Concrete Weight Coating

PETRONASCARIGALISDNBHD
PROVISIONOFFRONTENDENGINEERINGDESIGN(FEED)AND
ENGINEERING,PROCUREMENT,CONSTRUCTION,INSTALLATION&
COMMISSIONING(EPCIC)OFSK316DEVELOPMENTPROJECT
(CONTRACTNO.CHO/2012/D316/1000)
TABLEOFCONTENT
1
PROJECTINTRODUCTION............................................................................................................5
1.1
SCOPEOFDOCUMENT.......................................................................................................................7
1.2
DEFINITION.........................................................................................................................................7
1.3
ABBREVIATION...................................................................................................................................7
REFERENCES................................................................................................................................8
2.1
PROJECTDOCUMENTS.......................................................................................................................8
2.2
COMPANYSTANDARDS......................................................................................................................8
2.3
CODESANDSTANDARDS....................................................................................................................8
2.4
SYSTEMOFUNITS...............................................................................................................................9
GENERALREQUIREMENTS.........................................................................................................10
CONCRETECOATINGMATERIALS..............................................................................................11
4.1
CEMENT............................................................................................................................................11
4.2
AGGREGATES....................................................................................................................................11
4.3
WATER..............................................................................................................................................12
4.4
ADDITIVES.........................................................................................................................................12
4.5
REINFORCINGSTEEL.........................................................................................................................12
4.6
WELDEDSTEELWIREMESH..............................................................................................................13
4.7
STEELCAGETYPE..............................................................................................................................13
RECEIPT,HANDLINGANDSTORAGEOFBAREPIPES...................................................................14
CONCRETECOATINGAPPLICATION...........................................................................................15
6.1
VISUALANDHOLIDAYINSPECTIONOF3LAYERPECOATEDPIPES.................................................15
6.2
PLACEMENTOFREINFORCEMENTSTEEL.........................................................................................15
APPLICATIONOFCOATINGMATERIALS.....................................................................................16
7.1
PREPARATIONOFTHECUTBACKAREA............................................................................................16
7.2
FINISHINGOPERATIONSWITHINCONCRETECOATINGPLANT........................................................16
7.3
CURING.............................................................................................................................................17
7.3.1
WATERCURING...............................................................................................................................17
7.3.2
STEAMCURING................................................................................................................................18
7.3.3
CURINGBYSEALINGCOMPOUNDS.................................................................................................18
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7.3.4
CURINGUNDERPOLYETHYLENEWRAPPING...................................................................................18
7.3.5
FOGCURING....................................................................................................................................19
INSPECTIONANDTESTING........................................................................................................20
8.1
STACKINGOF3LAYERPECOATEDPIPES.........................................................................................21
8.2
CONTROL,IDENTIFICATIONANDSEGREGATIONOF3LAYERPECOATEDPIPES.............................22
8.3
DELIVERYANDSTORAGEOFCONCRETECOATINGRAWMATERIALS..............................................22
8.4
TESTTOBEPERFORMEDONCONCRETECOATINGMATERIALUPONRECEIPT...............................23
8.4.1
SIEVEANALYSISANDCLEANLINESSCONTROLOFAGGREGATES....................................................23
8.4.2
STEELREINFORCEMENTWIRESDIMENSIONALCONTROL..............................................................23
8.4.3
MIXINGWATERCHEMICALANALYSIS.............................................................................................23
8.5
VERIFICATIONOFCALIBRATIONOFTHETESTINSTRUMENTS.........................................................24
8.5.1
HOLIDAYDETECTOR........................................................................................................................24
8.5.2
PIPEWEIGHINGSCALES...................................................................................................................24
8.6
VISUALANDHOLIDAYINSPECTIONOFTHE3LAYERPECOATEDPIPES..........................................24
8.7
CONCRETECOATINGMIXCONTROL................................................................................................25
8.8
CONCRETECOATINGMIXTEMPERATUREMEASUREMENT.............................................................25
8.9
WATERCEMENTRATIOCHECK........................................................................................................25
8.10
REINFORCINGWIREPOSITIONCONTROL.........................................................................................26
8.11
CONCRETECOATINGAPPLICATIONCONTROL.................................................................................26
8.12
MEASUREMENTOFEXTERNALDIAMETEROFAPPLIEDCONCRETE.................................................26
8.13
CUTBACKCONTROL..........................................................................................................................27
8.14
WEIGHINGOFFRESHLYCONCRETECOATEDPIPE............................................................................27
8.15
CALCULATIONOFNEGATIVEBUOYANCY.........................................................................................27
8.16
VISUALINSPECTIONOFAPPLIEDCONCRETE....................................................................................28
8.16.1
SURFACEFALLOUTS(SPALLING)OFFRESHLYCONCRETECOATEDPIPES......................................29
8.16.2
CONCRETECOATINGDAMAGESONFRESHANDHARDENEDCONCRETE.......................................29
8.16.3
CRACKS............................................................................................................................................29
8.17
ELECTRICALRESISTANCEBETWEENSTEELREINFORCEMENTANDTHEPIPE...................................30
8.18
CONTROLOFCURINGPROCESS.......................................................................................................30
8.19
CONTROLOFSTACKINGOFPIPESDURINGTHECURINGPROCESS..................................................30
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8.20
CONTROLOFMARKINGONCONCRETECOATEDPIPES...................................................................30
8.21
CONTROLOFMARKINGONCONCRETECOATINGREPAIR...............................................................31
8.22
DETERMINATION OF FACTOR ALPHA IN THE FORMULA FOR CALCULATION OF NEGATIVE

BUOYANCY.......................................................................................................................................31
8.23
COMPRESSIONSTRENGTHTESTCUBES...........................................................................................31
8.24
COMPRESSIONSTRENGTHCORESAMPLES......................................................................................32
8.25
DETERMINATIONOFTHETIMEFORSTACKINGOFPIPESINMORETHANONELAYER...................33
8.26
WATERABSORBTIONTEST...............................................................................................................34
8.27
ADHESIONBETWEENTHE3LAYERPECOATINGANDCONCRETECOATING...................................34
8.28
IMPACTTESTING..............................................................................................................................35
8.29
STACKINGOFCUREDCONCRETECOATEDPIPES..............................................................................36
8.30
LOADOUTINSPECTIONS..................................................................................................................37
3LAYERPECOATINGREPAIR....................................................................................................38
10
CONCRETECOATINGREPAIRANDSTRIPPINGOFCONCRETECOATEDPIPES..............................40
11
PIPEMARKING..........................................................................................................................42
12
STORAGE,HANDLINGANDTRANSPORTATIONOFCONCRETECOATEDPIPES............................43
13
DOCUMENTATION....................................................................................................................45
13.1
GENERALREQUIREMENTS................................................................................................................45
13.2
TECHNICALDOCUMENTATIONTOBESUBMITTEDDURINGTHEBIDDINGPHASE..........................45
13.3
TECHNICAL DOCUMENTS TO BE SUBMITTED AFTER AWARD OF THE CONTRACT TO

SUBCONTRACTOR............................................................................................................................46
13.4
FINALTECHNICALDOCUMENTATION..............................................................................................47
13.5
CONTENTOFPARTICULARTECHNICALDOCUMENTS......................................................................48
13.5.1
CONCRETECOATINGAPPLICATIONPROCEDURE............................................................................48
13.5.2
INSPECTIONANDTESTPLAN...........................................................................................................49
13.5.3
DAILYPRODUCTIONREPORT...........................................................................................................49
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PROJECTINTRODUCTION
NC3andNC8aregasfieldslocatedinBlockSK316,approximately180kmNorthofBintulu,Sarawakwith
waterdepthrangingapprox.between70m105m.NC8fieldislocatedapproximately7kmSouthEaston
NC3field.ThenearbyriserfacilityE11RCislocatedapproximately80kmSouthWestofNC3.Theexisting
trunklineconnectingE11RCtoshoreTL6isavailableandprovisionedforinthisgasfielddevelopment.The
locationsofNC3,NC8andnearbyfacilitiesareillustratedinFigure11below.
Figure11LocationofProject
GasfromNC3andNC8fieldsarethemainfeedgassupplierintothePETRONASLNGComplexTrain9near
Bintulu which is expected to be ready for startup in December 2015.The scope demarcation between
upstreamanddownstreamfacilitiesisasdescribedbelowinFigure12.
Figure12UpstreamandDownstreamScopeDemarcation
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ThedevelopmentofNC3andNC8fieldsisenvisagedtobeincomplextypeconfiguration.NC3willbecome
ahubcomprisingofaCentralProcessingPlatform(CPP)withlivingquartersandabridgelinkedWellhead
Platform(WHP).AnotherWHPistobeinstalledatNC8;itwillbetiedbacktoNC3viaaninterfieldsubsea
pipeline. Though compression may not be required at the beginning of production, the need for gas
compressionisanticipatedafterapproximatelyfour(4)years.Hencetheprovisionforfuturecompression
facilitiesandmercuryremovalfacilitiesshallbeconsideredaspartofthisFEEDworkfortheNC3CPP.
Figure13OverallDevelopmentConcept
A new subsea pipeline connecting NC3 and E11RC will be installed to deliver the processed gas and the
spikeddehydratedcondensate.Duetoincompatibilityofthisgasqualitywiththeexistinggassupplyatthe
riser,adedicatedmanifoldatE11RCmayberequiredtoaccommodatethistiein.Thisistoensurethatthe
gasfromNC3andNC8fieldsdonotcontaminatetheentirenetworktoshore.Assuch,modificationwillbe
requiredtoconverttheexistingTL6tobededicatedforgasfromNC3andNC8.
Thefuturetrunkline(TL7)mayberequiredinthefutureshouldTL6nolongerbefitforservice.
The processed gas and dehydrated condensate will be separated at onshore receiving facilities prior to
beingintroducedintoLNGPlantTrain9.
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1.1 SCOPEOFDOCUMENT
Thepurposeofthisdocumentistodefinetheminimumrequirementsforconcreteweightcoatingtobe
usedforthefollowingoffshorerigidpipelineintheSK316DevelopmentProject:
32OffshorepipelinefromNC3WHPtoE11RCPlatform
32OffshorepipelinefromE11RCPlatformtoOnshoreBeachValveLocation
20OffshorepipelinefromNC8WHPtoNC3WHP(Diametertobeconfirmed)
1.2 DEFINITION
COMPANY
PETRONASCarigaliSdnBhd
CONTRACTOR
SAIPEM
SUBCONTRACTOR
PartyselectedbyCOMPANY/CONTRACTORresponsiblefor
application of the concrete weight coating on PROJECT
pipes in accordance with this specification and other
contractualdocuments
MANUFACTURER
Supplier of the raw materials or inspection and testing

equipmentrequiredtoperformthework
PROJECT
FEED for SK316 Facilities Development of the NC3 and

NC8GasFields
1.3
ABBREVIATION
FBE
FusionBondedEpoxy
N/A
NotApplicable
No.
Number
OD
Outsidediameter(externalpipediameter)
PQT
PreQualificationTest
3LPE
3LayerPolyethylene
3LPP
3LayerPolypropylene
CWC
ConcreteWeightCoating
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REFERENCES
Unlessotherwisestated,thelatestissueofthebelowlistedPTSCOMPANYSpecifications,Codes,Standards
andRegulationsshallapply.Equivalentalternativesmaybeoffered;theseshallbeidentifiedandmutually
agreedon.
2.1
PROJECTDOCUMENTS
DOCUMENT
NAME
/1/ 05SSPLBODU0001
PipelineAndRiserDesignBasis
/2/ TBC
InputforPipelineStudy
/3/ 05GENBODB0001
ProcessDesignBasis
/4/ 05SSPLREPU0001
SteadyStatePipelineSimulationReport
/5/ 05GENBODZ0002
CorrosionStudyMemorandum
/6/ 05SSPLREPU0002
PipelineTransientAnalysisReport
/7/ 05SSPLREPU0003
PipelineRouteSelectionReport
2.2
COMPANYSTANDARDS
DOCUMENT
NAME
/8/ 31.40.00.20
Pipeline&RiserEngineering
/9/ 31.40.30.30
Concretecoatingoflinepipe
2.3
CODESANDSTANDARDS
DOCUMENT
NAME
/10/ ISO218091
Petroleum and Natural Gas Industries External

CoatingsforBuriedorSubmergedPipelinesUsedin
PipelineTransportationSystemsPart1:Polyolefin
Coatings(3LayerPEand3LayerPP).
/11/ BSEN10288
Steel Tubes and Fittings for Onshore and Offshore

Pipelines External Two Layer Extruded
PolyethyleneBasedCoatings
/12/ ASTMC150
StandardSpecificationforPortlandcement
/13/ ASTMC33
StandardSpecificationforConcreteAggregates
/14/ ASTMA81001
Standard Specification for ZincCoated (Galvanized)

SteelPipeWindingMesh
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/15/ ASTMA615M
Standard Specification for Deformed and Plain

CarbonSteelBarsforConcreteReinforcement
/16/ ASTM18501
Standard Specification for Steel Welded Wire

Reinforcement,Plain,forConcrete
/17/ ASTMA8201
Standard Specification for Steel Wire, Plain, for

ConcreteReinforcement
/18/ ASTMC30998A
Standard Specification for Liquid Membrane

