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Pipecoating Part 3

MODULE 5Describes Concrete Weight Coating

Sacrificial Anode Installation

INTRODUCTION PIPE COATING

Module “4”” describes the requirements for inspecting and maintainingaceability of pipe when being loaded into and going through a Concrete

Weight Coating facility where concrete coatings are applied and Sacrificial

nodes attached.

oncrete Weight Coating is typically applied to pipe by using impingementr wrap on technology. Weight coating is applied to pipes to allow added

weight for stabilizing pipe on the sea bed offshore and/or through swampreas onshore. The coating also allows for protection from trawl boardmpact offshore and mechanical protection onshore (road crossings andlike).

is common that the density of concrete required for offshore pipelinectivities to be greater than traditional concrete densities. To allow for igher than normal concrete densities, the concrete mix often contains Iron

Ore as a constituent part of the concrete mix.

oncrete coating is usually applied to pipes that have already received annti corrosion coating, typically coatings are, Asphalt Enamel, Three layer olyethylene or Polypropylene and to a lesser extent Fusion Bondedpoxies.

or added corrosion protection, offshore pipelines are also fitted withegmented or bracelet type sacrificial alloy anodes. The anodes are usuallytted to the pipe at the pipe coating facility during the concrete installationrocess.

,0 MATERIALS

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ll incoming materials are checked against the material manufacturer’sertification and other specification requirements and recorded on anncoming receipt form ( IRF )

ement

ement shall conform to ASTM C 150 or BS 12 and to the Project specifiedhe Alkali and C3A content requirements.

ggregates and Sand

ggregates and Sand shall conform to ASTM C33. However, where ironre aggregates are used some aspects of the standard cannot be complied

with e,g, the Gradation envelope may not be achievable: in such case aechnical query should be raised and agreed to.

Reinforcement

ll reinforcement shall meet the minimum specified % cross sectional areaCSA) requirements .here are commonly two methods of reinforcement; rigid preformed cages

usually manufactured on site using Zublin machines) and wire mesh fabric.On occasions both methods are used simultaneously. (This usually occurswhere high thickness concrete coatings are required) .

Zublin Machine



Typical Zublin made Cage

Where rigid preformed cage reinforcement is used, the cages are fitted tohe pipe prior to the concrete application process. Wire mesh fabricowever, is wound into the concrete during the concrete applicationrocess. .

age reinforcement shall normally be required to meet the requirements of S 4482, BS4449 or ASTM A615/A615M using wire with typicallyiameters of 5 mm for longitudinal and 7-8 mm for circumferential.

Welded wire fabric reinforcement shall normally be required to meet theequirements of ASTM A82 for zinc coated drawn wires, Typically one layer f wire is required for concrete thicknesses up to 55 mm above 55 mmoncrete thickness two layers minimum are required.

otable water

Water used for concrete should be clean potable water which is analyzed



Materials Dept & QC Laboratory are responsible for ensuring that allmaterials are checked and comply with requirements of the agreed Projectnspection Plan (ITP)

.0 PROCESS DESCRIPTION

Incoming Pipe

t load in to the concrete facility pipes are passed through an “in line”oliday detector where the anti corrosion coating is checked for holidaysnd/or coating damage.

Holiday Detector

ipes with holidays detected are isolated for repair and re-holiday detectedefore further processing.

ipes that are designated for sacrificial anode installation shall beansported to the designated Anode Installation Rack See Anode

nstallation Section 9.0

Where rigid cage reinforcement is used, accepted bare and anode pipesre transferred to the caging area where predetermined lengths of cagingre fitted. Cages are rigidly held concentric to the pipe at the correctocation by electrically insulated plastic spacers.

n a six monthly basis for cleanliness and impurities

Responsibility:



he spacers are manufactured to precise dimensions that allows for theeinforcement to be set evenly and at the correct distance from the antiorrosion coating. Whilst at the caging area rubber end rings are fitted at aet distance each end of the pipe. The rings allow for the correct concreteutback distance to be established during the coating process.

Typical cage and spacers

Typical Rubber End Ring

On completion of the caging process the pipes are indexed to the incomingde of the concrete impingement area where end plugs are inserted to the

nternal pipe bore at both ends. The plugs prevent ingress of coating



materials.

Note: Where no rigid cage reinforcement is required, hooks are attached tohe lead end of the pipe which allow for the attaching of the wire meshabric reinforcement. The hooks shall be placed on rubber pads to protecthe anti-corrosion coating damage and are affixed to the pipe using a

rong banding method.

he pipe is then indexed directly to the impingement area.

Typical impingement Area

Responsibilities:

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he Incoming Supervisor shall ensure that the incoming holiday detection,einforcement installation, fitting of end rings and end plugs are performedorrectly. He shall quarantine pipes that are in need of repair and supervisehe repair operation. He is also responsible for ensuring that all tasks areonducted in the safest possible manner.

he QC inspector/Auditor shall be responsible for the release or uarantining of the incoming pipe. He shall maintain checks in accordance

with function described in an agreed inspection Test Plan (ITP)

he tally man shall be responsible for maintain pipe traceability andecording the disposition of rejected and repair pipes.

.0 Mixing of Concrete

rior to concrete coating, the batch plant, cement hopper and water feedystems are calibrated to allow accurate percentages of constituent

materials to be delivered to the mixer. Typical constituents of the concretemix are cement, high-density iron ore, sand and water. The concrete mix

esign is dependent on the Specific Gravity of materials being used and isroportioned accordingly.

