JCM Engineered Products Manual 8 24 2020

JCM Engineered Products manual features our custom built products and information on the fittings and fabrications for water, wastewater, irrigation and other water services.

JCM Engineered Products Manual Product Index Effective August 24, 2020

JCM Engineered Repair Fittings Page Number Engineered Repair Fitting Selection Guide..................................................................................................................2 JCM Engineered Fitting Introduction............................................................................................................................3 JCM 114 Mechanical Joint Repair Sleeve................................................................................................................4-5 JCM 116 Repair Sleeve for Concrete Steel Cylinder PIpe........................................................................................6-7 JCM 118 Large Diameter and Non-Standard Contour Pipe Repair Sleeve..............................................................8-9 JCM 136 Heavy Duty Stainless Steel Repair Clamp.............................................................................................10-11 Technical and Engineered Product Considerations...................................................................................................12 Large Diameter Repair Factors..................................................................................................................................13 JCM Engineered Pipe Connection Fittings Engineered Connection Fittings Selection Guide......................................................................................................14 JCM 201 Steel Coupling............................................................................................................................................15 JCM 203 Steel Transition Coupling............................................................................................................................15 JCM 204 Steel Reducing Coupling............................................................................................................................15 JCM 303 Fabricated Flanged Coupling Adapter........................................................................................................ 16 JCM 304 Fabricated Reducing Flanged Coupling Adapter........................................................................................ 16. JCM 230/231 H D PE Stainless Steel Stiffener........................................................................................................... 17 JCM Engineered Tapping Sleeves Engineered Tapping Sleeve Selection Guide.............................................................................................................18 Engineered Tapping Sleeve Introduction...................................................................................................................19 JCM 412 Fabricated Steel Tapping Sleeve...........................................................................................................20-21 JCM 414 Mechanical Joint Tapping Sleeve..........................................................................................................22-23 JCM 415 Tapping Sleeve for Concrete Steel Cylinder Pipe..................................................................................24-25 JCM 452 All Stainless Steel Tapping Sleeve with Outlet Seal Gasket..................................................................26-27 JCM 440 Line Stop Fittings...................................................................................................................................28-35 JCM Weld on Tapping Outlets....................................................................................................................................36

JCM Engineered Fittings Product Data Sheet...........................................................................................................37

JCM Specialty Engineered Fittings JCM 801/802 Expansion Joint Fittings..................................................................................................................38-39 JCM 800 Fabricated Spools..................................................................................................................................40-41 JCM 607 Weld On Restrainer/Joint Anchor Loops...............................................................................................42-43 JCM 617 Weld On Restrainer/Joint Harness Assembly........................................................................................44-45 JCM Fittings and Fabrications for High Density Polyethylene Pipe...........................................................................46 JCM Industry Product Cross Reference Chart......................................................................................................47-48

For JCM Industries, Inc. full product line of standard fittings and fabrications for the repair, connection and tapping of pipelines, see the JCM General Product Directory.

JCM Engineered Repair Fitting Selection Guide JCM provides repair fittings for repairs to all types and sizes of pipe. Selection of the proper fitting is a determining factor to the success of the repair and returning the pipeline to its original service capacity. This chart is an introduction to the Engineered Repair Fittings JCM fabricates and the types of applications for which they would be considered. For specific product application recommendations, contact the JCM Sales Team.

JCM Repair Fitting

Types of Pipe Cast Iron Ductile Iron Asbestos Cement Steel PVC HDPE Cast Iron Ductile Iron Asbestos Cement Steel PVC HDPE C301/SP-5/PCCP C301/SP-12/ECCP C303/SP-3/RCCP Cast Iron Ductile Iron Steel Other large diameter rigid pipe Cast Iron Ductile Iron Steel Asbestos Cement PVC

Application

JCM 114 MJ Split Repair Sleeve

Repairs cracks, splits, longitudinal and circumferential breaks. Especially useful for repairs to critical lines that cannot be shut down. Product is custom fabricated to accommodate all types and sizes of pipe. Pipe Sizes 4” and larger. Repairs cracked cast iron bells, split or leaking couplings, leaking joints. Repair fitting “houses” the leaking connection and provides permanent water tight joint. Product is fabricated to specific application dimensions, ensuring custom fit over damaged area. Pipe Sizes 4” and larger. Repairs holes, punctures, construction damage, and corroded areas on PCCP. Repairs directly on the steel cylinder preventing further corrosion damage to pipeline. Requires minimal excavation of pipeline. Pipe Sizes 14” and larger. Repairs holes, punctures, construction damage and corrosion areas on large diameter pipe. Concentration of gasket compression around damage area allows for high working pressure capability. Pipe Sizes 14” and larger Repairs holes, punctures, splits, cracks, breaks and other serious damage to pipelines. The fully gasketed stainless shell provides a complete seal on the full circumference of the pipe. Heavy duty tapping sleeve lug system provides for higher bolt torque capabilities. Pipe Sizes 4” and larger. Repairs holes, punctures, construction damage and corrosion areas on large diameter pipe. Accommodates application parameters such as limited space, non-standard pipe diameters, uneven pipe surfaces, out of round pipe high working pressure systems. Pipe Sizes 3” and larger.

