SpecificationforConcreteWeightCoating

SpecificationforConcreteWeightCoating 1of10
 TableofContents

1.0 SCOPE ..................................................................................................................................................................... 3

2.0 REFERENCEDOCUMENTS .......................................................................................................................................... 3
3.0 MATERIALS ................................................................................................................................................................ 3
4.0 EQUIPMENTANDLABOR........................................................................................................................................... 4
5.0 CONCRETECOATINGMIX .......................................................................................................................................... 5
6.0 CONCRETECOATINGPROCEDURES........................................................................................................................... 5
7.0 INSPECTIONANDTESTING ........................................................................................................................................ 7
8.0 REPAIRSANDACCEPTANCE....................................................................................................................................... 9
9.0 IDENTIFICATIONANDMARKING ............................................................................................................................... 9
10.0 STORAGE,HANDLINGANDSHIPPING...................................................................................................................... 10
11.0 PERFORMANCEOFWORK ....................................................................................................................................... 10

SpecificationforConcreteWeightCoating 2of10
1.0 SCOPE ASTMA90 TestMethodofWeightofCoating
onZincCoated(Galvanized)Iron
This specification shall govern the materials, orSteelArticles
application,inspection,repairs,handlingandother
requirementsforexternalconcreteweightcoating ASTMA185 Specification for Steel Welded
of pipe. The work includes the furnishing of all Wire, Fabric, Plain, for Concrete
labor, materials, tools and equipment and the Reinforcement
performance of all operations and incidentals
necessary for the coating, handling, storing and ASTMA641 Specification for ZincCoated
shippingofcoatedpipe. (Galvanized)CarbonSteelWire

Forthepurposesofthisspecification,thefollowing ASTMC31 Standard Method of Making and
definitionsapply: CuringConcreteTestSpecimensin
theField
COMPANY:
CONTRACTOR: Thefirmresponsiblebycontract ASTMC33 Standard Specification for
for the application of the ConcreteAggregates
concrete weight coating to the
pipe. ASTMC39 Standard Test Method for
CONTRACT: Signed work agreement Compressive Strength of
between COMPANY and CylindricalConcreteSpecimens
CONTRACTOR.
ASTMC150 Standard Specification for
CONTRACTOR shall obtain COMPANY's written PortlandCement
approvalforanydeviationsfromtherequirements
ofthisspecificationorspecifications,standardsand ASTMC309 SpecificationforLiquidMembrane
drawings referenced herein or elsewhere in the Forming Compounds for Curing
CONTRACT. In case of conflict between Concrete
documents, the order of precedence given in the
CONTRACTshallgovern. ASTMC642 Test Method for Specific Gravity,
Absorption, and Voids in
This document is not intended to be all inclusive, HardenedConcrete
andtheuseoftherequirementssetforthdoesnot
relieve the CONTRACTOR of his responsibility to AmericanPetroleumInstitute
supply a product capable of performing its
intendedservice. APISPEC5L SpecificationforLinePipe

2.0 REFERENCEDOCUMENTS 2.1 COMPANYSpecifications

Thecoatingshallbeappliedinaccordancewiththe 2136600SP016 SacrificialAnodesInstallation
latesteditionsandaddendaofthefollowingcodes toPipe
andstandards. 2136600SP017 PipeHandlingandStorage
2136600SP018 CorrosionPreventionCoating
AmericanSocietyforTestingandMaterials CoalTarEnamel