Typical Batch Plant Calibration Tolerances

Cement ± 2% Aggregates ± 3 %Water ± 2%Whole ± 3 %

and/aggregates are typically transported from their respective stockpileso the Mixing Plant hoppers using rubber tired front end loaders. From theeed hoppers the sand and aggregate are metered into the mixer at the mixesign quantities. Cement is typically auger fed from the cement silo into a

weigh hopper which weighs off the required amount to meet the mix designequirement.

Note: where aggregates are stored in outside open areas the working face



f the stockpiles should be regularly turned over to maintain even moisturemix in the material. It is inadvisable to take the material from the very

ottom of stockpiles where moisture is likely to be exceptionally high,

Typical Batch Plant feed System

fter weighing, the cement is added to the aggregate in the mixer. After aeriod of dry mixing, water is metered by volume into the mixer and theatch mixed for the prescribed mixing time. On completion of the mixinghe concrete is conveyed to the short feed hopper. From the hopper theresh mix is gravity fed onto a short belt which in turn progresses the mix tohe concrete application head.

Note: Regular samples of the fresh concrete mix shall be taken from theeed belt to enable moisture content and fresh analyses to be carried out.lso for mix control purposes fresh mix test cube specimens are prepared.

Cube Making



Cube Samples



Responsibilities:

he Batch Plant Supervisor shall be responsible for batch plant calibrationnd operation. He is to ensure that the parameters set through batch plantalibration are maintained throughout production. conveying aggregates tond from the correct holding hoppers ensuring that the correct amount of

water is added to the concrete mix to provide consistent moisture contentf the mix. He shall also be responsible in ensuring that the task isonducted in the safest possible manner.

he QC laboratory Technician shall be responsible for ensuring concretemix calibrations are carried out correctly, taking samples of the concretemix for analyzing and preparing samples for testing. He shall also beesponsible for consistently reporting test results to the Batch Plantupervisor, and for logging all test results.

.0 COATING PROCESS:

rom the impingement incoming rack or indexer, pipes are placed on theoncrete coating line rotation buggy’s using an overhead crane using apreader bar and suitably protected hooks. On the rotating buggy’s theipes are transported past the impingement coating head where premixedoncrete is applied at high velocity to the pipe using impingement rollers.he concrete plant operator selects the pipe rotation and forward travelpeeds at a setting that allows for the concrete to be applied to the correctoncrete coating thickness.



ipes with anodes fitted are coated as per a plain pipe with the exceptionhat a shadow plate and plastic wrap covering the anode is utilized torevent excessive concrete covering the anode. After processing thelastic wrap shall be removed and the outer surfaces of the Anodes shalle cleaned and be free of concrete coating materials.

Diameter or thickness of the concrete coating is controlled by measurementsing a girth or tree tape and is performed at the coating head and againerified at the weigh station.

Note Where wire mesh fabric reinforcement is used, the wire fabric is fedrom a spool tensioning arrangement then travels though guides and ontohe rotating pipe as the pipe is being impinged.

Welded Wire Fabric Feed

.0 CLEANING AND WEIGHING STATION

Upon completion of the concrete coating, the pipe cutback areas areleaned, the end plugs are removed and any debris in the pipe interior islso removed. The OD of the concrete is again measured: taking sixquidistant measurements along the pipe.

Taking Girth Measurements



Note : The concrete ends shall be finished square to the pipe axis and therown of the concrete shall be slightly rounded.

When all redundant material has been removed from the coated pipe, theipe is weighed using a calibrated weigh scale or load cell.

ipes that are out tolerances for thickness and or weight may be flashoated or scraped to enable correct tolerances to be achieved. Thisectification process shall be carried out whilst the concrete is in a greentate and only if agreed to by the client.

t the cleaning station continuity (anode to pipe) and isolation (rebar tonode & pipe) and reinforcement position checks shall be performed onipes in accordance with the agreed inspection frequency included in theroject inspection Test Plan (ITP)



Reinforcement placement check

Note : In the case where welded wire is used for reinforcement, the excesswire on the finish end of the pipe is trimmed back to just below the concreteurface to ensure no protruding wire is on the concrete surface.

Excess Wire Fabric

When accepted the details of the pipe weight and girth measurements arentered into a pre programmed computer that determines the negativeuoyancy (NB) of the pipe.

typical formula for NB calculation



Weighing devices used to determine the weight of the concrete-coatedoints shall be certified in writing to accuracy of 0.5%. The calibration of weighing equipment shall be checked by test weighing method previouslypproved by contractor unless other procedures have been agreed andonfirmed in writing. Calibration of the weighing equipment shall behecked daily.

he unsaturated (as applied) submerged weight per metre (N/m) for eachipe shall be calculated from the pipe weight in air immediately after oating.

he submerged weight, W (N/linear metre), shall be calculatedsing the following formula:

where:

Mc = Mass of fresh concrete coated pipe including reinforcement kgDc = Outer diameter concrete coated pipe m. Average of 6 girthmeasurements

Ds = Outer diameter of steel pipe plus twice the anti-corrosion coatinghickness, m1 = Density of field joint filing materials (assume 1025 )

= Cutback of concrete coating from bevelled end, m= Mill length of steel pipe, m

w = Density of seawater (assume 1025 )W = Submerged weight

Submerged



or anode and crack/buckle arrestor pipes, the specified maximumubmerged weight may be exceeded. Variations in buoyancy shall begnored and the submerged weight value shall be adjusted by usingn increased weight in air. The Principal shall specify the allowable weightariations in the Scope of Work.

he results shall be recorded and tabulated against pipe number and

resented to the Principal at the completion of each day’s production. Theubmerged weight of each coated pipe shall be within the acceptanceolerances stated by the Client in the Scope of Work.