JCM 114 MJ Bell Repair Sleeve JCM 116 Repair Sleeve for Concrete Steel Cylinder Pipe

JCM 116 Repair Sleeve for Large Diameter Pipe

JCM 136 Heavy Duty Stainless Steel Repair Sleeve

Cast Iron Ductile Iron Steel Asbestos Cement PVC HDPE

JCM 118 Fabricated Repair Sleeve

For standard repair fittings and applications for smaller pipe sizes, see JCM’s Product Directory. 2

JCM Engineered Repair Fittings

Today’s pipe systems have specific characteristics that place special demands on emergency repair fittings. Both large and small diameter repairs encounter critical factors to be considered that include type and size of pipe, the type and size of damage to be repaired and the system working pressure. When combined, these factors determine the design of the fitting that will be most suitable for the repair to successfully return the system to its original service rating capacity. As service requirements grow, the full capabilities of the pipeline must not be compromised due to inappropriate repair fittings. The repair fitting design and the system’s original service rating must be equally parallel in performance capabilities. This equality will insure systems ability to function as originally designed. Careful engineering and planning of repair applications to systems and the fittings installed will prevent life threatening situations and unnecessary, unproductive downtime. To eliminate costly down-time and hazardous safety risks, JCM promotes a well planned contingency program for systems which utilize pipelines of non-standard type or maintain crucial services which cannot be shut down. JCM offers several fittings for emergency repair service in these types of systems. JCM 114 Mechanical Joint Repair Sleeve - repairs cast iron bells, split or leaking couplings, leaking flanged joints and welded joints. The fabricated mechanical joint principle accommodates non-standard pipe diameters, out-of-round pipe, limited flat spots and fully encapsulates the problem area. Recommended for applications in which line shut down is impossible. JCM 116 Repair Sleeve For Concrete Steel Cylinder Pipe - repairs and reinforces both Prestressed and Pretension Concrete Cylinder Pipe of all sizes. The 116 Repair Sleeve requires only minimal pipe excavation, eliminates excessive concrete coating removal, provides a wide supportive stance, maintains critical pipe integrity and has a high working pressure capability. The standard fitting repairs up through a 12” diameter damaged area. Larger repair size capability available upon request. Available on both emergency and contingency basis. JCM 118 Large Diameter And Non-standard Contour Pipe Repair Sleeve - repairs large pipe in systems which require high working pressure capability. Engineered specifically for internal pressure forces involved with large diameter pipe and applications for unusual pipe contours and their working characteristics. Suitable for punctured and equipment damaged pipe.

JCM 114 Fabricated Mechanical Joint Repair Sleeve

Repair cast iron bells, split or leaking coupling and weld joints, or straight runs of pipe without costly shutdown or disruption to critical service.

No Shutdown or Interruption of Critical Service - by implementing a split fabricated mechanical joint design, the JCM 114 prevents costly down time and service disruption.

True Mechanical Joint Design - industrial grade, fabricated steel body and heavyweight pusher glands prevent the warpage and distortion experienced by lightweight repair sleeves using the split steel coupling designs. JCM 114 meets design criteria in AWWA C110/111, ANSI 21.10/21.11 for tolerances, dimensions and configuration of the time proven mechanical joint seal. Custom Built For Specific Application - this versatile mechanical joint fitting is built to meet the specific requirements of special applications. Eliminates lost time due to field or factory modifications. JCM 114 sleeves are available for both limited space and full pipe section encapsulation. Strong and Lightweight - the 114 sleeves are ideal for installations where strength, weight and continued service are critical. The reduced weight of high strength steel aids in installation and handling as well as minimizing weight load on the pipe.

Typical Application: Repair

Temporary/Permanent Repair Pipe In Service Cracked/Broken Pipe Joints Splits Holes Failed MJ Joints, Fittings or Couplings

Available in Two Styles - the 114 MJ Split Repair Sleeve for use on straight runs of pipe and the 114 MJ Bell Repair Sleeve which is fabricated to accommodate the specific dimensions of the bell, collar or coupling to be repaired. Optional Materials - the fabrication process of the 114 construction allows for various material options for the finished product. The 114 is available in carbon steel with special coatings and fasteners, or is available fabricated of all stainless steel (304, 316). HOW TO ORDER

For pricing and engineering, the following information must be furnished: JCM 114 is available fabricated of 304 stainless steel or 316 stainless steel Available American Iron and Steel Compliant

JCM 114 Mechanical Joint Bell Repair Sleeve The following information must be furnished. Type of Pipe

JCM 114 Mechanical Joint Split Repair Sleeve The following information must be furnished. Type of Pipe

Spigot or Pipe Outside Diameter Largest Bell or Coupling Dimension Length Requirements Line Content Line Pressure Finish or Coating Requirements

Pipe Outside Diameter Length Requirements

Line Content Line Pressure Finish or Coating Requirements

JCM 114 Mechanical Joint Split Repair Sleeve

The JCM 114 MJ Split Repair Sleeve represents an unusually simple method of coupling or repairing straight runs of cracked or split cast iron pipe and severe longitudinal and circumferential breaks on critical service lines which can not be shut down. This product is made to order for all types and sizes of pipe.

