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05
TABLE OF CONTENTS
1.0 SCOPE
4.0 MATERIALS
7.0 CURING
APPENDIX
ATTACHMENTS
1.0 SCOPE
1.1 General
This specification covers application of concrete coating to line pipe for use
offshore off the coast of West Africa. Contractor shall furnish all materials, labor,
equipment, utilities, supervision, services, and all other items required to perform
the work. Contractor shall make all arrangements and obtain permits required for
his performance of work at the coating application site, whether on property
owned or arranged for by Contractor, by Company, or by Others.
Contractor shall provide adequate shear strength between the concrete and the
fusion-bonded epoxy (FBE) corrosion coating to prevent slippage of the concrete
during installation.
Contractor shall demonstrate the ability of the enhancement technique to meet the
required minimum shear strength by means of a full scale push-off test or other
experimental method. The results of the test shall be submitted to Company for
approval of the proposed shear strength enhancement method.
For coating application by the impingement method over FBE coated pipe,
Contractor shall apply an intermediate barrier coating to protect the FBE from
damage.
1.4 Exceptions
Contractor shall obtain written approval of Company for any deviations from the
requirements of this specification.
This document is not intended to be all inclusive, and the use of the guidelines set
forth does not relieve Contractor of his responsibility to supply a finished product
capable of performing its intended service.
Contractor shall weigh each concrete-coated pipe joint immediately after coating,
and shall measure the outside diameter of the concrete either on the scale or as
soon as the joint is placed on the curing rack. The outside diameter shall be
measured at a minimum of five points evenly spaced along the length of the pipe
joint. The average of these measurements shall be reported and used in
calculations for coating thickness and concrete density. Report entries and
calculations required by Sections 2.2 and 2.3 shall be made within 30 minutes
after the pipe joint is placed on the curing rack.
Weighing devices used to determine the weight of the concrete-coated joints shall
be certified in writing to an accuracy of 0.5%. When specified on the data sheet,
the weighing device shall be calibrated just prior to start of coating by an
independent agency approved by Company. Checking of the weighing devices
shall be done at the beginning of each day's production, and Company shall retain
the option to request a check at any time. The check shall be performed using a
joint of pipe with a known weight, that weighs within plus or minus 25% of the
weight of a concrete-coated pipe joint to be coated.
2.2 Density
2.2.1 Density of concrete coating shall not vary from the design density by more than
plus 10% or minus 5%.
If the density varies from the specified density by more than the stated tolerance,
Contractor shall take corrective measures to obtain specified density, and shall
immediately inform Company of the deviation and corrective measures.
2.2.2 Density of "as-applied" concrete coating shall be determined using the weight and
dimensions of a concrete-coated joint, by the following calculation:
where:
2.3.1 The calculated weight for the pipe joint, in pounds, shall be:
where:
Wp, L, and h are as stated in Section 2.2.2, and Wc = concrete coating weight,
lb/ft.
The total weight of any single pipe joint shall not vary from the total design joint
weights by more than plus 7.5% and minus 5.0%.
The total weight of any 10 consecutive pipe joints shall not vary from the total of
design joint weights for those joints by more than plus 7.5% and minus 0.0%.
Coating thickness shall not vary by more than minus 0 or plus 1/4 inch from the
nominal thickness specified on the data sheet.
3.0 STANDARDS AND SPECIFICATIONS
Concrete weight-coating shall conform to the latest edition of the standards and
specifications listed in Appendix I.
4.0 MATERIALS
4.1 Cement
4.2 Sand
Sand shall be clean and graded. Clayey and schistose sands shall not be
acceptable. Sand shall be free of injurious amounts of salt, alkali, deleterious
material or organic impurities. Suitability of the natural sand for use in concrete
shall be determined in accordance with ASTM C-33.
4.3 Aggregate
The aggregate shall be granite, iron ore, or any other aggregate approved by
Company. The aggregate shall be well graded from fine to coarse.
The aggregate shall be clean and free from salt, alkali, deleterious material or
organic impurities. It shall conform in all respects to ASTM C-33.
