PICOTE DN50 Use and care manual

These instrucons are for your personal safety. Always ensure that you
have read and understood these instrucons before using the tools. SAVE
THESE INSTRUCTIONS FOR FUTURE REFERENCE.
OPERATION & SAFETY MANUAL
BENDY PACKER
Point Repair Installation Tool

Picote Soluons Oy Ltd 2www.picoteinstute.com
To watch practical demonstration videos, take a course, or to download an electronic copy of these Instructions,
please visit www.picoteinstitute.com. Please note that videos and courses are not intended as a replacement or
alternative to this operating and safety manual, but only as an additional learning tool.
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
TABLE OF CONTENTS
TOPIC PAGE
Safety Informaon 3
General Operaonal Safety Informaon 4
Environment, Transport, Storage & Disposal 5
General Informaon: DN70-100 -> Models 6
Operang Pressures 7
CE Declaraon of Conformity 8
Operang Instrucons 9
Before Operaon 9
Make a Test Run 10
Start Using the Tool 10
Navigaon Accessories 11
Connecon of Push Rods 12
Measuring Distance using CCTV Camera 14
Preparing the Bendy Packer 15
Locang the Repair on the Bendy Packer 16
Supporng Hose 18
Supporng Hose - Full Length of Bendy Packer 18
Supporng Hose - Ends of the Bendy Packer 20
APPENDIX 1: A Typical Repair Installaon Method 21
Inang the Bendy Packer 27
Removing the Bendy Packer (Post Installaon) 28
Maintenance, Service & Repair 29
Accessories & Spare Parts 30
Warranty Policy & Procedure 32

Picote Soluons Oy Ltd 3www.picoteinstute.com
Personal Protecve Equipment (PPE)
Always use Personal Protecve Equipment including suitable protecve clothing, footwear,
plus:
Suitable eye protecon to protect against sewage, chemicals or dust from
irritang eyes.
Suitable heat and cut-resistant gloves to help prevent any hand injuries. Any
open injuries or skin irritaons should always be covered to avoid contact with
sewage, chemicals or dust.
Suitable respirator to prevent any dust or fumes being inhaled or consumed,
which could cause occupaonal asthma or dermas.
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
SAFETY INFORMATION
This secon contains important safety informaon. Failure
to comply could result in serious injury or death.
Safety Symbols
Safety symbols are used throughout this manual to draw aenon to potenal hazards.
Danger risk of serious injury, follow instrucons.
Suitable ear protecon to protect against hearing loss.
Drains and Sewers may contain substances such as bacteria and chemicals. Take good care of
hygiene during work and only use serviced, working equipment without any damaged parts.

Picote Soluons Oy Ltd 4www.picoteinstute.com
Always read all safety warnings and instrucons. Failure to follow warnings and instrucons may result
serious injury or death.
This secon contains important safety informaon.
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
GENERAL OPERATIONAL SAFETY INFORMATION
Picote Bendy Packers are only intended for use in circular pipe proles!
The Picote Bendy Packers are designed for the installaon of Trenchless Point Repairs such as
Localised, Spot, Point or Patch Repairs in damaged or separated pipe bends. A resin impregnated
patch is loaded onto the Bendy Packer, pushed through the pipe, aligned over the damaged
secon of the bend and then inated using compressed air. The Bendy Packer expands from the
middle rst, expanding evenly to make the point repair ush against pipe wall. This enables a
near wrinkle-free end result. Every renovaon job is dierent and selecng the correct method
requires experience & skill. Installaon of a point repair may not be appropriate in all cases as
it may cause further damage to the pipe.
- Always wear suitable chemical resistant gloves, eye and ear protecon.
Other personal protecve equipment, such as respirator and overalls should be worn where
necessary.
- Choose correct size Bendy Packer for the job. Only use in pipes of the intended diameter.
- Before each use always inspect the Bendy Packer and associated installaon tools carefully
for any potenal wear or damage.
• Immediately replace any damaged equipment.
• Never inate the Bendy Packer outside of the pipe.
• Do not over-pressurise the Bendy Packer!
Avoid standing near the Bendy Packer when it is fully inated because if it bursts the debris
will y towards you at high speed and the loud bang noise could be harmful to hearing if
protecve hearing gear is not being worn.
- Never leave lled Packers unaended!
Only use the Bendy Packer with original Picote accessories & spare parts. Accessories and
spare parts should only be used in the manner intended and as described by Picote Soluons.