JCM 114 Mechanical Joint Bell Repair Sleeve

The JCM 114 MJ Bell Repair Sleeve is designed to permanently repair cracked cast iron bells, split or leaking couplings and leaking joints. By utilizing a split mechanical joint design, repairs to joints can be completed without down time or disruption to service. The JCM 114 is built to the application dimensions, ensuring a custom fit over the damaged area. These sleeves are ideal for installation where strength, weight and continued service are critical. JCM 114 Fabricated Mechanical Joint Repair Sleeve - Typical Specifications JCM 114 Mechanical Joint Split Repair Sleeve Repair Sleeves shall be of split mechanical joint design with separate end and side gaskets. The fittings shall be constructed of high strength steel, ASTM A-36, ASTM A-516 Grade 70 or equal. The mechanical joint end dimensions shall conform to AWWA standard C-110/C-111 with modification to allow for the specific pipe repair. Sleeves shall have a 3/4” outlet for venting and test purposes. Repair Sleeves shall be JCM 114 Mechanical Joint Split Repair Sleeve or approved equal. Repair Sleeves shall be ANSI/NSF Standard 61 Certified. JCM 114 Mechanical Joint Bell Repair Sleeve Repair Sleeve shall be split mechanical joint, with separate end and side gaskets, designed to accommodate the pipe joint area. The fittings shall be constructed of high strength steel, ASTM A-36, ASTM A-516 Grade 70 or equal. The mechanical joint end dimensions shall conform to AWWA standard C-110/ C-111 with modification to allow for the specific pipe repair. Sleeves shall have a 3/4” outlet for venting and test purposes. Repair Sleeves shall be JCM 114 Mechanical Joint Bell Repair Sleeve or approved equal. Repair Sleeves shall be ANSI/NSF Standard 61, Annex G and ANSI/AWWA 372 Certified. JCM 114 Mechanical Joint Repair Sleeve - Material Specifications BODY: Carbon Steel per ASTM A-36, ASTM A-516 Grade 70 or equal. Optional 304 or 316 Stainless Steel. GLANDS : ASTM A-36 Steel, Ductile Iron or equal. Optional 304 or 316 Stainless Steel. BOLTS: Corrosion resistant, high strength low alloy A242. Optional Stainless Steel, 18-8 Type 304 or 316; Epoxy Coated Bolts. STUDS: B7 Material GASKET: Nitrile rubber compounded for use with water, salt solutions, mild acids and bases. FINISH: Heavy coat of corrosion resistant shop coat primer. Optional Fusion Epoxy Coating (per ANSI/AWWA C-213) available. 5

JCM 116 Repair Sleeve for Concrete Steel Cylinder Pipe

The JCM 116 Repair Sleeve for Concrete Steel Cylinder Pipe provides a quick easy means of repairing and reinforcing damaged concrete steel cylinder pipe of all sizes. This repair sleeve permits repairs to be made on any side of the pipe - without requiring complete stripping of the concrete. The standard repair gasket seals around a 12” damaged area. Larger repair sizes are available. This sleeve is especially recommended for larger sizes of pipe and where the concrete and pipe require reinforcement.

Minimal Pipe Excavation - JCM 116 Repair Sleeve requires limited pipe exposure around the damaged area. Full section joint exposure is eliminated. Wide Supportive Body - reinforces pipe which is weakened due to structural interruption. The body’s grout seal assembly provides a system for replacement of the critical corrosion retarding concrete encasement. By restoring the concrete casing, the steel cylinder is protected from corrosive elements. Eliminates Excessive Concrete Coating Removal - concrete removal is limited to the damaged area only, preventing further pipe structural damage

Typical Application: Repair

Epoxy Coated Repair Plate - the internal repair plate is fusion epoxy coated to provide a quality repair protected against corrosion in the pipe interior. Eliminates Welding On Thin Cylinders - JCM 116 directly repairs the damaged cylinder making a watertight seal, preventing the line contents from infiltrating the concrete-steel interface.

Temporary/Permanent Repair Pipe In Service Holes Gouges Fortify weakened concrete

Availability - the JCM 116 Repair Sleeve for Concrete Steel Cylinder Pipe is available from JCM on both an emergency and a contingency basis. Timely delivery and installation prevents extensive pipe damage, content loss and environmental violations.

JCM 116 Repair Sleeve for Large Diameter Pipe The JCM 116 Repair Sleeve is also recommended for repairs on large diameter pipe including cast iron, ductile iron, steel, and other types of large diameter rigid pipe. The direct concentration of bolting pressure to the repair gland area enables the 116 to repair the damaged area while maintaining the pipeline’s pressure capability.

JCM 116 Repair Sleeve for Concrete Steel Cylinder Pipe The JCM 116 Repair sleeve provides fast, economical and permanent repairs to Concrete Pressure Pipe. Sealing around the damaged area on the steel cylinder, the JCM 116 prevents the line contents from leaking between the concrete/steel cylinder interface, and eliminates further possible damage caused by corrosion. The adjustable, separate gland seals directly on the steel cylinder over the damaged area requiring removal of the mortar coating only in the repair area. Universal grouting horns are located to accommodate re-grouting of the damaged area at any position on the pipe.

HOW TO ORDER For pricing and engineering, the following information must be furnished:

Type of pipe (also manufacturer and class if known) Diameter of damaged area Outside Diameter of Concrete and Cylinder Line Content and Pressure Any special requirements or options JCM 116 Repair Sleeve for Concrete Pressure Pipe - Typical Specifications JCM 116 Fabricated Repair Sleeves for Concrete Steel Cylinder Pipe shall be able to repair and reinforce damaged concrete steel cylinder pipe without requiring complete stripping of the concrete. The repair sleeves shall have a separate gland which permits installation and reinforcement of the pipe prior to the cutting of the prestress wires. The repair gland shall have a fusion epoxy coated pressure plate and a broad gasket set in a retaining groove of the pressure plate which is gusseted to eliminate flexing. Repair Sleeves shall be JCM 116 Repair Sleeves or approved equal. Repair Sleeves shall be ANSI/NSF Standard 61, Annex G and ANSI/ AWWA 372 Certified. JCM 116 Repair Sleeve For Concrete Pressure Pipe - Material Specifications BODY: Carbon Steel per ASTM A-36, ASTM A-516 Grade 70 or equal. GASKET: Nitrile rubber compounded for use with water, salt solutions, mild acids, bases and sewage. BOLTS: Corrosion resistant, high strength low alloy A242. Optional Stainless Steel, 18-8 Type 304. DRAW HARDWARE: B7 Material COATING: Heavy coat of corrosion resistant shop coat primer on sleeve, gland and straps. Pressure plate of gland is epoxy coated (fusion applied per ANSI/AWWA C-213). Optional epoxy coating on entire sleeve.

JCM 118 Large Diameter and Non-Standard Contour Pipe Fabricated Repair Sleeve

The JCM 118 Repair Sleeve repairs pipe in systems which require high working pressure capability. Engineered specifically for the internal pressure forces involved with large diameter pipe and its working characteristics. The JCM 118 Sleeve is available in pipe sizes up through 120” and larger and provides several design options for the specific application.