Responsibilities:

he concrete plant supervisor is responsible for ensuring that all equipmentnd personnel are adequately organized to carry out concrete batching,lacement of reinforcement, coating, repairing and checking all coatingarameters. He is also responsible in ensuring that the task is conducted inhe safest possible manner.

he concrete plant operator is responsible for maintaining the correct mixesign, travel and rotation speeds, placement of reinforcement, end ringsnd anode protection.

he coating Tally man is responsible for recording the traceability of theoated pipes, the correct recording of pipe weights, pipe lengths, coatingiameter, cutback lengths and submerged weight (NB) calculation. He willlso keep an ongoing log of running (NB) averages.

he QA inspector/Auditor is responsible for the correct calibration of theweigh scales (NB station), periodic checking of any repairs to anti corrosionoating, the concrete coating parameters, including wash out checks of theeinforcement, overlaps for reinforcement and periodic isolation/continuityhecks.

.0 CONCRETE CURING

rom the cleaning area acceptable coated pipes are lifted by overheadrane onto trucks having suitable cushioning and supports that protect thereen concrete. The pipes are transported to the curing area where thereshly concrete coated pipes shall be laid out in single layerspproximately 250 mm apart on suitable sand berms using either anverhead gantry or mobile crane.



ipes that are to be cured using the Fog Cure method shall be covered asoon as practical with a tarpaulin and ‘fog’ water spray shall be introducedia water pipes fitted with fine misting nozzles under the covers to maintainhigh humidity beneath the covers.

he pipes shall remain in the cure bay until the concrete has achieved a

minimum stacking strength of 14 Mpa (as determined by concrete cubetrength testing). On completion of the curing process and prior to stackinghe cutback end rings shall be removed and any concrete contaminationhall be removed from the coating steel cutback and internal bore.

ipes selected for concrete coupon testing shall be clearly marked andlaced on hold in an area suitable for coupon extraction work to beerformed. Coupon holes shall be repaired in accordance with thepproved Concrete Repair Procedure.

Note: Test cube specimens taken from the fresh mix at the batch planthall be placed in the curing bay and cured in a manner identical to theipe.

.0 REPAIRS

Repairs to the coatings shall be carried out in accordance with an approvedRepair Procedure. Coated pipes that cannot be repaired shall be rejected,

tripped and re coated. Unacceptable pipe shall be marked up withRed/White hazard tape and recorded on the NCR system.

fter the completion of acceptable repairs the pipe will then be placed in itsllocated storage area. The stacking height for concrete coated pipes shalle in accordance with the approved handling procedure.

Repairs on freshly applied concrete shall be carried out at the coating plantwhenever appropriate or at the curing bay.

ypical repair procedure

Upon visual examination, concrete coatings that are damaged, areefective or do not meet with requirements shall be repaired. Theircumstances of the damage or defects will dictate the appropriate methodf repair.

Repairs Criteria



f the area is less than 0.8m² in any 3 m length of pipe may be repaired byand patching providing that such repairs are carried out within 4 hours of oncrete application.

f the area is more than 0.8m² but less than 25% of total coating repairshall be made using gunite. The concrete remaining shall be undercut torovide a key lock.

racks caused by excessive deflection in handling or storage, with theollowing criteria shall be repaired by chiseling the crack not less than5mm and repair shall be made using the same basic material as theoating:-

racks in excess of 5mm width and extend over 180° circumferentialround the coated pipe.racks which are between 250mm – 1000mm in length longitudinally along

he coated with the addition that the ends of each crack shall be drilled withhole of 10mm nominal diameter to prevent crack propagation. The bottomf these holes shall be 7 -10mm from the anti-corrosion coating.

racks extending halfway through the concrete or penetrated to the cage

ongitudinal surface cracks of any width and less than 250mm in lengthhall not be considered a defect but holes of 10mm nominal diameter shalle drilled at the crack tips to prevent crack propagation. The bottom of hese holes shall be 7 -10mm from the anti-corrosion coating.

urface damage shall not be considered a defect if :-

he total surface area of damage per pipe is less than 0.1 m², andMax depth does not exceed 20% of coating thicknesses, and

he remaining concrete is sound.

Damage at the ends of the concrete coating need not be repaired providedhat the damaged area is less than one third of the circumference for aength less than 200 mm.

Hand Repairs

Damaged areas may be repaired by hand patching in its ‘green’ concretetate. Patching shall be carried out by removing the defective area down tonderneath the reinforcement and undercutting the sides to form a key. Theavity formed shall be filled with a mix similar to that used in the coatingrocess with the addition of just sufficient water to allow hand application.olythene wrap shall be used to seal the repair before curing. Maximumllowable time between concrete coating and repair of green pipe will be 4ours.



ore Holes

rior to filling cores holes, each site will be inspected for damage to thenti-corrosion coating. Damage to this coating will be brought to thettention of QC personnel and the Customer. Core holes shall be repairedsing concrete with the same proportion of constituents as the originaloating.

ore holes may also be repaired using concrete repair material “Mapegroutast-Set” (manufactured by Mapei) or “Certite” or similar product. A slight

ncrease in water content may be considered acceptable to aid cure for ome of the materials. The material shall be trowelled in such that theurface level is continuous with the level of the existing coating around theepair.