4.4 Water
Water shall be clean fresh water, free from oil, alkali, organic matter or other
deleterious matter. Water shall not contain more than 250 ppm of chlorides.
Source of water supply shall be identified, and an analysis of the water supply
shall be furnished when requested by Company.
4.5 Admixtures
4.6 Reinforcement
4.6.1 Reinforcement shall be high quality 1 1/2 by 1 1/2 inch No. 17 American Steel
Wire Gage galvanized woven wire mesh, hexagon weave with reverse twist,
conforming to ASTM A-390.
At the time concrete coating is applied, the wire fabric shall be free from rust,
scale dirt, oil or other coatings that may reduce the bond with the concrete.
4.6.2 Other reinforcement may be used if approved by Company in writing. Wire fabric
shall conform to ASTM-185 with galvanizing per ASTM A-153.
All materials shall be stored and handled in accordance with the applicable ASTM
Specification and the ACI Manual of Concrete Practice.
5.1 Proportioning
5.1.1 Contractor shall select the necessary proportioning of materials to produce the
required strength and density. The proportions of mix to be used shall be
submitted to Company for review. For concrete other than nominal 140 lb/ft3
density, Contractor shall determine the density of the proposed mix, and submit
test method and test results to Company before start of coating.
5.1.2 Concrete shall have minimum compressive strengths of 1000 psi at 24 hours,
3000 psi at 7 days, and 4000 psi at 28 days.
If the mix is changed for any reason after commencement of coating, the new mix
shall be tested, and test results accepted by Company before the mix is used.
5.2.2 Should Contractor propose a method other than batching or using sacked and
weighed materials, a description of such method, including the measures to be
taken to assure a coating conforming to the specification, shall be presented to
Company for approval prior to beginning of coating.
5.2.3 For the impingement method of application, the use of reclaimed rebound material
shall be allowed if placed within 30 minutes. Both freshly mixed material and
rebound material shall be placed so that there is no detrimental effect to the final
concrete product.
5.2.4 Any mixed concrete which has not been placed within 30 minutes after the
introduction of the water into the mixture shall be unacceptable and shall be
disposed of by Contractor.
5.3 Testing
5.3.2 Density
Density shall be determined twice daily by weighing the samples for the 24-hour
compressive strength test before making the compressive strength test, and
calculating density based on the measured volume.
5.3.3 All testing shall be at Contractor's expense and as approved by Company. Test
results shall be submitted to Company daily.
6.1 Equipment
6.2 Any temporary protection for the corrosion protective coating shall be completely
removed. Maximum bond must be achieved between the corrosion protective
coating and the concrete coating.
6.3.1 The reinforcement shall be spirally applied simultaneously with the concrete and
shall have an overlap of not less than 3/4 inch.
6.3.2 If cathodic protection anodes are to be installed, Contractor shall provide 2 inch
minimum and 3 inch maximum clearance between anode and the reinforcement.
Reinforcement may be applied over bonding cable where the concrete coating
covers the cable.
Concrete shall be applied to the rotating pipe by the high velocity impact method
so as to form a continuous coating. The surface shall be trimmed to give a
uniform thickness of concrete coating concentric with the pipe.
Concrete mix shall be extruded onto the rotating pipe, with the required
reinforcement fabric, and shall be simultaneously covered with a plastic sheet
outer wrap under suitable tension to give a smooth surface, with a uniform
thickness concentric with the pipe.
Concrete coating shall terminate to provide the holdback distance from the end of
the pipe as specified on the data sheet, or 3 inches short of the end of the
previously applied corrosion protective coating, whichever provides the greater
holdback. Coating edge shall be perpendicular to the axis of the pipe and the
steel reinforcement wire shall not protrude through the concrete coating edge.
Pipe ends shall be cleaned and examined immediately after removal from the
coating station to ensure the proper holdback distance and to remove any
concrete from the holdback area and the inside of the pipe. Where needed to
keep concrete out of the pipe, pipe ends shall be capped prior to concrete
application.