Minimal Pipe Excavation - the 118 sleeve requires limited pipe exposure around the damaged area. Full section joint exposure is eliminated. Reinforcement Pipe Wall - strong and lightweight steel directly reinforces the pipe wall on the circumference of the pipe. Heavy Duty Design - large fitting components, spacious bolt holes and heavy hardware combine to make installations in less than ideal environments easy and fast. The 118 especially lends itself for easy underwater and low visibility applications. Maximum Gasket Sealing - heavy duty bolts and material provides high levels of bolt torque which is transferred directly to gasket sealing compression. Higher bolt torques maintain greater working pressures. Low Profile Stance - the hydro-mechanical lip gasket is trapped both internally and externally in a recessed groove that provides a low profile stance on the pipe eliminating the chance of gasket displacement or “blow- out” in high pressure applications. Availability - the JCM 118 Repair Sleeve is available from JCM on both an emergency and a contingency basis. Timely delivery and installation prevents extensive pipe damage, content loss and environmental violations.

Typical Application: Repair Temporary/Permanent Especially Recommended for Large Diameter Pipe High Working Pressures

Splits Holes Punctures Corroded Areas Gouges

JCM 118 Large Diameter Repair Sleeve Offers Application Specific Options JCM 118 is available fabricated of 304 stainless steel or 316 stainless steel

The JCM 118 Repair Sleeve is recommended for applications on large diameter pipe, high working pressure systems and critical service applications. The 118 provides a variety of fabrication options for consideration such as space limitations, environment and service requirements. These special fabrication options include:

Laying Length Pipe Range

Gasket Coating Body Material Damaged area accommodation Hardware

JCM 118 Repair Sleeve - Available in Carbon Steel or Stainless Steel (304-316)

JCM 118 Large Diameter and Non-Standard Contour Pipe Fabricated Repair Sleeve

JCM provides various options for the JCM 118 Large Diameter Pipe Repair Sleeve. For special engineered fittings, contact the JCM Technical Services Sales Team and provide the application parameters. JCM will provide recommendations for the application and custom design the fitting to accommodate those parameters.

JCM 118 Large Diameter Repair Sleeve - Standard Design

HOW TO ORDER For pricing and engineering, the following information must be furnished: Type of Pipe Dimension of Damaged Area Pipe Outside Diameter Space Limitations Line Content Coating Requirements Line Working Pressure Optional Material Requirements JCM 118 Fabricated Repair Sleeve - Standard Fitting Typical Specification Repair fittings shall be the high strength type fabricated of Carbon Steel per ASTM A-36, A-516 Grade 70 or equal, which conforms to and reinforces the pipe. Sleeve shall be minimum 8” wide and be sized to fit and reinforce the pipe circumference. Sleeve repair area shall have a minimum 3/4” wide Buna-N gasket recessed in a machined groove. Repair fitting shall have a 3/4” outlet for venting and test purposes. Repair fitting shall be furnished with a corrosion resistant shop coat paint primer with high strength, low alloy corrosion resistant bolts and nuts (AWWA C-111, ANSI 21.11). Repair Sleeves shall be ANSI/NSF Standard 61, Annex G and ANSI/AWWA 372 Certified. JCM 118 Large Diameter Pipe Repair Sleeve - Material Specifications

BODY:

Carbon Steel per ASTM A-36, ASTM A-516 Grade 70 or equal. Optional 304 or 316 Stainless Steel. Corrosion resistant, high strength low alloy A242. Optional Stainless Steel, 18-8 Type 304 or 316; Electro Coated Bolts. Nitrile rubber compounded for use with water, salt solutions, mild acids and bases. Heavy coat of corrosion resistant shop coat primer, an excellent base for bitumastic coal tar or similar field coatings. Optional Fusion Epoxy Coating (per ANSI/AWWA C-213) available.

BOLTS:

GASKET: COATING:

JCM 136 Heavy Duty Stainless Repair Clamp Coupling

The JCM 136 Heavy Duty Stainless Steel Repair Clamp incorporates the corrosion resistance of stainless steel, the full circumferential gasketing of a Universal Clamp Coupling and the triangular bolting configuration of the 432 Stainless Steel Tapping Sleeve to provide a repair clamp coupling with high working pressure capabilities.

All Stainless Steel Construction - provides superior corrosion resistance in harsh or acidic environments. The JCM 136 is available fabricated of 304 or 316 stainless steel. Heavy Duty Stainless Material - the JCM 136 has a minimum standard material of 14 gauge certifiable prime material. This strong, yet flexible stainless shell conforms to uneven or unusual pipe surfaces and provides complete compression of the gasket on the pipe wall.

Typical Application: Repair Temporary/Permanent Especially Recommended for High Working Pressures

Tapping Sleeve Bolting System - with a triangular lug design, allows for pass-through, replaceable bolts. This lug configuration eliminates alignment problems and allows tightening from either side of the pipe.

Breaks Cracks

Splits Holes Corroded Areas Gouges

Full Circumferential Gasket - provides a water tight seal on the full circumference of the pipe. The gridded 1/4” thick gasket is of a durometer hardness that allows the rubber to conform to and fill the pits and voids of uneven pipe surfaces. The JCM 136 Heavy Duty Stainless Repair Clamp is available for all types and sizes of pipe. Options for this fitting includes: 304 Stainless Steel, 316 Stainless Steel, SBR, EPDM or Buna-N Gaskets, 304 Stainless Hardware, 316 Stainless Hardware. Call the JCM Inside Sales Team for product recommendations. The JCM 136 Heavy Duty Stainless Repair Clamp larger than 16” nominal pipe size may include multiple bands. Contact JCM for information.

