How Zap-Lok Works

The basic concept of the Zap-Lok process is relatively simple. A bell, or expanded area, is formed on one end of a joint of pipe, and a groove is formed on the opposite end. Both end-forming operations are accomplished with a hydraulic belling unit and a hydraulic groover, respectively, operated by hydraulic power units. These end preparations are automatically controlled to specifications required for the Zap-Lok joint.

In the field, or on the right-of-way, the belled end of one length of pipe and grooved end is of another are forced together by the Zap-Lok joining press, with a thin coating of epoxy serving as a lubricant. The Zap-Lok joint is made cold and formed from the pipe itself. This process takes about 10 seconds, and it is normal to average 90 seconds per connection, including driving to the next joint. In the drive to lower costs for oil and gas operators, Zap-Lok is seen as a way to reduce costs of pipeline construction by 25% -30% on land and by 45%–60% offshore.


Zap-Lok and Coatings

The Zap-Lok type 4 joint is used for installation of internally coated pipelines for corrosive service. Zap-Lok operates in H2S service under NACE MR-0175. Zap-Lok is used for culinary water and sewer lines.
Pipeline Codes Zap-Lok conforms to DOT pipeline Safety codes, and ANSI B.31.4. and B. 31.8

The Zap-Lok Experience

  1. Steel pipe is prepared for the Zap-Lok process at our Houston facility or at a steel mill or coating plant by special agreement. Pipe suppliers are experienced in making these arrangements.
  2. Customer or pipe supplier coats the pipe, if applicable, and delivers it to the right of way or dock.
  3. Zap-Lok technician delivers Zap-Lok model 5000 (2 3/8"-4 1/2") or model 8000-12 (6 5/8"-12 3/4") press and power unit, and all supplies to the customer or customer's contractor.
  4. Zap-Lok technician trains crew in the proper and safe operation of the Zap-Lok system. By agreement, the Zap-Lok technician may stay for the duration of the job, or remain on call if needed. Once a contractor is trained and certified, only occasional visits by Zap-Lok technicians are required.
  5. At the end of the job, the Zap-Lok equipment is returned to our facility by the Zap-Lok technician or common carrier.