ASTMA82 SpecificationforSteelWire,Plain, 3.0 MATERIALS
forConcreteReinforcement
Allconcretecoatingmaterialsshallbefurnishedby
the CONTRACTOR and shall consist of Portland
SpecificationforConcreteWeightCoating 3of10
cement, aggregate, reinforcing steel and water.
These materials shall conform to the following
specifications.
3.1 Cement
Cement shall conform to ASTM C150, Type II, or
approved equal and shall be stored in a manner
thatwillsatisfactorilyprotectitfromtheelements.
Cement that has hardened, partially hardened, or
becomelumpyshallnotbeused.Testcertificates
fromthecementmanufacturershallbepresented
totheCOMPANYforallcement.
3.2 Water
Water shall be clean and free from injurious
amountsofoil,acid,alkali,salt,organicmaterialor
other deleterious substances. Seawater or water
fromstagnantswampsorexcavationsshallnotbe
used.TheCOMPANYreservestherighttorequire
the CONTRACTOR to test the water and have the
resultsapprovedbytheCOMPANYpriortoitsuse
intheconcretemixture.
3.3 Sand(SilicaType)
Sand used shall be round grained and shall be
obtained by sieving. It shall be free of injurious
amounts of salt, alkali, deleterious substances or
organic impurities. Suitability of the natural sand
for making concrete shall be determined in
accordance with the requirements of ASTM C33.
Thesandshallbewellgradedtothefollowingsieve
sizes:
U.S.Standard %
SieveSize Passive
4 100
8 80100
16 5080
30 2555
50 530
100 010
3.4 Aggregate
SpecificationforConcreteWeightCoating
The aggregate shall be of a type approved by the
COMPANY.
Well graded iron or barium ore shall be added to
the aggregates to achieve the required
density.
Concreteaggregatesshallbeclean,soundandfree
from injurious amounts of salt, alkali, organic
impuritiesorotherdeleteriousmatter.Aggregates
shall meet the requirements of ASTM C33. The
aggregates shall be well graded to the following
sievesizes:
U.S.Standard %
SieveSize Passive
3/8in. 100
No.4 8090
No.16 4070
No.50 1030
No.100 010
Theaggregatesshallbestoredinasuitablygraded
area to ensure satisfactory draining of the
stockpipe.
3.5 ReinforcingSteel
The reinforcement shall consist of a woven or
welded wire mesh. Woven wire mesh shall be of
the hexagonal type with extra longitudinal wires.
Sizeofhexagonalmeshopeningsshallbe1.5inches
across the minimum dimensions. Welded wire
meshshallhaveopeningsof1inchby2inch.
The wire mesh shall be galvanized and the
materials shall conform to ASTM A82, A90, A185
andA641asapplicable.
Theminimumwirediametershallbe14gage.
4.0 EQUIPMENTANDLABOR
The CONTRACTOR shall provide equipment and
personnel capable of applying concrete coating to
the specified degree of uniformity with respect to
unit weight and strength. The CONTRACTOR's
equipmentshallprovideforeitherthebatchingof
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materialbyweightorcontinuousmixing,whereall
feedsareaccuratelycontrolledandpercentagesof
mixarecalibratedbyweight.Batchingscalesshall
be maintained in good condition. Any equipment
thattendstoseparatetheingredientsshallnotbe
used.
5.0 CONCRETECOATINGMIX
5.1 MixDesign
TheCONTRACTORshalldesignthemixesusingthe
approved aggregates and shall determine the
proportions which will give the required concrete
density and strength. All mix designs shall be
agreedwiththeCOMPANYbeforecommencement
ofcoating.Allconcretemixesshallbedesignedto
minimizedryingshrinkage.
FulldetailsshallbeprovidedbytheCONTRACTOR
withregardto:
a. The proportions and weights of the
respectivematerialsusedinthemix.
b. Thewater/cementratio.
c. Thegradingsofthevariousaggregateswith
combinedcurvesasnecessary.
d. Laboratory test results for compressive
strengthandunitweightofconcrete.
5.2 CompressiveStrengthRequirements
Theminimumcompressivestrengthasdetermined
fromtestsoutlinedinSection7.3.1shallnotbeless
than 3,500 psi after 7 days and 4,650 psi after 28
days.
5.3 WeightRequirements
The nominal weightperfoot of coated pipe shall
beasspecifiedintheCONTRACT.Theweightper
foot of a coated pipe joint shall not deviate in
excess of plus 7 percent or minus 5 percent from
the specified weightperfoot in air. Compliance
shall be checked by the tests outlined in Section
7.3.4.
Inaddition,theaverageweightperfootinairof5
successively coated joints shall be greater than or
equaltotherequiredweightperfootinair.
SpecificationforConcreteWeightCoating
5.4 WaterAbsorption
The water absorption after 48 hours, as
determined from tests outlined in Section 7.3.2 is
not to exceed four percent of the dry concrete
weightinair.
5.5 Density
The density of the concrete shall have a nominal
valueof190pcf.Thetoleranceofthedensityshall
beplusorminus5percentasdeterminedfromthe
testsoutlinedinSection7.3.2.
5.6 Thickness
Theconcretecoatingshallbeofuniformthickness
aroundthecircumferenceandalongthelengthof
thepipe.Aroundthecircumference,thethickness
shall not vary more than inch between the
highest and lowest points at any given cross
section. Along the length, the thickness shall not
varymorethaninchbetweensuccessivehighand
lowpoints.
The overall average thickness (as determined by
averaginggirthmeasurementsat5equallyspaced
locationsalongthelength)shallnotvarymorethan