6.7 Temperature
Concrete shall not be applied to the pipe when the ambient temperature is less
than 40F unless Contractor has made provisions acceptable to Company to
properly protect the newly applied concrete.
7.0 CURING
7.1 The concrete coating shall be cured for a minimum of 4 days at temperatures of
not less than 40F. During curing, the concrete coated pipe shall be placed on
sand ridge windrows and shall not be stacked. Sand windrows shall be placed in
sufficient number and position to eliminate detrimental deflection in the pipe. The
concrete shall not be allowed to dehydrate. The pipe shall not be transported
until after the minimum 4 days of curing except for the initial transfer of pipe from
the coating machine to the curing area.
7.2.1 Water curing, if used, shall commence as soon as possible but no later than
2 hours after coating. Water spray shall keep the coating continuously moist for
no less than 4 days providing temperatures are above 50F, or no less than
7 days if temperatures are below 50F.
The plastic sheet outer wrap must be kept in place a minimum of 7 days, and
preferably longer.
Concrete coating with defects or damage or which does not conform otherwise to
this specification shall be promptly repaired to the satisfaction of Company.
An area of defect or damage of 1 ft2 or less in any 5-foot run of pipe, for which the
depth is 25 percent or less of the total thickness of the coating, may be accepted
without repair, provided the remaining concrete is sound and the reinforcement is
not exposed.
A stiff mixture of grout or concrete shall be troweled into and through the
reinforcement, and built up until the surface is even and smooth with the original
coating around the repair. The coating resulting from the repair shall be equal in
strength to the coating originally applied.
The repaired joint shall be carefully laid in a safe position and moist cured or liquid
membrane cured for a minimum of 4 days before further handling.
8.2 Cracks
Hairline cracks less than 1/16 inch in width need not be repaired.
Circumferential cracks exceeding 1/16 inch in width at the surface and extending
more than 180 degrees shall be repaired.
Longitudinal cracks exceeding 1/16 inch in width at the surface and in excess of
12 inches in length shall be repaired.
Crack repairs shall be made by widening the crack to 1 inch for the necessary
depth and length and packing the prepared crack with the repair material specified
above until level with the existing coating. Pipe joints with repaired cracks shall
remain undisturbed for a minimum of 36 hours.
9.0 CAUSES FOR REJECTION
Causes for rejection of the concrete coating shall include but not be limited to the
following:
Anodes shall be attached to the pipe lengths after concrete coating application.
Installation shall comply with Section 7 of this specification, NACE Standard
MR-06-75 "Control of Corrosion on Offshore Steel Pipelines", Company Technical
Requirements, and manufacturer's instructions. If the anode rings are welded,
they shall be insulated from the corrosion protective coating. Bonding cables shall
be welded to the pipe and tested for electrical continuity prior to concrete
application. Steel reinforcing mesh shall not be within 2 inches of the anode. All
welded areas shall be recoated with corrosion protective coating. The gap
between the anode bracelet and the concrete coating shall be filled with a stiff
grout to provide an even surface between the anode and the adjacent concrete
coating.
Concrete shall be smoothly formed at a 1:4 taper to match the anode thickness
when there are differences between anode and weight-coating thicknesses.
Grout shall not be placed until the anode is installed and protective coating repairs
are approved by Company. After completing grouting, an ohmmeter check shall
be made to prove electrical continuity between the pipe and the anode.
12.1 The pipe mill shall paint a pipe joint number in 3-inch high letters on the inside at
each end of each pipe joint. Contractor shall indelibly paint this number, or his
own number, on the outside at each end of each weight-coated joint along with
the pipe size, wall thickness, and nominal weight-coating thickness. This
identification shall be located between 1 foot and 5 feet of both pipe ends.
12.2 The following information shall be recorded for each pipe joint and furnished at
least weekly to Company:
4. Defects at receipt
APPENDIX I
1. INDUSTRY STANDARDS
A-153 Standard Specification for Zinc Coating (Hot-dip) on Iron and Steel
Hardware
A-185 Standard Specification for Welded Steel Wire Fabric for Concrete
Reinforcement