Gunite Repair Criteria

Repair on cured concrete coating and large repair areas shall be rectifiedsing the gunite method of repair. The size of the gunite repairs shall beemonstrated and witnessed for suitability as an addendum to the Preualification trials for concrete coating. The concrete mix design used for unite repairs will be of the same constituent make up as that of the parent

mix material apart from the use of extra water to assist with the application.uring of the repairs will be carried out by wrap sealing of polyethylene

membrane.

Gunite Repairs

GREEN CONCRETE

Damaged or defective areas shall be prepared by undercutting andxposing the reinforcement throughout the damaged area and removing

ny loose concrete material. The area shall then be filled by Gunitepplication until the entire repair area is reinstated to the level of the parent

material. The completed repair shall be dressed in a manner that allows amooth transition to the parent material. Within 30 minutes of the repair ompletion the green concrete coated pipe shall be placed in the fog cure.

URED CONCRETE

hall be performed as that for green repairs with the addition of a water



wetting application to the cured concrete coating interfaces prior toGuniting. The repair area shall have a curing membrane tightly affixed andhall stay in place for a minimum of 48 hours to allow sufficienture.

esting

Repair materials used for concrete repairs shall be tested for compressivetrength as determined by 28 day cube strength results. The minimumtrength to be achieved shall be that of the strength specified for the parentoating. The frequency of testing shall be at start-up, middle and end of roject.

Responsibility

he repair foreman shall be responsible for coating repairs and shall ensurehe correct equipment and repair method is used for coating repair. He shalllso be responsible in ensuring that the task is conducted in the safestossible manner.

QC, Inspector/auditor shall be responsible for checking the preparation andhe completed repair.

ll repairs are to be recorded and inspected for compliance to the repair method statements.

.0 PIPE MARKING AND IDENTIFICATION

he identity of each pipe shall be established and entered into the pipeacking system such that traceability is maintained. Accepted pipes will be

eleased for transportation to the stockpiles or other processes.

ypical Marking Requirements

Pipe noLengthWTHeat no.Date of coating

Responsibilities

oad out Tally man, shall ensure that the correct pipe markings are appliedn accordance with the agreed marking system. He shall also beesponsible in ensuring that the task is conducted in the safest possible



manner.

QC, Inspector/Auditor shall be responsible for inspecting that the correctolour banding and markings are applied.

.0 SACRIFICIAL ANODE INSTALLATION

node are typically fitted to the corrosion coated pipe prior to caging andoncrete coating, however in some circumstances anodes can be retrotted i.e. after concrete coating.

rocess Descriptionhe Coated line pipe shall be positioned on the support racks, over thenode lifting saddle. The pipe will be positioned until the longitudinal seam

weld (if any) is located around either the 12 or 6 o'clock position or pproximately 150mm of the weld seam. Once positioned the lifting saddle

will raise the lower half shell of anode to the stationary pipe and hold it inosition. The second half shell of anode shall be offered to the pipe andositioned over the first half shell, by means of crane jib. The two halveshall be carefully aligned and drawn tightly together using webbingensioners, chain come-along or similar.he centering of the anode along the pipe shall be in a manner that allows

or casing segments to be fed onto the pipes.

Fit Up

illet WeldingWelding will be by metal arc process



ipe Preparation:

reas of anti corrosion (TLPE) coating are be removed within each gapetween half shells, each area of removal shall be as small as practical toccommodate the Thermit Graphite Mould

he removal of coating shall be achieved by using a heated knife and / or aolster type chisel cutting around the heated area that is to be stripped,ollowing the removal of the coating the steel substrate shall be power round to achieve a bright, clean roughened surface or St 3.

onnecting of Bonding Leads (Electrical Connection):

ach anode is normally manufactured complete with bonding leads; theonding leads may be cut to size using a cable cutter or hacksaw toemove. The cable should be looped (pig tailed) so as not to be taut after

welding.

he end 25mm of PVC/PE sheathing is stripped back to expose cleanopper cable. The cable may be cleaned with a wire brush if required.

ad welding process as follows:

lean the conductors and position them in the well dry mould;lace the metal retaining disc in the bottom of the crucible graphite mould;our the welding metal powder into the graphite crucible, spread startingowder onto the graphite mould edge;

Open the mould lid and ignite the welding powder using a flint gun byring the spark onto the starting powder;he exothermic welding process takes place inside the graphite mould; andnally the exothermic connection is finished.lean the mould using scraper and brush and proceed to the nextonnection cable(s) ready for connection.

fter welding, each completed weld shall be tested for electrical continuitynd mechanical bonding strength (1 blow with a 1 Kg Hammer)

Electrical Continuity using Ohm meter



nti corrosion Coating:

ubsequent to the satisfactory completion of anode installation, the anti-orrosion coating shall be reinstated as follows:

he exposed areas of steel substrate around the Cad weld and anodetraps shall be wire brushed to a clean finish. All bare steel shall then beoated using SOLVENTLESS 2 PACK EPOXY or other approved repair

material.

node Completion:

fter final inspection, the Anode completion procedure will be carried out,

onsisting of the infilling of the gaps between anode halves with either aunite concrete or hot poured marine mastic method.

he reinforcement used during concrete coating shall be trimmed back fromhe edges of anode allowing a 25- 50mm gap. Electrical continuity testhall be carried out to ensure that the reinforcement is electrically isolatedrom the anode/pipe.he gaps between the anode and the parent concrete weight coatinghall in filled with either a concrete mix similar to that of the parent coating



he test welds and coupons shall be sectioned and tested for copper enetration by a third party inspection house

Hardness shall not exceed 248 Hv10 when taken at 2mm intervalsxtending to 10mm either side of the extreme edges of the weld.

