FSERIES RETROFITS INSTALLATION INSTRUCTIONS BRAVO FIBERGLASS RETROFITS SERIES FOR SINGLE WALL FRP SUMPS ONLY FOR RETROFITTING ALL FLEXIBLE ENTRY BOOTS FIBERGLASS PIPE, GALVANIZED CONDUIT or PVCCOATED CONDUIT ONLY Conduit Flat & Curved Wall F05 / 07 / 10RetrofitS & SRND Fiberglass Pipe Flat & Curved Wall F20 / 30 / 40RetrofitS & SRND LCX Fiberglass Pipe Flat & Curved Wall F20 / 30 / 40RetrofitSLCX & SLCXRND BUILT LIKE A TANK Highend materials match UST spec UL1316 to ensure longevity and fuel compatibility READ THIS MANUAL FRONT TO BACK Note: Actual products may vary in appearance from illustrations in this manual 1 iifseriesretrofits12a S. Bravo Systems, Inc. The Leader in Secondary Containment 2929 Vail Ave. Commerce, CA 3238884133 FAX: 3238884123 www.sbravo.com 11A
The FSeries Singlewall RetrofitS Fittings from S. Bravo Systems, Inc. MUST be installed by a Bravo RetrofitCertified Installer. The Retrofit Test must be completed at www.sbravo.com/cert You must also be ConfinedSpace Certified when working within Tank Sumps. KEEP TRACK of your job by taking advantage of the Complete checkboxes paired with each major step. TABLE OF CONTENTS Fitting Warnings, Requirements & Warranty Terms... p. 3 Fitting Specifications and part numbers...p. 4 Fitting Components and Tools... p. 5 INSTALLATION SUMMARY... p. 6 Step 1 Fitting rules, sump evaluation and cleanup...p. 7 Step 2 Removing the existing fitting on the interior... p. 7 Step 3 Wrapping pipe with rubber strip... p. 8 Step 4 Cutting down fitting bolts and wall preparation...p. 8 Step 5 Dryfitting and outlining fitting position with marker...p. 8 PREPARING YOUR PIPE BY HAND SANDING... p. 9 MIXING YOUR ADHESIVE CRITICAL STEP... p. 10 WINTER WARNING INSERT Step 6 Gluing and Installing curved flange to wall...p. 11 Step 7 Gluing and Installing fitting body...p. 12 Step 8 Aligning and tightening clamp on fitting body... p. 13 Step 9 Securing fitting to wall via pusher clamp and beading adhesive... p. 13 Step 10 Lake testing (Water testing) your Installation... p. 13 If you have any problems with Bravo Systems components or accessories, Contact Bravo Systems Immediately: 180028BRAVO 13238884133 support@sbravo.com LIMITED WARRANTY Products sold by S. Bravo Systems, Inc. are warranted to be free from defects in material and workmanship for a period of one year from date of purchase. This warranty will be limited to the repair and replacement of Bravo parts only and will exclude all claims for labor or consequential damage. No other express warranties are given and no affirmation of S. Bravo Systems, Inc., or its agents and/or representatives, by words or action, will constitute a warranty. IT IS EXPRESSLY AGREED THAT THIS WARRANTY WILL BE IN LIEU OF ALL WARRANTIES OF FITNESS AND IN LIEU OF THE WARRANTY OF MERCHANTABILITY. This warranty is void if there is any evidence of modification, abuse, negligence, or improper installation including but not limited to installation or maintenance by a NonSpecialist Certified individual. If any fittings or components, other than S. Bravo Systems approved fittings or components, are used in conjunction with any S. Bravo Systems product, the warranty pertaining to these products is immediately void. 2 iifseriesretrofits12a
VENTILATE YOUR AREA. WEAR MASK, SAFETY GLASSES, GLOVES AND OTHER PROTECTION NO > > ELECTRIC TOOLS IGNITION SOURCES NOTE: BRAVO Ensure that the workspace is operating below the LEL (lower explosive limit). Test regularly or monitor continuously. RECOMMENDS THAT AT A MINIMUM, all flexible entry fittings on a sump are retrofit with the FSeries RetrofitS fitting. Having every entry fitting sealed with fuelcompatible adhesive will ensure the best lake test results. WARRANTY IS VOID OR YOUR CERTIFIED STATUS WILL BE REVOKED: IF ANY OF THE FOLLOWING OCCUR A) NOT Installing an FSeries RetrofitS fitting with Bravo ADHESIVERETROFITEPOXYKIT. B) Installing a FSeries RetrofitS fitting with adhesives that are not specified in this manual. C) FSeries RetrofitS Fittings are NOT installed by a Bravo Certified Contractor. D) Installing a FSeries RetrofitS fitting on Polyethylene sumps or flex pipe. E) Installing a FSeries RetrofitS fitting without monitoring lower explosive limit. 3 iifseriesretrofits12a
