INSTALLATION GUIDE

Important: If these instructions are not followed while installing tank(s)

into your system, we are not responsible for damage that happens due
to negligence to these instructions and your warranty will be voided.

 Installer is required to avoid continuous weight on flanges such as pipes, valves, and all
accessories. All weight needs to be supported by the ground and not supported by flanges
on tank.

 All flanges need to have the full face of the flange gasketed (gasket no less than

 3/16” thick) with 80 Duro or less.

 Tank must be insulated from any vibration source using adapters like but not limited to
expansion joints.

 Fittings should not be in direct contact with our plastic flange. Washer and lockwasher are
required.

 All bolt connections to the tank must be torqued according to the guidelines provided
here in this document, set by Plastics Pipe Institute’s Technical Notes # 38 2011 which can
be found at this web address:
http://plasticpipe.org/pdf/tn-38_bolt_torque_flanged_joints.pdf

 All instructions in following pages apply as a required action.

Please make as many copies of the “TORQUE AND INSTALLATION RECORD” as needed to
document the correct installation and torquing for each connection

Houston PolyTank  Hopkins, MO  660-778-3393  houstonpolytank.com  sales@houstonpolytank.com

 Installation Guide  Page 2

TORQUE AND INSTALLATION RECORD

Project: ____________________________ Flange Set Location: ____________________

Connecting HDPE Flange to _____________________________________Flange.

Bolt Dia. & Grade: ___________________ Nut Diameter & Grade: __________________

Lap-Joint Flange Dia. & Pressure Rating: _______________________________________

Lubricant Used: ______________________ Flange Temp: _________________________

Toque Wrench ID #: ___________________ Calibration Date: _____________________

If Specified: Full-face Gasket Info: Material: ____________ Thickness: _______________

Deep-Well Socket / Heavy-Hex Nut Wrench Size Used: ___________________________

Axis off-set:_____ Angular & Facial Gap: Top______ Bottom______L_____R______

“Initial” Each Step Upon Completion

1. Tank flange is being connected to a flexible connection.

2. Washers and lock washers are being used.
3. Connections’ weight is supported by ground and not causing continuous weight on tank flange.
4. Gasket used is no less than 1/8” Thick and 80 Duro or less

1. Visually examine and clean both flanges, bolts, nuts and washers. Replace damaged units.
2. Liberally lubricate bolt threads & nut threads & flange surface under nut.
3. Insert full-face gasket. Do not use wrinkled or damaged gaskets.
4. Number the bolt-holes in circumferential sequence starting at 12:00 position.
5. Check flange alignment, concentricity, angularity, and gap for acceptability.
6. To firm the flanges squarely together, hand tighten, then pre-tighten all bolts in proper
sequence to 10-20 foot-pounds torque. Do not exceed 20% of the TARGET TORQUE.
7. Re-check any flange-adapter face gap and LJF gap for uniformity. ****
8. Use the appropriate criss-cross pattern tightening in numerical sequence for Rounds 1,2,3, and
4 (tightening all bolts once in sequence constitutes a “round”).

****Note: Check LJF gap around the flange circumference between each of these rounds measured at
every other bolt. If any gap is not reasonably uniform around the circumference, make the apropriate
adjustments by selective bolt tightening before proceeding.

TARGET TORQUE (and 4 to 24-HOUR RE-TORQUE): _____________ foot-pounds.

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 Installation Guide  Page 3

_____ Lubricate, Hand tighten, Pre-tighten

_____ Round 1 – Tighten to ____ ft.lbs. (30%)

_____ Round 2 – Tighten to ____ ft.lbs. (60%)

_____ Round 3 – Tighten to ____ ft.lbs. (100%)

_____ Rotational (clockwise) Round

_____ For Large Flanges ≥ 16 + Bolts

_____Lubricate, Hand tighten, Pre-tighten

_____ Round 1 – Tighten to ____ ft.lbs. (25%)

_____ Round 2 – Tighten to ____ ft.lbs. (50%)

_____ Round 3 – Tighten to ____ ft.lbs. (75%)

_____ Round 4 – Tighten to ____ ft.lbs. (100%)

_____ Rotational (clockwise) Round

_____ Rotational (clockwise) Round: 100% of Target Torque. Use rotational clockwise tightening
sequence, starting with bolt #1, for one complete round and continue until no further bolt or nut
rotation occurs at 100% of the target torque value for each nut.

_____ 4 – 24 Hour Re-Torque & Inspection:

Re-torque to target torque value using one or two sequence-rounds, followed by one Rotational
round at the target Torque value

Must be properly initialed, signed, and dated for warranty to be valid on flange repairs.

Documentation Recorded By: ________________________________________ Date: ______________

Joint Technicial/Mechanic: __________________________________________ Date: ______________

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 Installation Guide  Page 4

TIGHTENING SEQUENCE:
Number the bolts in rotation around the Lap-Joint Flange circumference in a clockwise order, beginning
with the first bolt at the top in the nominal 12:00 position, the second being the next bolt to the right,
the third being the next bolt to the right, etc until all bolts are numbered sequentially.

