is applied. Drying time
is dependent upon atmospheric and surface temperature. Coating should be done in areas free of dust and
moisture.
COVERAGE RATE: POLYGUARD CA-9 MASTIC covers approximately 60 square feet per gallon (1.48m2liter) on
smooth surfaces. The dry film thickness will be approximately 12 mils with a wet film thickness of 20 mils to obtain
this coverage. Two coats are recommended.
POLYGUARD CA-14 MASTIC will cover approximately 75-80 square feet per gallon (1.96M2/Liter), on smooth
surfaces. The dry film thickness will be approximately 12 mils with a wet film thickness of 20 mils to obtain this
coverage. Two coats are recommended.
It is suggested that an application of POLYGUARD 400 WRAP be applied over the first mastic coating. The
second mastic coat shall be applied on top of the 400 WRAP which acts as a reinforcement in the coating. It will
also form a platform for the second coat. After the second coat is applied, another layer of 400 WRAP shall be
applied to the exterior surface of the mastic. Caution should be taken to lay the wrap into the outside surface of
the mastic and not to pull #400 wrap through mastic onto pipe surface. Use minimum tension during application.
BACKFILLING: Mastics are subject to displacement or damage from backfill. It is therefore good practice to let
each coat of mastic dry prior to backfilling to minimize this occurrence. If quick backfilling is desired (before the
mastic is set) the area may be overwrapped with Polyguard SP6 Outerwrap. This will provide protection against
displacement of the mastic.
TESTING: The applied coating shall be checked visually for bare areas. Recoat these areas with POLYGUARD
MASTIC to the required mil thickness.
TECHNICAL DATA: NOMINAL PROPERTIES: 400 MAT

Weight/Yd.2 0.3 oz.
Average Thickness ASTM D 1777 2.3 mils
LBS Tear Strength ASTM Machine Direction 3.4 lbs.
D 2263-68 Transverse Direction 2.4 lbs.
Air Permeability (CMF/ft2) ASTM D 737-69 13.00
PRECAUTIONS:
The mastics are industrial coatings and would be harmful or fatal if swallowed. They are marked as red label from
the standpoint of flash point. Prohibit flames, sparks, welding and smoking during application. Refer to product
label for handling, use and storage precautions. Solvents, including thinner, could be irritating to the eyes. In
case of contact with eyes, flush with water and contact physician.
Avoid prolonged contact with skin and breathing of vapor or spray mist from mastic. In confined areas, use
adequate forced ventilation, fresh air masks, explosion proof equipment, and clean clothing.
Close container after each use.
This material contains MEK and toluol as a solvent. It may not be acceptable for use under some fire and air
pollution regulations. Consult local regulations.
Material has a storage life of one year in unopened containers, from shipment date, when storage conditions as
prescribed by manufacturer are followed. Minimum storage temperature is 60°F (16°C).
Review precautions carefully in respect to flash point and other special handling procedures.
This material is sold by Polyguard Products, Inc. only for the purposes described in this literature. Any other use of
the products is the responsibility of the purchaser and Polyguard Products does not warrant nor will be responsible
for any misuse of these products. Polyguard Products will replace material not meeting our published specifications
within one year from date of sale.

understood by all user supervisory personnel and employees before using. Purchaser is responsible for complying
with all applicable federal, state or local laws and regulations covering use, health, safety, and disposal of the
product.
MAINTENANCE:
None required.
Technical Service:
PH: 214.515.5000
FAX: 972.875.9425
x:/lit/Pipeline/Mastics Product Data.doc R.3-20-07