FITTING SPECS FITTING MODELS FOR 020 DEGREE ADJUSTABILITY Model Number Wall type Pipe type and size Angle Adjustability O.D. Length Bravo Adhesive Included List F05RetrofitS Flat/Round 1/2 Conduit / RobRoy 0 20 deg. 5 ø 2 1 $ 165 F07RetrofitS Flat/Round 3/4 Conduit / RobRoy 0 20 deg. 5 ø 2 1 165 F10RetrofitS Flat/Round 1 Conduit / RobRoy 0 20 deg. 5 ø 2 1 165 F20RetrofitS Flat/Round 2 Fiberglass 0 20 deg. 7 ø 2 2 215 F30RetrofitS Flat/Round 3 Fiberglass 0 20 deg. 7 ø 2 2 215 F40RetrofitS Flat/Round 4 Fiberglass 0 20 deg. 8 ø 2 2 215 F20RetrofitSLCX Flat/Round 2 Ameron LCX 0 20 deg. 7 ø 2 2 215 F30RetrofitSLCX Flat/Round 3 Ameron LCX 0 20 deg. 7 ø 2 2 215 F40RetrofitSLCX Flat/Round 4 Ameron LCX 0 20 deg. 8 ø 2 2 215 FITTING MODELS FOR 2045 DEGREE ADJUSTABILITY Model Number Wall type Pipe type and size Angle Adjustability O.D. Length Bravo Adhesive Included F05Retrofit2045S Flat/Round 1/2 Conduit / RobRoy 20 45 deg. 7 ø 2 2 $ 275 F07Retrofit2045S Flat/Round 3/4 Conduit / RobRoy 20 45 deg. 7 ø 2 2 275 F10Retrofit2045S Flat/Round 1 Conduit / RobRoy 20 45 deg. 7 ø 2 2 275 F20Retrofit2045S Flat/Round 2 Fiberglass 20 45 deg. 7 ø 2 3 325 F30Retrofit2045S Flat/Round 3 Fiberglass 20 45 deg. 8 ø 2 4 375 F40Retrofit2045S Flat/Round 4 Fiberglass 20 45 deg. 9 ø 21/2 4 475 F20Retrofit2045SLCX Flat/Round 2 Fiberglass 20 45 deg. 8 ø 2 3 325 F30Retrofit2045SLCX Flat/Round 3 Fiberglass 20 45 deg. 9 ø 2 4 375 F40Retrofit2045SLCX Flat/Round 4 Fiberglass 20 45 deg. 11 ø 21/2 4 475 List BUILT LIKE A TANK Highend materials match UST spec UL1316 to ensure longevity and fuel compatibility Compatible when submerged in fuels, biofuels and alcohol blends up to E100 and B100 WWW.SBRAVO.COM/FS 4 iifseriesretrofits12a
FSeries RetrofitS COMPONENTS Included Parts (Per fitting) A) 1x Fiberglass RetrofitS Body (two halves) with SS Pipe Clamp B) 1x Loose Fiberglass Flange for curved walls (two halves) with 2 ZipTies C) Bravo ADHESIVERETROFITEPOXYKIT: (quantity chart on page 4) 1x Bravo Epoxy Adhesive Can 6oz 1x Bravo Epoxy Catalyst bottle 1oz 2x Pair of Industrial Nitrile gloves (Large) 1x Stir stick 1x 1 chip brush D) 1x 60 grit emery cloth strip E) 1x 80 grit sheet of sandpaper F) 1x 3bolt compression clamp G) 1x 15 long Rubber Strip REQUIRED TOOLS (NOT PROVIDED) Air Sander and Air Drill Steel Stator Mixer Eye protection Respiratory protection Approved Bonding Adhesive: Bravo ADHESIVERETROFITEPOXYKIT A Confinedspace Certification is required when installing this fitting inside Tank Sumps USE ONLY BRAVO SYSTEMS ADHESIVE WHEN INSTALLING THIS FITTING TO FIBERGLASS PIPE OR CONDUIT DO NOT SUBSTITUTE ADHESIVES, MIX THEM OR ADD LIQUIDS SUCH AS WATER OR ANOTHER RESIN. DO NOT USE ANOTHER CATALYST OTHER THAN WHAT IS PROVIDED. 5 iifseriesretrofits12a
Summary of Installation These steps are not a substitute for the detailed installation steps contained in the following pages. DO NOT ATTEMPT TO INSTALL THIS PRODUCT BASED ONLY ON THE SUMMARIZED STEPS LISTED ON THIS PAGE 1) Evaluate the sump, ensure sump material is FRP, and the piping is FRP or conduit. 2) Remove any necessary components that will obstruct your access to the Interior sump wall. 3) Clean interior and bottom of each sump. Remove all fuel, contaminants, water and debris. 4) Ensure each sump will be completely dry during all installation steps. 5) Remove the interior boot and any gaskets or seals from the wall. 6) Protect the pipe with the provided rubber strip and cut and grind down any bolts until just under flush with the fiberglass wall. 7) Clean and abrade the fiberglass wall in preparation of gluing. 