JCM 136 Heavy Duty Stainless Steel Repair Clamp Coupling All Stainless Steel Body Full Circumferential Gasket 1/4” Thick Recessed Stainless Steel Bridge Plates Heavy Duty Stainless Bolting System

JCM 136 Heavy Duty Stainless Repair Clamp Coupling

JCM 136 Heavy Duty All Stainless Repair Clamp Coupling - Standard Design

JCM 136 Heavy Duty All Stainless Repair Clamp Coupling - Typical Specifications All heavy duty repair clamps shall have a minimum material standard of 14 gauge certifiable prime 304 stainless steel construction. Clamps shall have a triangular lug design with bolts on 3” centers. Bolts shall be the pass-through, replaceable type to avoid alignment problems and allow tightening from either side of the pipe. Bolts shall not be integrally welded to the sleeve. Bolts shall be minimum 5/8” 304 stainless steel track head type furnished with permanently lubricated heavy hex nuts and stainless steel washers. The full circumferential gasket shall be molded of synthetic rubber compounded for use with water salt solutions, mild acids, bases and sewage. The gasket shall have a gridded surface, be a full 1/4” thick with 304 stainless steel bridge plates molded flush into the gasket. Clamps shall be fully passivated to insure corrosion resistance. Heavy duty clamps shall be JCM 136 All Stainless Steel Heavy Duty Repair Clamp Coupling or approved equal. Repair Clamps shall be ANSI/NSF Standard 61, Annex G and ANSI/AWWA 372 Certified. JCM 136 Heavy Duty All Stainless Repair Clamp Coupling- Material Specifications BODY : Stainless Steel 18-8 Type 304. LUGS: Stainless Steel 18-8 Type 304. BOLTS: Stainless Steel 18-8 Type 304. GASKET: The full circumferential gasket shall be molded of synthetic SBR rubber compounded for use with water salt solutions, mild acids, bases and sewage. The gasket shall have a gridded surface, be a full 1/4” thick with 304 stainless steel bridge plates molded flush into the gasket. Optional EPDM gasket available.

Optional All 316 Stainless Steel Repair Clamp available. Contact JCM Industries for information.

JCM Technical and Engineered Products

JCM Engineered Products are designed and built to accommodate the special needs of today’s piping applications. The growing demands made on water, wastewater, industrial and irrigation piping systems, which provide critical and expanded services, put stresses and forces never before experienced on the pipe and its fittings. To eliminate unnecessary and life threatening interruption of services, repair and expansion applications to these systems must take several factors into consideration. These crucial factors include: type of pipe, size of pipe, working pressure, type and size of application. These very important considerations will determine the type of fitting to be utilized to successfully complete the job and maintain the system’s original flow and service rating capacity. Changes in piping materials and service requirements in current systems, require fittings that will accommodate characteristic fluctuations and withstand the growing service demands of the system. JCM Engineered Products provide the solution for these requirements. In-service systems, especially those with large diameter pipe, offer special application considerations commonly involving irregular and out-of-round pipe, non-standard pipe diameters and high working pressures. JCM Engineered Products for large diameter pipe are time and field proven for performance and reliability. By monitoring field applications and their requirements JCM is able to provide the piping industry the most advanced engineering designs for large diameter pipe. JCM offers experienced service throughout the organization. Sales personnel are technically trained to assist with special applications. This assistance is supported by experienced production engineers and manufacturing staff knowledgeable in design fabrication. JCM invites inquiries from all phases of the piping industry. Engineered products are designed for and can be adapted to all types of pipe and line contents.

JCM Large Diameter Repair Clamps Selection and Application

In the repair applications to large diameter pipe, there are several factors to be considered to maintain pipe integrity and return to 100% service capacity. These factors, which are critical to the application, include: size and type of pipe, severity of damage, working pressure or service requirements, location of repair and time factor. Line pressure forces encountered in repair applications will determine the success or failure of a repair fitting. The forces of large pipe reduce the working capability and safety factor of large repair clamps. Performance of these fittings is determined by the relationship of bolting power to gasket area, fastener attachment, bolt efficiency and thickness of metal. Therefore, a repair clamp may not be the proper fitting for certain applications. JCM offers various repair fittings which are suitable for repairs to large pipe operating at higher working pressures. To understand the forces involved in the application, see the comparison values listed below relating size of pipe to the internal forces involved.

Nominal Pipe Size (In.)

Stress/Force on Clamp at 100 PSI

Outside Diameter

Area of 1/4” Break

12 16 20 24 30

13.20 17.40 21.60 25.80 32.00

10.37 sq. in. 13.67 sq. in. 16.96 sq. in. 20.26 sq. in. 25.13 sq. in.

1,037 lbs. PSI 1,367 lbs. PSI 1,696 lbs. PSI 2,026 lbs. PSI 2,513 lbs. PSI

On a repair clamp the mechanical seal is made by tightening bolts to create a greater force on the gasket (PSI) than is in the pipeline. Safety factor is that amount of sealing capability the clamp has above the operating pressure of the pipeline. Clamps are limited in performance by the relationship of bolting power to gasket area. Also entering into the picture are the fastener attachment, bolt efficiency and the thickness of the metal. JCM clamps have been designed to limit traditional clamp weaknesses, thereby giving a higher working capability and safety factor. Even so, they do have a limited capability. Other types of repair fittings should be taken into consideration. Fabricated repair sleeves are designed to overcome the forces involved with large diameter pipe and its characteristics.