RD-6 OS™ COATING APPLICATION SPECIFICATION -
OFFSHORE
U.S. PATENT NO. 4,983,449, U.S. PATENT NO. 5,120,381 and FOREIGN PATENTS
COATING SYSTEM FOR OFFSHORE GIRTH WELDS
DESCRIPTION:
POLYGUARD RD-6 OS™ COATING SYSTEM consists of a geotextile backed protective pipeline coating applied over a
companion liquid adhesive. Corrosion protection comes from a rubberized bitumen coating. Bonded to the outside
surface of this coating is a strong, tightly woven, polypropylene geotextile, which provides fail/safe properties plus
POLYGUARD 600 LIQUID ADHESIVE is fast drying, rubber based materials in a solvent solution. It is available in
solvent systems that will conform to most local air pollution requirements.
APPLICATION SPECIFICATIONS:
1.0 Surface preparation
1.1 In the cut back area (exposed pipe steel at girth weld area) remove any visual coating, corrosion, dirt or
debris with a wire brush or other company approved method.
1.2 Oil, grease or other hydrocarbon contamination shall be removed by washing with the appropriate and
company approved safety solvent that does not leave a residue
1.3 It is recommended the surface be blasted to SSPC SP-6 (NACE 3) commercial blast. If this is not feasible
to blast then a power buff or hand wire brush may be used to remove all loose and foreign materials. If
power tool cleaning is used, take care not to burnish or polish the pipe surface.
1.4 Abrade the coating approximately 6” from the coating cutback ends on the mainline coating using sanding
discs or brush blasting. Take care not to cause significant damage to the base coating.
1.5 For three layer coating or coal tar coated pipe, feather or taper the cut back edge of the mainline coating
to 45° or less angle to the pipe surface.
2.0 Liquid Adhesive Application
2.1 Using a dry, clean cloth or dry air remove any dust left from blasting or brushing before applying primer.
2.2 Apply a coat of Polyguard 600 Liquid Adhesive to the weld area and to extend up over the main line
coating on both sides of the weld area, at least 2 inches past where the Polyguard RD-6 OS Tape will
start and end on the main line coating.
2.3 Liquid adhesive shall be applied with a clean brush or roller to obtain uniform and complete coverage of
pipe surface making sure it is brushed out smooth and there are no drips.
2.4 Liquid adhesive shall be applied at a rate of 400 square feet per gallon and shall be dry or tacky/ dry to
touch (does not stick to skin) prior to coating application.
3.0 RD-6 OS Application by Tape Machine
3.1 The Polyguard RD-6 OS coating shall be applied in a cigarette wrap style with a Polyguard Products
approved tape machine on pipe after the liquid adhesive is applied.
3.2 RD-6 OS shall be applied with one width to cover a minimum of one inch over the girth weld, remaining
exposed pipe on the opposite side of the weld and extending a minimum of 2 inches onto the primary
coating.
3.3 Starting at the 3:00 o’clock position, make one and one half revolutions ending at the 9:00 o’clock
position.
3.4 Repeat this step on the opposite side of the girth weld with one width to cover a minimum of 1 inch over
the girth weld, remaining exposed pipe and extending a minimum of 2 inches onto the primary coating.
RD-6 OS Application Specification – Offshore Page 1 of 2 3/2/2007

3.5 This process shall result in the girth weld bead being covered by two layers of the RD-6 OS and the RD-6
OS extending at least two inches over the primary coating.
3.6 Operator shall make all necessary adjustments to machine to accomplish a uniform, tightly adhered
coating. Tightly adhered means the area where the RD-6 OS overlaps itself is completely sealed.
3.7 Care shall be taken that no wrinkles, puckers, voids, or breaks are left in the coating as a result of the
application.
4.0 Inspection
4.1 Polyguard RD-6 OS shall be holiday detected with an adjustable electronic detector.
4.2 Do not exceed 4000 volts. Excessive voltage can stress the coating and cause burn through.
5.0 Repairs
5.1 All holidays and defects shall be repaired before the pipe is placed in the water from the lay barge.
5.2 Small or pinhole type holidays can be repaired by applying liquid adhesive over the holiday area and when
dry to touch, patch of RD-6 OS shall be firmly pressed over the holiday. The patch and liquid adhesive
should extend a minimum of 2” (50.8 mm) in all directions from the holiday.
5.3 If the girth weld area is to be filled with foam or other in fill material, no further repair is needed.
5.4 If no infill material is to be used, circumferentially wrap the pipe and repair area with another wrap of the
RD-6 OS.
5.5 For larger holidays or where the coating is damaged that exposes pipe, remove the damaged coating and
smooth the edges.
5.6 Finish the repair as in 5.2 above.
5.7 Use a many circumferentially wrapped pieces of RD-6 OS as is necessary to completely cover the patched
area.
5.8 Re-inspect as in step 4.0.
PRECAUTIONS:
The liquid adhesive is an industrial coating and would be harmful or fatal if swallowed. It is marked as red label from the
standpoint of flash point. Prohibit flames, sparks, welding and smoking during application. Solvents could be irritating to the
eyes. In case of contact with eyes, flush with water and contact physician.
Avoid prolonged contact with skin and breathing of vapor or spray mist from liquid adhesive. In confined areas, use adequate
forced ventilation, fresh air masks, explosion proof equipment, and clean clothing.
This material is sold by Polyguard Products, Inc. only for the purposes described in this literature. Any other use of the
products is the responsibility of the purchaser and Polyguard Products does not warrant nor will be responsible for any misuse
of these products. Polyguard Products will replace material not meeting our published specifications within one year from date
of sale.
All Polyguard Products Material Safety Data Sheets (MSDS) and precautionary labels should be read and understood by all
user supervisory personnel and employees before using. Purchaser is responsible for complying with all applicable federal,
state or local laws and regulations covering use, health, safety, and disposal of the product.
MAINTENANCE:
None required.
Technical Service:

