QA Date of Issue; 07/05/10 Revision: 1

Page 1 of 4

APPLICATION INSTRUCTIONS Denso Butyl Tape System

80 YEARS OF PIPELINE PROTECTION

USE:
For the protection of pipes, welded joints, bends, fittings and similar structures from corrosion, above ground, buried or immersed. To protect the substrate from the environment the tape must cover and make intimate contact with the entire surface.

EQUIPMENT LIST
Power wire brush / scraper / blast cleaning equipment (optional) Brush or roller, cleaning solvent Utility knife, overalls, gloves, eye protection, cleaning cloth, hand cleaner, barrier cream

SURFACE PREPARATION:
Surfaces must be dry and free from dirt. Solvent wipe with a clean cloth to remove any grease deposits. Power wire brush to remove all scale, loose rust and old flaking coatings to achieve a finish of St2 according to ISO 8501-1 or Swedish Standard SIS 0055900. The preferred method for refurbishment of old pipe lengths is abrasive blast cleaning to Sa21/2 according to ISO8501-1 or Swedish Standard SIS 0055900.

APPLICATION:
1. PRIMING
Brush or roller apply a thin coat of DENSO BUTYL PRIMER over the entire area to be wrapped. Allow to tack dry*. Coat a wide enough section so that the primer will protrude slightly from under the tape edges after the tapes are applied. Coverage: Tack dry: Dry film thickness: 5m/l 5 - 10 minutes 20 - 30 microns

*Tape will need to be applied whilst the primer is still active. A slight tackiness indicates it is still active. Once completely set (20 minutes) a chemical bond is unlikely to be achieved. Only a weaker mechanical bond will be obtained.

Fig 1. Priming pipes: Apply DENSO BUTYL PRIMER to entire area to be protected with tape.

Fig 2. Priming butt welded joints. Apply DENSO BUTYL PRIMER to entire area to be protected with tape.

2. TAPE APPLICATION
a) Pipes: BUTYL MASTIC DENSO BUTYL MASTIC STRIP is applied to contour weld bends, step down on shop coatings and fill irregular surfaces so that subsequently applied tape can conform smoothly to the substrate being protected. It can be cut into smaller workable strips of mastic and moulded into crevices and cavities.

QA Date of Issue; 22/04/10 Revision: 1

Page 2 of 4

APPLICATION INSTRUCTIONS Denso Butyl Tape System

80 YEARS OF PIPELINE PROTECTION

2. TAPE APPLICATION (continued)

S43 SELF AMALGAMATING INNER WRAP TAPE Select as wide a width of S43 INNER WRAP TAPE as practical, e.g. 100mm wide for 100mm diameter pipe. Peel back about 0.5m of interleaving and apply the tape firmly to the pipe. Unroll the tape about 0.5m, peel back the interleaving and wrap the tape spirally ensuring correct alignment. Ideally maintain sufficient tension to reduce the width of the tape by 25% to ensure that the tape conforms to the surface without gaps. For ease of application use a DENSO WRAPPING MACHINE. Tape contact with the pipe must only occur on primed substrate. Overlap each turn by 55% to give a double layer thickness of S43 tape. Start new rolls by overlapping the ends by one tape width. Figures 3 to 8 below illustrates tape application. Note: Where longitudinal welds are included in the area to be wrapped, apply a 100mm wide DENSO BUTYL MASTIC STRIP longitudinally over the weld and profile or press into the contours before wrapping (figure 8). R23 OUTER WRAP TAPE Select the same width of R23 OUTER WRAP TAPE as the inner wrap tape used. The wrapping starting and finish points should overlap the edges of the S43 INNERWRAP TAPE by 25mm. The overlapped sections must contact the primer on the pipe surface. Compound side of tape is to be placed down on to the inner wrap tape. Ideally maintain sufficient tension to reduce the width of the tape by 25% to ensure that the tape conforms to the inner wrap tape surface without gaps. Once again for ease of application use a DENSO WRAPPING MACHINE. Overlap each turn by 25mm (3 layer finish) or 55% (4 layer finish). Start new rolls by overlapping the ends by one tape width.

Fig 3. Start at the 9 o clock position. Apply tape whilst primer is still tacky.

Fig 4. Diagram showing the correct application of tape.

