specification for line pipe concrete coating_a

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.Project N° Unit Document Code Serial N° Rev. Page

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WEST QURNA 2 – EARLY PRODUCTION FACILITIESLUKOIL MID-EAST LIMITED

42” OIL PIPELINE FROM CPF MISHRIF TO TUBA TANK FARM

EUPHRATES RIVER AND HOR AL HAMMAR HOR CANAL CROSSINGS BY OPEN CUT METHOD

SPECIFICATION FOR LINE PIPE CONCRETE COATING

A 10/10/2013 ISSUE FOR REVIEWREV. DATE STATUS WRITTEN BY

(name & visa)CHECKED BY(name & visa)

APPROV./AUTHOR. BY(name & visa)

DOCUMENT REVISIONS

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

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INDEX

Page

1. GENERAL .................................................................................................................41.1. PROJECT BACKGROUND.................................................................................................................41.2. DEFINITIONS AND ABBREVIATIONS....................................................................................................41.1.1 Definitions............................................................................................................................41.1.2 Abbreviation.........................................................................................................................4

1.3. CODES REFERENCE........................................................................................................................5

2. SCOPE OF DOCUMENT.............................................................................................6

3. DEVIATION TO SPECIFICATION...............................................................................6

4. GENERAL 74.1 RESPONSIBILITIES OF CONTRACTOR............................................................................................74.2 ANTI-CORROSION COATING OF PIPES...............................................................................................74.3 CONCRETE COATING REQUIREMENTS...............................................................................................74.4 CONCRETE COATING APPLICATION PROCEDURE...............................................................................84.5 PRE-PRODUCTION QUALIFICATION TESTS.........................................................................................84.5.1 GENERAL....................................................................................................................................... 84.5.2 REQUIRED DOCUMENTATION............................................................................................................94.5.3 PROCESS....................................................................................................................................... 94.5.4 TESTING 9

5. STORAGE, HANDLING AND TRANSPORT OF MATERIAL...................................105.1 STORAGE OF CEMENT, SAND AND AGGREGATES............................................................................105.2 LINE PIPE.................................................................................................................................... 105.2.1 HANDLING OF LINE PIPE................................................................................................................105.2.2 TRANSPORT AND MOVEMENT OF PIPES...........................................................................................10

6. MATERIAL 116.1 CEMENT 116.2 SAND AND AGGREGATES..............................................................................................................116.3 AGGREGATE GRADING.................................................................................................................. 116.4 WATER 126.5 ADDITIVES................................................................................................................................... 126.6 STEEL REINFORCEMENT................................................................................................................13

7. EQUIPMENT.............................................................................................................147.1 MATERIAL PROPORTIONING UNIT...................................................................................................147.2 CONCRETE MIXING EQUIPMENT......................................................................................................147.3 WEIGHING EQUIPMENT.................................................................................................................. 14

8. CONCRETE COATING FABRICATION....................................................................158.1 PROPORTIONING OF MATERIALS....................................................................................................158.2 INSTALLATION OF REINFORCEMENT................................................................................................158.2.1 GENERAL..................................................................................................................................... 158.2.2 CAGE REINFORCEMENT................................................................................................................. 158.2.3 REINFORCEMENT WIRE MESH........................................................................................................16


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8.3 PLACING OF CONCRETE................................................................................................................178.3.1 GENERAL..................................................................................................................................... 178.3.2 WORK OPERATION........................................................................................................................ 178.3.3 ENVIRONMENTAL LIMITATIONS........................................................................................................188.3.4 TIME LIMITATIONS......................................................................................................................... 188.3.5 RECLAIMED CONCRETE................................................................................................................. 198.4 CUT-BACK ON LINE PIPES.............................................................................................................198.5 CURING OF COATED PIPES............................................................................................................198.5.1 WATER CURING............................................................................................................................ 198.5.2 CURING BY POLYETHYLENE WRAPPING...........................................................................................198.5.3 MEMBRANE CURING...................................................................................................................... 20

9. INSPECTION AND TEST..........................................................................................219.1 VISUAL INSPECTION...................................................................................................................... 219.2 CONCRETE COATING THICKNESS MEASUREMENT............................................................................219.3 COMPRESSIVE STRENGTH.............................................................................................................219.3.1 CORE SAMPLES............................................................................................................................ 219.3.2 METHOD OF TESTING.................................................................................................................... 229.4 CUBES SAMPLES.......................................................................................................................... 239.5 ACCEPTANCE CRITERIA................................................................................................................. 239.6 SPECIFIC GRAVITY, ABSORPTION AND VOIDS..................................................................................239.7 AGGREGATES.............................................................................................................................. 239.8 NEGATIVE BUOYANCY................................................................................................................... 239.8.1 WEIGHING OF PIPE LENGTH...........................................................................................................239.8.2 CALCULATION OF NEGATIVE BUOYANCY..........................................................................................239.8.3 TOLERANCES............................................................................................................................... 249.9 LOCATION OF REINFORCEMENT......................................................................................................249.10 WATER ABSORPTION TEST............................................................................................................249.10.1 FREQUENCY AND METHOD.............................................................................................................249.10.2 TOLERANCES............................................................................................................................... 259.11 ELECTRICAL INSULATION TEST......................................................................................................259.12 CALIBRATION OF EQUIPMENT.........................................................................................................269.12.1 BATCH PLANT............................................................................................................................... 269.12.2 WEIGH SCALES............................................................................................................................ 269.12.3 GIRTH MEASUREMENTS................................................................................................................. 269.12.4 LABORATORY EQUIPMENT..............................................................................................................26

10. CONCRETE COATING REPAIR...............................................................................2710.1 CORE HOLES AND INSPECTION AREAS...........................................................................................2710.2 DAMAGED AREAS......................................................................................................................... 2710.2.1 REPAIR OF FRESH CONCRETE COATING.........................................................................................2710.2.2 REPAIR OF HARDENED CONCRETE COATING...................................................................................2710.2.3 CRACKS 28

11. MEASUREMENTS AND LOGGING..........................................................................29

12. NON ACCEPTANCE..................................................................................................31


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1. GENERAL

1.1. Project Background

Within the construction of 42” Oil pipeline (reaching CPF Mishrif with Tuba Tank Farm), LUKOIL – Middle East Limited shall realize the crossing of two main watercourses, namely:

Euphrates River (KP 15+625 approx)

Hor Al Hammar Hor canal (KP 61+400 approx)

At the moment being, the above crossings are already under construction with HDD method, but they shall be carried out in parallel by further alignments, by open cut method. HDD crossings (under construction) and “open cut” By-pass lines (in project and object of the present scope) shall be designed as two permanent waterway crossing solutions and shall allow the alternative use in the future.