No cracks or penetration of alloying elements along grain boundaries bymore than 0.5mm or any non-metallic inclusions will be detected at 200Xmagnification.

material (by hand or gunite method) Or by other approved in fill methodsfor example moulded hot bitumen) On completion a continuity checketween Anode and the steel pipe shall be performed prior to moving theipe to storage.nspection control:re-qualification

he anode installation procedure and inspection shall be pre-qualified prior o the start of production.

he pre-qualification will be limited to anode closure (strap) and Cad welds.

Weld / Welder Qualification

ypically each welder shall perform one fillet weld on a test couponometimes supplied by client. The test coupon shall be macro sectionednd tested for hardness.

ll required tests shall be carried out and reported by credited 3 rd Partynspection Laboratory.

hermit Weld Qualification

ypically each production welding operative will be qualified byemonstrating their capability to perform a series of Thermit welds on aoupon sample. Each weld shall be mechanically tested by a single blowrom a 1kg hammer, aimed at 90 degrees to the sample surface - no liftingr fracturing shall result. Electrical continuity test shall be carried outetween pipe and anode

he macro sectioned and hardness and penetration tests reports will bedentified by coupon unique numbers. Test results should meet the

ollowing:



0.0 OFFLINE TESTING

pecific Densityieve Analysis

Moisture Content

Deleterious Substancesresh Analysis

Water Absorptionompressive Strength Cubesompressive Strength Cores

mpact Testhear Test

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PECIFIC GRAVITY - BS 812: part 2 1985

Note: This practice may be modified by the requirements of the customer’specification, see relevant Project Inspection Test Plan (ITP)

cope

Determination of the Specific Gravity (SG) of Aggregate/Iron Ore

quipment

ycnometer lectronic balance

Gas ring or oven

rocedure

Obtain a sample weighing approximately 2000 grams.Thoroughly wash theample to remove all material finer than No. 200 Sieve (75micron).Dry theetained sample over the gas ring (or oven) and then allow it to cool tooom (ambient) temperature.



lace 500 g of dry aggregate (Weight, A) into the Pycnometer and fill it withwater. Whilst filling rotate the Pycnometer to eliminate all traces of trappedir within the sample material and allow settling. After settling, top up theycnometer with water again to remove any froth from the surface so that

he water level in the hole at the to of the cone is flat and level. Dry thexterior of the Pycnometer and weigh (Weight, C).

mpty all the contents of the Pycnometer into a tray, making sure that theggregate is completely emptied. Refill the Pycnometer to the original level

with water (only), dry the exterior and weigh (Weight, B).

he difference in water temperature between the first and second weighinghall not exceed 2°C.arry out the test twice.

valuation

alculate the Specific Gravity of the aggregate as follows:pecific Gravity (SG) = Weight A / ((Weight A + Weight B) – Weight C))

Report

Record Specific Gravity

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IEVE ANALYSIS (GRADATION) OF AGGREGATES - ASTM C 33


cope

o establish a Sieve Analysis (Gradation) of aggregates using interlocking,ircular sieves of standard aperture sizes

quipment

Nest of certified sievesieve shaker alibrated weigh scale

Oven or gas ringampling box

Oven trayslastic bucketampling scoop

rocedure

representative sample of material to be analyzed shall be taken in aroper sapling method. The sample shall be at least 1500 grams.



he sample shall be weighed and the weight recorded. After weighing theample shall be oven or gas ring dried making sure that none of the sample spilt from the heating tray.

fter drying the sample shall be passed through a set of known mesh sizeeves, making sure that all the sample is removed from the heating tray.

he sieves shall be interlocked in order of aperture size, starting with thearges mesh size at the top.

he interlocking sieves (including bottom pan) shall be agitated sufficientlynormally with the aid of mechanical vibrator/shaker) for a period of timeusually 4 minutes minimum), to ensure that the material has completelyassed through the respective grade sizes.

he aggregate which is retained in each of the sieves and the bottom panre then individually accurately weighed and the weights recorded.

alculations

fter the mass of aggregate retained on each sieve and in the receiver haseen determined, calculations are then carried out. Note that mass retainednd mass passing on each sieve are recorded and percentage passing isventually calculated from the obtained results.

Visual representation of the particle size distribution is carried out bemeans of gradation graph showing the sieve aperture size against the

ercentage passing that particular sieve size.

Due to the relative values of the aperture size, it is convenient to plot themo a logarithmic scale.

On completion of plotting, the points of the plot are joined together withtraight lines resulting in a graph that is termed the gradation curve.

valuation of results

he obtained grading curve should be within the envelope limits drawn byhe applicator and approved by the client and/or limits extracted from theSTM C33 Standard.

