Engineering Standards

Standard

4800
Page

1 of 4
FABRICATION AND INSTALLATION OF
SET-ON CONCRETE PIPELINE WEIGHTS

Issue Date

02/94
Rev. No.
Date

1.

SCOPE
This standard covers requirements for the supply and installation of set-on weights on steel pipe to achieve the
negative buoyancy required for laying pipe in marshes or through river bottoms.

2.

3.

GENERAL
2.1

The concrete density shall be as specified by Design Engineer or as specified in Design Drawings or other
documents. Set-on weight design and spacing are based on the specified concrete density and density of
buoyant medium. The set-on weights shall produce a negative buoyancy of 10 lbs per lineal foot or as
3.
specified in other contract documents. Concrete densities normally range from 140 to 190 lbs/ft

2.2

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

MATERIALS
3.1

Concrete
3.1.1

The minimum compressive strength of the concrete shall be 3000 psi at 28 days. High early
strength concrete shall have a minimum compressive strength of 3000 psi at 7 days.

3.1.2

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

3.1.3

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

3.1.4

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

3.1.5

Magnetite ore, if required, shall be free of clay and injurious amounts of alkali, deleterious
substances and organic impurities that may affect the strength of concrete and shall conform to
ASTM C 29. Magnetite ore shall be crushed to the following screen analysis:
100% passing 1/4" mesh screen
30-75% passing #16 mesh screen
10-40% passing #50 mesh screen
0-25% passing #100 mesh screen

* Indicates revised paragraph, this Rev. No.

Engineering Standards

Standard

4800
Page

2 of 4
FABRICATION AND INSTALLATION OF
SET-ON CONCRETE PIPELINE WEIGHTS

Issue Date

02/94
Rev. No.
Date

3.1.6
3.2

4.

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

Reinforcing Steel
3.2.1

Reinforcing bars shall be intermediate grade, deformed, new billet steel in conformance with
ASTM A 615. All reinforcing bars shall be Grade 60.

3.2.2

Welded steel wire fabric for concrete reinforcement shall conform with ASTM A 185.

3.2.3

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

TESTING
4.1

4.2

Concrete Strength
4.1.1

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

4.1.2

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

4.1.3

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

4.1.4

Company's Representative shall be furnished a copy of the results of each test required by this
section, prior to weights being installed.

4.1.5

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

4.1.6

Contractor shall bear all costs in connection with testing.

Weights
Contractor shall furnish the necessary scales to accurately weigh the set-on weights. At the beginning of
operations each day, the scales shall be checked by weighing a set-on weight of known weight.
Adjustments of the scales shall be made if necessary. Final acceptance of the weights to be in accordance
with section 8.0 of this standard.

* Indicates revised paragraph, this Rev. No.

Engineering Standards

Standard

4800
Page

3 of 4
FABRICATION AND INSTALLATION OF
SET-ON CONCRETE PIPELINE WEIGHTS

Issue Date

02/94
Rev. No.
Date

5.

APPLICATION
5.1

Concrete
The set-on weights shall be free of burrs or irregularities on the inside that could damage coating or pipe.

5.2

Reinforcement
For the form and pour method, the reinforcing steel shall be tied in place using wires, concrete and metal
supporters, spacer bars and chairs to maintain reinforcement in proper position during concrete
application. Spacers or chairs shall be sized and positioned to allow 3" concrete cover over reinforcement.

6.

CURING
6.1

7.

Concrete surface shall be kept from dehydrating using one of the following methods:
6.1.1

The concrete shall be sprayed with a pigmented membrane sealant conforming to ASTM C
309.

6.1.2

The concrete shall be continuously kept moist for at least seven (7) days when Type I cement
has been used or three (3) days when Type III cement has been used.

6.1.3

The concrete shall be wrapped in impervious sheet materials while curing. Application shall
concur with Concrete Construction Handbook guidelines or per contractor's approved
procedure.

6.2

Before further handling, the concrete should be allowed to cure for a minimum of seven (7) days when
Type I cement has been used or three (3) days when Type III cement has been used.

6.3

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

REPAIRS TO WEIGHTS
Weights may be repaired per the following guidelines. Company Representative shall be responsible to accept or
reject any repaired weights.
7.1

Spalling
7.1.1

A loss of concrete of more than 25% of the total concrete thickness or sufficient loss to cause
the reinforcing steel to be visible shall be repaired.

7.1.2

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

7.1.3

If an area of spalling is more than one, but less than two square feet, the concrete remaining in
place over that area shall be removed as necessary to expose the reinforcing steel throughout
the damaged area. Edges of the spoiled area shall be undercut to provide a key lock for the

* Indicates revised paragraph, this Rev. No.

Engineering Standards

Standard

4800
Page

4 of 4
FABRICATION AND INSTALLATION OF
SET-ON CONCRETE PIPELINE WEIGHTS

Issue Date

02/94
Rev. No.
Date

repair material. The set-on weights having damaged area more than two square feet will be
rejected.
7.1.4
7.2

8.0

9.0

Repaired set-on weight shall be carefully stored and allowed to moist cure a minimum of 36
hours before further handling.

Cracking
7.2.1

Concrete cracks shall be repaired where they are over 1/16" wide or extend over 12"
irrespective of width.

7.2.2

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

REJECTION OF WEIGHTS
8.1

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

8.2

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

8.3

Improper placement of reinforcing steel shall be cause for rejection.

8.4

Set-on weights that weigh less than the weight specified shall be rejected, unless the average weight of the
set-on weight is maintained by compensating for each set-on weight location that is underweight by
placing a compensatory extra weight on the surrounding set-on weight locations. On all pipe sizes, the
weight of the set-on weight must be within 5% below and 7-1/2% above the specified weight.

INSTALLATION OF WEIGHTS
When set-on weights are to be used, the following sequential actions will be implemented unless the Company's
Representative specifically approves otherwise.
9.1

The ditch will be de-watered to a level where the upper half of the pipe is above water elevation. The
pipe may have been previously placed in the ditch and submerged to grade by filling with water.

9.2

Rockshield will be placed on pipe at the locations specified for weights to be installed. The rockshield
will extend 12" longitudinally beyond the end of weight and 12" beyond the vertical tangent on the sides.

9.3

The weight will be carefully installed achieving full contact with the rockshield through the top 180 of
the pipe.

9.4

The ditch will be backfilled with suitable material after the weights have been successfully installed.

* Indicates revised paragraph, this Rev. No.