1.2. Definitions and Abbreviations

1.1.1 Definitions

COMPANY LUKOIL – Middle East Limited

CONTRACTOR The COMPANY awarded the contract to perform the work described herein

WORK all activities included in CONTRACTOR’ scope, as per Contract. The complete scope of the work, to be performed as described in this document.

WORK SITE The site or location where the work is to be performed, including rights-of-way, working areas, offices and shops.

1.1.2 Abbreviation

AG Above groundFOC Fiber Optic CableHDD Horizontal Directional DrillingSoW Scope of WorkUG Underground


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R.O.W. Right-of-Way QA/QC Quality Assurance & Quality control

1.3. Codes Reference

The latest revision of the following Codes and Standards shall apply to the work. The ASTM Standards can be replaced by the relevant British Standards.

ASME B31.4 Pipeline Transportation System for Liquid Hydrocarbons and Other Liquids (2006)

API 5L Specification for Line Pipe ISO International Standards

ASTM C-31 Standard Method of Making and Curing Concrete Compressive and Flexural Strength Speciments in the Field

ASTM C-29 Standard Test Method for Unit Weight and Voids AggregateASTM C-33 Standard Specification for Concrete AggregatesASTM C-39 Standard Method of Test for Compressive Strength of Cylindrical

Concrete SpecimensASTM C-42 Method of Obtaining and Testing Drilled Cores and Sawed Beams of

ConcreteASTM A-82 Standard Specification for Cold Drawn steel Wire for ConcreteASTM C-87 Standard Method for Effect of Impurities in Fine aggregates on

Strength MortarASTM C-94 Specification For ready Mix ConcreteASTM C-136 Standard Method for Sieve Analysis of Fines AggregatesASTM C-143 Test Method for Slump of Hydraulic-Cement ConcreteASTM C-150 Standard Specification for Portland CementASTM C-171 Standard Specification for Sheet Materials for Curing ConcreteASTM A-185 Standard Specification for Welded Steel Wire Fabric for Concrete

ReinforcementASTM C-309 Standard Specification for Liquid Membrane-Forming Components

for Curing ConcreteASTM C-452 Test Method for Potential Expansion of Portland Cement Mortar

Exposed to SulphateASTM C-494 Standard Specification for Chemical Admixtures for ConcreteASTM C-641 Zinc Coated (Galvanised) Carbon Steel WireASTM C-642 Test for Specific Gravity, Absorption and Voids in Hardened

ConcreteASTM C-670 Standard Practice for Preparing Precision and Bias Statements for

Test Method of Construction MaterialsBS 12 Specification for Ordinary and Rapid Hardening Portland CementsBS 812 Methods for Sampling and Testing of Mineral Aggregates, Sands

and FillersBS 882, Part 2 Aggregates from Natural Sources for ConcreteBS 1881 Methods of testing Concrete (British Standards Institute)


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BS 3148 Test for Water for Making Concrete


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2. SCOPE OF DOCUMENT

This specification covers the minimum requirements for the supply of materials, application, testing application and inspection, of continuous concrete coating of line pipe.

Pipeline stabilization against floating shall be assured by application of continuous concrete coating on line pipe, as per SOC requirements. No alternative overweighing methods will be admitted.

CONTRACTOR shall apply continuous concrete coating to 42” pipe string to be installed at watercourse crossings. Line pipe string, will be supplied by COMPANY already welded, polyethylene coated, hydrotested and ready for concrete coating application.

CONTRACTOR, based on requirements of the present specification, shall provide to COMPANY for approval a dedicated Concrete Coating Procedure and application procedure and the Buoyancy Calculation Report.

3. DEVIATION TO SPECIFICATION

Exception to this specification may be considered by COMPANY if the proposed exceptions are clearly highlighted to aid evaluation of the CONTRACTOR construction standard that meets all the required mechanical and operating requirements and if documentary evidence is provided of technical and/or economic advantages for the proposed alternative solution.


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4. GENERAL

4.1 Responsibilities of CONTRACTOR

CONTRACTOR shall be responsible for the design, supply of material and application of all concrete coating, including all associated handling and transport.

CONTRACTOR shall furnish all materials, components, equipment, labor, supervision, working area and services incidental to and necessary for the application and testing of concrete in accordance with this specification and the applicable codes and standards. All materials, components and equipment shall be subject to COMPANY approval.

4.2 Anti-corrosion Coating of Pipes

Line pipes to be concrete coated will be supplied by COMPANY to CONTRACTOR already externally coated with Polyethylene coating.

Polyethylene coating will have a thickness of 3.5 mm and a density value of 950 kg/m3.

4.3 Concrete Coating Requirements

The concrete coating thickness shall be defined by the CONTRACTOR: Buoyancy calculations shall be shown in the Buoyancy Calculation report, to be provided by CONTRACTOR to COMPANY for approval.

The line pipe shall be coated with a continuous reinforced concrete coating of constant thickness. The concrete coating outer surface shall be smooth, without corrugation and concentric with the steel pipe.

The characteristics of concrete coating shall meet the following requirements:

The mass of the dry concrete, after 28 days curing, shall have a minimum density of 2400 kg/m3.