FormingCompoundsforCuringConcrete
/19/ ASTMC171
Standard Specification for Sheet Materials for

CuringConcrete
/20/ ASTMC39/C39M01
Standard Test Method for Compressive Strength of

CylindricalConcreteSpecimens
/21/ ASTMC61798
Standard Practice for Capping Cylindrical Concrete

Specimens
/22/ BSEN1971
Cement Part 1: Composition, Specifications and

ConformityCriteriaforCommonCements
/23/ BSEN1008
Mixing Water for Concrete Specification for

Sampling, Testing and Assessing the Suitability of
Water, Including Water Recovered from Processes
in the Concrete Industry, as Mixing Water for
Concrete
/24/ BS4482
Cold Reduced Steel Wire for the Reinforcement of

ConcreteProductsSpecification
/25/ BS4483
Steel Fabric for the Reinforcement of Concrete

Specification
/26/ BSEN123902
Testing Hardened Concrete Part 2: Making and

CuringSpecimensforStrengthTests
/27/ BSEN123903
Testing Hardened Concrete Part 3: Compressive

StrengthoftestSpecimens
2.4
SYSTEMOFUNITS
The International Unit System (SI) shall be utilized throughout the project, unless otherwise highlighted.
Anyconversionshallbeprovidedinparenthesiswhereapplicable.
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GENERALREQUIREMENTS
FortestingpurposesspecifiedinthisSpecification,theproductionshiftshallbeconsideredofmaximum12
hours depending on the SUBCONTRACTORs internal organization. In case SUBCONTRACTOR intends to
workmorethan12hoursperday,COMPANY/CONTRACTORshallconsiderthattheworkisperformedin
morethanoneshiftandtherelevanttestingfrequencyshallberespectedasperthisSpecification.
AllSUBCONTRACTORsdocumentsshallcomplywiththelimitationsofthisSpecification.SUBCONTRACTOR
shallpromptlyinformCOMPANY/CONTRACTORofanyneedtomakechangestothesedocuments,which
shallhavetobespecificallyacceptedbyCOMPANY,whohastherighttorequireadditionaltestingwithout
additionalcosts.
Any technical deviations to this Specification shall be obtained by SUBCONTRACTOR only through a
concessionrequestformat.InanycaseitisnotallowedtoinsertanydeviationfromthisSpecificationin
anySUBCONTRACTORsdocumentpriorthatthisdeviationhasnotbeenpreviouslypresentedseparately
toCOMPANY/CONTRACTORandapprovedinwrittenbyCOMPANY/CONTRACTOR.
Concession requests require COMPANYs review and approval prior to implementation of the proposed
changes. Pipes coated by implementing the technical changes prior to the COMPANYs approval shall be
rejected.
Priortothecommencementoftheproductionandduringtheproduction,COMPANYshallreservetheright
toperformauditsintheSUBCONTRACTORsfacilities.
COMPANYandCOMPANYsrepresentativesshallbepermittedbySUBCONTRACTORtheunlimitedaccess
to all SUBCONTRACTORs facilities related to the SUBCONTRACTORs scope of work for the PROJECT
startingfromthemomenttheworkhasbeenawardedtoSUBCONTRACTORuntilSUBCONTRACTORhas
completedalloftheobligationsrelatedtohisscopeofworkinthePROJECT.
It is mandatory requirement for SUBCONTRACTORs coating facilities that all of the inspection activities
accordingtotheactionpointsspecifiedininspectionandtestplanscanbeperformedbyinspectorsfrom
all involved Parties in safe manner for all personnel involved in these activities. In case the inspection
activities cannot be safely performed for all persons involved in inspection (CONTRACTOR,
SUBCONTRACTORs, COMPANYs and Third Partys personnel), SUBCONTRACTOR shall stop all of the
activitiesatthatparticularinspectionpointandshallorganizetheworkspaceinamannerthatallactivities
canbeperformedinsafemanner.AllcostsduetosuchstoppagesshallbeborneonlybySUBCONTRACTOR.
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CONCRETECOATINGMATERIALS
Theconcretecoatingappliedonlinepipesshallhavethefollowingnominaldryandcuredconcretedensity
of3044kg/m3.
4.1 CEMENT
UnlessotherwisespecifiedinthePurchaseOrder,allcementusedforthepreparationoftheconcreteshall
bePortlandCementconformingtotherequirementsofoneofthefollowingstandardsdependingonthe
availabilityatthelocationwheretheconcretecoatingapplicationshallbecarriedout:
ASTMC150TypeIIandV;
MS522standard;
BSEN1971standard.
All batches of cement shall be supplied to SUBCONTRACTOR with test certificate stating the compliance
either with the ASTM C 150 (Type II and V) or BS 12 or EN 1971 standard which shall then
SUBCONTRACTORsubmittoCOMPANYforreviewpriortoitsuse.
The certificates must be presented to COMPANYs review to verify that also the following mandatory
requirementsaremet:
thatthecontentofalkaliis<0.6%;
thatthecontentoftricalciumaluminateC3Ais<8%.
Cementthathashardened,partiallysetorlumpywillberejectedandshallberemovedfromtheworksite.
Regroundandgradedcementshallnotbeused.
CementnotmeetinganysingleofabovementionedrequirementsshallnotbeusedinthePROJECT.
Cementshallbestoredincoveredareasorcoveredbyplasticsheeting.
4.2
AGGREGATES
Thesandshallbeofthesilicatype.Clayeyandschistosesandsshallnotbeused.
Sandshallbestoredinamannertoavoidcontaminationfromsoilorotherforeignmatter.
Heavy aggregates shall be made of crushed granite, or any other aggregate approved by the
COMPANY/CONTRACTOR. Aggregates shall not be made from chalky or decomposed stone. In case high
densityconcreteisrequired,SUBCONTRACTORmayaddironoretotheconcretecoatingmix.
AllaggregatesshallbecertifiedaccordingtoASTMC33standardwithexceptionofgrading.
SUBCONTRACTOR shall propose the grading of aggregates in the concrete mix which shall be confirmed
duringthePreQualificationTest.Howeveritismandatorythatallaggregatesshallbeofthesizethat100%
oftheirquantitywillbeabletopass10mmsieves.
Allaggregatesshallbewashedandshallbefreefrominjuriousamountsofsalts,alkali,organicimpurities
or deleterious substances such as oxides of lead and zinc that may affect the strength of the concrete.
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Samplingandtestingforcleanlinessofaggregatesshallbecarriedoutforeachdeliveryofeachaggregate
inaccordancewithASTMC33standardandotherstandardsreferredintheASTMC33standard.
Duringproductionthegradingandcleanlinessshallbecheckedatleastonceeverythreedaysfromeach
stockpileandeachnewconsignmentforcleanlinessandgrading.Thegradingshallbeasperthenominal
valuesandtolerancesspecifiedbySUBCONTRACTORandverifiedduringthePQT.Thetestforcleanliness
shall mean visual inspection for presence of any foreign material in tested sample beside the tested
aggregateitself(wood,shells,oranyothersimilarcontaminant).SUBCONTRACTORshallberesponsiblefor
properstorageofaggregatesandallcostsrelatedtotheCOMPANYsrejectionofcontaminatedaggregate
shallbebornebySUBCONTRACTOR.
Differenttypesofaggregatesshallbestoredseparatelyinbinsorwellpreparedareas,i.e.cobbled,paved
orwellcompactedareasallowingadequatedrainageofmaterials.
4.3 WATER
WaterusedinconcretecoatingmixshallbefreshandshallcomplywithAppendixAofBSEN1008.
Water shall be of potable quality and obtained from a public supply where possible. Water shall not be
takenfromaspring,well,lakeorsimilarsourceunlesstestindicateitssuitability.
DuringthebiddingstageofthePROJECTtheSUBCONTRACTORshallpresentthecertificateforthemixing
waterusedinthecoatingplantandtheSUBCONTRACTORshallprovidetheguarantythatthesamewater
shallbeusedduringentireSUBCONTRACTORsworkinthePROJECT.
4.4 ADDITIVES
Additivescontainingchloridesshallnotbeusedintheconcretemix.Thetotalquantityofchlorideswithin
theconcretemix,calculatedasfreeCaCl2,shallnotexceed0.4%oftheweightofthecement.
Waterreducingagentsforconcretemaybeusedintheconcretemix.
Airentrainingagentsshallnotbeusedintheconcretemix.
4.5 REINFORCINGSTEEL
Thereinforcingsteelmaybeusedinthefollowingforms:
weldedsteelwiremesh(typeWWCortypeWWNaspertheASTMA81001standard);
steelcagetype.
Chickenwiremeshandsteelpoultrynettingarenotallowedasthereinforcementmaterial.
Thediameterofthereinforcingsteelshallbeselectedinamannerthatallofthefollowingrequirements
aremet:
theminimumcircumferentialreinforcementshallbe0.5%ofthelongitudinalcrosssectionalareaof
theconcretecoating;
theminimumlongitudinalreinforcementshallbe0.08%ofthetransversecrosssectionalareaofthe
concretecoating;
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minimumdiameterofthereinforcingwirefortheweldedsteelwiremeshshallbe1.6mm;
minimumdiameterforthereinforcingwireinthecagetypeshallbe3mm.
4.6 WELDEDSTEELWIREMESH
Theweldedsteelwiremeshshallbegalvanized.Theonlyapprovedtypeofthereinforcingsteelwiremesh
areTypeWWCandTypeWWNaspertheASTMA81001standard.
ThephysicalandchemicalpropertiesofthewireandwiremeshshallbeinaccordancewiththeASTMA
641andASTMA81001standard.
4.7 STEELCAGETYPE
The reinforcement shall be in the form of spirally wound cages having a continuous hoop wire with a
numberofstraightlongitudinalbarsevenlyspacedaroundthespiralandweldedateachwireintersection.
Alternatively, the continuous hoop wire may be replaced by single circumferential hoops. The material
usedshallbenharddrawnwiretoBS4482orASTMA615M(deformed),ortoCOMPANY/CONTRACTOR
approvedequivalentstandard.TheweldingofmaterialsshallresultinasteelfabricinaccordancewithBS
4483orASTMA185.
Thediameterofthecircumferentialandlongitudinalbarsshallbecalculatedfromtherequiredpercentage
ofreinforcing,withaminimumdiameterof3mm.
Thespacingofthelongitudinalbarsshallbebetween50and250mmbutnotlessthanfourlongitudinal
barsatapproximatelyequalspacingshallbeprovided.Thecircumferentialhoopspacingshallnotbemore
than100mm.Cagesshallhavetwohoopsspaced50mmapartateachpipeend.
Thephysicalandchemicalpropertiesofthereinforcingwireandofthewiremeshshallbeinaccordance
withtheASTMA8201(orASTMA615M)andASTMA18501standard.
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RECEIPT,HANDLINGANDSTORAGEOFBAREPIPES
Pipescoatedonlywith3layerpolyethyleneshallbehandled,storedandtransportedinamannerthatthe
pipesteelandpipecoatingshallnotbedamaged.
Allforeignsubstancessuchasexcessivedirt,debrisofcoatingmaterialsoranyotherforeignobjectsshall
beremovedfrominternalpipesurfacebeforestackingofpipesorapplicationofconcretecoating.
Coated pipes can be handled using slings, lifting hooks padded with soft material with suitable spreader
bars, forklifts having lifting forks padded with soft material, front loaders padded with soft material and
vacuumlifting.Chainsorwireropesoranyotherdevicethatmaydamagethepipesteelorpipecoating
shallnotbeused.
Whenmorethanonepipeislifted,separateslingsorhooksshallbeusedforeachpipe.
Pipesshallbepickedupfromthestackingpointandatnotimeshallbedraggedorrolled.
Coatedlinepipeshallnotbesubjectedtojarorimpactandallpipesupportsshallbepadded.
Pipesupportsshallbespacedtoavoidbendingoflinepipes.
Thecoatedlinepipesshallalwaysbestackedtoavoidsurfacecontactwiththeground.Thepipesshallbe
stacked on approved supports which shall be free of any material that could potentially damage the
appliedcoating.
The stacking height of 3LPE/3LPP coated line pipes shall be limited to avoid damage of the coated line
pipesduetotheweightofotherones.Themaximumnumberofstackinglayersforthecoatedlinepipes
shallbecalculatedbySUBCONTRACTORandrelevantcalculationshowingcalculationstepsandresultsshall
be submitted to COMPANY/CONTRACTOR for review and approval however, for safety reasons the
maximumheightofanystackshallbe3m.IncaseSUBCONTRACTORdoesnotprovideanycalculationnote
related to stacking of coated pipes acceptable for COMPANY/CONTRACTOR, the coated pipes shall be
stackedinmaximum4rows.
Thestacksofcoatedpipesshallbeseparatedforeachofthefollowingcombinations:
pipenominalODxpipenominalwallthickness.
Thelinepipesshallbestackedataslightangletoallowdrainageofanyrainwater.
The coated pipes shall not be stacked below and near electrical lines or near any facility which may
increase residual magnetism in the pipes (at all times it shall be kept the minimum distance of 30 m
betweenthestoredpipesandanyelectricalcablemeasuredfromtheverticalprojectiontothegroundof
thenearestelectricalcable).
Incaseitisdetecteddisbondmentofthe3layerPEcoatingfromthepipeatthecoatingedgeswhenthe
coated pipes are stacked either before or during the load out operation, that particular pipe shall be
rejectedandthe3layerPEshallbestrippedandreappliedatSUBCONTRACTORscost.
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6.1
CONCRETECOATINGAPPLICATION
VISUALANDHOLIDAYINSPECTIONOF3LAYERPECOATEDPIPES
Prior to placement of the steel reinforcement and/or application of concrete coating, the entire factory
appliedanticorrosioncoatingofthepipeshallbevisuallyinspected.
Any foreign matter shall be removed from the surface of the anticorrosion coating and each detected
coatingdamageshallberepairedaccordingtotheapprovedprocedurepriortothecommencementofthe
concretecoatingapplication.
Then, the entire coated surface of the pipes shall be inspected using a holiday detector at a voltage of
minimum 25 kV. The holiday detector shall be equipped with a visual and an acoustic signalling device
clearlyaudibleintheprevailingworkingconditions.Alldamagesdetectedbytheholidaydetectorshallbe
repaired.
6.2
PLACEMENTOFREINFORCEMENTSTEEL
Forconcretethicknessupto50mm,onewrapofreinforcingshallbeused.Forthicknessesofmorethan50
mm, two layers should be considered. Additional layers may be necessary for concrete thicknesses in
excessof120mm,butthiswouldthenrequirefurtherCOMPANY/CONTRACTORsapproval,sothenumber
ofsteelreinforcinglayersshallbeasfollows:
concretecoatingthicknessupto50mm1layer;
concretecoatingthicknessfrom51mmupto100mm2layers;
concretecoatingthicknessfrom101mmupto140mm3layers.
According to SUBCONTRACTORs discretion, SUBCONTRACTOR may apply also the combination of the
reinforcing steel cage and reinforcing steel welded wire mesh but the above mentioned number of
reinforcinglayersvs.concretecoatingthicknessandtherequirementsforpercentageofreinforcingsteelin
concretecoatingcrosssectionalareasmustberespected.
Duringtheapplicationofthereinforcingsteel,atalltimes,thefollowingrequirementsmustbemet:
minimum15mmdistancebetweenthereinforcingsteelandthefactoryappliedanticorrosionpipe
coating;
minimum10mmdistancebetweenthereinforcingsteelandtheoutersurfaceofappliedconcrete
coating;
minimum10mmdistancebetweentwolayersofreinforcingsteel.
Incasethereinforcingsteelweldedwiremeshisused,thelongitudinaloverlapofthewiremeshshallbe
minimum25mm.
Incasethecagetypeofreinforcementisused,thesteelreinforcementshallterminate:
10mm30mmfromtheendofconcretecoating.
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APPLICATIONOFCOATINGMATERIALS
It will be the SUBCONTRACTORs decision to apply the concrete coating using impingement method or
compressioncoatmethod(extrusion),howeveronlytheapplicationmethodusedduringthesuccessfully
passedandcompletedprequalificationtestshallbeused.
Prior to the application of the concrete coating, the temperature of the concrete coating mix shall be
withintherangebetween+5Cand+35C.
In case the temperature of the concrete coating mix is less than +5C, the concrete coating shall not be
performeduntilSUBCONTRACTORmanagestoheattheentireconcretemixupto+5C.
Incasethetemperatureoftheconcretecoatingmixishigherthan+35C,themixingwatershallbecooled
withiceorasuitablecoolingsystemshallbeprovidedforthemixingwaterinordertoobtaintheconcrete
mixtemperatureofmaximum+35C.
Thefreewater/cementrationshallnotexceed0.45byweight.
Theconcretecoatingapplicationmethodshallbesuchthatthecoatingtimeforeachpipedoesnotexceed
30 minutes (starting from the moment that the water was added to the concrete mix and the concrete
coatingapplicationstartedonthatparticularpipeuptothecompletionofapplicationofconcretecoating
onthesamepipe)otherwisetheconcretecoatingonthatpipeshallberejected.
Useofreclaimed/reboundmaterialmightbeallowedprovidingitisdemonstratedthatitdoesnothaveany
detrimentaleffectonthefinalconcreteproduct.
Secondary mixing of the reclaimed material with freshly batched concrete must follow immediately and
must produce a homogeneous cohesive mixture. The amount of recycled material used shall not exceed
10%ofthetotalmixbyweight.Ifabreakofthisoperation,forwhateverreason,exceeds30minutesany
reclaimedmaterialnotpreviouslyaddedtothemixshallbediscardedandremovedfromthecoatingarea.
7.1
PREPARATIONOFTHECUTBACKAREA
Theconcretecoatingshallberemovedatbothpipeendstakingcarenottodamagepipesteelorfactory
appliedanticorrosioncoating.Thelengthofsuchpreparedconcretecoatingcutbackshallbe380mm(0
mm/+20mm).Thecutbackshallbesquarewithrespecttopipeaxis.
7.2
FINISHINGOPERATIONSWITHINCONCRETECOATINGPLANT
Surfacefallouts(spalling) shallbefilledbyguniting. Therepair mixshallbesimilarincompositiontothe