Picote Soluons Oy Ltd 5www.picoteinstute.com
TRANSPORT & STORAGE
The Bendy Packer should be transported unpressurised in a protecve tube to protect it from
the elements and to prevent any premature wear that could cause accidents and/or bladder
malfuncons.
The Bendy Packer should be stored indoors to protect it from rain and sunlight and
somewhere with a constant ambient temperature.
Where the Bendy Packer has been stored for long periods of me it, will need to be slowly
inated/deated with compressed air a few mes before being used. This helps the elasc
materials to stretch, enabling the Bendy Packer to perform correctly.
If the Bendy Packer has been stored in an environment colder than 0oC (32oF), the Packer
should be stood at room temperature for approximately 2 hours prior to use.
DISPOSAL
The two end caps, lock plate, connectors, bolts and wires can be recycled in metal waste
collecon points. The hoses can be disposed of as rubber waste.
Always follow local waste handling rules and regulaons.
ENVIRONMENT
Operaonal Ambient Temperature Range: 0 oC to +50 oC (32 oF to 122 oF)
Storage Ambient Temperature Range: -20 oC to +50oC (-4 oF to 122 oF) condensaon free
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
ENVIRONMENT, TRANSPORT, STORAGE & DISPOSAL

Picote Soluons Oy Ltd 6www.picoteinstute.com
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
GENERAL INFORMATION: DN75-100 -> MODELS
The Bendy Packers in sizes DN70-100 (3”-4”) to DN225-300 (9”-12”) are ed with a short
connecon hose which allows the aachment of the Picote Push Rods. The amount of push
rods required will vary by installaon length and project requirements.
The use of the Picote Push Rods enables the operator to push/pull the Bendy Packer
through the pipe, rotate, inate and deate using mulple quick connect rods. (Picote Push
Rods sold separately).
For the Bendy Packers in sizes DN70-100 (3”-4”) to DN225-300 (9”-12”) you can insert
an addional glass bre rod through the Bendy Packer and all the way to the end cap.
This patented feature is referred to as “front wheel drive” and it helps navigate the
Bendy Packer through the pipes and can be used in combinaon with the Picote Push
Rods when required.

Picote Soluons Oy Ltd 7www.picoteinstute.com
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
OPERATING PRESSURES
Model Max. Operang
Pressure Bar/PSI
Bendy DN70 (3”) COMING SOON
Bendy DN75-100 (3”-4”) 3.5 Bar / (50 PSI)
Bendy DN100-125 (4”-5”) 2.5 Bar / (36 PSI)
Bendy DN 125-150 (5”-6”) 2.5 Bar / (36 PSI)
Bendy DN150-200 (6”-8”) 2.0 Bar / (29 PSI)
Bendy DN225-300 (9”-12”) COMING SOON
Before use: ensure correct (maximum) operang pressure for the tool.
Excessive pressure can cause the Bendy Packer to fail or explode.
The correct operang pressure can also be found marked on the end cap.
Picote Bendy Packers are only intended for use in circular pipe proles!

Picote Soluons Oy Ltd 8www.picoteinstute.com
We Picote Soluons Oy Ltd as the responsible manufacturer, declare that the following Picote
Soluons Oy Ltd point repairing tool:
Picote Bendy Packer
Models: DN50 (2”), DN70 (3”), DN75-100 (3”-4”), DN100-125 (4”-5”), DN125-150 (5”-6”), DN150-200
(6”-8”) & DN225-300 (9”-12”).
are of series producon and
Conform to the following EU Direcve:
2014/68/EU
The technical documentaon is kept by our authorised representave in Europe who is:
Picote Soluons Oy Ltd, Pienteollisuuse 24
06450 Porvoo, Finland
4th October 2022
8
Katja Lindy-Wilkinson
C.E.O.
Picote Soluons Oy Ltd
Pienteollisuuse 24, 06450 Porvoo, Finland
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
CE DECLARATION OF CONFORMITY