The minimum compressive strength of the concrete shall be as defined here below

After 7 Days After 28 Days

Cubes 25 N/mm2 35 N/mm2

Cores 20 N/mm2 30 N/mm2


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4.4 Concrete Coating Application ProcedureExecution Plan

CONTRACTOR shall prepare a Concrete Coating Execution Procedure Plan for the whole concrete coating applicationworks. The This Execution Planmethod statement shall be submitted to COMPANY, for approval xxx days before the planned start of concrete coating production. The data and information contained in the Execution Procedure Plan shall be sufficient to enable the COMPANY to evaluate the CONTRACTOR’s capability to perform the concrete coating application, in accordance with the requirements of this specification and the construction schedule.

The Execution Procedure Plan shall include, as a minimum:

i) Procedures for handling transport and storage of linepipe and coating material;ii) Procedures for identification of the jointsiii) Procedure for external corrosion coating inspection and repair;iv) Procedures for steel reinforcement installation and testv) Procedure for concrete application;vi) Procedure for inspection and testing of concrete coated pipes;vii) Procedure for concrete curing;viii) Procedure for measuring and weighing of linepipe;ix) Procedure for concrete coating removal from pipes;x) Equipment used to carry out the work, including transportation and handling;xi) Procedure for staking of concrete coated pipe;xii) Characteristics of water, cement, sand and aggregates;xiii) Characteristics of reinforcement;xiv) Certified laboratory and site equipment used for tests;xv) Time schedule.

4.5 Pre-production Qualification Tests

4.5.1 General

At least xxx days before start of production the materials, the coating process, the equipment and the application and repair procedures to be used shall be qualified through a pre-production qualification test.

Minimum two pipes of each concrete thickness to be applied shall coated and tested.


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CONTRACTOR shall not be allowed to start the production upon successful pre-production test and written consent of the COMPANY.

CONTRACTOR shall not modify or changes material specification and operational parameters without written approval of the COMPANY.

4.5.2 Required Documentation

Before the pre-qualification testing takes place, the following documentation is required by COMPANY.

Materials and mix designi) Proportions, and weights of the materials usedii) The water/cement ratioiii) The grading of the various aggregates, with combined curves as necessaryiv) Material certificates or chemical analyses of cement, aggregates, iron ore, water

and additivesv) Reinforcement material.

ProceduresAll procedures for production, concrete application, repair, inspection and testing of concrete coating outlined above.

4.5.3 Process

The CONTRACTOR shall give a demonstration of the process, and the equipment’s suitability for the performance of the work. All procedures, including curing and repair shall be demonstrated.

4.5.4 Testing

During the pre-production trials, all production tests and inspection as detailed in in this specification shall be performed on each individual test pipe.

4.5.5 Pre-qualified Procedures

In lieu of qualifying Concrete Coating Application procedures, pre-qualified procedures for similar works may be submitted for COMPANY review complete with proper qualification tests reports, and used upon approval.


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5. STORAGE, HANDLING AND TRANSPORT OF MATERIAL

5.1 Storage of Cement, Sand and Aggregates

Cement shall be protected to prevent its deterioration during storage by keeping it in sealed silos, if loose, or in closed rooms if in bags.

Sand and aggregates shall be stored on paved and suitably drained areas. Steel reinforcement shall be stored in a sheltered place and shall not be contaminated by air, water, scales, oil, paint or other polluting materials.

5.2 Line Pipe

Line pipes to be concrete coating will be supplied by COMPANY to CONTRACTOR already externally coated with Polyethylene coating, ready on site for concrete coating.

5.2.1 Handling of Line pipeAll operations relevant to the handling of line pipe shall be performed using lifting equipment provided with fixed or mobile arms, spread bars and slings. Slings shall be provided with lateral ropes to guide the pipe when suspended.

During handling operations, the pipe shall not be bumped or scraped against obstacles or other pipes.

The use of chains shall not be permitted.

All lifting equipment, including cranes, spread bars and slings shall be certified according to recognized standards.

5.2.2 Transport and movement of Pipes

Special attention shall be given to the effects of acceleration and deceleration forces that could induce stress into the concrete coated pipe during transport / movement. If particular environmental conditions are present then they shall be taken into consideration.


Rabee Abdelaal, 12/10/2013,

Is there a need for the CONTRACTOR to carry out holiday test and repairs if any?

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6. MATERIAL

6.1 Cement

Cement shall comply with ASTM C-150 Type V (sulphate resistant). The C3A content shall not exceed 5%. The SO3 shall not exceed 2.3%. Alkali content shall be 0.6% maximum, as per Table 1A of ASTM C-150. When sulphate resistance is doubtful testing, in accordance with ASTM C-452, shall be performed by CONTRACTOR prior to use of the cement. The cement shall not contain any special additive.

Hardened or partially hardened lumpy cement shall not be used.

Manufacture’s test certificate shall be supplied for each delivery of cement and shall confirm that the cement complies with the above requirements and shall be submitted to the COMPANY not later than the day of delivery of the cement.

The COMPANY shall have the right to call for tests on each delivery of cement, if necessary, to establish or confirm that the cement meets the above requirements.

6.2 Sand and Aggregates

Sand shall consist of round grained sand and shall be free of clay and silt. Suitability of the sand for making concrete shall be determined in accordance with the requirements of ASTM C-33 or BS 882.

Aggregates shall consist of crushed or uncrushed gravel or crushed stone, depending form the source of supply. Aggregates shall be well graded from fine to coarse and shall conform to ASTM C-33 or BS 882.

Sand and aggregates shall be washed and shall be clean and free from detrimental amounts of organic impurities, salt, alkali or other deleterious substances which may impair the strength and durability of the concrete.

Sampling and testing of sand and aggregates shall de carried out in accordance with ASTM C-33 or BS 882.