+inchfromthenominalspecifiedthickness.
5.7 ConcreteCutbackEndTaper
The concrete coating shall be cutback from the
ends of the pipe joints and no concrete shall be
appliedforadistanceof12inchesfromtheends.
Attheends,theconcretecoatingshallbetapered
ata60slopewithrespecttothelongitudinalaxis
ofthepipe.Thebaseofthetapershallbenocloser
than12inchesandnofurtherthan14inchesfrom
therootfaceofthebeveledends.
6.0 CONCRETECOATINGPROCEDURES
6.1 ConcreteApplication
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The concrete weight coating shall be applied by
either the high impact velocity method or by the
compression method. The concrete shall be
appliedonjointsofpipethathavebeenpreviously
coated with coaltar enamel as per COMPANY
Specification2136600SP018.
Noconcreteshallbeappliedwhenthesurrounding
temperature at the curing station is 40F. At any
phase of the coating, if the temperature can go
below 40F the CONTRACTOR shall submit his
procedureforweightcoatingbelow40F.Ifduring
the coating period the temperature goes below
40F, the coating shall be protected according to
theapprovedprocedure.
All mixed concrete which is not placed within 45
minutesaftertheinitialintroductionofwaterinto
themixtureshallberejectedandshallnotbeused
tocoatthepipe.
Each joint of pipe shall be coated in a continuous
operation. Where practical, the total thickness of
coatingshallbeappliedinasinglepass.Nomore
than 30 minutes shall be allowed between passes
inanycase.
The uncoated portion of the pipe ends and the
bevels shall be kept clean and free from concrete
spatter,oil,grease,etc.
If kraft paper has been placed on the joint to
protect the corrosion coating, the paper shall be
completely removed before the joint is concrete
coated.
6.2 ReinforcingandForming
The reinforcing steel shall be applied in such a
mannerastoprovidecontinuityofreinforcement.
All circumferential and longitudinal reinforcing
splicesshalloverlapnolessthan6inches.
For concrete thicknesses less than or equal to 2
inches,onelayerofreinforcementshallbeplaced
midway between the outer and inner surfaces of
theconcrete.Aminimuminchofcovershallbe
maintained between the reinforcement and the
outsideoftheconcrete.
SpecificationforConcreteWeightCoating
For concrete thicknesses greater than 2 inches,
two layers of reinforcement shall be used.
Reinforcement layers shall be placed equidistant
from the pipe, the outer surface of the concrete
andeachother.Aminimum3/4inchofcovershall
be maintained between the outer layer of the
reinforcementandtheoutsideoftheconcrete.
The reinforcing steel shall not be in electrical
contactwiththepipe.Atthebeginningofcoating
for each pipe diameter/concrete thickness
combination, a joint randomly selected by the
COMPANY shall be checked with electric power
sourceandmeter.Thischeckshallberepeatedat
random approximately every 100 joints. Any
concrete removed to make the test shall be
repaired.
Reinforcingwireshallnotbeexposedattheendsof
theconcretecoating.
6.3 AnodeJoints
Anodesshallbeinstalledonthepipeinaccordance
withCOMPANYSpecification2136600SP016.For
anode joints, care shall be taken to ensure that
there is no contact between the anode and the
reinforcing wire. A minimum 2inch separation
shall be maintained between the anode and
reinforcingwire.Concreteweightcoatingshallbe
applieduptoeachsideoftheanodeandtapered
to the outer diameter of the anode. Following
installationoftheweightcoating,theoutersurface
of the anode shall be brushed cleaned for any
concrete or other materials, and the
anode/reinforcing wire shall be meter tested to
assureisolationoftheanode.Anodejointsshallbe
cured and stored separately from other weight
coatedjoints.
6.4 Curing
Followingconcretecoatingapplication,thecoated
pipe shall be carefully handled and moved to a
curing area. In the curing area, the pipe shall be
placedinasinglelayerandsupportedinamanner
that does not damage the concrete or allow the
concretetocurewiththepipeinadeflectedshape.
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Thecoatedjointsshallnotbetransportedfromthe Pipecoatingnotmeetingtherequirementsofthis
curing area to storage until they have cured specificationshallberejectedandrecoatedbythe
satisfactorily for 4 days. No coated pipe shall be CONTRACTOR without expense to the COMPANY.
shippedfromthecoatingyarduntilithascuredfor Coatingshallberejectedforthereasonsasfollows:
atleast10days.
a. Mechanical/Strength
Eitherwaterormembranecuringmaybeused,but
whichever is used, the concrete shall not be i. Improper placement of reinforcing
allowedtodehydrate. steel or reinforcement which is in
electricalcontactwiththelinepipe
6.4.1 WaterCuring oranodes.
ii. Concrete compressive strengths
Water curing shall come later than 2 hours after belowthespecifiedvalues.
coating.Theconcreteweightcoatingshallbekept iii. Damage to handling or storing
continuously moist by means of intermittent considered by the COMPANY to be
wateringforaperiodnotlessthan4days,andkept excessiveandbeyondrepair.
surfacewet during daylight hours for seven days. iv. Impropercuringprocedures.
Either manual or mechanical watering may be
used. b. Weight/Dimensional