originalmix.Therepairshallbecarriedoutinaccordancewithapprovedprocedurewithin30minutesafter
applicationoftheoriginalconcretecoatingmix.
Surfacedamageonconcretecoatingshallnotbeconsideredasadefectifallofthefollowingconditions
havebeenmet:
damageisnotexposingreinforcingsteel;
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damageisnotextendedtomorethan20%ofthenominalconcretecoatingthickness;
damagedareaislessthan1000cm2(0.1m2).
Incasethetotalareaoffallouts(spalling)ismorethan20%oftheconcretesurface,theconcretecoating
shallberemovedfromthatparticularpipe.
The cutback area and internal pipe surface shall be completely free from any residual concrete coating
materialandfromanymaterialsdetrimentaltothewelding,NDTandfieldjointcoatingoperationswhich
shallbeperformedbypipelayingCONTRACTORduringthepipelayingoperations.
Finally,eachpipeendshallbeprotectedwithendcapandtheexposedsteelandthefirst100mmof3
layerPEcoatingshallbewrappedwithpolyethylenesheetthatdoesnotcontainanyadhesiveandwhich
shallbefirmlytightenedaroundthispipelocation.
7.3
CURING
Immediatelyaftercompletionoftheapplicationofconcretecoatingoperations,theconcretecoatedpipe
passingallonlineinspectionsandtestsshallbetransferredtothecuringarea.
Duringthecuringperiod,thepipesshallbestackedinasinglelayer.
Curingshallbeperformedeitherbyusingwatercuring,steamcuring,curingbysealingcompoundsorby
polyethylenewrapping.Theexposedsurfacesoftheconcretecoatingshallbeprotectedduringthecuring
periodfromanyadverseeffectsofsunshine,dryingwinds,rainorrunningwater.
The curing process shall continue until a minimum compressive strength of 14 MPa has been achieved
whenthecompressionstrength testisperformedoncoresamplesafterwhichthe concretecoated pipe
can be lifted, transported and stacked in more than one layer up to the maximum allowed number of
stacking layers. In case the period when the pipe reaches minimum 14 MPa of compression strength on
coresampleshasnotbeendeterminedbypracticaltests,thepipesshallremainstackedinasinglelayerfor
minimumsevendays.
Locations where the core samples shall be taken from the pipe for this purpose shall be selected by
COMPANY/CONTRACTOR.
7.3.1
WATERCURING
Watercuringshallconsistofwettingandmoisteningtheconcretecoating,startingnotlaterthan6hours
aftercompletionofconcretecoatingapplication.
The concrete coating shall be kept continuously moist by intermittent spraying for a period of at least 7
days.Theintervalbetweensprayingshallnotbemorethan24hours.Attheambienttemperaturesbelow
+4C,suitableprecautionsshallbetakentopreventdamageduetofreezing.
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7.3.2
STEAMCURING
If the curing process involves steam or warm highhumidity air, then it shall be demonstrated that the
process will have no deleterious effects on the concrete. Under no circumstances shall the pipe wall be
allowedtoreachatemperaturethatwouldcauseanydamagetotheanticorrosioncoating.
Curingbysteamshallnotstartsoonerthan3hoursaftercompletionoftheconcretecoatingapplication
completion.
Concretecoatedpipesshallbeenclosedinplasticorsimilarcoversuitabletomaintainsteamcirculation.
Steam circulation shall start at the ambient temperature and shall be controlled to give a temperature
gradientofapproximately10C/houruptothemaximumsteelorcoatingtemperatureof+60C.
The pipes shall be held under steam curing for at least 6 hours and then allowed to cool for a similar
period.SUBCONTRACTORshalldemonstrateduringtheprequalificationtestthatthecuringtimeusedis
sufficienttomeetthespecifiedconcretestrengthlevels.
7.3.3
CURINGBYSEALINGCOMPOUNDS
SealingcompoundsshallmeetrequirementsofASTMC30998Astandard.Thematerialshallbestored,
prepared and applied in accordance with instructions supplied by the MANUFACTURER of sealing
compounds.
The compound shall be nontoxic and nonflammable and shall not react with any constituent of the
concrete,reinforcement,protectivecoatingorpipesteel.
Unless otherwise specified by the compound MANUFACTURERs instructions, membrane sealing
compounds shall be sprayed over the complete concrete surface within 6 hours after completion of the
concrete application and shall remain for a minimum of 7 days. The materials shall not be applied at
temperatureslessthan+4C.
7.3.4
CURINGUNDERPOLYETHYLENEWRAPPING
Wrapping in polyethylene film shall be done during the application of concrete coating. A light spray of
water shall be applied before applying the plastic film. The polyethylene film shall have a minimum
thicknessof0.2mmandtheoverlapofthesheetshallnotbelessthan25%ofthesheetwidth.
ThepolyethylenefilmshallbeinaccordancewithASTMC171standard.
Theinterfacebetweentheconcreteandthebaresteelatthepipeendsshallalsobeprotectedinorderto
achieveanairtightseal.
Thepolyethylenewrappingshallremainonthepipeforminimumsevendaysbutitshallberemovedprior
tofinalloadoutofthepipe.
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7.3.5
FOGCURING
Fresh concrete coating is continuously moistened by mist released from fogging tips and covered with
tarpaulinsheetstoprovideaclosedenvironmentforcuring.
Atomizedmist,withhighwetabilityisintroducedgraduallybuildingtoaclosedhighhumidity,near
saturation ambience to facilitate proper curing environment. The continuous introduction of atomized
fog/mist into tarpaulin shall be continued for one shift before the pipe is removed/subject to further
handling.
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INSPECTIONANDTESTING
ThePreQualificationTestshallbeperformedonfivefullyconcretecoatedpipesandshallbecompleted
beforethestartofactualproductioninthePROJECT.Thecombinationofpipematerialvs.pipeexternal
diametervs.pipewallthicknessvs.concretecoatingthicknessselectedforPreQualificationTestshallbe
agreedbetweenSUBCONTRACTORandCOMPANY/CONTRACTOR.
Itismandatorythatallfiveconcretecoatedpipesareconcretecoatedinasequencewithoutanystoppage
of the concrete coating plant in order to allow performance of the offline PQT tests. In case this
requirementisnotmet,thePQTshallberepeated.
Alloftheinspectionsandtestslistedinthisdocumentshallbeaddressedintheinspectionandtestplan.
Defects or anomalies detected during coating process shall start immediate corrective actions from the
SUBCONTRACTOR.
All line pipes to be submitted to the inspections and tests shall be selected in agreement with the
COMPANY/CONTRACTORsInspector.
Intheeventthataproductionlinepipefailstomeettheacceptancecriteriaforthetestslistedinthetable
thetestcanberepeatedonlyshouldthefailurebecausedeitherbyimproperuseofthetestingequipment
orbyerrorinthetestingprocedure.
Thefollowinginspectionsandtestsshallbecarriedout:
Inspection/Test
Inspectionofthe3layerPEcoatedpipesduring
thereceipt
Visual inspection of the stacking of the 3layer
PEcoatedpipes
Inspections of the concrete coating materials
duringtheirreceipt
Reference
Section6
Section8.2
Section8.1
BeforethestartofthePQT.
Production
Beforethestartof
production.
Periodically.
Mixing water certificate to
bedeliveredbeforethestart
ofthePQT.
Onceperday.
EachPQTpipe.
Eachpipe.
Section8.7
Onceperweek.
Concretecoatingmixtemperaturecheck
Section8.8
Once.
Watercementratiocheck
Section8.9
Once.
Whentheambienttemperatureiswithinthe
rangefrom+10C upto+25C,thetestshall
notbecarriedout.
In case the ambient temperature is outside
the above mentioned range the concrete
coatingmix
temperature shall be measured at the
beginning of each working shift and then
every4hours.
Firstworkingshiftof
eachworkingday.
Verification of calibration of the holiday

detector and the concrete coated pipes
weighingscale
Visual and holiday inspection of 3layer PE
coated pipes immediately before application of
concretecoating
Concrete coating mix control (verification of
calibrationoftheconcretecoatingmixingplant)
Section8.3
Section8.4.1
Section8.4.2
Section8.4.3
Section8.5
Section8.5.1
Section8.5.2
Section8.6
PQT
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Each package of received concrete coating