JCM Engineered Connection Fitting Selection Guide

JCM Coupling Fitting

Types of Pipe

Application

Cast Iron Ductile Iron Steel PVC HDPE Other Types Cast Iron Ductile Iron Steel PVC HDPE Other Types Cast Iron Ductile Iron Steel PVC HDPE Other Types Cast Iron Ductile Iron Steel PVC HDPE Other Types Cast Iron Ductile Iron Steel PVC HDPE Other Types

For joining plain end pipe. Implements the principle of bolted gasket compression. Easy to install, elminates costly pipe threading, beveling, exact alignment and other downtime pipe preperations. Avaialable in both common and custom sizes and widths.

JCM 201 Steel Coupling

Simple means of joining plain end pipe in the same nominal size with different outside diameter dimensions. Avaialable in both common and custom sizes and widths.

JCM 203 Steel Transition Coupling

The answer to joining plain end pipe of two different nominal sizes. Available in both common and custom sizes and widths.

JCM 204 Reducing Coupling

Flanged adapters provide the means of joining the same nominal pipe size of plain end pipe to flanged fittings within the piping system. Avaiable with optional types of flanges, lengths, restraint systems, coatings, hardware and more.

JCM 303 Flanged Coupling Adapter

Flanged adapters provide the means of joining plain end pipe to flanged fittings with different nominal pipe size within the piping system increasing or decreasing sizes. Avaiable with optional types of flanges, lengths, restraint systems, coatings, hardware and more. JCM 309 Dismantling Joints provide the solution for adding, repairing or replacing flanged fittings within a flanged pipe system. Adjustable, slip joint design accommodates either wide gaps or close quarter installations and eliminates the need for precise measurements between flange connections.

JCM 304 Reducing Flanged Coupling Adapter

Cast Iron Ductile Iron Steel PVC HDPE Other Types

JCM 309 Dismantling Joint

JCM Steel Couplings

JCM 201 Steel Bolted Couplings JCM 201 Steel Couplings provide an easy means of joining plain end pipe. These couplings are especially applicable for use on steel, galvanized, PVC and other pipe with standard steel dimensions. Implementing the principle of bolted gasket compression, the JCM 201 Steel couplings are easy to install and eliminates time consuming costly threading, beveling, exact pipe alignment and other downtime preparations. Available in both common and custom sizes with optional coatings, gaskets and hardware combinations. Pipe Sizes 1/2” and larger.

JCM 203 Steel Transition Couplings The JCM 203 Steel Transition Coupling provides a simple means of joining plain end pipe of the same nominal size but different outside diameter dimensions. Available in common sizes for Cast Iron, Ductile Iron, PVC, HDPE and others. Non-standard sizes available upon request. Pipe Sizes 3” and larger

JCM 204 Steel Reducing Couplings The JCM 204 Steel Reducing Coupling is the simplest means of connecting any combination of two sizes or types of pipe. There is practically no limit to the pipe sizes that can be connected - either to reduce or increase in size. Pipe Sizes 4” and larger.

Typical Application: Connection/Repair Temporary/Permanent Join Plain End Pipe Install Repair Section of Pipe Transition or Reduce between two pipe sizes

Applications in which pipe may move out of the coupling, correct anchorage of the pipe must be provided.

For applications on HDPE Pipe, JCM Recommends the use of of the JCM 230/231 Stainless Steel Pipe Stiffener and JCM 600 Series Pipe Restrainers.

JCM Flanged Adapters and Dismantling Joints

JCM 303 Fabricated Flanged Coupling Adapters JCM 304 Fabricated Reducing Flanged Coupling Adapters The JCM 303 Fabricated Flanged Coupling Adapter provides a simple means of joining plain end pipe to flanged fittings, valves and equipment. Ideal for installing flanged valves, backflow preventors, monitoring equipment and other pipeline accessories to be retrofitted into a piping system. Fabricated without pipe stops, the JCM 303 Flanged Adapter can be slid back on the plain end pipe for quick fitting installation and adjustment. Available in either size on size or reducing sizes (JCM 304), optional coatings and hardware and flange types.

Optional Flanges Available - ANSI/AWWA C207 Class D, ANSI 150 Drilling

ASME/ANSI B16.5 Class 150, 300 Weld Neck, Blind, Slip-on, Reducing, Threaded, Socket Weld, Lap Joint, Angle Face, Van Stone Concentric and Eccentric Flanges

Pipe Sizes 3” and larger

JCM 309 Fabricated Dismantling Joints Dismantling joints simplify installations and replacement of flanged fittings in retrofitting applications. JCM 309 Dismantling Joints provide the solution for adding, repairing or replacing flanged fittings within a flanged pipe system. Adjustable, slip joint design accommodates either wide gaps or close quarter installations and eliminates the need for precise measurements between flange connections. Restrained design standard. Available in sizes 2” (50mm) and larger, for ductile iron or flanged steel pipe systems. JCM 309 Dismantling Joints Offer: • Greater longitudinal adjustment ability speeds installations and reduce system downtime. • Accommodates future modifications and system adjustments. • Simplifies installation - one fitting integrates into system operating as flanged adapter and an adjustable spool piece.

Material Specifications - 201, 203, 204

MIDDLE RING: Carbon Steel per ASTM A-36 or equal. FOLLOWERS: 1/2” - 12” Ductile Iron ASTM A-536 or equal; 14” and larger: ASTM A36 BOLTS: 1/2” through 2”: ASTM A242 low alloy with yellow dichromate seal. Sizes 2-1/2” and larger: Corrosion resistant, high strength low alloy ASTM A242, A193 B5, B7. Optional A193 B8 304 stainless steel or 316 stainless steel. GASKETS : Nitrile Butadiene Rubber (NBR, Buna-N) per ASTM D2000. Molded virgin rubber. Gasket temperature range -40 o F to 212 o F (-40 o C - 100 o C) Recommended for water, salt solutions, mild acids, bases, sewage and natural gas. Optional: EPDM FINISH: Heavy coat of corrosion resistant shop coat primer. Optional Fusion Epoxy Coating available. 303, 304, 309: ANSI/AWWA C207 Class D Flange with ANSI 150 lb. drilling, ASME/ANSI B16.1 Class 125 Compatible Steel Ring Flange or equal

JCM 200 and 300 Series fittings are ANSI/NSF Standard 61, Annex G and ANSI/NSF Standard 372 Certified. JCM 200 and 300 Series fittings meet ANSI/AWWA Standard C219 as applicable.