6.4.2 MembraneCuring i. Weight in air outside the specified
tolerances.
Membranecuringcompoundshallbeofthewhite ii. Coating thickness outside the
pigmentedtypeconformingtoASTMC309.Itshall specifiedrange.
beappliedbymechanicalapparatustothecoated iii. Concrete density outside the
surface in sufficient quantity to provide complete specifiedrange.
coverage in accordance with manufacturer's iv. Coating which has abrupt
recommendations. The application of this curing irregularities and variations in
companyshalltakeplaceimmediatelyaftercoating thicknessaroundthecircumference
is completed and preferably before the pipe is and along the length outside the
removedfromtheconcretecoatingapparatus. specifiedrange.
v. Water absorption greater than
Thesurfaceoftheconcreteshallbelightlysprayed specifiedvalue.
with water before applying the curing compound. vi. Coating cutback outside the
The membrane shall be continuous over the specified range or which is not
concrete and shall remain so for a minimum of 7 properlytapered.
days.
7.3 TestingMethods
7.0 INSPECTIONANDTESTING
Daily samples of the concrete mix, as applied
7.1 General during the coating operation, shall be taken to
determine the compressive strength and unit
TheCOMPANYshallhavefullandfreeaccesstothe weight of the concrete coating. In addition, each
office,plant,everypartofthecoatingyard,andthe joint of pipe shall be weighed and the coating
on/off loading facilities of the CONTRACTOR. thicknessmeasured.
CONTRACTOR shall assist the COMPANY or his
representativeateverystage. All testing shall be at the CONTRACTOR's expense
and as directed by the COMPANY or his
7.2 CausesforRejection representative.Thetestingmethodstobeusedare
outlinedbelow.
SpecificationforConcreteWeightCoating 7of10