Picote Soluons Oy Ltd 9www.picoteinstute.com
BEFORE OPERATION:
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
OPERATING INSTRUCTIONS
Use CCTV inspecon camera to:
1. Check the severity and extent of the damage.
2. Measure the diameter of the pipe and length of the repair required.
3. Check possible changes in pipe diameter and any holes or damage over Ø25mm (Ø 1”)
4. Is the point repair the correct repair method for the job? If damage is severe and/or
spread over a long area, other repair methods should be considered.
5. Select the correct diameter Bendy Packer and length for the repair. If longer repairs are
required you can make mulple repairs by overlapping, but will need to take into
account that this reduces the internal diameter of the pipe.
If there are connecons, transions or large areas of pipe damage on the repairable area, the
Bendy Packer must be properly supported using suitable material to prevent the bladder
from over expanding. The Bendy Packer can swell out and burst if no supporng hose/liner
etc. is used. (Refer to Page 18)
• Ensure that you have selected the correct size Bendy Packer for the job and visually in-
spect it for signs of damage or wear. Make sure that there is an air regulator on the air
supply line which can be used to adjust the pressure precisely and control the inaon
speed.
• The pipe must be clean and free of any dirt, burrs, sharp edges etc. Depending on the
resin system being used, the inner wall on the pipe should be dry.
• When installing a repair in a plasc pipe, it is worth abrading the inside of the pipe, us-
ing the Picote Smart Cuer™, as this will help the repair bond to the host pipe.
• Keep your working area clean and prevent unauthorised access to the work site. Ensure
proper venlaon and lighng.
This secon contains important safety and operang informaon.
Picote Bendy Packers are only intended for use in circular pipe proles!

Picote Soluons Oy Ltd 10 www.picoteinstute.com
12
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
OPERATING INSTRUCTIONS
13
STARTING & USING THE TOOL
Where the Bendy Packer has been stored for long periods of me it will need to be slowly
inated/deated with compressed air a few mes before being used. This helps the elasc
materials to stretch enabling the Bendy Packer to properly perform. Prior to doing this you
need to fully place the Bendy Packer inside the pipe.
It is important to make a test run prior to installing the repair to ensure you’re able to set-up
& navigate the Bendy Packer to the desired spot within the cure me of the resin. Do not
aempt to repair the pipe using this method if the installaon me exceeds the curing
me.
Consider whether or not you need to pull or push the Bendy Packer into the correct posion.
Take suitable measurements and then mark the Push Rods and/or pulling-in rope to use as an
aid to help locate the Bendy Packer to the correct posion within the pipe.
MAKE A TEST RUN

Picote Soluons Oy Ltd 11 www.picoteinstute.com
12
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
OPERATING INSTRUCTIONS
13
NAVIGATION ACCESSORIES
The following range of accessories will assist in pushing / pulling the Bendy Packer through the
pipe to locate the repair.
• A rope can be aached to the Filler
Cap to assist pulling the Bendy
Packer out of the pipe.
• An M8 eye bolt and pull rope can
be ed to the End Cap to enable
the operator to pull the Bendy
Packer into the posion.
• A Navigaon Guide can be screwed
into the End Cap to help guide the
Bendy Packer around bends when
pushing it into place.
A complete set of equipment is
available.
Product ordering numbers can be found
listed on pages 30-31.

Picote Soluons Oy Ltd 12 www.picoteinstute.com
12
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
OPERATING INSTRUCTIONS
13
CONNECTING PICOTE PUSH RODS
Using Picote Push Rods gives you possibility to push, pull, rotate, inate and extend the
install length of the repair. Each push rod is 1.5 metres (5 ) in length.
The Push Rod ngs have a hex
socket that must be aligned to
connect.
Le: Male-type connector
Right: Female-type connector with
turning lock ring.
To join the rods together you align the
hex socket, push ngs together and
then ghten the locking ring.
Ensure ngs are completely pushed
together and won’t come loose if you try
to pull them apart.
Loosen the locking ring.
The ngs can be disconnected by
pulling the collar from the female-type
ng towards the locking ring.

Picote Soluons Oy Ltd 13 www.picoteinstute.com
12
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
OPERATING INSTRUCTIONS
13
The Picote Push Rods have to be secured
with the locking ring, which is located on
the rear of the female-type ng.
Screw the locking ring unl it’s
completely against the collar.
Wrap protecve tape around each
ng to prevent resin from geng
inside ngs.