JCM 230/231 Stainless Steel Stiffeners for HDPE Pipe For applications on High Density Polyethylene Pipe, using mechanical bolt on fittings to join or connection systems, JCM recommends the use of the JCM 230/231 Stainless Steel Pipe Stiffeners. JCM 230/231 Stiffeners provide:

• Corrosion Resistance • Rigid Reinforcement of Pipe Wall for Pipe Connections • Accurate Pipe I.D. Sizing maintains proper Outside Diameter • 1/8” Tapered Insert End provides for Easy Installation • 90° 1/8” Flared End Secures Stiffener to End of Pipe • Positive Reinforcement without interference

JCM HDPE Pipe Stiffeners are designed to support the interior wall of HDPE for critical pipe joining applications. Recommended for all pipe end connections utilizing mechanical bolt-on fittings, the JCM Pipe Stiffeners support the pipe’s end and controls the “necking down” reaction to the pressure applied during normal installation of fittings used in pipe joining applications. The JCM HDPE Pipe Stiffeners are formed of stainless steel, 304 or 316 material, to the actual inside pipe diameter provided by the customer. This accurate formation provides for ease of installation and maintains the proper outside diameter for a successful, trouble free application that provides long-term service. JCM Pipe Stiffeners are available for Steel Size and Ductile Iron Size HDPE in SDR11,13.5, 17, 21, 26, 32.5 JCM Pipe Stiffeners Material Specifications: ASTM A240 - TP 304 Stainless Steel or 316 Stainless Steel

JCM Engineered Tapping Sleeves

JCM Tapping Fitting

Types of Pipe

Application

Cast Iron Ductile Iron Asbestos Cement Steel PVC HDPE Reinforced Concrete Other various types Cast Iron Ductile Iron Asbestos Cement Steel PVC HDPE Reinforced Concrete Other various types Cast Iron Ductile Iron Asbestos Cement Steel Other various types

For tapping both rigid and non-rigid types of pipe. Especially recommended for applications on systems with fluctuating or high working pressure requirements. Individual engineering and fabrication ensures a close, custom fit to unusual or non-standard pipe surface characteristics. Pipe sizes 6” and larger.

JCM 412 Fabricated Steel Tapping Sleeve

For tapping both rigid and non-rigid types of pipe in corrosive or acidic environments. All stainless construction combines superior corrosion resistance with high working pressure capabilities. Manufactured to provide maximum corrosion resistance in applications on mains which are not subject to beam breaks. Pipe sizes 6” and larger. For tapping pipelines which are subject to beam breaks and where strength, weight and beam load considerations are critical. Lightweight, yet strong, fabricated steel construction ensures a close, custom fit to older, out-of- round or non-standard pipe surfaces. True mechanical joint design encompasses the tap area and seals completely around the pipe. Pipe sizes 14” and larger.

JCM 452 All Stainless Steel Tapping Sleeve

JCM 414 Fabricated Mechanical Joint Tapping Sleeve

For tapping both Prestress and Prestension Concrete Steel Cylinder Pipe. Designed to meet the AWWA M-9 Manual. Provides reinforcement of the pipe and easy installation with maximum safety factor. Special requirements and modifications are easily adapted to the 415. Manufacturing flexibility accommodates modifications, adaptations and special engineering requirements without delay in product availability. Pipe sizes 14” and larger.

C301/SP-5/PCCP C301/SP-12/ECCP C303/SP-3/RCCP

JCM 415 Tapping Sleeve for Concrete Steel Cylinder Pipe

Cast Iron Ductile Iron Asbestos Cement Steel PVC HDPE Other various types

Engineered for line stopping applications on all types of pipe. Adapts to all popular line stopping machines. Heavy duty standard design provides a 150 PSI working pressure capability. Catalog pipesizes 4” - 12”. Larger line stop fittings (14” and larger) available, for information contact JCM Technical and Engineered Sales.

JCM 440 Line Stop Fitting

JCM Engineered Tapping Sleeves

JCM Engineered Tapping Sleeves are designed and built to accommodate the special needs of today’s piping applications. The growing demands made on water, wastewater, industrial and irrigation piping systems, which provide critical and expanded services, put stresses and forces never before experienced on the pipe and its fittings. To eliminate unnecessary and life threatening interruption of services, expansion applications to these systems must take several factors into consideration. These crucial factors include: type of pipe, size of pipe, working pressure, type and size of application. These very important considerations will determine the type of fitting to be utilized to successfully complete the job and maintain the system’s original flow and service rating capacity. Changes in piping materials and service requirements in current systems, require fittings that will accommodate characteristic fluctuations and withstand the growing service demands of the system. JCM Engineered Tapping Sleeves provide the solution for these requirements. Existing service systems, especially large diameter systems, offer special application considerations commonly involving irregular and out-of-round pipe, non-standard pipe diameters and high working pressures. JCM Engineered Tapping Sleeves for large diameter pipe are time and field proven for performance and reliability. Monitoring field applications and requirements enables JCM to provide the most engineering advanced designs for large diameter pipe to the industry. These fittings include: JCM 412 Fabricated Tapping Sleeves - built-in benefits make these heavy fabricated steel sleeves increasingly popular for making larger taps on all types of pipe. By placing the design emphasis on eliminating problems inherent with older pipe and field installations, JCM 412 Tapping Sleeves have taken the complexity out of tapping larger pipe. JCM 452 All Stainless Steel Tapping Sleeves - incorporates the heavy duty design of the fabricated steel tapping sleeve with the corrosion resistance of all stainless steel. This heavy design utilizes a broad cross section, hydromechanical outlet gasket in lieu of the full body gasket. The JCM 452 is engineered for installations requiring higher working pressure, higher safety factor or longer service life than standard all stainless or cast iron sleeves and is manufactured to provide superior corrosion resistance in applications on mains which are not subject to beam breaks. Available in 316 stainless steel. JCM 414 Fabricated Mechanical Joint Tapping Sleeves - combines the high strength and versatility of fabricated steel with the traditional side and end gasketed mechanical joint design. These sleeves are ideal for potential problem installations where strength, weight and beam load considerations are critical. Available in 304 or 316 stainless steel. JCM 415 Tapping Sleeve for Concrete Steel Cylinder Pipe - is designed to reinforce the pipe and provide easy installation with maximum safety factor. The 415 provides a separate body and tapping gland. By separating the outlet gland from the sleeve body, the sleeve reinforces the pipe prior to removal of the critical prestress wire from the outlet area. JCM 415 Tapping Sleeves are in accordance with the AWWA M-9 Manual. Available in 304 or 316 stainless steel.