6.3 Aggregate Grading

The aggregates shall conform to ASTM C-33 or BS 882 except for the sieve analysis, which shall be graded within the following limits:

Sieve Percent Passing

9.6 mm 100

5.6 mm 82-93


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13/32

COMPANY Code


Sieve Percent Passing

2.8 mm 60-78

1.4 mm 41-63

0.6 mm 22-45

0.3 mm 10-30

0.15 mm 2-10

Other grading may be accepted provided that concrete made with such aggregates will have relevant properties equal to or better that those of concrete made with the above mentioned grading.

The grading and cleanliness of the supplied aggregate shall be checked during the execution of the work at least twice a week.

Where heavy density concrete is required, a portion or all of the aggregates shall be made up from heavy aggregates like powder of barium or iron ore; the latter may be used only after COMPANY verifications and approval.

6.4 Water

Water for concrete shall be clean fresh water, free from injurious amount of acid, oil, alkali, salt, industrial contamination, inorganic or organic matter either dissolved or suspended, in accordance with BS 3148.

The COMPANY shall approve all sources of water to be used for the concrete coating.

On COMPANY request, CONTRACTOR shall carry out the analysis of the proposed mixing water at its own expense. The results shall be submitted to the COMPANY for review.

6.5 Additives

Silica fume may be added up to a maximum amount of 10% of the cement weight. Water reducing agent for concrete will be accepted.

Additives that may cause air entrainment are not permitted in the mix.

Additives containing chlorides shall not be used in the mix. The total amounts of chloride within the concrete mix, calculated as free CaCl2, shall not exceed 0.4% of the weight of the cement.


Rabee Abdelaal, 12/10/2013,

Suggest to leave aggregate gradation to CONTRACTOR decision, and accepted upon successfully qualified coating procedure.

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14/32

COMPANY Code


Admixture for concrete, if added, shall conform to the requirements of ASTM-C-494.

6.6 Steel Reinforcement

Concrete coating shall be reinforced by layers of steel reinforcement to limit spalling and to control the cracking of the concrete according to provisions hereinafter described. The use of chicken mesh or thin gauge binding wire in the reinforcement is not permitted. The wire mesh reinforcement shall be according to ASTM A-185 and the wire steel shall comply with ASTM A-82.

Three types of reinforcement will be used:

i) Cages of welded steel wire fabric, manufactured in flat sheets or in rolls (ribbon mesh), formed by rolling and welded or tying together.

ii) Spirally wound cages with continuous circumferential hoops and a number of straight longitudinal bars evenly spaced around the hoops and welded at each intersection.

iii) Wire mesh fabricated as a spot-welded netting made of low carbon steel wire. The steel wire shall be galvanized according to ASTM A-90 and ASTM A-641.

The proportion of reinforcement shall not be less than of the following:

The circumferential steel reinforcement shall be 0.6% minimum of the longitudinal cross sectional area of the concrete coating.

The longitudinal reinforcement shall be 0.08% minimum of the transversal cross sectional area of the concrete coating.

The fulfillment of reinforcement cross sectional area in both longitudinal and circumferential directions shall be achieved by the use of appropriate size and thickness of reinforcement.

The type and characteristics of reinforcement shall be proposed by the CONTRACTOR and approved by the COMPANY prior to use.


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15/32

COMPANY Code


7. EQUIPMENT

7.1 Material Proportioning Unit

CONTRACTOR shall provide all the necessary equipment capable to produce and apply the concrete coating to the required degree of uniformity; observing the required thickness and position of reinforcement, to obtain a concrete coating with a density and compressive strength in accordance with this specification.

The CONTRACTOR shall provide documentary evidence that the proportioning and mixing unit produces concrete in accordance with ASTM C-94.

7.2 Concrete Mixing Equipment

Concrete mixing equipment shall be capable of weighing the batch of materials with 2% accuracy should materials not be packed in standard weights.

Weighing apparatus shall be kept in good condition and be calibrated using weights with an accuracy of 0.25% or better.

The quantity of water to be added shall be measured in liters, by measuring apparatus, so that only the quantity required for the concrete will be discharged into the mixer to an accuracy of 2% of specified quantity.

Equipment that tends to separate the concrete mixture ingredients shall not be used.

7.3 Weighing Equipment

Weighing equipment used for the determination of the line pipe weight shall have an accuracy certified by the Manufacturer of 0.5%. Weighting equipment shall be calibrated at the start of each working shift. Calibration shall be carried out by using weights with accuracy of 0.1%.


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16/32

COMPANY Code


8. CONCRETE COATING FABRICATIONAPPLICATION

8.1 Proportioning of Materials

The CONTRACTOR shall select the proportioning of material to produce the concrete mixture which meet the required strength and density.Each batch shall be weighed separately and mixed to ensure an accurate thorough mixing of all the materials used in the batch.

Water added to the mixture and the application of concrete to line pipe shall produce an even and smooth concrete coating.

Continuous mixing shall be allowed provided that all additions are accurately monitored and the mixture components are suitably weighed.

For constant control of the water/cement ratio in the concrete mixture the humidity content of aggregates shall be taken into consideration.

Controls on the fresh concrete mixture shall be performed to check the compactness and the slump factor.

Instruments for these tests shall be available on site as per ASTM C-143.

The maximum slump measured by Abrams cone method shall range between 100 and 150 millimeters.

8.2 Installation of Reinforcement

8.2.1 General

Reinforcement shall be placed around the pipe in such a way so as to cover the entire length of pipe to be concrete coated. The reinforcement shall terminate at a distance of 30mm (max), 5mm (min) from the concrete coating cut back.

A spike of the reinforcement or wire mesh shall be left protruding from the circumferential surface so as to allow checks of the electrical resistance in air. Alternatively, the electrical resistance test shall be performed on reinforcement wire exposed on the cutback surface. No other element of the reinforcement shall be permitted to protrude from the circumferential surface of the concrete coating.

8.2.2 Cage Reinforcement

When a reinforcement cage is used, the reinforcement shall rest on spacers forming a "crown" whose positioning shall be selected so as to prevent any contact between the reinforcement cage and the anti-corrosion coating.


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17/32

COMPANY Code


Distance between the spacers in longitudinal direction shall be 350 to 450 mm. One crown of spacers shall always be positioned at each end of the cage.

Cages reinforcement shall be positioned within the middle third of the concrete coating with a minimum concrete cover of 15 mm.

The diameter of circumferential and longitudinal bars shall be calculated from the required percentage of reinforcement steel area stated at paragraph 6.6 of this specification. The minimum diameter of circumferential and longitudinal reinforcing shall be 5 mm.

The longitudinal bars shall be equidistantly spaced around the circumference at a distance between 50 and 200 mm, equally spaced.

The circumferential bars shall be spaced at 120 mm interval maximum.

Single hoop reinforcement shall have a welded overlap of 25mm or a non-welded overlap of 200mm minimum.

Supplier shall propose the size of bars and spacing for COMPANY approval. However the steel reinforcement area shall not be less than the value specified in this specification.

CONTRACTOR shall submit for COMPANY approval, the method of welding and welding procedures in accordance with recognized code or standard prior to use.

The welding process shall produce a cage that fit over the anticorrosion coated pipe rigidly, concentric and perpendicular to the axis of the to the pipe.

8.2.3 Reinforcement Wire Mesh

When wire mesh reinforcement is used, the reinforcement and the concrete will be applied simultaneously in one operation where the placed concrete has the same function as spacers.

During the pre-production qualification tests, CONTRACTOR shall demonstrate that the proposed method shall ensure a minimum spacing of 15mm between steel reinforcement and pipe anti-corrosion coating over its entire length.

If a wire mesh is used, the mesh type will be selected as 2.50/2 mm wire diameter. The required number of layers will depend on the concrete thickness.CONTRACTOR shall define the number of wire mesh layers foreseen for the pipe in project. Calculation and evidence shall be clearly indicated in the Execution ProcedurePlan, and submitted to COMPANY for approval.


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18/32

COMPANY Code


The amount (size and spacing) of reinforcement shall meet the values for longitudinal and transversal cross section specified in this specification.CONTRACTOR may propose other wire size and spacing for COMPANY approval. However the steel reinforcement area shall not be less than the specified values.

The overlap for wire mesh shall be 1.5 times the distance between the wires or 25mm whichever is greater.

The reinforcement shall be evenly distributed and shall not be exposed on the external surface of concrete coating or touch the underlying corrosion coating of pipe.

The minimum spacing between the reinforcement and the outer anti-corrosion coating of pipe shall be 15mm.

The minimum spacing between the reinforcement and the outer concrete surface shall be 20mm.

When more than one layer of reinforcement is used, the minimum spacing between layers shall be 15 mm.

8.3 Placing of Concrete

8.3.1 General

The concrete coating shall be applied on-site, by casting method.

Each pipe joint shall be coated in a continuous operation and in a manner such that the required thickness of concrete is applied uniformly over the entire length of the pipe. The application method shall ensure that the concrete coating satisfies the minimum requirements of this specification for the following:

concrete coating sizing and shaping concrete coating specific density concrete coated pipe actual dry weight and negative buoyancy concrete coating compression strength concrete coating water absorption Placement and layers of steel reinforcement. the method of concrete application (especially the impingement method) shall: avoid any damage to the anti-corrosion coating obtain a compact homogeneous composition, free from foreign matters ensure thorough adherence onto the anti-corrosion coating surface

8.3.2 Work Operation


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19/32

COMPANY Code


Here below a list of operations to be followed for Concrete application is reported as reference. CONTRACTOR shall endorse or modify the application method operations, detailing all phases in its Execution ProcedurePlan.

Check the integrity of the corrosion protection coating of the pipe and execute repairs if necessary;

Clean very carefully the pipe and remove potential ground and other debris; Installation of the reinforcement (e.g. steel wire mesh), laid down in layers as

per project requirements.; installation spacers ( wooden or plastic) to separate the metallic nets, Spacers shall be fixed (e.g. by plasticized iron wire or similar), to avoid

possible movements during casting operation. Other spacers will be used for support of formworks and they will be disposed

in order to ensure the required minimum cover of the steel mesh with 2 cm concrete;

The formworks shall be placed and anchored, so that the thickness of the concrete results uniform in every point;

The casting operation shall be performed by a pump and the concrete shall be vibrated in order to get a homogeneous mixture without empty areas and it shall be fully adherent to the pipe;

If necessary, additives for cement could be used, after COMPANY approval, only if they will have no impact on the final strength of the concrete.

The handling/moving of concrete coated pipe shall be performed only when the necessary strength is achieved (usually within 24 hours after the casting; this value shall be proved by tests performed before casting);

During every cast, samples of concrete shall be taken and then subjected to strength tests. The compression strength of the samples shall be in accordance to requirements of this specification. The result of tests will be submitted to COMPANY;

8.3.3 Environmental Limitations

During normal coating operations, the temperature of the concrete is to be maintained between 5°C and 35°C. Therefore, the following provisions shall apply during cold and hot weather.

Suitable means shall be provided by CONTRACTOR to ensure that, during coating operations, the temperature of the concrete does not exceed 35°C.

Suitable precautions shall be taken to prevent that during curing period concrete drying out pre-maturely.

In the event of low ambient temperature, CONTRACTOR shall control the temperature of water and aggregates so that the temperature of concrete moisture shall be not less than 5°C.


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20/32

COMPANY Code


8.3.4 Time Limitations

The elapsed time from adding water to the mix and final placement of concrete coating must not exceed 30 minutes.

Concrete placement shall be completed as quickly as reasonably possible and the exposed surface of concrete shall be immediately covered to reduce excessive evaporation of water.

8.3.5 Reclaimed Concrete

The use of reclaimed material is allowed provided that the amount shall not exceed 10% of the total mix by weight. The reclaimed material shall be added and homogeneous mixed with freshly batch of concrete in a secondary mixture.

When breaks in operation occur for an interval exceeding thirty minutes, reclaimed material not previous added in the mix shall be discarded.

8.4 Cut-back on Line Pipes

Both ends of each pipe for a length of 300 mm, shall be free from concrete to allow welding of pipes and installation of the anti-corrosion coating (e.g. heat shrinkable sleeves) over the joint.

Concrete shall be taper back from these points with an angle between 60° and 90° degrees until the required thickness of coating shall be reached.

Before starting the concrete coating application, CONTRACTOR shall confirm in the Execution Procedure Plan the length of cut back.

Concrete splatters, if any, found inside and outside the pipe shall be removed before they harden.

8.5 Curing of Coated Pipes

After completion of concrete coating the pipes shall be removed from coating applicator and after weighting and concrete thickness measurement the pipe shall be transferred to curing yard.

Concrete shall be cured by keeping it wet by using curing by water, polyethylene wrapping or membrane.

Other curing methods proposed by the CONTRACTOR shall be approved by the COMPANY prior to use.

8.5.1 Water Curing


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21/32

COMPANY Code


Water curing shall consist of wetting and moistening the concrete coating, starting not later than 6 hours after completion of concrete placement.

The concrete coatings shall be kept continuously moist by intermittent spraying for a period of at least 7 days. The total duration of spraying time shall not be less than 24 hours distributed evenly over the period.

8.5.2 Curing by Polyethylene Wrapping

A plastic film shall be wrapped around the concrete coated pipe immediately after the concrete coating is applied to the pipe, possibly before removal of pipe from coating apparatus.

Before application of plastic film, the concrete coated pipes shall be wetted by light of water spraying.

The plastic film will be of polyethylene material. The overlap of film shall be 30 mm minimum.

Concrete coated pipes shall not be handled until the concrete has reached a compressive strength of 14 N/mm2 minimum.

When wrapping method is adopted the plastic film shall be removed after the curing time to allow the inspection of the concrete coating.

8.5.3 Membrane Curing

The membrane curing shall use a clear sealing compound white-pigment compound or plastic membrane type in accordance with the requirement of ASTM C-309.

The compound shall be non-toxic and non-inflammable and shall not react with the concrete constituents, the reinforcement and the external coating of steel pipe

The membrane shall be applied in accordance with Supplier’s instructions, by mechanical apparatus immediately after concrete application is completed, to the surface of concrete coating in quantity sufficient to provide a complete coverage.


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22/32

COMPANY Code


9. INSPECTION AND TEST

9.1 Visual Inspection

All coated pipe shall be visually inspected and checked by tapping the whole pipe surface to discover defects. Should this method indicates faulty coating, cores shall be taken from coating and inspected. If cores samples fail crushing strength test, the CONTRACTOR shall remove the defective coating from pipe.

Coating removal shall be carried out by a method defined in the procedure proposed by the CONTRACTOR and approved by the COMPANY.

9.2 Concrete Coating Thickness Measurement

Immediately after concrete coating application, the CONTRACTOR shall check the concentricity and the mean concrete thickness, of each concrete coated pipe, in accordance with the following requirements.

The concrete coating shall be concentric with the pipe and the difference between high and low points of the finished coating surface shall not be more than 10 mm measured every 500 mm along the pipe.

The concrete coated pipe diameter shall be measured in five positions equally spaced along the pipe body with the two end measurements taken at 0.4 meters maximum from the end of concrete coating. The pipe diameter measurement results shall be used to define the mean concrete thickness of each pipe.

The mean of the calculated concrete coating thickness shall be that specified on Concrete Coating Data Sheet with a tolerance of 5 mm .

Coated pipes resulting outside the stated tolerances shall be repaired or stripped and re-coated, unless otherwise decided by the COMPANY.

9.3 Compressive Strength

During the normal production, the concrete coating compressive strength shall be verified using core samples and test cubes.

9.3.1 Core Samples

At least one pipe every 25 produced or two joints per day, whichever is more appropriate, shall be selected by COMPANY’s Representative for core sampling. For each of the selected pipe joints, 4 cores shall be tested at 7 days and 4 cores at 28 days age. The position of the cores shall be selected at random in the circumferential direction and equidistant in the longitudinal direction.


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23/32

COMPANY Code


The cores shall be drilled at three locations on the pipe body, between one and two meters from the ends of concrete and two meter astride the middle of pipe.

The core diameter shall be selected as follows:

Cores shall be drilled using a diamond core cutter set, to ensure a cut perpendicular to the pipe surface. The cutter shall be fitted with a positive depth or limit stop to prevent damages to the corrosion coating of the pipe.

Cores shall be perfectly cylindrical and perpendicular to the pipe. Cores not cylindrical or not perpendicular to the pipe shall not be used for test.

9.3.2 Method of Testing

The testing method of core samples shall be in accordance with ASTM C-39 or BS 1881. The compressive strength of the applied concrete shall be determined after 7 and 28 curing days.

The compressive strength results after 7 days curing shall be used to provide the indication of variation in the strength of the concrete. The compressive test on 28 day core samples shall be the only results to be used for comparison.

Acceptance criteria of the concrete coating production shall be based on ASTM C-670.

The core samples tested at 7 and 28 days curing shall have a minimum mean compressive strength value stated in the relevant section of this specification.

Single core strength value result shall not be less than 90% of the specified minimum compressive strength value.

In the event that a single core has the strength less than of the specified minimum, three additional cores shall be taken from the same pipe as the failing core. If the strength value of each of three cores taken from pipe, meet the minimum core strength value and the mean strength of the three cores shall be within the specified minimum, the coating will be accepted.

If the mean strength value from three acceptable cores shall be less than the specified minimum the coating of that pipe shall be rejected and two further pipes produced over the shift or batch shall be tested.


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COMPANY Code


In the event that the single or mean strength test fail below the specified minimum the CONTRACTOR shall investigate the cause of failure. COMPANY reserves the right to reject the pipes coated with the concrete of the same batch or that produced in the shift.

9.4 Cubes Samples

The test cubes will be made and cured according to ASTM C-39 or BS-1881. Three cubes from each sample shall be tested after 7 days and the remaining cubes shall be tested at 28 days.

9.5 Acceptance Criteria

The cubes tested shall have a minimum mean compressive strength as specified in the relevant section of this specification. Single cubes strength value result shall not be less than 90% of the specified minimum compressive strength value.

9.6 Specific Gravity, Absorption and Voids

Specific gravity, absorption and voids in applied concrete shall be determined according to ASTM-C-642.

The average value of permeable voids shall not exceed 20% of all the void volume. However, the core compressive strength shall be duly accounted for prior to rejection of any coated pipe joints.

9.7 Aggregates

The grading, cleanliness and moisture contents of the aggregates shall be checked every day according to ASTM-C-136 and ASTM-C-87.

9.8 Negative Buoyancy

9.8.1 Weighing of Pipe Length.

Each pipe joint shall be weighed immediately before and after concrete coating. All weighing of concrete coated pipe lengths shall be performed using a suitable weighing device having an accuracy of 0.1%. Calibration of the weighing device shall be checked at least once every shift.

9.8.2 Calculation of Negative Buoyancy

Buoyancy calculations shall consider the following:

stability safety factor of minimum 1.15 (relation between weight of pipeline and buoyancy);

water density should be taken as 1025 kg/m3;


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25/32

COMPANY Code


thickness 3.5 mm of external polyethylene coating with density 950 kg/m3; density of concrete shall be conservatively taken as minimal; The weight of backfilling and weight of oil shall not be taken in to account.

CONTRACTOR shall provide detailed Buoyancy Calculation report for COMPANY approval, before any coating activities.

9.8.3 Tolerances

The negative buoyancy of each individual concrete coated pipe shall be as stated in the data sheets with the following allowable tolerances:

i) Each individual pipe length: ± 5% or ±10 kg/m (whichever is greater)

ii) Rolling 25 consecutive joints average: ± 2,5%

9.9 Location of Reinforcement

One pipe joint out of every 25 produced can be chosen at random by the COMPANY’s Representative to verify the location of the reinforcement. A water jet shall be used to clear away the freshly placed concrete down to the corrosion coating for an area 25 mm wide and 250 mm long in the axial direction. This exposed area shall be used to verify that the position of the reinforcement within the concrete coating.

If the reinforcement is not positioned in accordance with this specification, the pipe shall be rejected and re-coated. Subsequently, each pipe of the next produced batch shall be inspected in succession in this manner until an accepted position of the reinforcement is obtained.

9.10 Water Absorption Test

9.10.1 Frequency and Method

During the pre-production period, prior to start of the main production coating operations, full scale and laboratory water absorption tests shall be performed at least on two pipes coated and on two laboratory specimens.

During normal production, water absorption tests shall be carried out for every production shift. These tests shall consist of one full scale water absorption test (on pipe joint) and one laboratory test on concrete specimen removed from pipes according to procedures approved by COMPANY.

The procedures for full-scale test shall include the following:

i) The weight of the pipe joint prior to concrete coating shall be measured and recorded.


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COMPANY Code


ii) After concrete coating, the coated pipe joint shall be weighed in air when dry and the weight recorded as "dry weight". The "dry weight" means the weight of the pipe that has been stored and cured for a minimum of three days under a roof, protected against the elements, rain, snow etc.

iii) The pipe joint shall be completely submerged in water of known density.

iv) At regular intervals, the pipe joint shall be removed from the water, the surface dried, weighed and then re-immersed in the water. This procedure shall be repeated until water saturation is reached. "Water saturation" shall be deemed as achieved when the difference between the final two consecutive weights at 6 hour intervals is within the accuracy of the weighing device. The final saturated weight and the time to reach it shall be recorded as "saturated weight".

The Water Absorption shall be calculated as:

9.10.2 Tolerances

For the full scale tests, the water absorption (as a percentage of the concrete weight) shall not exceed 5%. For laboratory test, the water absorption (as a percentage of the concrete weight) shall not exceed 3%.

Water absorption tests using cores only are acceptable.

Water absorption exceeding the above limits shall result in rejection of all coated pipe joints in the batch represented by the tested pipe.

9.11 Electrical Insulation Test

After application of the concrete coating, the electrical resistance between the reinforcement wire mesh and the pipe wall metal shall be measured. Such electrical measurements may be performed in the shop area ensuring no contact between the line pipe steel and any sand supports or the ground.

During these electrical measurements, the ends of concrete coated sections must be dry.

The measurement shall be carried out using an Ohm-meter with a DC voltage not lower than 1000 V.

The electrical resistance, measured between the reinforcement and the line pipe, shall not be less than 1000 . Pipe sections with electrical measurements recording less than this limit shall be set aside for further inspections by the COMPANY. CONTRACTOR shall propose corrective actions for COMPANY review.


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27/32

COMPANY Code


Electrical insulation tests using welding machines or equipment other than that specified are not accepted.

9.12 Calibration of Equipment

9.12.1 Batch Plant

The batch plant weigh scales shall be calibrated at least once per production day against a series of known weights placed on the weigh hoppers. Supplier may submit alternative system to COMPANY for approval.

9.12.2 Weigh Scales

Calibration of the weighing devices shall be checked at least once per shift against weight similar to the actual ones used.

9.12.3 Girth Measurements

Automatic girth measuring equipment shall be calibrated at least twice per shift. Supplier may submit alternative system to COMPANY for approval.

9.12.4 Laboratory Equipment

Up-to-date calibration certificates for the compression testing equipment, valid for the entire duration of the contract, must be provided from an independent certification authority.

Other testing or measuring equipment shall be calibrated according to COMPANY approved procedures.


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COMPANY Code


10. CONCRETE COATING REPAIR

10.1 Core Holes and Inspection Areas

Core holes and areas of concrete removed for inspection shall be refilled by hand with a concrete contain the same proportion of constituents as the coating of pipes; water/cement ratio may be higher to correct the workability.

10.2 Damaged Areas

Repair shall be allowed for the type and extension of damages defined in the following paragraphs.

CONTRACTOR shall prepare and submit to the COMPANY for approval, the procedures for repair application and curing of coating. The repair coating shall have the compressive strength, at least equal, to that of strength of coating.

10.2.1 Repair of Fresh Concrete Coating

Concrete coating found defective at the time of coating application shall be repaired in accordance with the following requirements.

Areas of damage not more than 0.6 m2 every 5 m length of pipe, to a maximum two areas any 12 meter pipe length, will be repaired by hand patching, provided that repair shall be carried out within 4 hours from concrete coating application.

Areas damaged more than 0.6 m2 but less than 20% of the total coated area shall be repaired prior pipe removal from coating applicator by re-apply the coating on the damaged area using the same application process utilized to coat the pipe.

When the damage of concrete coating is more than 20% of the pipe coated area, the repair shall not be allowed, then concrete coating shall be removed and the pipe re-coated.

10.2.2 Repair of Hardened Concrete Coating.

All defect shown up after removal from coating applicator or damages of the concrete coating due to handling and storage shall be carefully analyzed and classified as acceptable without repair or unacceptable and therefore subject to repair.

Defective concrete coating areas affected by spalling of the concrete coating with a loss of not more than 25% of the total thickness of the coating at the point of damage shall be repaired.

Any damage affecting an area less than 0.1 m2 per pipe and the depth of damage is less than 20% of the total concrete thickness will be accepted without repair if the remaining coating is sound.


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29/32

COMPANY Code


Any damage greater than 0.1 m2 but less than 0.3 m2 per pipe, shall be repaired by removing the defective concrete to enable a good locking face for the same basic material as the coating.

For any damaged areas greater than 0.3 m2 per pipe the concrete coating shall be removed from the pipe completely over the length of the damaged section and throughout the pipe circumference.

Repairs shall be made by removing the cracked and broken concrete coating down to sound concrete, so as to form a cavity to allow the anchoring of material used for repair, the reinforcement, if damaged, shall be removed and replaced as well.

The sound concrete shall be wetted and concrete mixture, consisting of cement, water and aggregates (same components and same proportion as the mixture used for the concrete coating) shall be prepared and applied with trowel paying attention to make it penetrate through the reinforcement

The mixture shall be applied until the surface is level with the coating around the repair. The repaired pipe shall then be carefully laid in a position that the fresh concrete shall be allowed to moist cure for at least four days.

The repaired coating shall have the same weight smoothness and compressive strength of the originally applied coating.

10.2.3 Cracks

Concrete cracks that are in excess of 1.5 mm in width and extending more than 180 degrees around the pipe or cracks of any width extending more than 300 mm in length longitudinally along the pipe or extending more than halfway through the concrete or penetrating to the steel wire mesh, irrespective of width, shall be repaired.

The repairing of cracks be carried out by chipping out the crack, to a width of 25mm minimum, throughout the length of the crack.

The crack shall then be repaired with the same material that used for the coating in a manner similar to that outlined above.

The repair shall be kept moist and kept undisturbed for period of 36 hours minimum.


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COMPANY Code


11. MEASUREMENTS AND LOGGING

All measurements mentioned hereinafter shall be taken during the various stages of the production and clearly logged in approved log-book. A special log-book shall be used for recording tests and trial results.

The following parameters shall be measured and/or logged.

Line pipe

i) Pipe joint numberii) Mill serial numberiii) Joint lengthiv) Length of bare pipe (this information may be taken from the pipe

manufacturer’s data book).v) Average outside diameter. The average outside diameter shall be obtained

from girth measurements at a minimum of five points spaced equidistant over the length of the pipe joint.

Anti - corrosion coating.

Since CONTRACTOR is not awarded for application of the anti-corrosion coating, the following information may be recorded without measurements.

i) Type of coatingii) Coating thicknessiii) Weight of coated pipeiv) Date of coating application.

Concrete coating

i) Batch identification No.ii) Date of concrete coating applicationiii) Average concrete coating weight for the production shiftiv) "Wet weight" of concrete coated pipe and date of weighingv) "Dry weight" of concrete coated pipe (weight and date of weighing) or related

weight 28 days after placing of concrete (if so identifiable). vi) Set of the 5 measured diameters and associated concrete thickness. These

measurements shall be obtained from girth measurements at five points over the length of the pipe joint. Two of such measurements shall be approximately 40 cm from the pipe ends and the others spaced equidistant in between.

vii) Average outside diameter of the concrete coated pipeviii) Average concrete thickness, derived from vi) above.ix) Insulation electrical resistance between pipe body and reinforcement

The log-book shall also record the parameters derived from calculations; namely:


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31/32

COMPANY Code


i) "Unit dry weight" of concrete coated pipeii) “Unit negative buoyancy" of concrete coated pipeiii) “Rolling average” of negative buoyancy for 25 consecutive pipe jointsiv) “Unit saturated weight" of the relevant test pipe


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32/32

COMPANY Code


12. NON ACCEPTANCE

Causes of non-acceptance of the concrete coating may be due to the following

incomplete concrete coating application over the pipe within the maximum time of 30 minutes (i.e. failure of the coating plant);

insufficient or uneven thickness; incorrect position of the steel reinforcement; lack of insulation between the reinforcement and the pipe; concrete coating damaged during handling or stacking (damage that cannot be

repaired); concrete coating defects (e.g. voids, pockets, separation, excessive cracks,

porosity, non-hardening,); cracks that show the reinforcement or cause a weakening of the

circumferential strength of the concrete; defects that result in the weighted pipe being unsuitable for the expected use

and scope.

All concrete coating that does not meet the established requirements shall be removed and the pipe shall be re-coated by CONTRACTOR.


specification for line pipe concrete coating_a

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