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Inspection/Test
Verification of the correct positioning of the
concretecoatingsteelreinforcement
Reference
Section8.10
PQT
FirsttwoPQTpipes.
Concretecoatingapplicationcontrol
Measurement of external diameter of applied
concretecoating
Cutbackcontrol
Weighingoffreshlyconcretecoatedpipe
Calculationofnegativebuoyancy
Visualinspectionofappliedconcrete
Measurement of the electrical resistance
betweenthesteelreinforcementandthepipe
Section8.11
Section8.12
EachPQTpipe.
EachPQTpipe.
Section8.13
Section8.14
Section8.15
Section8.16
Section8.17
Eachpipe.
Eachpipe.
Eachpipe.
Eachpipe.
Reinforcingsteelwiremesh:eachPQTpipe.
Steelcage:
On the pipes where the test for verification
of the correct positioning of the concrete
coating steel reinforcement has been
performed.
Control of the curing process and control of

stacking of concrete coated pipes during the
curingprocess
Controlofmarkingonconcretecoatedpipes
Section8.18
Section8.19
EachPQTpipe.
EachPQTpipe.
EachPQTpipe.
EachPQTpipe.
Reinforcingsteelwiremesh:
eachPQTpipe.
Steelcage:
On the pipes where the test
forverificationofthecorrect
positioning of the concrete
coating steel reinforcement
hasbeenperformed.
EachPQTpipe.
Section8.20
EachPQTpipe.
Eachpipe.
Controloftheconcretecoatingrepair
Controloftheconcretecoatingrepair
Section8.20
Section8.21
EachPQTpipe.
EachPQTpipe.
Determination of factor in the formula for

calculation of negative buoyancy (performance
ofthistestisnotmandatory)
Compressionstrengthtestcubes
Section8.22
Two PQT pipes not

submitted to the water
absorptiontest.
EachPQTpipe.
Eachpipe.
Eachpipeonwhichtheconcretecoating has
beenrepaired.
N/A.
Compressionstrengthtestoncoresamples
Section8.24
Determinationofthetimeforstackingofpipes
inmorethanonelayer(performanceofthistest
isnotmandatory)
Waterabsorptiontest
Section8.25
ThreePQTpipes.
Section8.26
TwoPQTpipes.
Section8.27
Onetest.
One pipe coated each day during the first

threeproductiondays.
In case all tests had acceptable results the
testshallbeperformedoncepershift.week
N/A.
Section8.28
Section8.29
Section8.30
WhenRequested
N/A
N/A
WhenRequestedoneperweek
Eachpipe.
Eachpipe.
Adhesion between the 3layer PE coating and

concretecoating
Impacttesting
StackingofcuredCWCpipes
Loadoutinspections
8.1
Section8.23
EachPQTpipe.
Production
One pipe concrete coated at the beginning
and on one pipe concrete coated in the
middleofeachworkingshift.
Eachpipe.
Eachpipe.
Periodically.
4 cubes from first pipe at the beginning of

eachworkingshiftandthenevery25pipes.
2x3coresfromfirstpipeatthebeginningof
eachworkingshiftandthenevery15pipes.
N/A.
STACKINGOF3LAYERPECOATEDPIPES
Periodicalvisualinspectionshallbeperformedintheareadedicatedforstackingofthepipescoatedwith
3layer PE awaiting the application of concrete coating in order to verify that these pipes have been
stackedinamaximumallowednumberoflayersandthattheyhavebeenstackedonapprovedsupports.
In case of nonconformance with relevant requirements SUBCONTRACTOR shall inform
COMPANY/CONTRACTORwhowillbringfurtherdecisionsandCOMPANY/CONTRACTORsdecisionshallbe
binding.
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8.2
CONTROL,IDENTIFICATIONANDSEGREGATIONOF3LAYERPECOATEDPIPES
The 3layer PE coated pipes shall be visually inspected for bevel damages, dents, gauges, flat ends and
coatingdamages.Alsothecontentofagreedpipemarkingrequiredatthisstageofworkshallbeverified
onthepipe.
Incasebeveldamages,significantcorrosion,dents,gouges,laminationorflatendshavebeendetectedon
barepipeportionatthecutbackarea,thepipeshallbemarkedwithcolouredtape,segregatedifpractical
to do so, and brought to COMPANY/CONTRACTORs attention who will instruct SUBCONTRACTOR about
actionstobetakenonthispipe.
Incasethecoatingdamagehasbeendetected,damagedareashallbemarkedandcolouredtapeshallbe
put around that pipe which shall remain on the pipe until the coating repair has been completed and
approvedbyCOMPANY/CONTRACTOR.
Incaseoil,greaseoranysimilarcontaminationhasbeendetectedatthecutbackarea,thecontamination
shallberemovedwithfreshwateranddetergent,solventoranyothersuitablemethod.
Incasethemissingorincorrectpipemarkinghasbeendetected,thepipeshallbemarkedwithcoloured
tape, segregated if practical to do so and brought to the COMPANY/CONTRACTORs attention who will
instructSUBCONTRACTORabouttheactionstobetakenonthatpipe.
8.3
DELIVERYANDSTORAGEOFCONCRETECOATINGRAWMATERIALS
Ateach deliveryofthecoatingrawmaterials,thereceived documentationshallbereviewedagainstthe