Picote Soluons Oy Ltd 14 www.picoteinstute.com
12
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
OPERATING INSTRUCTIONS
13
MEASURING DISTANCE USING CCTV CAMERA
Carefully push the camera through the
pipe unl the camera head is in the
centre of the damaged secon of pipe
where the repair is to be installed.
Mark the distance on the camera cable
using a piece of PVC tape. Make sure the
tape cannot move.
Place the camera head and Bendy
Packer (with Push Rods aached) side by
side. Make sure that the camera is
posioned in the middle of the Packer
and replicate the distance on the Push
Rods.
Using the marker tape on the camera as a
guide, fasten another piece of PVC
marking tape onto the Picote Push Rod to
indicate the correct distance to install the
repair in the pipe.

Picote Soluons Oy Ltd 15 www.picoteinstute.com
12
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
OPERATING INSTRUCTIONS
13
PREPARING THE BENDY PACKER
The Bendy Packer has to be
unpressurised.
The outer surface of the Bendy Packer
has to be covered with a stretch lm.
This reduces the need for cleaning the
Bendy Packer and ensures a longer
lifeme.
Ensure that the whole length of the
Bendy Packer is covered with the lm.
Before covering the Bendy Packer with
the stretch lm, aach pull ropes etc.
Ensure that the threaded connectors,
on either of the cap ends, are not
covered.
At an approximately 45° angle, wrap
the packer from front to rear,
overlapping each pass by 150mm (6”).
Tape each end to secure the protecve
wrapping.

Picote Soluons Oy Ltd 16 www.picoteinstute.com
12
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
OPERATING INSTRUCTIONS
13
LOCATING THE REPAIR ON THE BENDY PACKER
Due to the structure of the Bendy Packer, both ends must be liner/patch free as the rubber
does not fully inate around the end caps. If the Point Repair is located too close to the end
caps, the Bendy Packer will not fully inate and the Point Repair will not make full contact
against the inner wall of line to be repaired. Therefore, it is recommended to use the following
measurements at minimum to be on safe side.
The ‘o-limits’ zone is measured at each end of the Bendy Packer, from the end of the
bladder where it meets the metal cap (refer to photograph and table below).
BENDY PACKER SIZE MEASURE FOR
OFF-LIMITS-ZONE
DN75-100 (3”-4”)
DN100-125 (4”-5”)
DN125-150 (5”-6”)
15cm (6”)
DN150-200 (6”-8”) 17.5cm (7”)

Picote Soluons Oy Ltd 17 www.picoteinstute.com
12
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
OPERATING INSTRUCTIONS
13
Check the o-limits-zone from the
table on Page16, measure the distance
on the on the surface of the lm using
a suitable marker pen.
Cut the required amount of liner/patch
staying within the secon between the
o-limit-zones.
When inang, the Bendy Packer could swell out and burst if no supporng hose is used!

Picote Soluons Oy Ltd 18 www.picoteinstute.com
12
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
OPERATING INSTRUCTIONS
13
Depending on the situaon, the supporng hose can be installed on one end, both ends or
for the whole length of the Packer.
Measure out the ‘support hose’ and
cover the Bendy Packer from the end
cap to the adapter hose located in the
ller cap.
Fold support hose neatly around end
cap.
SUPPORTING HOSE - FULL LENGTH OF BENDY PACKER
If there are any connecons, transions, major pipe damage or brile pipe on the
repairable area the Packer must be properly supported using a suitable restricng material,
such as a length of calibraon hose.
When inang, the Bendy Packer could swell out and burst if no supporng hose is used!
SUPPORTING HOSE

Picote Soluons Oy Ltd 19 www.picoteinstute.com
12
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
OPERATING INSTRUCTIONS
13
Finally, use rubber bands (doubled over
if needed), approximately every 25cm
(10”), to secure the support hose on to
the bladder.
Secure the support hose in posion by
taping it to both end caps. Do not
cover the threaded connectors on the
end caps.

Picote Soluons Oy Ltd 20 www.picoteinstute.com
12
SAVE ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE
OPERATING INSTRUCTIONS
13
SUPPORTING HOSE - ENDS OF THE BENDY PACKER
When using support only on the ends,
the hose should be measured in way it
will reach at minimum 10cm (4”) under
the patch. The same rule applies when
patches are shorter than the full length.
Secure the supporng hose by taping it
to the metal end cap and use a doubled
over rubber band at the far end of the
support hose.
Copy the o-limit-zone measure on to
the surface of the support hose using a
marker pen.