Report

he type of aggregateResults and percentages calculate



Sieve Analysis

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MOISTURE CONTENT OF AGGREGATES


cope

Determination of the mass of water in an aggregate, expressed as a

ercentage of the mass of the oven-dry, sample material.

quipment The moisture content can be determined by any one of twomethods.

n oven or gas ringcalibrated weigh scale

Oven panSpeedy” moisture content tester (alternative method)

rocedure & Calculation (oven/gas ring dried method)

he sample is weighed, and then, after being oven- dried, it is re-weighed.Weigh the masses before and after drying W1 and W2, respectively, then:Moisture content, % = (W1 – W2) / W2 x 100

Use of “ Speedy” moisture content tester (use only in case of ccelerated test)



his is a proprietary device whose action is based on the very rapidbsorption of water by calcium carbide. Standardized quantities of ggregate and calcium carbide are mixed by a standard procedure in aand-held, sealed pressure vessel. Acetylene gas is formed by the actionf the moisture on the calcium carbide, and the pressure of the gas iselated to the quantity of moisture. The vessel is fitted with a pressure

auge calibrated to give a direct reading of the moisture content.

Note : This test is unsuitable for larger sizes of coarse aggregate.

Report

Moisture Content in %

Moisture Content



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DELETERIOUS SUBSTANCE IN AGGREGATES - ASTM C40-92


cope

o determine the organic impurities, including silt and clay in theggregates

pparatus

Glass bottle, 500mlodium hydroxide solution, 3% NaOH

Reference color standards

rocedure (extract from ASTM C40-92)

reparation of solution :

Dissolve reagent grade potassium dichromate (K2Cr207) in concentratedulfuric acid (SG 1.84) at the rate of 0.250 g/ml of acid. The solution muste freshly made for the color comparison by gently heating, if necessary, toffect solution



ill a glass bottle to the 130ml level with sample of aggregate to beested.and add the 3% NaOH solution into the bottle until the volume of theggregate and liquid after shaking is about 200ml.

ork the bottle, shake it vigorously and allow it to stand for 24ours.afterward fill a fresh glass bottle to the 75ml level with referencetandard color solution prepared not more than 2 hours earlier per the

reparation procedure described in Sub-clause B.3.1

ompare the color of the supernatant liquid of the test sample with that of he reference color solution.

Record the color comparison result to that of the reference standard, e.g.ghter, darker or same color.

valuation

f the color of the supernatant liquid is darker than that of the referencedtandard, the aggregate tested is considered to contain possible traces of njurious organic compounds. As such perform further tests.

Report

Record

Deleterious Substances

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RESH ANALYSIS

Note: This practice may be modified by the requirements of the customer’s

pecification, see relevant Project Inspection Test Plan (ITP)

cope

o verify W/C ratio, cement and aggregate content of the concrete mix.his procedure applies to fresh concrete coating drawn from the batching

mixer or feed conveyor to the application head.

quipment



et of test sievesMechanical sieve shaker

alibrated Electronic balance to an accuracy of 1.0gGas ring (to accelerate drying)

ucketGunny sacks

rocedure

rior to carrying out a mix analysis, it is necessary to carry out a gradationn a representative sample of each aggregate used in the concrete. It islso necessary to know the nominal mix design in percentage terms.

Obtain a representative sample of at least 2kg of freshly mixed concreterom the feed belt, place in a suitable bucket , cover the bucket with aamp gunny sack and immediately transfer the sample to the laboratory.his test shall be carried out without any delays.

Weigh a 500g sample into a tray and determine the moisture content of theample.

Weigh a further 1,000g into a 150 micron sieve. Wash this sample carefullynder a gentle flow of clean water until the water draining from the sieve islean and clear. Be very careful to ensure that no material spills over thede of the sieve.

When washing is complete, transfer the cleaned sample onto a tray, usingfurther quantity of clean water to wash all traces of material out of theeve and into the tray. Carefully drain off excess water, making sure thato material is lost in the process.

lace the tray over a burner and dry it thoroughly. Ensure that the rate of rying is gentle enough to prevent material being ejected from the tray ashe water vaporises, or alternately cover the tray with an identical tray toap any ejected material.

Once the sample is completely dry, remove from the heat and allow it toool before transferring to the sieve stack.

When the sample has been placed into the sieve stack close the sievetack securely and operate the shaker for five minutes. Remove the stackrom the shaker. Carefully separate the nested sieves and weigh andecord the amount of material retained on each sieve, ignoring the contents



f any) in the sieve pan.

nput the weights into the pre formatted calculation spreadsheet, or lternatively write by hand on a blank fresh mix analysis form. For manualalculation, the procedure is as follows:

Record the weight on each sieve in turnDetermine the cumulative weight retained on each sieve by adding theweights of all

revious sieves in the stackDetermine the dry weight of the 1,000g sample used for each sieve

alculate the cumulative weight retained as a percentage of the sample dryweight

or each sieve, calculate the percentage of the dry weight passing thateve by subtracting

he value from the previous step from 100%

he preformatted spreadsheet automatically calculates the mix ratios. Too this manually, the following procedure is used:

Determine the weight of fines ( < 150 micron) particles of each aggregate inhe mix sample by multiplying the percentage of that aggregate passing the50 micron sieve (from the aggregate gradation) by the percentage of thatggregate in the mix by the dry weight of the fresh mix sample.

xample: If 15% of the sand passes the 150 micron sieve in the sandradation, and the mix design incorporates 20% sand, and the fresh mixample weighs 1,000g with a moisture content of 6%, then the weight of and fines in the sample is:-

5% x 20% x (1,000 x 94%), or 0.15 x 0.2 x 1000 x 0.94 = 28.2g

Repeat this step for each aggregate, and total the weights determinedn this way. This gives the total weight of fines in the fresh mix sample.

rom the fresh mix gradation, calculate the total weight passing the 150micron sieve by subtracting the cumulative weight retained on that sieverom the dry weight of the sample. This is the apparent weight of cementn the sample.