Following the table below, tighten the given bolt number to the desired torque value for the given
round of tightening as specified on the Torque Record Checklist.

TABLE 1 [refer to ASME Document PCC-1 for Bolt Sequences]

NUMBER
CRISS-CROSS PATTEREN TIGHTENING SEQUENCE
OF BOLTS

4 1-3-2-4

8 1-5-3-7 >> 2-6-4-8

12 1-7-4-10 >> 2-8-5-11 >> 3-9-6-12

16 1-9-5-13 >> 3-11-7-15 >> 2-10-6-14 >> 4-12-8-16

20 1-11-6-16 >> 3-13-8-18 >> 5-10-15-20 >> 2-12-7-17 >> 4-14-9-19

24 1-13-7-19 >> 4-16-10-22 >> 2-14-8-20 >> 5-17-11-23 >> 3-15-9-21 >> 6-18-12-24

1-15-8-22 >> 4-18-11-25 >> 6-20-13-27 >> 2-16-9-23 >> 5-19-12-26 >> 7-21-14-28 >>
28 3-17-10-24
1-17-9-25 >> 5-21-13-29 >> 3-19-11-27 >> 7-23-15-31 >> 2-18-10-26 >> 6-22-14-30 >>
32 4-20-12-28 >> 8-24-16-32
1-2-3 >> 19-20-21 >> 10-11-12 >> 28-29-30 >> 4-5-6 >> 22-23-24 >> 13-14-15 >> 31-32-
36 33 >> 7-8-9 >> 25-26-27 >> 16-17-18 >> 34-35-36
1-2-3-4 >> 21-22-23-24 >> 13-14-15-16 >> 33-34-35-36 >> 5-6-7-8 >> 25-26-27-28 >>
40 17-18-19-20 >> 37-38-39-40 >> 9-10-11-12 >> 29-30-31-32
1-2-3-4- >> 25-26-27-28 >> 13-14-15-16 >> 37-38-39-40 >> 5-6-7-8 >> 29-30-31-32 >>
44 17-18-19-20 >> 41-42-43-44 >> 9-10-11-12 >> 33-34-35-36 >> 21-22-23-24
1-2-3-4 >> 25-26-27-28 >> 13-14-15-16 >> 37-38-39-40 >> 5-6-7-8 >> 29-30-31-32 >>
48 17-18-19-20 >> 41-42-43-44 >> 9-10-11-12 >> 33-34-35-36 >> 21-22-23-24 >> 45-46-
47-48
1-2-3-4 >> 29-30-31-32 >> 13-14-15-16 >> 41-42-43-44 >> 5-6-7-8 >> 33-34-35-36 >>
52 17-18-19-20 >> 45-46-47-48 >> 21-22-23-24 >> 49-50-51-52 >> 25-26-27-28 >>
9-10-11-12 >> 37-38-39-40

The criss-cross bolt tightening sequence and multi-round tightening are necessary to counteract the
flange / bolt elastic interaction.

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 Installation Guide  Page 5

TABLE 2
EXAMPLES OF ESTIMATED BOLT TORQUE TO SEAL HDPE FLANGE FACES:

The engineer of record is usually responsible for establishing each flange joint criteria, and performing
the required calculations to determine the initial and residual torque values.

These estimated values are based on non-plated bolts and studs, using a nut factor of K =0.16 for lightly
greased bolts and nuts. The calculations uses a HDPE flange face seating stress of 1200-psi as a
minimum and 1800-psi as a maximum, and assumes the flanged joint is between two HDPE flange
adapters (in which the contact area is largest), without a rubber gasket.

NOTE: For bolting to ductile-iron pipe, steel flanges or butterfly valves, the flange face contact area is about half, so bolt torque
for that flange pair will be measurably less (refer to Table #3).

IPS Nominal LJF Bolt Number Minimum Lubed Maximum Lubed Flange
Initial Initial
Pipe Size Diameter of bolts Torque (Ft-Lbs) Torque (Ft-Lbs) OD/ID (in.)
2” 0.625 4 23 35 3.9/1.94
3” 0.625 4 33 50 5.0/2.86
4” 0.625 8 33 50 6.6/3.68
5” 0.75 8 44 66 7.5/4.40
6” 0.75 8 50 75 8.5/5.42
8” 0.75 8 80 120 10.63/6.76
10” 0.875 12 80 120 12.75/8.79
12” 0.875 12 105 160 15.00/10.43
14” 1 12 180 270 17.50/11.45
16” 1 16 180 270 20.00/13.09
18” 1.125 16 200 300 21.12/14.73
20” 1.125 20 200 300 23.50/16.36
22” 1.25 20 260 390 25.60/18.00
24” 1.25 20 290 435 28.00/19.64
26” 1.25 24 290 435 30.00/21.27
28” 1.25 28 290 435 32.30/22.91
30” 1.25 28 325 488 34.30/24.54
32” 1.5 28 425 640 36.50/26.18
34” 1.5 32 425 640 38.50/27.82
36” 1.5 32 460 690 40.80/29.45
40” 1.5 36 460 690 46.00/35.29
42” 1.5 36 460 690 47.50/37.06
48” 1.5 44 460 690 54.00/43.43
54” 1.75 44 560 840 60.00/48.86