receivedmaterialpackagesandagainstthePurchaseOrderdocumentsinordertoverifythatthereceived
documentsandmaterialsconformtotherequirementsspecifiedinthepurchaseorder.
Incaseofanynonconformance,itshallbetheSUBCONTRACTORsresponsibilitytoresolvethisissuewith
the supplier of the nonconforming material. However, the batch of the material delivered in
SUBCONTRACTORspremisesnonconformingtotherequirementsofthisspecification,shallnotbeusedin
thePROJECT.
Periodically,avisualinspectionshallbeperformedinordertoverifythatthecoatingmaterialshavebeen
storedinconditionsasrecommendedbythematerialMANUFACTURER.
Thecementshallbestoredinproperwaterproofsilos.
The aggregates can be stacked in stockpiles at the open on clean site, free from the possibility of
contamination.
Thegalvanizedwiremeshmaybestoredattheopencleansitefreefrompossibilityofcontaminationbut
thewiresusedformanufacturingofsteelcagemustbestoredinclosedstoragefacilityindryplace.
Thepolyethylenewrappingthatshallbeusedforcuringofconcretecoatedpipesmaybestoredoutsidein
cleansitebutitmustbecoveredwithappropriatesheetingtoavoidexposuretotherainandraisedfrom
thegroundtoavoidflooding.
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COMPANY/CONTRACTORreservestherighttorejecttheuseofimproperlystoredmaterialinthePROJECT.
8.4
8.4.1
TESTTOBEPERFORMEDONCONCRETECOATINGMATERIALUPONRECEIPT
SIEVEANALYSISANDCLEANLINESSCONTROLOFAGGREGATES
Thegradingandcleanlinessofaggregatesshallbecheckedfromeachstockpileforcleanlinessandgrading.
ThegradingshallbeasperthenominalvaluesandtolerancesspecifiedbySUBCONTRACTORandverified
duringthePQT.Thetestforcleanlinessshallmeanvisualinspectionforpresenceofanyforeignmaterialin
testedsamplebesidethetestedaggregateitself(wood,shells,oranyothersimilarcontaminant).
In case of test failure, the test shall be repeated on doubled number of samples taken from the same
batch.Incaseofrepeatedfailure,theaffectedbatchofsuppliedmaterialshallnotbeusedinthePROJECT
oritshallbecleanedfromallcontaminationasperCOMPANY/CONTRACTORssatisfaction.
RelevantinspectionreportshallbepreparedbySUBCONTRACTORrelatedtothisinspectionactivity.
Thereportshallcontainthefollowingitems:date,shift,testedmaterial,materialsupplier,materialbatch
numberifapplicable,acceptancecriteria,testresults,remarks.
8.4.2
STEELREINFORCEMENTWIRESDIMENSIONALCONTROL
Foreachbatchofreceivedreinforcingsteelsomeofthereceivedrollsofwiremeshand/orthewiresfor
cagetypereinforcementshallbecheckedbymeasuringthediameteroflongitudinalandstaywireswitha
calliper.
The measured value shall correspond to the minimum value provided by the reinforcing steel
MANUFACTURER required to meet the requirements for reinforcing steel in concrete coating in this
specification(minimumtolerancespecifiedfirstbyrelevantstandardandifthisvaluecannotbefoundin
thestandardthentheminimumtolerancevaluecanbespecifiedbytheMANUFACTURER).
In case of test failure, the test shall be repeated on doubled number of samples taken from the same
batch.Incaseofrepeatedfailure,theaffectedbatchofsuppliedmaterialshallnotbeusedinthePROJECT.
Thereportshallcontainthefollowingitems:date,shift,testedmaterial,materialsupplier,materialbatch
numberifapplicable,acceptancecriteria,testresults,remarks.
8.4.3
MIXINGWATERCHEMICALANALYSIS
WaterusedinconcretecoatingmixshallbefreshandshallcomplywithAppendixAofBSEN1008.During
thebiddingstageofthePROJECTtheSUBCONTRACTORshallpresentthecertificateforthemixingwater
usedinthecoatingplantandtheSUBCONTRACTORshallprovidethewrittenguarantythatthesamewater
shallbeusedduringentireSUBCONTRACTORsworkinthePROJECT.
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In case the above mentioned requirement is not met, the chemical analysis of mixing water shall be
completed and the certificate submitted to COMPANY/CONTRACTOR two weeks before the
commencementofthePreQualificationTestotherwiseSUBCONTRACTORshallnotbeallowedtostartthe
performance of the prequalification test. In case the quality of mixing water does not meet the
requirementsofthisspecification,theconcretecoatingplantshallnotbequalifiedforthework.
8.5
VERIFICATIONOFCALIBRATIONOFTHETESTINSTRUMENTS
The verification of calibration shall be verified for the holiday detector and pipe weighing scales each
working day while the calibration of other testing equipment shall not be verified but the Third Partys
calibrationcertificatesshallbeused.
The instruments whose accuracy is not meeting the relevant acceptance criteria for each particular
instrument shall not be used in the PROJECT until the instruments accuracy is brought back within
acceptablelimits.
The report shall contain the following items: date, shift, testing equipment, testing equipment serial
number,acceptancecriteria,testresults,remarks.
8.5.1
HOLIDAYDETECTOR
The voltage of the holiday detector shall be compared with the voltage of the certified calibration high
voltage instrument recommended by the MANUFACTURER of the holiday inspection equipment for this
purpose. The holiday detector shall be considered acceptable when the voltage of the holiday detector
when checked with the high voltage calibration instrument set at 25.0 kV shows the values within the
rangefrom25.0kVto25.5kV.
8.5.2
PIPEWEIGHINGSCALES
Theverificationofcalibrationoftheweighingscaleswhichshallbeusedfordeterminationoftheweightof
freshlyconcretecoatedpipesshallbeperformedbyweighingoftheminimum11.5mlongminimum10
diameterpipehavingknownandcertifiedweight.Theweighingbridgeshallbeconsideredacceptablefor
usewhenthemeasuredvalueoftheknownweightiswithintherange:
Nominalweightofthepipehavingknownandcertifiedweight0.3%.shift.
8.6
VISUALANDHOLIDAYINSPECTIONOFTHE3LAYERPECOATEDPIPES
Prior to the commencement of application of the concrete coating, the 3layer PE coated pipes shall be
submittedtothevisualinspectionandholidayinspectionat25kV.
Thepipesshallhavenomajorsteeldefectsandthepipecoatingshallbewithoutvisibledefects.
Thereshallbenoholidaysdetectedafterholidayinspectionat25kV.
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The 3layer PE coating shall be repaired in accordance with the SUBCONTRACTORs coating repair
procedureapprovedbyCOMPANY/CONTRACTOR.
RelevantinspectionreportshallbepreparedbySUBCONTRACTORrelatedtothisinspectionactivityonlyin
caseanynotconformanceoccurred.
8.7
CONCRETECOATINGMIXCONTROL
Prior to the commencement of the prequalification test and during the production once per week,
SUBCONTRACTORshallperformtheverificationthattheirbatchingplantprovidesthecompositionofthe
concretecoatingmixwithinthetolerancesselectedbytheSUBCONTRACTORhimself.Productionshallnot
startifthebatchingplantisnotproperlycalibrated.
Within the concrete coating application procedure, SUBCONTRACTOR shall describe in details the
verification of calibration of batching plant for determination of percentage of each component in the
concretecoatingmix.
8.8
CONCRETECOATINGMIXTEMPERATUREMEASUREMENT
Whentheambientairtemperatureislessthan+10Canditishigherthan+25C,SUBCONTRACTORshall
measure the temperature of the concrete coating mix at the beginning of each working shift and then
every4hours.
Approximately310kgofconcretemixshallbetakenattheendofthebeltlocatedafterexitofthemixer
andputintothebucketoranyothersuitablecontainer.
Then,theimmersionprobeofthedigitalthermometershallbeimmersedinthefreshconcretemixandthe
temperatureshallbereadfromthedisplayoftheinstrument.
In case the temperature of the concrete coating mix is less than +5C, the concrete coating shall not be
performeduntilSUBCONTRACTORmanagetoheattheentireconcretemixupto+5C.
Incasethetemperatureoftheconcretecoatingmixishigherthan+35C,themixingwatershallbecooled
withiceorasuitablecoolingsystemshallbeprovidedforthemixingwaterinordertoobtaintheconcrete
mixtemperatureofmaximum+35C.
Thereportshallcontainthefollowingitems:date,shift,acceptancecriteria,testresults,remarks.
8.9
WATERCEMENTRATIOCHECK
Thefreewater/cementratioshallbecheckedatthebeginningofthefirstworkingshiftofeachworking
day.
Thewatertocementratioshallnotexceed0.45byweight.
In case the acceptance criterion is not met, the concrete coating operations shall not start it has been
verifiedthatthewater/cementratioiswithinacceptablelimits.
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Thereportshallcontainthefollowingitems:date,shift,acceptancecriteria,testresults,remarks.
8.10 REINFORCINGWIREPOSITIONCONTROL
On one pipe concrete coated at the beginning and on one pipe concrete coated in the middle of each
working shift, the proper positioning of the reinforcing steel wire mesh shall be verified by opening a
windowofapproximatedimensions200mmx75mmpenetratingdowntotheanticorrosionpipecoating
whiletheconcretecoatingisstillfresh.
During this visual inspection it shall be verified that the requirements specified in Section 8.2 of this
specificationhavebeenmet.
Only in case the cage type steel reinforcement is used by SUBCONTRACTOR, during this test it shall be
tested also the electrical resistance between the bottom layer of the reinforcing steel and the pipe end.
Oneelectrodeoftheohmmetershallbeinthecontactwiththebottomlayerofthereinforcingsteelofthe
cageandanotherelectrodeshallbeinthecontactwithbarepipeendatthecutbackarea.Theminimum
measuredresistanceshallbe1000Ohm.
Incasetheacceptancecriteriahavenotbeenmet,thetestingshallcontinueuntilitisdeterminedontwo
consecutive pipes concrete coated before and on two consecutive pipes concrete coated after the test
failure,thatthesetestsaresuccessfullypassed.Thepipesnotpassinganysingleofthesetestsshallhave
theconcretecoatingremoved.
8.11 CONCRETECOATINGAPPLICATIONCONTROL
Duringtheapplicationoftheconcretecoatingthefollowingverificationsshallbecarriedoutoneachpipe:
thattheconcretehasbeenappliedreasonablyuniformlythroughouttheentirepipelengthandthat
ithasbeenappliedwithoutanymajorirregularities;
thatthespallingisrepairedonthefreshlyconcretecoatingpipemaximum30minutesafteradding
thewaterintheconcretecoatingmixintheconcretebatchingplant;
whenthereinforcingsteelintheformofwiremeshisusedthatthepolyethylenewrappinghasbeen
applied immediately after the concrete application with minimum overlap of 25 % of the sheet
width.
Pipesnotmeetingacceptancecriteriashallhavetheconcretecoatingremoved.
8.12 MEASUREMENTOFEXTERNALDIAMETEROFAPPLIEDCONCRETE
Theexternalcircumference/diameterofappliedconcreteshallbemeasuredoneachconcretecoatedpipe
usingaflexiblemeasuringtapeatfiveequidistantpointsalongthepipelength.
The measurements shall not be taken at first 400 mm from the ends of applied concrete coating. The
average of five measurements for external diameter of applied coating shall than be inserted in the
formulaforcalculationofnegativebuoyancy.
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Thereportshallcontainthefollowingitems:date,shift,pipesequencenumber,pipenumber,pipeexternal
diameter,pipewallthickness,pipenominalconcretecoatingthickness,testresults,remarks.
8.13 CUTBACKCONTROL
The cutback length shall be measured on each concrete coated pipe end. The average of two
measurementsshallbeinsertedintheformulaforcalculationofnegativebuoyancy.
Theedgesofconcretecoatingatthecutbackareashallbeperpendicularwithrespecttothepipeaxisand
entire concrete coating cutback area shall be free of residual concrete coating and from any materials
detrimentaltothewelding,NDTandfieldjointcoatingoperationswhichshallbeperformedbythepipe
layingCONTRACTORduringthepipelayingoperations.
Theconcretecoatingcutbacklengthshallbe380(0mm/+20mm).
Incasetheacceptancecriteriahavenotbeenmet,thepipeshallbequarantineduntiltheremedialworkis
takenwhichshallresultinacceptableconcretecoatingcutback.
Relevant inspection report specifying cutback lengths shall be prepared by SUBCONTRACTOR related to
thisinspectionactivity.
diameter,pipewallthickness,pipenominalconcretecoatingthickness,acceptancecriteria,resultofeach
cutbacklengthmeasurement,remarks.
8.14 WEIGHINGOFFRESHLYCONCRETECOATEDPIPE
Eachfreshlyconcretecoatedpipeshallbeplacedonaweighingscalewhereitsweightshallbemeasured.
Theresultshallbedisplayedandwhenthepipeweighthasstabilized.Theresultofmeasurementshallbe
insertedintheformulaforcalculationofnegativebuoyancy.
8.15 CALCULATIONOFNEGATIVEBUOYANCY
Thenegativebuoyancyshallbecalculatedoneachpipeasfollows:
NB
= negativebuoyancy[kg/m];
Wbp
= weightofbarepipe,informationsuppliedfromthepipeMANUFACTURER[kg];
W3LPE/3LPP
= weight of applied 3layer PE/3layer PP not including mass of bare pipe, calculated using either
nominaloraverage3layerPEorotherexternalanticorrosioncoatingthickness[kg];
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= lengthofthelinepipetakenthedatafrompipeMANUFACTURER[m];
CB3LPE/3LPP
= averageoftwomeasurementsofthe3layerHDPE/3layerPPcutbacklength;
theoreticalaverageisalsoallowedforthispurpose[m];
CBCWC
= averageoftwoactuallytakenmeasurementsoftheconcretecoatingcutbacklengthonwhichthe
lengthhasbeenmeasured[m];
= factor of change in the weight of concrete coating from wet and fresh to dry and cured; unless
otherwisedemonstratedduringthePQT,thefactor=0.99[nondimensionalvalue];
WCWC
= weightofthepipecoatedwithfreshconcrete,measurementtakenimmediatelyafterapplicationof
concretecoating[kg];
DCWC
= external diameter of the concrete coated pipe obtained by average of five measurements of the
concretecoatingcircumferenceasperthisspecificationdividedby[m];
= densityofseawater.
Theacceptancecriteriafornegativebuoyancyforeachcombinationofpipeexternaldiametervs.pipewall
thicknessvs.concretecoatingthicknessshallbeprovidedbyCOMPANY/CONTRACTORinduetime.
OnlyunlessotherwisecommunicatedbyCOMPANY/CONTRACTORthefollowingtolerancesshallapply:
perworkingshift:nominalvalueofnegativebuoyancy(0%/+4.5%);
persingleconcretecoatedpipe:nominalvalueofnegativebuoyancy(0%/+10%).
Eachpipenotmeetingacceptancecriteriahavetheconcretecoatingremoved.
diameter, pipe wall thickness, pipe nominal concrete coating thickness, acceptance criteria, test results,
remarks.
8.16 VISUALINSPECTIONOFAPPLIEDCONCRETE
Eachfreshlyconcretecoatedpipeshallbevisuallyinspectedfordefects.
Surfacedamageonconcretecoatingshallnotbeconsideredasadefectifallofthefollowingconditions
havebeenmet:
damageisnotexposingreinforcingsteel;
damageisnotextendedtomorethan20%ofthenominalconcretecoatingthickness;
damagedareaislessthan1000cm2(0.1m2).
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Thefollowingshallbeconsideredduringvisualinspectionofconcretecoatedpipes.
8.16.1 SURFACEFALLOUTS(SPALLING)OFFRESHLYCONCRETECOATEDPIPES
Incasethespallingoccurs,itshallberepairedonlyifthemaximum20%oftheconcretecoatingsurfaceis
affectedbyit.Thespallingshallberepairedinproductionlinewithin30minutesafterapplicationofthe
originalconcretecoatingmixorincasethistimeisexceededbygunitingusingtheconcretecomposition
similartotheoriginalconcretecoatingmixappliedonthepipe.Afterrepairthepipeshallbereweighedfor
calculationofnegativebuoyancy.
8.16.2 CONCRETECOATINGDAMAGESONFRESHANDHARDENEDCONCRETE
Damages caused by taking of core samples for compression strength test shall be repaired unless the
anticorrosionpipecoatinghasbeendamaged.Incasetheanticorrosioncoatinghasbeendamagedduring
thecoresamplingprocess,theconcretecoatingshallberemovedfromthatpipe.
In case reinforcing steel has been only cut but not removed from the pipe, the concrete coating can be
repairedandthereinforcingsteelshallbepositionedproperlyduringtherepair.
However,ifanyportionofreinforcingsteelhasbeenremovedfromthepipe,theconcretecoatingshallbe
removedfromthatpipe.
Concrete coating damages resulting also in damage of the 3layer PE coating shall have the concrete
coatingremoved.
Considering above mentioned limitations, repair of concrete coating damages is allowed when the
concrete coating has been damaged or it has been removed from the pipe for repair purposes up to
maximum20%oftheconcretecoatingsurface(notoftheconcretecoatingvolume.
8.16.3 CRACKS
Circumferential surface cracking of the concrete not exposing reinforcing steel having a crack width less
than5mmshallnotbeconsideredasadefect.
Circumferentialannularcrackingvisibleatpipeendsisgenerallynotacceptableandallpipeshavingsuch
cracksintotalcircumferentiallengthgreaterthan200mmshallhavetheconcretecoatingremoved.
Allcrackspenetratingdowntothe3layerPEcoatingshallnotbeacceptableandsuchpipeshallhavethe
concretecoatingremoved.
Longitudinal surface cracks less than 250 mm in length and having a width of 8 mm or less shall not be
consideredasadefectbutholesof10mmnominaldiametershallbedrilledatthecracktipstoprevent
propagationofthecrack.Thebottomoftheseholesshallbe710mmfromtheanticorrosioncoating.
Longitudinal cracks having a length from 250 mm up to 1000 mm shall be repaired by chiselling out the
cracktoawidthofatleast25mmthroughoutitslengthtakingcarenottodamageanticorrosioncoating.
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Thepreparedareashallbeundercuttoformanadequatekeyforrepairmaterial.Thentheconcreterepair
materialshallbeinsertedintothepreparedvoiduntilthevoidiscompletelyfilled.Thentherepairmaterial
shallbesmoothedwiththeadjacentconcretecoating.
Longitudinal cracks having a length over 1000 mm shall not be acceptable and such pipe shall have the
concretecoatingremoved.
8.17 ELECTRICALRESISTANCEBETWEENSTEELREINFORCEMENTANDTHEPIPE
WhenthesteelreinforcementinaformofwiremeshisusedbySUBCONTRACTOR,theelectricalresistance
between the reinforcing steel and the pipe end shall be carried out by placing one electrode of the
ohmmeter connected to the protruding reinforcing steel at the concrete coating cutback and by placing
anotherelectrodeonbarepipeendatthecutbackarea.Theminimummeasuredresistanceshallbe1000
Ohm.Thistestshallbeperformedoneachpipe.
Allofthepipesnotmeetingacceptancecriterionshallhavetheconcretecoatingremoved.
remarks.
8.18 CONTROLOFCURINGPROCESS
Periodically it shall be verified the conditions of curing process in order to verify that the curing process
meetstherequirementsspecifiedinSection8.6ofthisSpecification.
AllpipesnotbeingcuredinaccordancewithPROJECTdocumentsshallbequarantinedandsubmittedto
COMPANY/CONTRACTORsdecisionwhoreservestherighttorejecttheconcretecoatingonthesepipesor
in case to avoid concrete coating removal to ask additional testing without any extra cost borne by
COMPANY/CONTRACTOR.
8.19 CONTROLOFSTACKINGOFPIPESDURINGTHECURINGPROCESS
Periodicalinspectionofpipesstackedincuringareashallbecarriedoutinordertoverifythatthepipeshas
beenstackedinasinglelayerandonapprovedsupports.
All pipes not conforming to the PROJECT Specification shall be marked with coloured tape and
COMPANY/CONTRACTOR shall inform the SUBCONTRACTOR about the actions to be taken on non
conformingpipes.
8.20 CONTROLOFMARKINGONCONCRETECOATEDPIPES
Themarkingappliedonconcretecoatedpipeshallbecheckedinordertoverifythatthemarkingandits
content meet the requirements specified by COMPANY/CONTRACTOR and that it has been applied in
accordancewithagreedprocedure.
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8.21 CONTROLOFMARKINGONCONCRETECOATINGREPAIR
Whentherepairofconcretecoatinghasbeenallowed,itshallbeverifiedthattheconcretecoatingrepair
material approved by COMPANY/CONTRACTOR has been used, that the repair material completely filled
damaged area and that it has been reasonably smoothed with the adjacent previously applied concrete
coating.
Pipes not conforming to the requirements of this Specification related to the repair of concrete coating
shall have the concrete coating removed unless repair cannot be redone in accordance with this
Specification.
The report shall contain the following items: date, shift, pipe number, pipe external diameter, pipe wall
thickness,pipenominalconcretecoatingthickness,descriptionofcoatingdamagesfoundonthepipe,test
results,remarks.
8.22 DETERMINATION OF FACTOR ALPHA IN THE FORMULA FOR CALCULATION OF NEGATIVE
BUOYANCY
Thistestshallbeperformedonlyduringtheprequalificationtestinordertoverifythedifferenceinthe
weightbetweenfreshlyconcretecoatedpipeanddryandcuredconcretecoatedpipeinordertocalculate
negativebuoyancymoreprecisely.
Incasethistestisnotperformedthefactorshallremain0.99.
During the prequalification test it shall be verified the difference between the weight of the concrete
coated pipe after minimum 7 days passed after the application of concrete coating and the weight of
concrete coated pipe having freshly applied concrete coating. This verification shall be performed on
minimumtwoPQTpipesnotsubmittedtothewaterabsorptiontestbyweighingofthepipesimmediately
afterapplicationofconcretecoatingandatleast7daysafterapplicationofconcretecoatingasfollows:
8.23 COMPRESSIONSTRENGTHTESTCUBES
Thecubesshallbetakenatafrequencyofonesampleforevery25pipejointscoated,uptoamaximumof
threetimesperworkshift.Aminimumof4cubes(100x100x100mm)fromeachsampleshallbetaken.
Twocubesshallbetestedat7daysageandtheremainingcubesat28daysage.Thetestcubesshallbe
made,curedandtestedaccordingtoBSEN123902andBSEN123903,orASTMC39.Thetestcubesshall
betestedfordensityandcompressivestrength,toindicatetheconsistencyoftheconcrete.Theminimum
compressivestrengthshallbeexpressedasequivalentcorestrength.
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8.24 COMPRESSIONSTRENGTHCORESAMPLES
The compression strength on core samples shall be performed on the first concrete coated pipe at the
beginningofeachworkingshiftandthenevery15concretecoatedpipespassingonlinetests;2setsof3
corespecimenshallberemovedbypipesusingadiamondcuttertoensurethatthecutisperpendicularto
thepipesurface.
Coresamplesshallbetakenwithinfourdaysofconcreteapplicationandstoredinacuringtankuntiltest
performance.
Thediameterofthecoresampleshallbebetween35mmand44mmandwhentrimmedfortesting,the
ratio core sample diameter / core sample length shall be approximately 1:1. In case the capping of core
samplemustbeperformed,themaximumheightofappliedcappingatanypointshallbe8mmasperthe
Table1oftheASTMC61798standard.
Three core samples shall be taken approximately 500 mm from the edge of concrete coating from pipe
leadend,threecoresamplesshallbetakenfromthecentreofthepipeandthreecoresamplesshallbe
takenapproximately500mmfromtheedgeofconcretecoatingfromthepipetailend.
Incaseofcagereinforcementtypethecoresampleshallbetakeninamannerthatthereisnoreinforcing
steelincludedincoresample.
Onecoresampletakenfromthepipeleadend,onecoresampletakenfromthecentreofthepipeandone
coresampletakenfromthepipetailendshallbesubmittedtothecompressionstrengthtest7daysafter
application of concrete coating (first set of core samples). The same shall be done also for compression
strengthtest28daysafterapplicationofconcretecoatingonthatpipe(secondsetofcoresamples).
Remainingsetofcoresamplesshallbesparecoresamplesincaserelevantcoresampledoesnotpassthe
testandthesparecoresampleshallberetestedinstead(forexample,incaseoftestfailureofcoresample
onpipeleadend,thesparecoresampletakenfromthepipeleadendshallbetested).
Onlyincasewhenthereinforcingsteelintheformofweldedwiremeshisusedandthereinforcingsteelis
includedincoresampleandthiscannotbeavoided,SUBCONTRACTORmayusethefollowingnumberof
sparecoresamplesduetothenegativeinfluenceofreinforcingsteelincoresampleontestresults:
from40mmto45mmnominalconcretethickness:10corestakenfromthepipeleadend,10cores
fromthecentreofthepipeand10coresfromthepipetailend;
fornominalconcretecoatingthicknessabove45mm:5corestakenfromthepipeleadend,5cores
fromthecentreofthepipeand5coresfromthepipetailend.
