Co-Flex™  Co-Flex piping is an environmentally compatible, double wall, flexible piping system designed for direct bury. Continuous piping runs connecting tanks and dispensers utilize sumps to contain and protect pipe terminations. This installation guide is to be used by trained and certified installers. Please contact Western Fiberglass, Inc. for certification information. Co-Flex warranty is valid only if installation and testing procedures described within this manual are followed by certified installation personnel. Co-Flex piping is currently available in 1 1/2” I.D. Operating pressure should not exceed 75psi at a temperature of 150 degrees F. (66C). Co-Flex flexible piping system installation and testing procedures are unique and traditional rigid, metal or fiberglass, piping procedures do not apply. Please read this manual completely prior to installation. Obey all local regulations and requirements. Western Fiberglass, Inc. is pleased to assist you in your site planning. Forward a copy of your site plan to our office for a prompt, computer generated, piping layout and materials print out. SPECIFICATIONS: Permeability: The primary pipe shall be impermeable ( less than 1% over a 180 day period) to the fluids to be delivered. Compatibility: The Co-Flex piping system shall be compatible with all fuels and blends. Expansion: The primary pipe shall not expand more than 2 cc/ft for every 25 psi between the pressures of 50 psi and 100 psi. This permits accurate readings from in-line, pressure sensitive, leak detection. (All testing at room temperature). Terminations: All piping terminations are to be within contained, accessible, sump areas to facilitate testing and inspection after installation. Bend Radius: 1 1/2” Co-flex piping is capable of a 24” bend radius without cracking, kinking or breaking. On site air temperature does effect the flexibility during installation, the piping is more pliable when warm. Testing: Primary piping shall be capable of maintaining 50 psi for minimum of one (1) hour. Secondary interstitial space shall be capable of maintaining 5 PSI for a minimum of one (1) hour. These tests may be performed after installation is complete, but before backfill. Note; the interstitial space of the Co-Flex 1 1/2” has a capacity of approx. one (1) fluid ounce per linear foot. Care needs to be taken when pressurizing the secondary, add pressure slowly and do not exceed 10 psi during pressurization process. Always use safe procedures when pressure testing piping systems. Western Fiberglass, Inc. assumes no liability or responsibility for testing procedures. Please see product technical data for additional information. PIPING ROUTE DESIGN: Flexible piping system routes and excavation requirements are quite different than for traditional ridged pipe. Direction changes are made with “sweeps” rather than 90’s or 45’s. In most installations, pipe trenching requirements are reduced.
Series system type piping runs are continuous, with the piping originating from one sump and passing through additional sumps until termination. Series routing is most desirable for pressure systems. The piping system runs from the tank sump to each successive dispenser. All piping terminations are to be within enclosed sump areas, not direct buried. Single and\ or dual pipe lines can be installed to accommodate any total number of product dispensers. Note: 1 1/2” I.D. Co-Flex piping is typically suitable for continuous operation of up to six (6) product dispenser nozzles. Suction system routing requires direct runs where each dispenser is connected to the tank sump via it’s own pipe line. Co-Flex, flexible piping, may be installed in a conducting or “duct” system such as CPVC, which includes piping sweeps, or other similar materials if required. After installation of conduit, the flexible pipe is pulled through the conduit by threading a cap with an “I” bolt to the pipe termination and attaching a rope or cord. If direct buried, Co-Flex pipe routing may require “Crossover Supports” at the point of intersection of each pipe run. Crossovers can be necessary to maintain dispenser product sequence.
Back to top of page Trenches should be at least twice the width of all piping and/or conduits to be installed within. One pipe diameter spacing between each pipe run is required. Piping systems requiring “fall” should have a minimum of 1% or 1/8” per linear foot from pipe run termination point back to the tank sump(s). The recommended backfill and trench bed material is rounded pea gravel 1/8” to 3/4” in diameter. Crushed stone, 1/8” to 3/4”, and \ or river sand may be used if washed and it is free flowing. A 6” bed of recommended backfill material, free from any debris, is placed in the piping trench prior to installation.