Fig 5. Diagram showing the correct tension for wrapping tape.

Fig 6. Starting a new roll of tape.

Fig 7. Overlapping each turn by 55% effectively gives a double layer thickness.

Fig 8. Apply Denso Butyl Mastic Strip along the longitudinal weld.

QA Date of Issue; 22/04/10 Revision: 1

Page 3 of 4

APPLICATION INSTRUCTIONS Denso Butyl Tape System

80 YEARS OF PIPELINE PROTECTION

b) Butt Welded Joints: Prior to commencing abrade the existing coating surface that will be wrapped, to provide a key for the primer. Proceed as per (a) but start and finish wrapping with a minimum of 75mm overlap (or width of the tape being used, whichever is the greater) on to the existing pipe coating either side of the joint area.

Fig 9. Butt weld and existing coating ready for over wrapping with tape. Note cutback of coating can be 75mm 150mm either side of the weld except on FBE coated pipe. Fig 10. Note method of wrapping. 1. Start with one circumferential turn Onto factory coating. 2. Then change to spiral wrap with 55% overlap over weld area. 3. Finish with one circumferential turn over factory coating the opposite side of the weld. Overlap tape at least 75mm onto existing coating. This applies to both the S43 inner wrap and R23 outer wrap tape.

c) Damaged Coatings: Cut away and remove loose coating from damaged area and smooth or chamfer edges. Clean area thoroughly then prime the exposed substrate or surface extending 50mm either side of the damage. Repair the damaged area with a patch of DENSO BUTYL MASTIC STRIP. Wrap the section of pipe as per (b).

Fig 15. Damaged pipe coating.

Fig 16. Remove loose or damaged area then clean thoroughly.

Fig 17. Smooth edges and prime area at least 50mm onto sound coating.

Fig 18. Repair damaged area with a patch of DENSO BUTYL MASTIC STRIP overlapping at least 25mm onto primed sound coating area before wrapping with tape as per section (b).

Fig 19. Over wrap repair as per section (b).

QA Date of Issue; 22/04/10 Revision: 1

Page 4 of 4

APPLICATION INSTRUCTIONS Denso Butyl Tape System

80 YEARS OF PIPELINE PROTECTION

3. INSPECTION
Ensure that the entire surface is covered with no gaps or air pockets.

Fig 20. Examine for gaps or air pockets (see repair procedure figs. 15 to 19).

Fig 21. Adhesion can be tested by pulling/removing a 25mm - 50mm wide coupon of tape from the surface. Refer to Denso method LT709 for details.

Fig 22. Perform holiday test using a ring or brass brush (10kV for single layer and 15kV for double layer). See ASTM G62-07 for details.

SAFETY DATA:
Storage: Ambient conditions. Use Class 3 dangerous goods storage for Denso Butyl Primer. Store away from direct sunlight. Avoid prolonged exposure to high temperatures during transit, preferably in an enclosed vehicle. This material is not a static accumulator, but use proper bonding and/or grounding procedures. Denso Butyl Primer is a flammable liquid, please refer to safety data sheet for further details Extinguish with water fog, dry powder, carbon dioxide or chemical foam. Self-contained breathing apparatus required. Wash with warm water and mild soap. Pumiced heavy duty hand cleaner for stubborn stains. If feeling unwell, seek medical advice In a fire situation avoid inhaling fumes. Negligible hazard at ambient temperatures (-18 to 38C) Tapes not hazardous. Pick up and collect material by hand. Denso Butyl Primer is a flammable liquid, please refer to safety data sheet for further details. Incineration or landfill in accordance with local regulations. For more information please refer to Denso safety data and technical data sheets. Available for all system components.
Denso (New Zealand) Limited Tel: + 64 21 304 660 Email: info@denso.co.nz MEMBERS OF WINN & COALES INTERNATIONAL

Transport: Handling:

Action in case of fire: Skin Contact: Swallowing: Inhalation: Spillage:

Disposal: Other:

411 -413 Victoria Street, Brunswick Vic 3056, Australia MELBOURNE SYDNEY ADELAIDE BRISBANE PERTH Tel: + 61 3 93567600 or 1300 658 590 (toll free) Email: denso@densoaustralia.com.au Web: www.densoaustralia.com.au