Whencagetypeofreinforcingsteelisused,onlyonesparecoresampleforeachlocationisallowed(pipe
leadend,centreofthepipeandpipetailend).
Foracceptanceorrejectionofthepipe,onlythe28daystestresultshallbeconsideredwhilethe7days
testshallbeperformedonlyforinformation.
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The test performance shall be in accordance with the ASTM C39/C39M01 standard with exception of
requirementscontradictingthisstandardspecifiedinthisSpecification.
Incasetheacceptancecriteriavalidfor28daystesthavebeenachievedafter7days,the28daystestshall
notbeperformedonthatpipe.
Thefollowingacceptancecriteriashallapplyfor28daytest:
minimumvalueforindividualcore:32MPa;
minimumaveragevalueofthreecores(onetakenatthepipeleadend,onetakenatthecentreof
thepipeandontakenatthepipetailend):35MPa.
Incaseoftestfailureonfirstsetofcoresamplesandonallowednumberofsparesamplesthefollowing
remedialactionsshallbeperformed:
allofthepipesconcretecoatedbetweentheprevioussuccessfulcompressionstrengthtestbefore
thetestfailureandafterthefollowingsuccessfulcompressionstrengthtestperformedonthepipe
coatedafterthepipeonwhichthetestfailureoccurredshallbequarantined;
then,thecompressionstrengthtestshallbeperformedontwopipesconcretecoatedimmediately
before and on two pipes concrete coated immediately after the pipe on which the test failure
occurred.Incaseoftestfailureonanysingleofthesetestpipes,allofthequarantinedpipesshallbe
eithersubmittedtothecompressionstrengthtestuntilacceptabletestresultshavebeenfoundon
three consecutive pipes concrete coated before and on three consecutive pipes concrete coated
afterthetestfailure,otherwisethequarantinedpipesshallhavetheconcretecoatingremoved;
thepipesnotmeetingacceptancecriteriashallhavetheconcretecoatingremoved.
remarks.
8.25 DETERMINATIONOFTHETIMEFORSTACKINGOFPIPESINMORETHANONELAYER
SUBCONTRACTORshalltakecoresamplesfromthreedifferentpipes(threecorestakenpereachpipeas
described in previous paragraph) and submit them to the compression strength test considering core
sampling and compression strength testing requirements specified in previous paragraph. Then
SUBCONTRACTOR shall decide how much time shall pass from the completion of application concrete
coatingontestpipeandtestingofcoresample.
However, the time allowed for stacking of pipes in more than one layer shall be considered as the time
wheneachsingletestedcoresampleachievedtheminimumcompressionstrengthof14MPa.Incasethis
testisnotperformed,thepipesshallremainstackedinasinglelayerforminimumsevendays.
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8.26 WATERABSORBTIONTEST
The water absorption test shall be performed on one pipe coated each day during the first three
productiondays.Incasealltestshadacceptableresultsthetestshallbeperformedonceperweek.
Thetestshallbeperformedasfollows:
freshlyconcretecoatedpipeselectedforthewaterabsorptiontestshallbeplacedinthecuringarea
togetherwithotherpipesbutitshallbemarkedasatestpipeanditshallremaininthecuringarea
forminimumsevendaysafterwhichthepipecanbesubmittedtothewaterabsorptiontest;
immediatelypriortotheperformanceofthewaterabsorptiontest,thetestpipeshallbeweighedon
the weighing scale and the result of measurement shall be recorded and used in the formula for
waterabsorption(W1);
immediatelyafterweighingthepipeshallbecompletelyimmersedeitherinseawaterorinthefresh
wateraspertheSUBCONTRACTORsdiscretionandleftconstantlyimmersedforminimum24hours;
afterimmersionofminimum24hours,thepipeshallbeweighedagainontheweighingscale(W2);
thewaterabsorptionshallbecalculatedasfollows:
Maximumallowedvalueofthewaterabsorptiontestshallbe5%.
Incaseoftestfailureallofthepipescoatedbetweentheprevioussuccessfulwaterabsorptiontestandthe
nextsuccessfulwaterabsorptiontestperformedafterthetestonwhichthewaterabsorptiontestfailure
occurredshallbequarantined.Thepipeonwhichthetestfailureoccurredshallhavetheconcretecoating
removed.Then,twopipesselectedfromthequarantinedpipesshallbesubmittedtothewaterabsorption
test and in case of test failure on any of these test pipes all quarantined pipes shall be submitted to
COMPANY/CONTRACTORs decision who deserves the right to ask for additional testing or to reject all
quarantinedpipeswithoutanyadditionalcostsbornebyCOMPANY/CONTRACTOR.
remarks.
8.27 ADHESIONBETWEENTHE3LAYERPECOATINGANDCONCRETECOATING
During the PreQualification Test, on one concrete coated PROJECT pipe (minimum 1 m length of the 3
layerPEandconcretecoatedpipepieceisallowedforthispurpose),theadhesiontest(pushofftest)shall
beperformedinordertodeterminetheshearstrengthbetweentheexternalanticorrosioncoatingofline
pipesandconcretecoating.
Thetestshallbeperformedinaccordancewithagreedprocedure.
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The minimum value of the shear strength between the external anticorrosion coating of line pipes and
concretecoatingshallbe0.5MPa.
SUBCONTRACTORshallprepareareportrelatedtothistestactivity.
8.28 IMPACTTESTING
Impact testing may be required to demonstrate suitability for use in offshore applications where fishing
activitiesoccur.
ImpacttestingshallbecarriedoutonqualificationtestpipesselectedbytheCOMPANY/CONTRACTORand
on one concrete coated pipe per week or at the COMPANY/CONTRACTOR's discretion until the
COMPANY/CONTRACTOR is satisfied that the concrete coating procedures produce a consistent product
withacceptableimpactresistance.
Theimpacttestingequipmentandprocedurearedetailedbelow.Theexactdetailsofthetestrigshallbe
submittedtotheCOMPANY/CONTRACTORforapprovalandshallincludedetailsofsafetymeasurestobe
takentoavoidinjurytopersonnel.
Pipessubjecttoimpacttestingshallbescrappedandnotrepairedorincorporatedinthepipeline.
The impact test rig is designed to simulate impact by the trawl beam shoes of typical fishing trawl
equipmentasusedine.g.theNorthSea.
It shall consist of a steel framework on which a heavy cylindrical impact 'hammer' is suspended. The
hammershallbesupportedinthehorizontalpositionbytwosetsofwireropesattachedtothesupporting
framework.
Theimpacthammershallbedesignedtosimulatethemassandmomentumofa2.68tonnetrawlboard
travellingat7knotsovertheseabed.The'hammer'shallbe300mmlong,havea10mmradiustip,andbe
connectedtoaplateperpendiculartothepipeaxisasshownin(Figure3).Themassofthehammershall
be2.68tonnewiththecapabilityofreducingthemassto1.84tonne.Theverticaldropofthehammershall
be660mmgivingavelocityonimpactof3.60mls(7knots).
Note: The aboveindicated values are based on specific North Sea trawling equipment, for other areas
differentvaluesmaybeapplicable.
Theconcretecoatedtest pipeshallberigidlysupportedfromtherearoveritsfulllengthbymoistsand.
Thepipeshallbeheldrigidlyatitsendsbywoodencradlesandwedgestopreventmovementofthepipe
underimpact.
Thepointofimpactontheconcreteshallbeatthe3o'clockposition.Thepipeshallbesupportedsothat
impactoftheconcreteismadewhenthehammerisatthelowestpointinitsswing.
Testingshallbecarriedoutinthreeways:
1.
90topipeaxisatonelocation(2.68t)
2.
90topipeaxisatfivelocationseach300mmapart(2.68t)
3.
60topipeaxisatonelocation(1.84t).
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Foralltests,recordingofimpactlocationsshallinclude:
a)photographaftereachblow;
b)diagram(s)ofcrackpatternsandspaliedareasincludingdimensionsofmajorcracks(lengthandwidth);
c)dimensionalchanges,ifany,ofthepipe;detectedbyvisualinternalinspectionandsubsequentexternal
measurement.
The concrete area covering crack arrestors shall be impacted during qualification tests, for information
purposes.
Test1
Thetestpipeshallbesupportedwithaminimumof2mconcretesectioneithersideofthesectionunder
test.Impactblowsshallbedirectedonthesamelocationandtheconditionoftheconcreterecordedafter
eachblow,untiltheanticorrosioncoatingisexposed.
The anticorrosion coating shall not be visible and the steel pipe wall shall not be indented or damaged
after5blows.
Spallingshallnotoccuroveranaxialdistancegreaterthan300mmeachsideofthepointsofimpact,after
5blows.
Test2
The test pipe or rig shall be moved along at least 2 m and then a single blow shall be directed on five
locations,each300mmapart.Theconditionoftheconcreteshallberecordedaftereachblow.
Anyspallingshallnotextendfromoneimpactlocationtoanother.
Test3
Thetestpipeorrigshallbemovedalongatleastanother2mandthepipeimpactedinthe60positionto
the line of motion of the hammer. Five impact blows shall be directed on the same location and the
conditionoftheconcreterecordedaftereachblow.
Theanticorrosioncoatingshallnotbevisibleafterfiveblows.
8.29 STACKINGOFCUREDCONCRETECOATEDPIPES
PeriodicalinspectionshallbeperformedinstorageareatoverifythattherequirementsspecifiedinSection
12ofthisspecificationaremet.
All pipes not conforming to the PROJECT Specification shall be marked with coloured tape and
COMPANY/CONTRACTOR shall inform the SUBCONTRACTOR about the actions to be taken on non
conformingpipes.
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8.30 LOADOUTINSPECTIONS
Thefollowinginspectionsshallbeperformedoneachconcretecoatedpipeduringtheloadoutoperation
(pipes not conforming to the requirements of PROJECT specifications for external coating and concrete
coatingshallnotbeacceptedforloadout):
checkofpipemarking;
visualinspectionof3layerPEcoatingattheconcretecoatingcutbackareaand
verificationthat3layerPEcoatingdidnotdisbondfromthepipeattheedges;
visualinspectionforthepresenceandintegrityofendcapsandpolyethylenesheeting
protectingthe3layerPEcoatingcutback;
visualinspectionofconcretecoating;
checkofresidualmagnetismonbothpipeends(onlywhenrequestedbyCOMPANY/CONTRACTOR).
Inspection report shall be prepared only for nonconforming pipes quarantined during the load out
inspection.
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3LAYERPECOATINGREPAIR
3layerPEcoatingdamagesandtherelevantexternalcoatingrepairarenotallowedatthecutbackarea
wheretheexternalcoatinghasbeenbevelled(atthecoatingangle).
All coating damages located on the area 100 mm measured from the coating edge after cutback
preparationtowardscentrepointofthepipeonbothsidesofthepipecanberepairedonlyiftherepair
materialisperfectlysmoothedwithadjacentfactoryappliedcoating.
Acceptance of coating repair at this area shall be done only according to the COMPANY/CONTRACTORs
discretion(thisrequestisinsertedduetothepositioningofthesupportforwelding/NDTequipmentand
forapplicationofheatshrinksleevesasthefieldjointcoatingmaterial).
Defectsreducingthecoatingthicknessbelowtheminimumallowedtotalcoatingthicknessorexposingthe
primerorbaresteelarenotallowedwhentheyoccurbeforethecompletionofthevisualinspectionofthe
pipeattherelevantinspectionpointwithinthecoatingplant.Allsuchlinepipesshallberejected,stripped,
cleanedandrecoated.
Coatingrepairsareallowedonlyforlinepipesdamagedafterthecoatingandquenchingprocessoncethe
visualinspectionofthecoatedpipesiscomplete(duetohandlingandstorage).
Classificationofcoatingdamages:
Coating damage Class A: coating damage not reducing the total coating thickness below the minimum
allowedtotalcoatedthicknessspecifiedinthisSpecification.
Coating damage Class B: coating damage reducing the total coating thickness below the tolerances
specifiedinthisSpecificationbutnotexposingtheprimerorpenetratingdowntothesteel.
CoatingdamageClassC:coatingdamageexposingtheprimerorpenetratingdowntothesteel.
Maximum10coatingdamagesClassBareallowedoneachlinepipeotherwisethewholelinepipeshall
berejected,stripped,recleanedandrecoated.
Incaseofanyindividualareagreaterthan50cm2exposingtheprimer/baresteel(coatingdamageClassC)
the pipe will have to be stripped. A maximum of three coating damages exposing the primer/bare steel
(coatingdamageClassC)areallowedpereachpipebutthetotaldamagedareashallnotexceed150cm2.
Allrepairedareasshallbesubjectedtothefollowingcheckandacceptancecriteria:
visualinspectionon100%ofrepairs:nodefects;
thicknessteston100%ofrepairs:asperthisspecification;
holidaydetectionteston100%ofrepairs:noholidaysat25kV.
EachrepairofthecoatingdamageClassBandClassCshallbereportedandtherelevantreportshall
include:
date;
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linepipenumber;
typeofanydamage(classificationofdamage);
locationofanydamage;
dimensionofanydamage;
resultsofchecks.
Thefollowingcoatingrepairmaterialsarepermittedforrepairofthe3layerPEcoating:
Melt Stick supplied either by Berry Plastics or by Canusa: for repair of 3layer PE coating
damagesnotexposingFBElayerorbaresteelhavingmaximumsizeofthedamageof20mm20
mm.
FillermasticS11375033000+PErepairpatchPERP60(suppliedbyBerryPlastics):forrepair
of 3layer PE coating damages not exposing FBE layer or bare steel having maximum size of the
damageof150mm150mm.
Filler mastic + PE repair patch CRP 65 (supplied by Canusa): for repair of 3layer PE coating
damagesnotexposingFBElayerorbaresteelhavingmaximumsizeofthedamageof150mm150
mm.
Liquidepoxyprimer+fillermasticS11375033000+PErepairpatchPERP60(suppliedbyBerry
Plastics):forrepairof3layerPEcoatingdamagesexposingFBElayerorbaresteelhavingmaximum
sizeofthedamageof50cm2.
Liquidepoxyprimer+fillermastic+PErepairpatchCRP65(suppliedbyCanusa):forrepairof3
layerPEcoatingdamagesexposingFBElayerorbaresteelhavingmaximumsizeofthedamageof50
cm2.
SUBCONTRACTORshallprepareadetailedcoatingrepairprocedure,includingalltypesofexpecteddefects,
and coating stripping procedure for line pipes. Coating repair and stripping procedures shall be both
qualifiedandapprovedbyCOMPANY/CONTRACTORbeforethecommencementofproduction.
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10 CONCRETECOATINGREPAIRANDSTRIPPINGOFCONCRETECOATEDPIPES
The COMPANY/CONTRACTOR may reject concretecoated pipes when any of the previously stated
acceptance criteria are not met, and in such case the coating shall be completely removed rather than
partiallyrepaired.WhererepairsarepermittedinaccordancewiththisSpecification,theyshallberepaired
inaccordancewiththissection.
Concreteusedforrepairsshallcontainthesameproportionsofdryconstituentsastheoriginalcoatingbut
thewater/cementratiomaybehigher,toimproveworkability.
Priortoapplicationofrepairmaterial,thedefectiveareashallbethoroughlycleanedbyremovingconcrete
coatingsufficientlytocleanunderthereinforcingbarsandtheconcreteedgesshallbecutsoastoforma
holdingkey.Theunderlyinganticorrosioncoatingshallbeexaminedfordamagethatmayhaveoccurred
during concrete removal and tested by holiday detector. Any damaged anticorrosion coating shall be
repairedandretestedbeforesubsequentrecoatingwithconcrete.
Allrepairsshallbemoistcuredforaminimumperiodof48hours,oruntiltherepairedareahasattaineda
compressivestrengthof14MPa.
TheSUBCONTRACTORshalldemonstratethattheproceduresforrepairapplicationandcurewillresultin
anacceptablecoatingwiththecompressivestrengthofrepairbeingatleastequaltothestrengthofthe
coating.AllrepairmethodsshallbesubjecttotheCOMPANY/CONTRACTOR'sapproval.
Damagedareasshallberepairedwhentheyareconsidereddefectsasdefinedin8.16.
Areasofdamagenotexceeding0.8m2inany3mlengthofpipe(restrictedtotwosuchareasinany12m
length of pipe) may be repaired by hand patching, providing that such repairs are carried out while the
concreteisina'green'state(i.e.within4hoursofcoatingapplicationandpriortocuring).
IntheeventthattheCOMPANY/CONTRACTORwishestorepairareasoncuredconcrete,agunitingprocess
shallbeusedandtheprocedureshallbeapprovedbytheCOMPANY/CONTRACTOR.
Areas where the coating has been damaged during coating application in excess of 0.8 m2 but not more
than25%ofthetotalcoatingareashallberepaired.Allsuchrepairsshallbecarriedoutimmediatelyprior
tothepipebeingremovedfromthecoatingapplicator,byreapplicationofconcretetothespaliedareas
usingtheapplicationmachineusedtocoatthepipe.
Wheredamagetoconcreteisinexcessof25%ofthetotalcoatingarea,repairsshallnotbeallowed.All
concrete coating shall be removed and the pipe recoated. The SUBCONTRACTOR shall propose, for
COMPANY/CONTRACTORsapproval,aprocedureforremovingrejectedcoating.
Longitudinal cracks in excess of 250 mm in length shall be repaired as specified below with the addition
that the ends of each crack shall be drilled with a hole of 10 mm nominal diameter to prevent crack
propagation.Thebottomofthisholeshallbe7to10mmfromtheanticorrosioncoating.
Repairs to cracks shall be made by chiselling out the crack to a width of at least 25 mm throughout its
length. The preparedareashallbe undercuttoformanadequatekeyfortherepairmaterial.Therepair
concrete,whichshallhaveadensityequaltothatoriginallyapplied,shallbetrowelledorimpingedintothe
preparedareaandsmootheddowntotheleveloftheoriginalcoating.Priortorepairing,thepreparedarea
shallbeinspectedfordamagetothecoatingormetalsurface.
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Coreholesshallnotberefilledwithoutpriorinspection.Thecoreholesshallthenbehandfilledwithastiff
mix similar to that used in the coating process. The SUBCONTRACTOR shall propose, for
COMPANY/CONTRACTOR's approval, a detailed procedure for inspection and refilling of core holes and
inspectionareas.
Thepipesonwhichtheconcretecoatinghasbeenremovedshallbesubmittedtothevisualandholiday
inspectionpriortoreapplicationofconcretecoating.
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11 PIPEMARKING
TheitemstobemarkedontheconcretecoatedpipesshallbedefinedbyCOMPANY/CONTRACTOR.
Unless otherwise agreed or communicated by COMPANY/CONTRACTOR the pipe marking on concrete
coatedpipeshallbeappliedasstatedbelowwithinthisparagraph.
Besidethemarkingrequiredtobeappliedafterapplicationofthe3layerPEcoating,allconcretecoated
pipes shall have the following applied on the internal pipe surface of both pipe ends irrespective of the
pipeexternaldiameterusingthewaterproofandweatherproofwhitestencil:
pipenumber;
pipelengthin[m];
massofconcretecoatedpipein[kg].
All concrete coated pipes shall also be colour coded in order to readily identify different categories as
follows:
pipeMANUFACTURER(ifmorethanoneMANUFACTURERsuppliedbarepipe);
pipenominalexternaldiameterandpipenominalwallthickness;
concrete coating nominal thickness (if there are more different nominal concrete coating
thicknesses).
SUBCONTRACTOR shall apply marine paint colour bands on both pipe ends approximately 300 mm from
theendoftheconcretecoatingcutbacktowardthecentreofthepipe.Thepaintshallbeclearlyvisibleon
applied concrete coating and shall be suitable for long term storage at the designated final delivery
location. The painted bands shall be 100 mm wide and each band shall be applied around entire
circumference of the concrete coated pipe. The bands shall be applied immediately after completion of
concretecuring.
Exampleformarkingofconcretecoatedpipes:
1st band: pipe MANUFACTURER if more than one pipe MANUFACTURER supplied the pipes for concrete
coatinginthisPROJECT(differentcolourforeachpipeMANUFACTURER);
2ndband:combinationofdifferentpipeoutsidediametervs.pipenominalwallthickness(differentcolour
foreachdifferentnominalwallthickness);
3rdband:concretecoatingnominalthickness(differentcolourforeachdifferentconcretethickness).
ThelegendofcolourforeachbandshallbespecifiedintheSUBCONTRACTORsprocedure.
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12 STORAGE,HANDLINGANDTRANSPORTATIONOFCONCRETECOATEDPIPES
Concrete coated pipes shall be handled, stored and transported in a manner that the pipe steel,
anticorrosioncoatingandconcretecoatingshallnotbedamaged.
Concrete coated pipes can be handled using slings, lifting hooks padded with soft material with suitable
spreader bars, forklifts having lifting forks padded with soft material, front loaders padded with soft
materialandvacuumlifting.Chainsorwireropesoranyotherdevicethatmaydamagethepipesteelor
coatingshallnotbeused.
Whenmorethanonepipeislifted,separateslingsorhooksshallbeusedforeachpipe.
Pipesshallbepickedupfromthestackingpointandatnotimeshallbedraggedorrolled.
Coatedlinepipeshallnotbesubjectedtojarorimpactandallpipesupportsshallbepadded.
Pipesupportsshallbespacedtoavoidbendingoflinepipes.
During the curing process, the concrete coated pipes shall be stored in a single row until they reach the
compressionstrengthmeasuredoncoresamplesofminimum14MPa.Concretecoatedpipesmaybelifted
from the curing area and stacked in more than one layer when the concrete coated pipes reach the
compressionstrengthmeasuredoncoresamplesofminimum14MPa.However,incasethepolyethylene
wrapping is used for curing process, the polyethylene wrapping shall not be removed from the concrete
coatedpipeforminimumsevendaysafterapplicationofconcretecoating.Thepolyethylenewrappingshall
beremovedfromthepipesmaximumimmediatelybeforetheloadoutfromthestoragearea.
Thecoatedlinepipesshallalwaysbestackedtoavoidsurfacecontactwiththeground.Thepipesshallbe
stacked on approved supports which shall be free of any material that could potentially damage the
appliedcoating.
Thestackingheightofconcretecoatedpipesshallbelimitedtoavoiddamageofconcretecoatingdueto
theweightofotherpipes.Themaximumnumberofstackinglayersforconcretecoatedlinepipesshallbe
calculated by SUBCONTRACTOR and relevant calculation showing calculation steps and results shall be
submitted to COMPANY/CONTRACTOR for review and approval considering the allowed compression
strength of concrete coated pipes for stacking of 14 MPa (unless SUBCONTRACTOR intends to leave the
pipes stacked in a single row for minimum seven days). In case the period when the concrete coating
reaches compression strength of 14 MPa tested on core samples was not qualified in front of
COMPANY/CONTRACTORsrepresentativesduringtheprequalificationtest,thepipesshallbestackedina
singlelayerforminimumsevendays.Howeverforsafetyreasons,thepipesshallnotbestackedmorethan
3mhighevenifpresentedcalculationshowsthatthepipescouldbestackedhigherthan3m.
Thestacksofcoatedpipesshallbeseparatedforeachofthefollowingcombinations:
Pipe MANUFACTURER vs. pipe nominal OD x pipe nominal wall thickness vs. concrete coating
nominalthickness.
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Concretecoatedpipeshavinganodesshallbestackedseparatelyfromtheconcretecoatedpipeswithout
anodes.
Thepipesshallbestackedataslightangletoallowdrainageofanyrainwater.
The concretecoatedpipesshallnot bestacked belowandnearelectricallinesornearanyfacilitywhich
mayincreaseresidualmagnetisminthepipes(atalltimesitshallbekepttheminimumdistanceof30m
betweenthestoredpipesandanyelectricalcablemeasuredfromtheverticalprojectiontothegroundof
thenearestelectricalcable).
Depending on the mean of the transport, the transport shall be performed in accordance with the
standardsAPI5L1andAPI5LW.
Allforeignsubstancessuchasexcessivedirt,debrisofcoatingmaterialsoranyotherforeignobjectsshall
beremovedfrominternalpipesurfacebeforestackingandloadout.
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13 DOCUMENTATION
13.1 GENERALREQUIREMENTS
AlldocumentsandcorrespondencerelatedtotheactivitiesdescribedbythisSpecificationshallbewritten
inEnglishLanguage.SUBCONTRACTORmay translaterelevant workinstructionsandotherdocumentsto
anylanguageaccordingtoSUBCONTRACTORsconvenienceadaptedtothelocalworkforce,however,the
translationinEnglishlanguageshallbebinding.
All documents issued by SUBCONTRACTOR to COMPANY/CONTRACTOR shall be prepared in the format
approvedbyCOMPANY.
13.2 TECHNICALDOCUMENTATIONTOBESUBMITTEDDURINGTHEBIDDINGPHASE
DuringtheBiddingPhasetheSUBCONTRACTORshallsubmitthefollowing:
Statement of compliance with technical documents issued by CONTRACTOR to SUBCONTRACTOR