Note, this weight will include fine particles of aggregate. Subtract from ithe total fines weight calculated previously. The result is the corrected

weight of cement.



ubtract the corrected weight of cement from the dry weight of the mixample. The result is the corrected weight of aggregate.

Determine the weight of water in the sample by multiplying the samplewet weight by the moisture content.

he water to cement ratio is given by dividing the weight of water by theorrected weight of cement.

he aggregate to cement ratio is given by dividing the corrected weight of ggregate by the corrected weight of cement.

Report

Record

resh AnalysisFresh Analysis

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ONCRETE DENSITY


cope



o determine concrete density on removed samples (coupons or cores)emoved from a concrete coating.

quipment

alance sensitive to 1.0gontainer suitable for transporting coupons to lab/cure bay

ore drilling equipment (core sampling)Hand tools to assist in removal of samplesWire cutters (coupon sampling)

est specimen

Draw specimen (coupon) at production line taken immediately after coatingr from a cure pipe (core) dependant on the agreed method of sampling.

rocedure (coupon method)

rush the sample with a fine bristle brush to remove all loose particles fromhe sample surface.

Weigh sample and record as Weight A.

ransfer the sample to pipe curing bay with the pipe and allow the sampleo cure for the same period of time as of the coated pipe (a minimum of our (4) days). Sample may also be oven dried to the constant weight.

rocedure (coupon and core)

fter cure immerse sample in seawater filled tank at room temperature for ot less than 24 hours. Draw sample from tank, let it surface dry or removexcess surface moisture, weigh and record as Weight B.

uspend the sample from a wire and weigh it in water and record as Weight (this is to check bulk density of concrete).

With the weights determined in accordance with the above procedures,alculate the following:

) Water absorption after Immersion, % = (B – A) / A x 100



) Density (Air- dry), Kg/m3 = A / (A – C)) Density (Saturated), Kg/m3 = B / (B – C)

Report

Record

ample IDoncrete coating dateample typealculation and results

Density Density Test

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OMPRESSIVE STRENGTH OF CUBES


cope

reparation and testing samples of concrete for compressive strengthroperties using the cube mold method of sampling.

quipment



00mm Cube Moldsrowelucket or Container

Vibrating hammer complete with square face (50mm x 50mm) tamping footalibrated Compression Testing Machine.

rocedure

Draw concrete samples of the production working mix from the conveyor uring transfer of concrete from the mixer to the application head. Ensurehat only freshly mixed concrete is used for the sampling.

lace sample material in a bucket and over the bucket with a moistunnysack to prevent premature dehydration of the sample.

repare the required amount of cubes required for each sampling periodlus two extra cubes to used as spares. Make the test cubes as soon asracticable after sampling to avoid dehydration.

ill each test cube mold with concrete in three layers of 50mm. Compactach layer until refusal using a vibrating hammer equipped with a squareaced tamping foot attachment.

On completion of compacting the topmost layer of the sample the surfacehall be prepared level with the top edges of the mold using a squaredged trowel. Each sample shall be marked with it’s ID and sampleumber. Also for day night operations the ID should include the letters D/Sr N/S

uring of sample

mmediately after the sample preparation, cover the molds with a moistunny sack and place the cubes in the fog cure. Check closely that anninterrupted moist condition exist throughout the curing period.

fter overnight curing, the mold screws are loosened, the mold dismantlednd cube sample is carefully removed and placed in a water tank. Theamples shall remain saturated until required for crushing.

Note : ensure that before placing the samples in the water tank that aorrect, legible ID exists on each sample

ompression Testing



NOTE : The drawing and Test on drilled CORES is in accordance withS1881 Part 120. Cube: Core Compressive Strength Correlation (if

equired) is carried out by this standard

ompressive Strength Cubes

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OMPRESSIVE STRENGTH OF CORES - BS1881


cope

reparation and testing samples of concrete coating for compressivetrength properties using the extracted core method of sampling.

quipment

ore drill, support stand and correctly sized core bitsalibrated Compression Testing Machine.acing sawxternal caliperscetate filmapping compounducket, Container or plastic bags

Water & Power source

rocedure

ipes selected during production for core sampling shall be clearly markedCORE TEST” and the pipe number and date coated shall be entered intohe laboratory “LOG”

fter a curing period (minimum 48 hrs) the core test pipe shall be located inhe designated area for core drilling. The core drilling equipment shall behecked for good working condition and properly connected to the power ource. The core drill bit shall be of a size that will allow 35 – 45 mm



iameter cores to be removed. Core diameters shall remainonstantthroughout the project. Only suitably qualified/trained operatorshall perform core drilling.

he core drilling rig shall be firmly located on top of the pipe ( 90°) and theore drilled in a downward direction. Whilst drilling, water shall be used toubricate the drilling bit and the core rig shall be fitted with a positive stopystem to ensure the core bit does not exceed the limitation of penetrationbeing 7 mm from the PE coating). Core samples shall NOT be taken fromhe end 300 mm of the concrete coating.

On completion of drilling, the core drill, including core shall be carefullyemoved from the concrete coating. The core sample shall then bearefully removed from the drill bit. When removed, all cores from the testipe shall have a band of electrical tape fastened around them on which theipe number shall be marked using a ball point pen. The cores shall belaced in unique plastic bag for each test pipe. DO NOT MIX CORESROM OTHER TEST PIPES. The bag containing the cores shall also belearly marked with the test pipe number.