JCM 412 Fabricated Tapping Sleeve

Built-in benefits make these heavy fabricated steel sleeves increasingly popular for making larger taps on all types of pipe. By placing the design emphasis on eliminating problems inherent with older pipe and field installations, JCM 412 Tapping Sleeves have taken the complexity out of tapping larger pipe.

Custom Engineered Range - assures proper fit on the pipe. Non-standard, oversized, undersized and out of round pipe is easily accommodated in the manufacturing process. Ease Of Assembly - eliminates extra equipment, time and specially trained personnel. Readily Available - means taps can be made without long delays - even taps on special sizes of pipe - or services requiring high pressure flanges. Direct Reinforcement Of Pipe - by sleeve eliminates flexing or pipe deflection of opposite the tap. Less weight than heavy cast iron sleeves reduces the load on the pipe.

JCM 412 Tapping Sleeves Assure A Safe Dependable Tap - a large gasket cross section provides a positive initial seal which increases with increases in line pressure. The built-in test plug provides a means of checking all seals prior to beginning the tap. Options - the JCM 412 offers a wide variety of options to ensure a successful long term fitting installation for non-standard or custom applications. These engineering options include: Flanges - AWWA C207, Class E, Class F, ANSI 150, ANSI 300, Raised Face, Mechanical Joint, Vanstone and other optional flanges Outlets - Offset, Angle, Material Thickness Body - Laying Length, Material Grade, Material Thickness Coating - Shop Coat Primer, Fusion Applied Epoxy, Bitumastic and other various coatings Hardware - Standard Alloy, Stainless Steel Various other options, call for availability JCM provides engineering recommendations for all types of applications for the JCM Tapping Sleeves. Call the JCM Inside Sales Team with your job requirements for submittal.

Fabricated tapping cross accommodates multi-branch applications.

Outlets at 45 o angle.

JCM 412 Fabricated Tapping Sleeve The JCM 412 Fabricated Tapping Sleeve is a safe, economical solution to tapping today’s pipelines. Custom engineering service assures proper fit and conformation to the pipe diameter increasing safety factor and installation efficiency. By directly reinforcing the pipe, the sleeve eliminates flexing or deflection of the pipe opposite of the tap. The large cross section gasket provides a positive initial seal which increases with increases in line pressure. The JCM 412 Tapping Sleeve is available in various option styles and materials. Call the JCM Sales Team with your requirements.

JCM 412 Fabricated Tapping Sleeve - Typical Specifications Tapping Sleeves shall be the high strength type having a wide body, made of ASTM A-36, ASTM A-516 Grade 70 or equal which conforms to and reinforces the pipe. The sleeves shall have as a minimum 7/8” wide recessed Buna-N gasket around the outlet, 3/4” corrosion resistant alloy bolts (per AWWA C-111, ANSI 21.11), a 3/4” forged steel test outlet and hydrostatic test pressure capability of 300 PSI in 12” and smaller outlet sizes. Flanged outlet shall be recessed per MSS-SP60. Tapping Sleeve shall be furnished with corrosion resistant shop coat paint primer. Optional Epoxy Coated sleeves shall be furnished with a 3/4” stainless steel type 304 plug in the test outlet. Tapping Sleeve for pipe sizes 36” and larger shall be of the heavy duty type with a body width of 4” wider than smaller sizes and integral strengthening of the outlet half to provide additional gasket sealing and pressure holding capability. Tapping Sleeves shall be JCM 412 or approved equal. Tapping sleeve shall be ANSI/NSF Standard 61, Annex G and ANSI/AWWA 372 Certified. JCM 412 Fabricated Tapping Sleeve - Material Specifications BODY : Carbon Steel per ASTM A-36, ASTM A-516 Grade 70 or equal. BOLTS : Corrosion Resistant, high strength low alloy A242. Optional Hardware: Stainless Steel 18-8 Type 304, 316; Electro Coated Hardware. FLANGE : AWWA C207 Class D, ANSI 150lb. Drilling, recessed for tapping valve MSS-SP60. Other flanges and outlet available upon request. GASKET : Nitrile rubber compounded for use with water, salt solutions, mild acids and bases. FINISH : Heavy coat of corrosion resistant shop coat primer. Optional Fusion Epoxy Coating (per ANSI/AWWA C-213) available. SERVICE RATING : 4” to 12” Outlets: 175 PSI. Higher service rating available for specific applications and sizes. JCM Industries Tapping Sleeves meet or exceed the ANSI/AWWA C-223 and MSS-SP 124 Standards as applicable. Note: Large diameter sleeves incorporate multi-section design.

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