8) Prepare the conduit or fiberglass pipe by removing excess adhesive, contaminants, coatings or fuel oils with hand tools or solvents and abrade. 9) Clean, dry and rough up pipe or conduit surface in preparation for gluing. 10) Dryfit your angle flange and/or body for correct fit and mark a stripe across all assembled fitting components and the wall with a permanent marker. If installing the body only outline position with marker. 11) Glue and assemble curved flange to wall (only for curved walls). 12) Glue fitting body to wall, keeping fitting within the marked outline. 13) Clamp fitting to the wall with provided pusher clamp. 14) Fingerbead adhesive on every joint and seam. 15) Allow fitting installation to fully cure without being disturbed. 16) Water test per all local regulations. 6 iifseriesretrofits12a
VENTILATE YOUR AREA WEAR SAFETY PROTECTION NO > > ELECTRIC TOOLS IGNITION SOURCES Ensure that the workspace is operating below the LEL (lower explosive limit) before starting work. Test regularly or monitor continuously A Confinedspace Certification is required when installing this fitting inside Tank Sumps STEP 1 READ THIS ENTIRE MANUAL FRONT TO BACK BEFORE BEGINNING INSTALLATION BEFORE BEGINNING WORK ON YOUR JOBSITE. YOU MUST EVALUATE THE EXISTING SUMPS, PIPE, CONDUIT AND FLEXIBLE ENTRY BOOTS YOU WILL BE RETROFITING. FOLLOW THESE RULES: A) Ensure the sump material is fiberglass only. B) Ensure the piping is fiberglass, galvanized steel or PVC coated steel only. C) If the PVC coated conduit is OcalBlue brand, you must strip the PVC away from the fitting area and rough up the steel conduit beneath. D) Ensure that the conduit has not rusted through. This fitting should not be bonded with any adhesive to a corroded or partially corroded conduit line. You must replace the conduit. WHEN READY, BEGIN WORK ON YOUR JOBSITE BY ENTERING ALL THE SUMPS YOU WILL BE INSTALLING THE FSERIES RETROFITS FITTING IN AND REMOVE: E) Any components that will obstruct your access to the sump wall. F) Any and all fuel, oils, contaminants, water or debris. Dispose of HAZMAT per local codes. STEP 2 Interior Bolts Before starting work, ensure all fuels and flammbles have been removed. Test/monitor your LEL s and ventilate. Remove interior boot from the wall to expose the fitting interior and bolts. DO NOT USE TOOLS THAT CAN DAMAGE THE PIPE. Interior Boot Use a protractor or other measurement tool to measure piping angles. 7 iifseriesretrofits12a
STEP 3 Cutting down the bolts pipe wrapped with provided rubber strip Before starting work, ensure all fuels and flammbles have been removed. Test/monitor your LEL s and ventilate. Wrap the provided rubber strip around your pipe or conduit to prevent damage to it during the grinding step. Secure with ziptie or strong tape. This will protect the pipe from cutting and grinding operations. STEP 4 3 3 ABRADE Wrap the provided rubber strip around your pipe or conduit. Secure with ziptie or strong tape. Cut away and grind down any exposed bolts so that they are just underflush with the wall. Proceed to grind your walls clean of any paint, gelcoat, adhesives or sealants until open fiberglass is clearly visible 3 INCHES AWAY FROM THE HOLE. STEP 5 STRIPE MARK mark across the wall and all components DRY FIT ONLY STABILIZE YOUR CONDUITS BY BRACKETING OR SECURING TO EACH OTHER OR THE RISER. DO NOT SECURE CONDUITS TO ANY OTHER COMPONENTS FLAT WALLS: Dry fit the body on your pipe and use a marker to outline the fittings position on the wall. The curved flange will not be used. CURVED WALLS: Dry fit the body and the curved flange and use a marker to mark a large stripe across the sump wall, body and flange. Also outline the fittings position. 8 iifseriesretrofits12a