7.3.1 CompressiveStrengthTest
Compressive strength of the mix shall be
determinedfromsamplespreparedatthejobsite.
TestsshallbecarriedoutinaccordancewithASTM
C39.Aminimumoftwotestcylinders(preparedin
accordance with ASTM C31) shall be taken in the
morning,andtwointheafternoonforeachdayof
production. These cylinders shall be tested to
determine the 7 day and 28 day compressive
strengthoftheconcrete.
7.3.2 Concrete Unit Weight and Water
AbsorptionTests
The density of the concrete shall be determined
fromhardenedandcuredconcretethatisnotless
than the 4 days of age, and is taken from the
coating mix as applied in normal coating
operations.Onecylindertypemodelshallbetaken
for each morning and one for each afternoon of
production to be used for these tests. Water
absorption tests for the concrete shall be carried
outinaccordancewiththefollowingrequirements
andASTMC642.
Asampleshallbeovendriedat210Ftoconstant
weight. When constant weight is attained, a
sample shall be allowed to cool to room
temperatureandbeweighedtothenearestgram.
The sample shall be submerged in seawater at
room temperature for not less than 48 hours.
While submerged in seawater, itshallbeweighed
to the nearest gram. It shall then be withdrawn
from the water, the excess of surface moisture
removed, and the sample weighed again to the
nearest gram. The weight per cu. ft. and water
absorptionshallbecalculatedasfollows:
Thecoatingthicknessshallbecheckedattheends
of the coating to determine if the line pipe is
concentrically placed inside the weight coating
jacket. The variation in coating thickness around
the circumference shall not exceed the limits
definedinSection5.6ofthisspecification.
Thediameter(andaveragecoatingthickness)shall
bedeterminedatfivelocationsalongthelengthof
eachpipejointbytakinggirthmeasurements.The
locations for the girth measurements shall be
equallyspacedandshallincludeatlest80%ofthe
coated length. The variation in average coating
thickness shall not exceed the limits defined in
Section5.6ofthisspecification.
In addition, the surface of the concrete coating
shall be spot checked to determine that surface
irregularities do not exceed the limits defined in
Section5.6.
7.3.4 CoatedPipeWeightTests
The coated pipe weightperfoot in air shall be
computedusingthefollowingformula:
w =[W W
air m steel(LpLc)]/Lc
where
wair = calculated weightper
footinair(lb./ft.)
Wm = the measured
weightinair of the
fully cured weight
coated joint of pipe,
(lb.)
Wsteel = the weightinair per