NOTE: Uniform bolt pre-load (torque), without large “scatter”, is as useful as the target pre-load. Within the limits of the HDPE
flange adapter, gasket, or metal LJF, higher pre-load is desirable. The higher the pre-load is safely achievable, the more closely
the assembly will behave like the theoretical model and seal well. Higher pre-load means that a given internal pressure will
result in the least possible change in contact sealing pressure. Be consistent (avoid changes) with materials and tools when
following written assembly procedures.

Train and supervise the bolting personnel. Tell the crew what is to be accomplished, why, and explain that good results are not
automatically achieved. Skill and care are essential. Bolted Joint assembly is a technical skill that is not common in the
construction and maintenance profession, being considered more like a specialty. There is no universally accepted testing, nor
certification, of bolted-joint assembly mechanics. With no common training, certification, nor standards, it is no surprise there
is +/- 25% variability in assembly torque. Specifications and instructions by the engineer, followed by trained mechanics, help to
solve the dilemma.

(NOTE: Consult ASME Document PCC-1, Appendix A for training and certification of bolted joint assemblers)

660-778-3393  houstonpolytank.com  sales@houstonpolytank.com

 Installation Guide  Page 6

TABLE 3
Examples of Estimated Bolt Torque to Seal the HDPE Flange Face To a Butterfly-
Valve, Steel Pipe Flange, or Ductile Iron Flange

The engineer of record is usually responsible for establishing each flange joint criteria, and performing the required
calculations to determine the initial and residual torque values.

These estimated liberally lubricated torque values assume the flanged joint connects one HDPE flange-adapter to a
Butterfly-Valve or Steel Pipe flange of Schedule 40 ID, or a Ductile-Iron flange. For bolting to steel flanges or
butterfly valves, the flange face contact area is just over half that of HDPE to HDPE flanges, so calculated bolt
torque for this flange pair will be measurably less than the values listed in Table #2.

Dimensional flange data should be obtained for each case from the pipe flange suppliers, so as to be able to
calculate the face contact area.

These estimated values are based on non-plated bolts and studs, using a K=0.16 for lightly greased bolts and nuts.
These calculations use an HDPE material minimum and maximum compressive seating stress of 1200-psi to 1800-
psi.

IPS Nominal LJF Bolt Number Minimum Lubed Maximum Lubed Flange OD
Initial Initial
Pipe Size Diameter of bolts Torque (Ft-Lbs) Torque (Ft-Lbs) Steep Pipe ID (in.)
2” 0.625 4 22 32 3.90/2.067
3” 0.625 4 30 45 5.00/3.068
4” 0.625 8 30 45 6.60/4.026
5” 0.75 8 44 66 7.50/4.40
6” 0.75 8 44 66 8.50/6.06
8” 0.75 8 58 88 10.63/7.98
10” 0.875 12 58 88 12.75/10.02
12” 0.875 12 75 114 15.00/11.94
14” 1 12 140 210 17.50/13.13
16” 1 16 140 210 20.00/15.00
18” 1.125 16 140 210 21.12/16.88
20” 1.125 20 140 210 23.50/18.81
22” 1.25 20 160 240 25.60/21.25
24” 1.25 20 180 270 28.00/23.25
26” 1.25 24 180 270 30.00/25.25
28” 1.25 28 180 270 32.30/27.25
30” 1.25 28 180 270 34.30/29.25
32” 1.5 28 240 360 36.50/31.00
34” 1.5 32 240 360 38.50/33.00
36” 1.5 32 260 390 40.80/35.00
40” 1.5 36 310 465 46.00/39.00
42” 1.5 36 310 465 47.50/41.00
48” 1.5 44 310 465 54.00/47.00
54” 1.75 44 365 550 60.00/53.00

Train and supervise the bolting personnel. Tell the crew what is to be accomplished, why, and explain that good results are not
automatically achieved. Skill and care are essential. Bolted Joint assembly is a technical skill that is not common in the
construction and maintenance profession, being considered more like a specialty. There is no universally accepted testing, nor
certification, of bolted-joint assembly mechanics. With no common training, certification, nor standards, it is no surprise there
is +/- 25% variability in assembly torque. Specifications and instructions by the engineer, followed by trained mechanics, help to
solve the dilemma.

(NOTE: Consult ASME Document PCC-1, Appendix A for training and certification of bolted joint assemblers)

660-778-3393  houstonpolytank.com  sales@houstonpolytank.com