ROUGHINGUP YOUR FRP PIPE WITH SAND STRIP DO NOT USE ANY POWER TOOLS ON PIPE, EVER! Your pipe must be hand roughed in preparation for Gluing DO NOT USE ANY POWER TOOLS ON PIPE, EVER! 9 iifseriesretrofits12a
MIXING YOUR ADHESIVE Your adhesive should be stored in a cool place until ready to be mixed. You should warm your adhesive and fiberglass fitting components if the ambient temperature is below 70 F. DO NOT MIX MORE THAN ONE CAN AT A TIME DO NOT ATTEMPT TO MIX HALF A CAN ONLY USE 1 BOTTLE OF CATALYST PER ADHESIVE CAN USE ONLY BRAVO SYSTEMS ADHESIVE WHEN INSTALLING THIS FITTING TO FIBERGLASS PIPE OR CONDUIT DO NOT SUBSTITUTE ADHESIVES, MIX THEM OR ADD LIQUIDS SUCH AS WATER OR ANOTHER RESIN. DO NOT USE ANOTHER CATALYST OTHER THAN WHAT IS PROVIDED. ADHESIVE HAS AN ACTIVE COLORANT ADD CATALYST TO ADHESIVE AND MIX THOROUGHLY UNTIL THE COLOR IS EVEN AND CONSISTENT WITH NO SWIRLS NOT MIXED NOT MIXED NOT MIXED NOT MIXED NOT MIXED THOROUGHLY MIXED THOROUGHLY MIXED THOROUGHLY MIXED 10 iifseriesretrofits12a
STEP 6 ADHESIVE APPLIED TO ALL CONTACT SURFACES FOR CURVED WALLS OR ADDON WEDGES: Apply your reinforced adhesive to all Contact Surfaces; between both halves of the curved flange or wedge where they contact each other, the pipe, the wall, and the face of the flange that will contact the wall. Stick this assembly to the wall by applying manual pressure. Make sure to align the marked stripe. Use provided ziptie to lock these halves together tightly. In weather below 90 F this should remain in place without any assistance while you prepare the body for gluing. USE ONLY BRAVO SYSTEMS ADHESIVE WHEN INSTALLING THIS FITTING TO FIBERGLASS PIPE OR CONDUIT 11 iifseriesretrofits12a
STEP 7 ADHESIVE APPLIED TO ALL CONTACT SURFACES PACK INTERIOR OF FITTING HEAVILY WITH ADHESIVE APPLY ADHESIVE TO THE SURFACES THAT CONTACT EACH OTHER When only installing the body on flat walls, apply adhesive generously to all contact surfaces (including any flanges already on the wall), the pipe, interior of the fitting body, the surfaces of the fitting halves that will meet each other and the face of the body that will contact the curved flange or bare wall. Be generous on the interior, this is an area where a large amount of adhesive is critical. ADHESIVE SHOULD BE PACKED HEAVY ON THE INTERIOR! ENSURE THAT YOU HAVE FULL ADHESIVE CONTACT! USE ONLY BRAVO SYSTEMS ADHESIVE WHEN INSTALLING THIS FITTING TO FIBERGLASS PIPE OR CONDUIT 12 iifseriesretrofits12a
STEP 8 BEAD ADHESIVE HEAVILY ON ALL SEAMS 360 DEGREES AROUND FITTING PIPE CLAMP SEAL YOUR FITTING BODY TOGETHER. Assemble the two halves of the body to the wall, aligning the marked stripe and/or positioning the fitting within the outline marked on the wall. and secure with the pipe clamp provided for the body. Adhesive should ooze from the fitting as you clamp it together. Fingerbead the adhesive around all seams so it is thick and heavy. STEP 9 Use provided pusher clamp to hold the fitting against the wall while it cures. First clamp to the pipe, then turn each bolt to put even force on the fitting. Fingerbead adhesive so it is visibly built up on all joints. Do not use a paint brush to brush seams clean. CLAMP THE FITTING SECURELY TO THE WALL WHILE THE ADHESIVE CURES It is OK to coat the ziptie(s) and the SS Pipe Clamp. Make sure that the seams between all halves are coated generously. CLEAN UP: You can use acetone to clean up the adhesive while it is wet to create a clean and picture perfect install. ALLOW A FULL CURE PER THE INSTRUCTIONS ON THE ADHESIVE CAN. After a full cure, remove the 3bolt clamp and reapply adhesive where necessary. STEP 10: LAKE TESTING (Water Testing): After the FSeries RetrofitS Fittings are installed and have fully cured, water level test to a maximum of 2 above the highest penetration fitting on the sump. Follow local regulations. 13 iifseriesretrofits12a