PH: 214.515.5000
FAX: 972.875.9425
w.xlp.RD 6 OS Application Spec Offshore

RD-6 OS Application Specification – Offshore Page 2 of 2 11/15/2007

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FAIL / SAFE CORROSION CONTROL COATINGS

FOR UNDERGROUND PIPE

This Information is based on our best knowledge, but

POLYGUARD PRODUCTS, INC • ENNIS, TEXAS 75120-0755

U.S. PATENT NOS. 4,983,449 AND 5,120,381 AND FOREIGN PATENTS

This Information is based on our best knowledge, but

Web Site: www.polyguardproducts.com - Deutscher Akkreditierungs Rat

MATERIAL SAFETY DATA:

Polyguard Products Inc.

SPECIFICATION FOR HANDLING AND MACHINE APPLICATION OF

1.1.1 RD-6 is 50 mils (1.27 mm)

1.2 ROLL WIDTH

1.2.1 Suggested roll widths for

Diameter of Pipe Being Coated Width of RD-6 Roll suggested

1.2.2 Roll widths based upon:

1.3.1 Unbonded type: POLYGUARD SP-6 OUTERWRAP

1.3.1.1 POLYGUARD SP-6 OUTERWRAP consists of a strong non woven, felt-like

This Information is based on our best knowledge, but

POLYGUARD PRODUCTS, INC • ENNIS, TEXAS 75120-0755

1.4.1 Polyguard RD-6 or

2. HANDLING OF COATING MATERIALS:

3.1.1 Surface Preparation

Surface preparation of the pipe shall include:

D. Blast Cleaning (if specified): It is required to obtain a commercial finish (minimum), as

3.1.2 Liquid Adhesive Application

3.1.3 Weld Stripping Material (where required)

3.1.4 Coating (by machine)

4. INSPECTION AND REPAIR:

6.0 MATERIAL SAFETY DATA:

x.xl.RD6 Spec Mach Applic R.2-15-07

COATING SYSTEM FOR GIRTH WELDS AND RECONDITIONING

The coating is supplied in rolls for easy application by

Proper tension on the roll of the RD-6 coating as it is applied

At minimum, the use of a manually operated wrapster is

RD-6™ can also be applied manually, without machine.

Use of POLYGUARD SP6 OUTERWRAP is strongly

This Information is based on our best knowledge, but

POLYGUARD PRODUCTS, INC • ENNIS, TEXAS 75120-0755

MATERIAL SAFETY DATA:

Polyguard Products Inc.

Rolls of Coating Required to Coat 100 LF of Pipe

1/2" 22.0 5.3

This Information is based on our best knowledge, but

POLYGUARD PRODUCTS, INC • ENNIS, TEXAS 75120-0755

PHYSICAL PROPERTIES TYPICAL RESULTS

This Information is based on our best knowledge, but

POLYGUARD PRODUCTS, INC • ENNIS, TEXAS 75120-0755

Polyguard Products Inc.

w.xlp.600 Quick Dry Primer 3-1-07

PROPERTY ASTM Test English Metric

This Information is based on our best knowledge, but

POLYGUARD PRODUCTS, INC • ENNIS, TEXAS 75120-0755

MATERIAL SAFETY DATA:

Polyguard Products Inc.

w.xlp.606 Filler Tape R. 11-15-07

SP-6 UNBONDED OUTERWRAP provides the following performance properties:

This Information is based on our best knowledge, but

POLYGUARD PRODUCTS, INC • ENNIS, TEXAS 75120-0755

Typical properties of the SP-6 non-woven fabric are: