Engineering Standards

Standard

4763
Page

1 of 7
YARD APPLIED
CONCRETE PIPE COATING

Issue Date

Rev. No.
Date

06/86
2
10/93

1.

SCOPE

This standard covers requirements for the application of concrete coating to steel pipe to achieve the negative
buoyancy required for laying the pipe in marshes or water or to provide mechanical protection. Concrete
application methods covered include impingement (gunite), rotary extrusion, or forming and pouring.

2.

GENERAL

2.1

Concrete coating for pipelines shall consist of a uniform thickness of reinforced concrete applied over the
corrosion protective coating.

2.2

Coating work shall be in accordance with the requirements of Engineering Standard 6604, "Coating Yard
General Requirements", in addition to this standard.

2.3

Concrete coating shall be of the density and thickness required to provide the resultant specific gravity
(S.G.) as specified in Engineering Standard 6604 (specification sheet) by the Design Engineer for the
specific application, or as specified in other contract documents. Slight variations in concrete thickness
and density are acceptable to Company, provided the coating meets the S.G. requirement. Concrete
densities normally range from 140 to 190 lbs/ft 3. When negative buoyancy is not a critical requirement
such as for undercrossings, the concrete density testing and control requirements and rejection criteria in
Sections 4, 5 and 9 of this standard will be waived if specified or agreed to in writing by the Company.

2.4

Coating Contractor shall locate and repair all holidays and damaged spots in the corrosion protective
coating just prior to concrete application. An approved electronic holiday detector shall be used and be set
at the voltage recommended by the Company for the type and thickness of coating to be inspected. All
necessary coating repairs shall be the responsibility of the Coating Contractor and be performed in
accordance with the applicable Company standard for the type coating and then reinspected electronically.
Repair of pipe coating damaged while in the Coating Contractor's custody shall be at said Contractor's
expense.

2.5

All materials and procedures shall conform to the specifications set forth by the American Concrete
Institute (ACI) and the American Society for Testing and Materials (ASTM), latest revision, as applicable,
and be acceptable to Company's Representative.

3.

MATERIALS
3.1

Concrete

3.1.1

The minimum compressive strength of the concrete shall be 3000 psi at 7 days and 4000 psi at
28 days.

3.1.2

All concrete materials shall be furnished by the Coating Contractor and shall consist of
Portland Cement, sand and aggregate, water, and if necessary to achieve the specific gravity
specified, crushed magnetite ore (ilmenite, hematite, etc.).

* Indicates revised paragraph, this Rev. No.

Engineering Standards

Standard

4763
Page

2 of 7
YARD APPLIED
CONCRETE PIPE COATING

Issue Date

Rev. No.
Date

3.1.3

Cement shall conform to ASTM C 150, Type I or III; shall be stored in a manner that will
protect it from the elements; and shall be rejected and removed from the coating site if it has
hardened, partially set or become lumpy.

3.1.4

Sand and aggregate shall conform to ASTM C 33; shall be well graded from fine to coarse;
and shall be clean and free from injurious amounts of salt, alkali, deleterious substances or
organic impurities.

3.1.5

Magnetite ore, if required, shall be free of clay and injurious amounts of alkali, deleterious
substances and organic impurities that may affect the strength of concrete and shall conform to
ASTM C 29. Magnetite ore shall be crushed to the following screen analysis:
100%
30-75%
10-40%
0-25%

3.1.6
3.2

4.

06/86
2
10/93

passing 1/4" screen

passing #16 mesh screen
passing #50 mesh screen
passing #100 mesh screen

Water shall be potable and free from oil, acid, alkali, scale, organic matter or large quantities
of sulfates.

Reinforcing Steel

3.2.1

For the impingement and rotary extrusion methods of concrete application, reinforcing steel
shall be galvanized wire mesh, 1-1/2" x 17-gauge, conforming to ASTM A 810.

3.2.2

For the form and pour method of concrete application, reinforcing steel shall be welded,
galvanized wire fabric, conforming to ASTM A 185. Minimum area of reinforcement per 12inch width in each direction shall be 0.027 square inches.

3.2.3

Alternate combinations of mesh pattern, size, wire gauge and manufacturing specification are
allowed to accommodate a specific concrete application process, provided equivalent
reinforcement will be obtained.

TESTING
4.1

Concrete Density
4.1.1

The dry concrete weight per cubic foot is to be determined from cured concrete not less than 4
days old. A sample of not less than 36 square inches shall be taken from coating materials as
applied during normal coating operations.

4.1.2

Oven Dry Weight: The sample shall be oven-dried at 210F to constant weight. When
constant weight is attained, the sample shall be allowed to cool to room temperature and
weighed to the nearest gram.

* Indicates revised paragraph, this Rev. No.

Engineering Standards

Standard

4763
Page

3 of 7
YARD APPLIED
CONCRETE PIPE COATING

Issue Date

Rev. No.
Date

06/86
2
10/93

4.1.3

Suspended Immersion Weight: The sample shall be submerged in water at room temperature
for a minimum 24 hours. The submerged sample shall be weighed to the nearest gram.

4.1.4

Saturated Weight: The sample shall be withdrawn from the water, the excess surface moisture
removed, and weighed to the nearest gram.

4.1.5

The dry concrete weight, per cubic foot, is calculated as follows:

(Oven Dry Weight x 62.4
Saturated Weight - Suspended Immersion Weight

4.2

4.1.6

It shall be necessary to establish wet weight of concrete coating for the specified dry weight
per cubic foot so that acceptance or rejection can be made by weighing each coated joint of
pipe immediately after coating is applied. This relationship shall be determined by tests
conducted under actual plant conditions and shall yield a procedure mutually agreed upon
between Company's Representative and the Coating Contractor.

4.1.7

Coating Contractor shall furnish all materials to be tested and all testing apparatus required.

Concrete Strength
4.2.1

Representative samples of concrete mix and samples of cured concrete shall be furnished not
less than four days of age to a reputable laboratory for tests.

4.2.2

The tests shall include a 7-day and a 28-day compressive test as well as a bulk density test.
The test specimen shall be taken from coated pipe and tested according to ASTM C 31.

4.2.3

Tests shall be conducted until the control of the equipment and the mixture of materials are
satisfactory to meet the above specifications. Tests shall be conducted throughout the coating
operations to assure adequate quality control of the coating.

4.2.4

Company's Representative shall be furnished a copy of the results of each test required by this
section.

4.2.5

A previously tested mix may be used if done according to the above requirements and meets
the requirements of this standard.

4.2.6

Coating Contractor shall bear all costs in connection with testing.

5.

APPLICATION

5.1

5.2

Internal Braces and Supports (Form & Pour Method)

5.1.1

During the coating process, the pipe must be internally braced if necessary to maintain pipe
ovality within a tolerance of +0.5% of the pipe diameter within 4" of both ends.

5.1.2

During the coating process, the pipe must be supported as necessary to limit bending to a
tolerance of 0.2% of the pipe length.

Concrete

* Indicates revised paragraph, this Rev. No.

Engineering Standards

Standard

4763
Page

4 of 7
YARD APPLIED
CONCRETE PIPE COATING

Issue Date

Rev. No.
Date

06/86
2
10/93

5.2.1

In all cases, the concrete shall be placed within 30 minutes after the water is first added to the
mix. No additional mixing water shall be added to the mix in order to return the concrete to
the original slump. Any equipment that tends to separate the ingredients shall not be used.

5.2.2

Each joint of pipe shall be coated in a continuous operation. If more than one application is
required to produce a coating of the specified thickness, the time allowed between the first
coat and the last coat shall not exceed 30 minutes. If a time lapse greater than 30 minutes
does occur, the coating shall be removed and the entire joint of pipe recoated.

5.2.3

Coating which has abrupt irregularities or variations in thickness such that would be difficult
to push the coated pipe through rollers or shoes on lay barges and ramps or through road bores
will be rejected.

5.2.4

Coating Contractor shall furnish the necessary scales to accurately weigh the coated pipe as it
is removed from the coating machine or forms. At the beginning of operations each day, the
scales shall be checked by weighing a joint of pipe of known weight. Adjustments of the
scales shall be made if necessary.
From the measurement of the coated joint length, the weight of the coated joint, the field joint
material and the cross sectional area of the pipe and coating, Coating Contractor shall
determine the S.G. of the coated pipe. In calculation of the S.G., the O.D. (outside diameter)
of the field joint material shall be assumed to match the O.D. of the concrete coating. Unless
otherwise specified, the specific gravity shall be based on sea water at 64.0 lbs. per cu. ft.
These specific gravity calculations shall be performed as frequently as may be necessary to
properly determine that the mixture of materials and the equipment speed is adequate to
produce a coating which will meet the above specifications.
A copy of Coating Contractor's computations shall be furnished to Company's Representative
at the end of each day's work, along with a record of coating operations showing the length of
each joint of pipe coated, its weight and it calculated specific gravity.

5.3
*

Reinforcement
5.3.1

Reinforcing steel mesh shall be applied to form a continuous sheath, each spiral or wrap
overlapping the adjacent one by at least 1/2" except for the form and pour method where the
minimum overlap shall be two (2) inches.

5.3.2

In no case, shall the reinforcing steel be in physical or electrical contact with the pipe, anodes,
or anode leads. The Coating Contractor will supply a suitable electrical power source and
meters for checking that there is electrical isolation.

5.3.3

For the form and pour method, the reinforcing steel shall be tied in place using spacers to
separate reinforcement from the coating surface. Sufficient spacers and ties shall be provided
to maintain reinforcement in proper position during concrete application. Spacers shall be
sized and positioned to allow 1/2" concrete cover over reinforcement. Spacers shall be made
of materials compatible with concrete and designed to prevent damage to the corrosion
coating.

* Indicates revised paragraph, this Rev. No.

Engineering Standards

Standard

4763
Page

5 of 7
YARD APPLIED
CONCRETE PIPE COATING

Issue Date

Rev. No.
Date

06/86
2
10/93

5.3.4

For the rotary extrusion and impingement methods, reinforcing steel shall be placed as nearly
as possible at mid-depth of the concrete coating. If more than 2-3/4" thickness of concrete is
needed to obtain the required specific gravity, a second layer of reinforcing steel shall be
applied. The first layer shall be placed 1-1/4" from the outside surface of the base coating and
the second wrap shall be placed 3/4" from the outside of the concrete coating.

5.3.5

Field Joints

a.

Field joint material and density is to be as specified in Engineering Standard 6604 or

other contract documents.

b.

If the pipe is to have concrete coated field joints, reinforcing steel shall be extended a
minimum of 2" beyond the beveled ends of the concrete on each pipe joint.

c.

If the pipe is not to have concrete coated field joints, the reinforcing steel shall cut back,
or otherwise applied, so that it will extend to within 2" of the end of the concrete coating
but not protrude beyond the beveled edges of the concrete on each pipe joint.

6.

CUT-BACK ON THE CONCRETE COATING

Unless specified otherwise, concrete shall be applied to within 12" of the ends of the joints of pipe. The ends of the
concrete coating shall be beveled 45. No concrete resulting from rebound, etc., shall be left on the ends of the
pipe where it may interfere with the application of the field joint.

7.

CURING

8.

7.1

Immediately after the pipe has been removed from the coating process and the necessary specific gravity
calculations have been made, it shall be stored for curing.

7.2

Concrete coating shall be kept from dehydrating using one of the following methods:
7.2.1

The concrete shall be sprayed with a pigmented membrane sealant conforming to

ASTM C 309.

7.2.2

The concrete shall be sprayed continuously with a mist of water for at least four (4)
consecutive days after being removed from the coating machine.

7.2.3

The concrete shall be wrapped with a polyethylene tape.

7.3

Freshly coated pipe shall be bedded evenly on sand and the concrete coating allowed to cure for a
minimum of four (4) days before further handling.

7.4

No concrete shall be applied while the ambient temperature is 40F and falling. If during the curing
period the temperature falls below 40F, the coating shall be protected in accordance with the standard
practices recommended by the American Concrete Institute and to the satisfaction of Company's
representative.

REPAIRS TO CONCRETE COATING

8.1

Spalling

* Indicates revised paragraph, this Rev. No.

Engineering Standards

Standard

4763
Page

6 of 7
YARD APPLIED
CONCRETE PIPE COATING

Issue Date

Rev. No.
Date

8.2

9.

06/86
2
10/93

8.1.1

A loss in concrete of more than 25% of the total coating thickness at the point of damage shall
be repaired.

8.1.2

An area of spalling less than one square foot, where the remaining concrete is sound, will be
acceptable without repairs.

8.1.3

If an area of spalling is more than one, but less than three square feet, the concrete remaining
in place over that area shall be removed as necessary to expose the reinforcing steel
throughout the damaged area. Edges of the spoiled area shall be undercut to provide a key
lock for the repair material. For damaged areas more than three square feet, the coating shall
be removed from the entire circumference of the pipe for the length of the damaged area.
Repairs shall be made by satisfactorily restoring the reinforcing steel, if necessary, and
replacing the damaged coating with the same basic coating material.

8.1.4

Repaired pipe shall be carefully stored and allowed to moist cure a minimum of 36 hours
before further handling.

Cracking
8.2.1

Concrete coating cracks shall be repaired where they are over of 1/16" wide and extend over
180 circumferentially around the pipe, or where longitudinal cracks extend over 12" along
the pipe, irrespective of width.

8.2.2

Repair shall be made by chiseling material from the crack to a width not exceeding one (1)
inch and filling with materials similar to that from which the coating is made. The repairs
shall be allowed to remain undisturbed for a period not less than 24 hours.

8.3

Wherever the concrete coating is damaged to the extent that Company's inspector deems it likely that the
coating underneath the concrete is also damaged, an area of concrete sufficient in size for adequate
inspection shall be removed.

REJECTION OF CONCRETE COATING

9.1

Any failure to meet the requirements of this standard shall be cause for rejection.

9.2

Coating damaged in handling or storage that is excessive and beyond repair shall be cause for rejection.

9.3

Coatings that are allowed to remain unfinished for a period of time exceeding 3/4 of an hour for any
reason, shall be rejected.

9.4

Improper placement of reinforcing steel shall be cause for rejection.

* Indicates revised paragraph, this Rev. No.

Engineering Standards

Standard

4763
Page

7 of 7
YARD APPLIED
CONCRETE PIPE COATING

Issue Date

Rev. No.
Date

9.5

06/86
2
10/93

Coatings that weigh less than the weight specified shall be rejected, unless the average weight of the pipe
joint is maintained by compensating for each joint that is underweight by placing a compensating extra
weight on the surrounding joints. On all pipe sizes, the weight of the coated joint of pipe must be within
5% below and 7-1/2% above the specified weight. Not more than 5 successively coated joints of pipe
bearing underweight coating of any percentage will be accepted.

* Indicates revised paragraph, this Rev. No.