duringthebiddingstage.
List of deviations from technical requirements specified in technical documents issued by

SUBCONTRACTORtoCOMPANY/CONTRACTORduringthebiddingstage.
The list of deviations shall contain the following (in case SUBCONTRACTOR presents the list of
deviations not mentioning only one of the items listed below, CONTRACTOR reserves the right to
considerdeviationpresentedbySUBCONTRACTORasnotvalid):
- Document number and document revision number and relevant paragraph of the
documentfromwhichSUBCONTRACTORintendstodeviate;
- Quotation of the text within the document from which SUBCONTRACTOR intends to
deviate;
- SUBCONTRACTORsproposalexplainingthereasonfordeviationandproposedactions;
- Quantification of cost impact and of the impact on delivery schedule of coated pipes in
casethedeviationisnotaccepted;
Workprogramanddeliveryscheduleofcoatedpipes;
SUBCONTRACTORsorganisationchart;
Layoutofthecoatingfacilitiesincludingstorageandofficeareas;
TechnicaldatasheetsoftheconcretecoatingmaterialsthatSUBCONTRACTORintendstouseinthe
PROJECT; cement, sand, heavy aggregates (gravel and iron ore), water (certificate for compliance
withAppendixAoftheBS3148standard),reinforcingsteel;
AnyotherdocumentbesideabovementionedrequestedbyCOMPANY/CONTRACTOR.
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13.3 TECHNICAL DOCUMENTS TO BE SUBMITTED AFTER AWARD OF THE CONTRACT TO
SUBCONTRACTOR
When the contract for coating of pipes has been awarded by CONTRACTOR to SUBCONTRACTOR,
SUBCONTRACTORshallsubmitforreview/approvalthefollowingdocumentsatleastsixweeksbeforethe
commencementofthePreQualificationTest:
concretecoatingapplicationprocedure;
calculationforstackingof3layerPEcoatedpipes(foreachcombinationofpipediameterpipewall
thickness)andforstackingofconcretecoatedpipes(foreachcombinationofpipediameterpipe
wallthicknessconcretecoatingthickness);
inspectionandtestplanforPreQualificationTest;
inspectionandtestplanforproduction;
materialandsafetydatasheetsoftheconcretecoatingmaterials;
inspectionandtestreportformats;
3layerPEcoatingrepairreportformat;
concretecoatingrepairreportformat;
listofinspectionandtestequipmentandrelevantcalibrationcertificates;
dailyreportformat;
anyotherdocumentbesideabovementionedrequestedbyCOMPANY.
The PreQualification Test and production cannot start when the above mentioned documents have not
beenapprovedbyCOMPANY/CONTRACTOR.
After performance of the PreQualification Test, SUBCONTRACTOR
COMPANY/CONTRACTORthePreQualificationTestReportforreview/approval.
shall
submit
to
Duringproduction,SUBCONTRACTORshallsubmittoCOMPANY/CONTRACTORforreview,thecertificates
foreachbatchofthefollowingmaterialssuppliedbythematerialMANUFACTURERtoSUBCONTRACTOR:
cement,sand,gravel,ironore,reinforcingsteelandmaterialusedforcuringofconcretecoating.
During production, SUBCONTRACTOR shall submit to COMPANY/CONTRACTOR for review/approval the
followingdocumentationwithin12hoursafterthecompletionofeachparticularworkingshift:
dailyreport(inelectronicformat);
inspectionandtestreportsrelatedtotheproductionperformedduringtheshift;
3layerPEcoatingandconcretecoatingrepairreports;
listofpipesonwhichremedialactionhasbeenperformedafternotconformancehas
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occurred and the pipe was quarantined (date of not conformance, pipe number, reason for
quarantineanddateofsuccessfulimplementationofthecorrectiveaction);
releasenoterelatedtothepipesintendedforloadoutoperation(formatshallbeagreedbetween
SUBCONTRACTORandCOMPANY/CONTRACTOR).
13.4 FINALTECHNICALDOCUMENTATION
Final documentation and relevant format shall be agreed between SUBCONTRACTOR and
COMPANYandCONTRACTOR.
However, the SUBCONTRACTOR shall prepare also the Final Manufacturing Book which shall contain the
following:
tableofcontentoftheFinalManufacturingBook;
pipetrackingsysteminelectronicandpaperformat;
revisionsofallofthePROJECTdocumentsrelatedtotheSUBCONTRACTORsscopeofworkissued
byCOMPANY/CONTRACTORtoSUBCONTRACTORwhichhavebeenusedduringtheproduction;
revisions of all of the documents issued by SUBCONTRACTOR which have been used during the
production;
NonConformity Notes/Corrective Action Requests issued by COMPANY/CONTRACTOR to

