Overview
The Zap-Lok pipeline system is designed specifically to satisfy the fast-paced, cost-conscious requirements of today's pipeline construction projects.
Over our 30 year history, Zap-Lok connections have been utilized extensively throughout the energy industry for thousands of miles of flow lines, gathering lines, water lines and aided-injection systems.
Zap-Lok advantages
Zap-Lok connections enable significant advantages in construction speed and overall cost when compared with other pipe joining methods. Our system replaces the variable performance, reliability and cost of welders and other skilled labor with a highly efficient, hydraulic Zap-Lok machine.
- Achieve consistent construction rates of 1,000 ft./hr.
- Drastically reduced labor costs
- Improved corrosion protection
Mechanical Interference Connection
The Zap-Lok system relies on an engineered mechanical interference connection between a cold-expanded "bell-end" and an opposing, slightly larger "pin-end".
The process derives its strength from the metal-to-metal friction generated as the two ends are hydraulically pressed together and highly compressive forces are transferred from the bell-end onto the pin-end - permanently holding it in place.
- Achieves joint strength over 140% SMYS
- No reduction in internal diameter
- Produces "holiday-free" connections
- 100% electrical continuity
End Preparation
Every Zap-Lok joint is carefully prepared and inspected by hand to ensure the highest connection integrity in the field. Our quality control procedures confirm that every heat of pipe meets both API and Zap-Lok specifications - reducing a large percentage of complications that commonly occur during construction.
- Zap-Lok connections are ordered through a pipe distributor as a specification for bare ERW or seamless line pipe
- Pipe is shipped from the distributor to our facility in Houston, TX
- The pipe ends are then prepared to Zap-lok specifications and shipped to the job site and/or coating facility
Pipe Specification & Logistics
Current size range & insertion depth
| Pipe OD | Max. wall thickness @ X-60 | Insertion depth |
|---|---|---|
| 2 3/8" | .218" | 3.75" |
| 2 7/8" | .276" | 5.875" |
| 3 1/2" | .300" | 5.875" |
| 4 1/2" | .337" | 5.875" |
| 6 5/8" | .432" | 9.50" |
| 8 5/8" | .500" | 10.50" |
| 10 3/4" | .594" | 11.50" |
| 12 3/4" | .562" | 13.00" |
**Pipe bound for domestic projects is prepared at our Houston, TX facility. Depending on logistics and project size, mobile end-preparation operations are also possible. Additionally, we maintain international production capabilities at the Boresan Mannesman facility in Turkey.
In the field
The Zap-Lok System Requirements
Zap-Lok Equipment (daily rental)
- Zap-Lok hydraulic press
- Zap-Lok all-in-one power-unit includes:
- Diesel-powered hydraulic pump
- Generator
- Zap-Lok automatic epoxy mixing machine
- Compressor
Additional requirements
- 2 field machines for pipe and machine handling (back-hoe, track-hoe, or side-boom)
- 5 man crew
Onshore and offshore capabilities
Due to its excellent strength and versatility, the Zap-Lok system is used in a wide range of applications both in onshore and offshore pipelines.
The speed and cost-saving benefits are increasingly significant in conditions such as:
- Offshore installations with high equipment costs
- Pipelines requiring corrosion protection
- Projects in developing or remote locations where construction costs are inflated.
Speed and simplicity
- Eliminates X-ray inspection
- Eliminates field joint coatings and increases corrosion protection
- Increases construction speed to over 8,000 ft. / day