Weightpercu.ft.=OvenDryWt.x64 unit length of

Saturated Wt. Suspended uncoated steel pipe.
ImmersionWt. API5L nominal
weight per unit
% Water Absorption = Saturated Wt. Oven Dry length is acceptable,
Wt.100 (lb.ft.)
OvenDryWeight Lp = the measured length
(bevel to bevel) of
7.3.3 CoatingThicknessandCoatedDiameter thepipejoint,(ft.)

SpecificationforConcreteWeightCoating 8of10
 Lc = the measured length
(centerof taper to
centeroftaper) of
theconcretecoating,
(ft.)
8.0 REPAIRSANDACCEPTANCE
8.1 RepairofPipe
CONTRACTOR shall inspect any pipe furnished by
others upon receipt. All flaws discovered in pipe
notfurnishedbytheCONTRACTORandnotcaused
bytheCONTRACTORwillberepairedasapproved
bytheCOMPANY.AtCOMPANY'sdiscretion,these
joints shall be set aside, with no cost to the
CONTRACTOR. The CONTRACTOR shall provide
storagespaceforandshallhandleallpiperepairs.
All damage to the pipe bevels or facing, which
exceeds API5L allowances for bevel or face
damage,suchasdents,gougesandflattening,shall
becutoutandthepiperebevelledandrefacedor,
attheCOMPANY'sdiscretion,shallbesetaside.
8.2 CoatingRepairs
After concrete coatings have hardened, damage
during handling and storage shall be repaired as
describedbelow.
8.2.1 Spalling
Spallingcausedbyimpactwithotherobjects,shall
berepairedasfollows:
i. Damagedareaoflessthan1sq.ft.,where
depthofdamageddoesnotexposethereinforcing
wire,andwherethesurroundingconcreteissound,
shallbeacceptablewithoutrepairs.
ii. Damagedareaexceedinganyofthecriteria
ofi.,uptoatotaldamagedareaof3sq.ft.,shallbe
undercuttoprovideakeylockforrepairs.
iii. Damagedareaexceeding3sq.ft.shallhave
the concrete coating removed around the entire
pipe circumference and for a sufficient length to
includetheentiredamagedportion.
SpecificationforConcreteWeightCoating
Repairsshallbemadebysatisfactorilyrestoringthe
reinforcement (if necessary); removing all cracked
orbrokenconcreteatthepointofcoatingdamage;
wetting the fresh surface of the broken coating;
andtrowelingastiffmixtureofcementwaterand
aggregate (of the same materials and proportions
asthecoating)intoandthroughthereinforcement.
This mixture shall be built up until the surface is
levelwiththecoatingaroundtherepair.Thepipe
shall then be carefully laid in a position where it
shallbeallowedtomoistcureforaminimumof7
days.
Nopipesshallbeacceptedifspallingextendstothe
enamellayer.
8.2.2 CrackingDuetoPipeDeflection
Cracksthatareinexcessof1/16inchinwidthand
extend over 180 circumferentially around the
pipe, or longitudinal cracks over 12inch in length
(irrespective of width), shall be repaired. Repair
shallbemadebychiselingthecrackouttoawidth
ofnotlessthan1inchthroughoutthelengthofthe
crack. The crack shall be repaired with materials
similartothatformwhichthecoatingismade.The
repairs shall be kept moist and be allowed to
remain undisturbed for a period of not less 48
hours.
9.0 IDENTIFICATIONANDMARKING
9.1 PaintStenciling
The CONTRACTOR shall paint stencil the inside of
eachjointofpipewiththeinformationasfollows:
a. Concretecoatingthicknessanddensity
b. Measuredweightinair(emptypipe)
9.2 ColorCoding
Foragivenpipediameter,theCONTRACTORshall
propose a color coding system which uniquely
identifiedeachconcretethickness.
Eachjointofcoatedpipeshallthenbecolorcoded
accordingly with a 3inch wide band painted
aroundthecircumferenceateachendofthejoint.
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In addition, a second band shall be painted to 11.0 PERFORMANCEOFWORK
identifyanodejoints.
CONTRACTORshallguaranteethatworkperformed
9.3 Records on external coating of pipe shall be inaccordance
with this specification and that the application of
In addition to the above, the CONTRACTOR shall thecoatingsystemshallbeinaccordancewiththe
maintain daily logs and promptly provide specificationsofthecoatingmaterialmanufacturer.
COMPANY with a permanent certified record for The COMPANY's representative shall have proper
eachjointofpipewhichshowstheinformationas accessrightstoCONTRACTOR'splantandproperty
follows: to assure the COMPANY that the foregoing
specificationsarebeingfollowed.
a. Serialnumber
b. Pipemillandmillnumber
c. Pipediameter,wallthicknessandgrade
d. Measured pipe joint weight prior to and
afterconcreteapplication
e. Measuredpipejointweightaftercuring
f. Measured average diameter of concrete
coating
g. Dateofcoating

10.0 STORAGE,HANDLINGANDSHIPPING

Pipeshallbehandledandstoredinamannerto
preventdamagetopipewalls,beveledends,and
coating. Pipe shall be handled, transported and
stored in accordance with COMPANY
Specification No. 2136600SP017. All pipe
handling shall be with equipment approved by
the COMPANY's representative. Pipe or coating
damaged by the CONTRACTOR in handling or
otheroperationsshallbesatisfactorilyrepairedat
noexpensetotheCOMPANY.

The coated pipe shall be stacked in such a

manner that the exterior coating does not
contact a hard surface which will cause coating
damage. Stacking height shall be reduced at
COMPANYrepresentative'srequestifheobserves
detrimentaleffectstothepipeorcoatingdueto
stacking.

Pipewillbetransportedfromthecoatingyardto
thejobsitebytruck,railorbarge,asspecifiedin
the CONTRACT. Pipe shall be shipped in such a
mannerastoadequatelyprotectthepipeandits
coating. Pipe shall be loaded for shipping in
compliance with existing shipping standards and
regulations.

SpecificationforConcreteWeightCoating 10of10