SUBCONTRACTOR(ifany);
NonConformityReportsissuedbySUBCONTRACTOR(ifany);
MinutesofMeetingbetweenCOMPANY/CONTRACTORandSUBCONTRACTOR;
any communication issued to SUBCONTRACTOR where any concession related to the PROJECT
documentshasbeengiventoSUBCONTRACTOR;
technicalandsafetydatasheetsofallmaterialsusedbySUBCONTRACTORrelatedtotheirscopeof
work;
batchcertificatesofallmaterialsusedbySUBCONTRACTORduringtheproduction;
listoftheinspectionandtestingequipmentusedbySUBCONTRACTORduringtheproduction;
copiesoftheinspectionandtestingequipmentcalibrationcertificates;
PreQualificationTestreports;
productioninspectionandtestsreports;
releasenotes;
anyotherdocumentissuedbySUBCONTRACTORrelatedtotheloadoutoperations.
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13.5 CONTENTOFPARTICULARTECHNICALDOCUMENTS
13.5.1 CONCRETECOATINGAPPLICATIONPROCEDURE
TheSUBCONTRACTORscoatingapplicationprocedureshallcontainthefollowing:
scopeofthedocument;
definitions of various Parties involved in the PROJECT related to the SUBCONTRACTORs scope of
workanddefinitionofabbreviationsusedinthedocument;
listofreferencedocumentsrelatedtotheSUBCONTRACTORsscopeofwork;
listofmaterialsusedforproduction:cement,sand,gravel,ironore,reinforcingsteelandmaterialfor
curing of concrete coating including trade names and suppliers name where applicable (for each
materialitshallbespecifiedthemethodsfortheirstorage);
procedure for receipt of 3layer PE coated pipes, handling of 3layer PE coated pipes within
SUBCONTRACTORsfacilities,theirstorageandtheirtransport;
descriptionoftheconcretecoatingplantandthelistofequipment;
descriptionoftheverificationofcalibrationoftheconcretecoatingbatchingplant;
detailproductionstepsdescribingtheactivitiesoneachconcretecoatingstation;
inspections and tests (each single inspection or test shall be inserted in separate section and the
following shall be described: the test/inspection name, brief testing procedure when there is no
reference international standard, test frequency, testing equipment, acceptance criteria, remedial
actionsincasetheacceptancecriteriahavenotbeenmet);
procedure for handling of concrete coated pipes within SUBCONTRACTORs facilities, their storage
andtheirtransport;
concretecoatedpipesmarkingprocedure;
3layerPEcoatingrepairprocedure;
concretecoatingrepairprocedure;
procedureforremovalofthefreshandhardenedconcretecoating;
materialtechnicaldatasheetsofthematerialsusedforproduction(cement,sand,gravel,ironore,
reinforcingsteel,certificateformixingwater,materialusedforcuringofconcretecoating).
According to his convenience, SUBCONTRACTOR can divide this procedure as separate documents
butallabovementioneditemsmustbeincludedinthesedocuments.
Omissiontoinsertintotheconcretecoatingapplicationprocedureanytechnicalrequirementspecifiedin
this specification and in other contractual documents shall not relieve SUBCONTRACTOR from the
obligationtofulfilthatparticularrequirementevenifthisconcretecoatingapplicationprocedurehasbeen
approved by COMPANY/CONTRACTOR unless this requirement has been waived by COMPANY through
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Concession Request or approved by COMPANY as a deviation when the list of deviations has been
presentedtoCOMPANY/CONTRACTORduringthebiddingphase.
13.5.2 INSPECTIONANDTESTPLAN
TheinspectionandtestplanshallbeissuedseparatelyforthePreQualificationTestandforproduction.
Theinspectionandtestplanshallcontainthefollowing:
itemnumber;
activity;
referencetotherelevantsectionsofthedocumentssuppliedbyCOMPANY/CONTRACTORor
SUBCONTRACTORsdocumentsorinternationalstandardapplicabletothisparticularactivity;
testfrequency;
acceptancecriteria;
referencetotheinspectionandtestreportnumberissuedbySUBCONTRACTORforthisparticular
activity;
action codes for SUBCONTRACTOR, CONTRACTOR, COMPANY and any other Third Party appointed
byCOMPANY/CONTRACTORifthelatestisrequired.
Omission to insert into the inspection and test plan any technical requirement specified in this
SpecificationandinothercontractualdocumentsshallnotrelieveSUBCONTRACTORfromtheobligationto
fulfil that particular requirement even if this inspection and test plan has been approved by
COMPANY/CONTRACTOR unless this requirement has been waived by COMPANY through Concession
Request or approved by COMPANY as a deviation when the list of deviations has been presented to
COMPANY/CONTRACTORduringthebiddingphase.
13.5.3 DAILYPRODUCTIONREPORT
Dailyproductionreportshallbecomposedofthefollowingitems:
master sheet (pipe number, nominal pipe external diameter, nominal pipe wall thickness, pipe
material, pipe length, mass of bare pipe in kg, type of applied coating, coating date, shift, pipe
sequencenumber,pipestatusaccepted/quarantined);
material batch number (pipe number, coating date, shift, pipe sequence number, material trade
name and material batch number for each coated pipe for primer, adhesive, topcoat and rough
coat);
listofquarantinedpipes(pipenumberandreasonforquarantine);
productionstops(date,shift,plantstoppagestarttime,plantstoppageendtime,reason);
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externalcoatingrepair(classificationofdamages,pipenumber,coatingdamageclass,coatingrepair
date,repairstatus,remarks);
loadoutofcoatedpipes(number,pipenumber,nominalpipeexternaldiameter,nominalpipewall
thickness, pipe material, pipe length, pipe mass in kg, type of applied coating, vessel and
destination).
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Concrete Weight Coating

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Concrete Weight Coating

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