Protecto 401¹ has been tested extensively. Because the specifications for application and testing of Protecto 401 Ceramic Epoxy have been developed for ductile iron pipe using test data and performance history, no deviations from the specification shall be permitted without prior written approval of the lining manufacturer. If required, third-party inspection of Protecto 401 Ceramic Epoxy–lined ductile iron pipe shall be done only after written notice to the applicator of Protecto 401 Ceramic Epoxy. Any third-party inspection shall be accomplished using standard Protecto 401 Ceramic Epoxy Quality Control Procedures.

The material shall be an amine-cured novalac epoxy containing at least 20% by volume of ceramic quartz pigment. Any request for substitution must be accompanied by a successful history of lining pipe and fittings for sewer service, a test report verifying the following properties, and a certification of the test results.

• A permeability rating of 0.00 when tested according to Method A of ASTM E-96-66, Procedure A, with a test duration of 30 days.
• An abrasion resistance of no more than 3 mils (.075 mm) loss after 1 million cycles using European Standard EN 598: 1994 Section 7.8 Abrasion Resistance.

The following test must be run on coupons from factory-lined ductile iron pipe:

1. ASTM B-117 Salt Spray (scribed panel) – Results to equal 0.0 undercutting after two years.
2. ASTM G-95 Cathodic Disbondment 1.5 volts at 77° F. Results to equal no more than 0.5 mm undercutting after 30 days.
3. Immersion Testing rated using ASTM D-714-87.
   1. 20% Sulfuric Acid – No effect after two years.
   2. 140° F 25% Sodium Hydroxide – No effect after two years.
   3. 160° F Distilled Water – No effect after two years.
   4. 120° F Tap Water (scribed panel) – 0.0 undercutting after two years with no effect.

The lining shall be applied by a certified firm with a successful history of applying linings to the interior of ductile iron pipe and fittings.

Prior to abrasive blasting, the entire area to receive the protective compound shall be inspected for oil, grease, etc. Any areas with oil, grease or any substance that can be removed by solvent, shall be solvent cleaned to remove those substances. After the surface has been made free of grease, oil or other substances, all areas to receive the protective compounds shall be abrasive blasted using sand or grit abrasive media. The entire surface to be lined shall be struck with the blast media so that all rust, loose oxides, etc., are removed from the surface. Only slight stains and tightly adhering oxide may be left on the surface. Any area where rust reappears before lining must be reblasted.

After the surface preparation and within eight hours of surface preparation, the interior of the pipe shall receive 40 mils nominal dry film thickness of Protecto 401. No lining shall take place when the substrate or ambient temperature is below 40° F. The surface also must be dry and dust free. If flange pipe or fittings are included in the project, the lining shall not be used on the face of the flange.

Due to the tolerances involved, the gasket area and spigot end up to 6 inches back from the end of the spigot end must be coated with 6 mils nominal, 10 mils maximum, using Protecto Joint Compound. The joint compound shall be applied by a roller or brush to ensure coverage. Care should be taken that the joint compound is smooth without excess buildup in the gasket seat or on the spigot ends. Coating of the gasket seat and spigot ends shall be done after the application of the lining.

The number of coats of lining material applied shall be as recommended by the lining manufacturer. However, in no case shall this material be applied above the dry thickness per coat recommended by the lining manufacturer in printed literature. The maximum or minimum time between coats shall be that time recommended by the lining material manufacturer. To prevent delamination between coats, no material shall be used for lining which is not indefinitely recoatable with itself without roughening of the surface.

Protecto Joint Compound shall be used for touch-up or repair in accordance with manufacturer’s recommendations.

1. All ductile iron pipe and fitting linings shall be checked for thickness using a magnetic film thickness gauge. The thickness testing shall be done using the method outlined in SSPC-PA-2 Film Thickness Rating.
2. The interior lining of all pipe barrels and fittings shall be tested for pinholes with a nondestructive 2,500-volt test. Any defects found shall be repaired prior to shipment.
3. Each pipe joint and fitting shall be marked with the date of application of the lining system along with its numerical sequence of application on that date and records maintained by the applicator of his work.

The pipe or fitting manufacturer must supply a certificate attesting to the fact that the applicator met the requirements of this specification, and that the material used was as specified.

For additional information, visit Protecto401.com or contact Induron Protective Coatings at 1-888-SPEC401.