When received at the laboratory the cores shall be removed from their espective bags and checked for condition and quantity. If more cores areequired, advise the core man as soon as possible. All cores are to beimmed and left to dry for 24 hours. When dry, the cores shall be capped

apart from cores that will be used for density and water absorption tests).hese cores will be capped later. When capped, each core top cap shall be

dentified with the date coated and with the letters D (day) or N (night) andlaced into the storage tank with the identification facing upward. The same



rocedure will apply to density and water absorption samples after testsre complete. Cores will be stored in a water tank maintained at 23 ± 2°C.

rushing

pecimens shall be removed from the curing tank and shall be in saturatedondition when tested, ideally removed from the tank approximately 30

minutes prior to crushing.

elect appropriate testing machine platens to suit anticipated compressiveorce. Clean platen surfaces and ensure absence of extraneous matter.he core-seating rig (if required), fabricated in accordance with BS 1881, islaced in the centre of the location circle and the cores inserted.pply the load, without shock, at a nominal loading of 0.2 N/mm2/sec. - 0.4

N/mm2/sec. at a constant rate for cores. Observe the fast advance andnsure seat correctly on the apparatus. Operate the controls as failure ispproached to maintain load rate(s) above as far as practicable. When

ailure occurs the maximum load applied shall be recorded.

Report

Recordhe specimen IDipe number ompressive strength to the nearest 0.5 MPa

Core Samples

Core crushing



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WATER ABSORPTION


ope

etermination of water absorption on sample removed from concreteoating (coupon or core)

etermination of water absorption using a fully coated concrete pipe (full-cale method)

quipment

st Samplealibrated Balanceontainer suitable for immersing sampleesh concrete sample (at least 500 grams)ll Scale

alibrated weighbridge or load cellitable water tankane

ocedure (Sample testing)

ush the removed sample (coupon or core) with a fine bristle brush toemove all loose particles



om the sample surface.Weigh dry sample and record as Weight A.

ansfer the sample (coupon) to pipe curing bay with the pipe and allowuring for the same period of time as the coated pipe.

mmerse sample in seawater tank at room temperature for not less than 24ours. Remove the sample from the tank, let it surface dry or remove

xcess surface moisture before weighing and record as Weight B.

spend the sample from a wire and weigh it in water and record as Weight (this is to check bulk density of concrete).

alculate the water absorption of the sample as follows:

Absorption after Immersion, % = (B – A) / A x 100

alculate the bulk density as follows:

Bulk Density (Air- dry), Kg/m3 = A / (A – C)……… IF REQUIREDBulk Density (Saturated), Kg/m3= B / (B – C)……….. IF REQUIRED

ocedure (Full scale method)

eigh a fully concrete coated pipe that has been cured record as weight A.

ace the pipe in a water tank filled with seawater at room temperature, if resh water is used alculation between sea and fresh water shall be used in the calculationrocess.

low the concrete to fully saturate, normally 24 hrs

ter 24 hrs remove the pipe from the water tank and allow all free water torain off. Weigh thepe and record as weight B

alculate the water absorption of the concrete coated pipe as follows;

bsorption after Immersion, % = (B – A) / A x 100

eport

ecordmple(coupon)



ll scale water immersionater Absorption sample

Water Absorption test



he test shall be supported with a minimum of 2M concrete sections onither side of the section under test. Impact blows (5 times) shall beirected on the same location. Hammer should have a vertical drop of 60mm giving a velocity of impact of 3.60 m/second (7 Knots).

fter each impact a photograph of the impact area shall be taken together with a sketch of spalled areas including dimensions of cracks (length and

width).

cceptance criteria:- Typically

he anti- corrosion coating shall not be visible after impact (5 blows).palling has not occurred further than 300mm from the impact location.

Report

Recordmpact Testing of Concrete

Impact Test Rig Drawing



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HEAR TEST OF CONCRETE


cope

o evaluate the inter facial shear strength between the anti-corrosion andoncrete coating applied to a pipe.

quipment (typical)

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00MT Hydraulic Jack complete with pressure gaugeupporting fixtures (design to suit testing set-up)

Measuring gauge for displacement of upper platenalibrated dial gauge

rocedure

pre prepared coated section of pipe shall be selected having concreteipe sections of minimum of 500mm test length. The preferred maturity of he coating is a minimum 7-days after coating.

Oxy cut from a cured concrete coated pipe approximately 900mm concreteoated test pipe. Cut only one test piece from each individual coated pipe.lternatively, pipe can be coated partly at a section length of 0.50 to 0.90

meter located at one end of pipe (proximity to cutback). This is dependingn what fixture is available from the time of carrying out test.

fter having cut the test piece, prepare the cross-sectional surface of theoncrete at one end so that it is near perpendicular to the axis along theiece length.

arefully center the test piece on the lower platen of the Hydraulicack (Compression machine) unit with the concrete section supported byhe appropriate supporting fixtures. Then slowly lower the top platen to justouching the steel pipe end. Without shock, apply and increase the loadontinuously at a nominal rate within the range of 0.2N/mm2 per secondntil no greater load can be sustained.

Record the maximum load applied and calculate the surface area (SA) of he anti- corrosion coating surface as follows:

urface area, mm2 = 3.1416 x d x L

Where,

= Pipe OD + anti-corrosion coating thickness= Length of concrete coating

Minimum required load (Kg-f) = 0.17N/mm2 x SA / 9.81

Report

Recordhear Testing results

Shear Bond Test



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painting coating 3

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