Co-Flex piping installed under reinforced concrete surfaces of a minimum of 4” (100mm) thickness require a minimum cover of 6” (150 mm) of the recommended backfill material. Asphalt, 2” (50mm) minimum thickness, requires 6” (150mm) minimum cover of the recommended backfill material. Unpaved surfaces require a minimum of 14” (350mm) cover of recommended backfill material. After pressure testing is complete, care must be taken to insure even distribution and packing of the backfill material around the piping during the back fill process. Hand shovel material around and over piping to insure correct spacing is maintained. Backfill slowly. Additional care should be taken when initially filling the piping system to insure that all air is removed from the product piping prior to starting any pumps to prevent damage. Be certain that the operating pressure of the pumping system does not exceed the maximum operating pressure of the Co-Flex piping of 75 psi. Periodic testing of both the primary and secondary sections of the Co-Flex system may be performed at any time after installation. Please see installation instructions for DMA, dispenser mounting assemblies, and Western Fiberglass, Inc. tank sumps for details on piping penetrations. MEASURING PIPE RUNS: Co-Flex piping is available in 200 ft or 1000 ft sections. It may be ordered by the foot if required. The greatest care is taken after manufacture to package and ship your piping to insure against damage. Do not drag Co-Flex along the ground, step or place heavy objects on top of the pipe. Cold weather will affect the flexibility. Leaving the pipe coils in the sun prior to installation will make them more pliable and easier to handle. In extreme cold weather, store the piping indoors, at room temperature before measuring and cutting. A personal type hair dryer can be inserted into one end of the pipe coil to warm up and relax the pipe. Cut and discard the first 12” (300mm) of pipe where any heating device has been attached. This section may be damaged by heat exposure. The Co-Flex termination fittings are 5” in length. 2” of pipe is inserted within the termination. An additional 3” is added to the total pipe length at each end of each pipe run by the installation of the terminations. For example, if the required pipe length between the internal or “T” connections inside two separated dispenser boxes is a total of 32’ 9”, you must subtract 6” to account for the terminations at each end of the pipe length. This pipe length will now be 32’ 3” before termination. When measuring pipe lengths, use a pre-stretched line or flat tape to calculate the distance between connection points. Be certain to account for all sweeps and additional pipe lengths required within containment sumps for all connections before cutting. Co-Flex piping may be installed “lazy” within the piping trench. It does not have to be stretched straight or tight and can be routed to accommodate any pipe run requirements. It is important to maintain proper fall or slope. Piping lengths can be cut and terminated outside of the piping trench for ease of installation. Piping lengths may be pre-cut and terminated off-site. CUTTING AND TERMINATION: Co-Flex piping may be cut with any clean, sharp instrument. Be certain to make all cuts square and even. 1). Cut Co-Flex pipe to proper lengths. NOTE: SLIP TEST/CROSSOVER BOOTS OVER PIPE ENDS PRIOR TO INSTALLATION OF PIPE TERMINATIONS.
2). Strip off final 2” (50mm) of outer containment jacket and remove. This can be done with a razor knife. Be careful not to cut primary pipe outer jacket. 3).The swaging machine may be manual, electric or pneumatic (See product data). The procedure for preparation of the pipe end is the same for all types. 4). Attach proper guide block to swage ram unit. (Not used with female fittings.) 5). Insert draw bar through ram unit. 6). Carefully oil or grease the inside of the piping termination. 7). Insert pipe termination thread first into guide block on ram unit. 8). Screw swage mandrel onto draw bar and firmly against and partly within the pipe termination. 9). Grease or oil swage mandrel to insure a smooth swage draw cycle. 10). Slide termination swage sleeve (silver) over termination. 11). Insert pipe onto termination and inside swage sleeve. Must be in at least 1 1/2” or until just visible through holes in swage sleeve. 12). Pump hand pump or push button to draw swage mandrel through pipe termination. 13). Release pump pressure and remove fitting. Swaging must be done in one complete action, do not stop once you have started. CAUTION: USE ONLY FURON/ WESTERN FIBERGLASS APPROVED TERMINATIONS. INSTALLING PIPE LENGTHS: Crossover Supports are installed over Co-Flex piping to prevent any chafing where two runs cross. After test/crossover boots, and if required crossover supports, have been installed and pipe termination has been swaged on, insert pipe through pipe penetration boots one side at time. Remove penetration hose clamp or loosen first for ease of installation.
Prepare coupling fitting and attach Co-Flex termination fitting (male or female) to connector within sump area/s. Tighten. Position pipe within trench. Lay out piping runs while maintaining separation between pipe lengths and at crossover points. TEST & CROSSOVER BOOT/TUBING INSTALLATION: The Test/Crossover Assembly Boots are attached to the Co-Flex Piping ends to provide a sealed access and test point for the interstitial/secondary space within the pipe. The Test/Crossover Boots utilizes two (2) #28 stainless steel hose clamps which when tightened around the termination fitting swage sleeve and the Co-Flex outer jacket isolate the interstitial space. An air valve stem is installed in the boot on the bottom for an outlet opening for connecting the crossover and/or test tubes. These tubes are used for the testing of and the interconnection of the interstitial space from pipe section to pipe section. Crossover tube assemblies are used for junctions within dispenser sumps, pipe to pipe in line connections, piping run termination points, tank sump connection points and any piping manifold connection points. Test/Crossover Boots and tubes are fitted and tightened in place after the piping terminations and their connections have been made. After installation and tightening of all test and crossover boots and tubes pressure testing may be done. (See Above).
INITIAL PIPE SYSTEM FILLING: Upon completion of connection and testing of your Co-Flex system, initial filling of the system may begin. Be careful to provide a venting point or place which will allow any air within the piping to escape during this initial filling. Do not operate any pumping devices until all air has been purged from piping system. Small bubbles trapped within the system will be purged under normal operating conditions. Do not exceed the safe operating pressure of the Co-Flex piping of 75 psi. If you have any questions or requests, please call 1-800-688-3375 between 7:00am - 5:00pm PST. Western Fiberglass, Inc. COPYRIGHT 1995 BY WESTERN FIBERGLASS, INC. |
