Dokumen - Tips - Pipeline Coating Process

8/13/2019 Pipeline Coating Process
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may not be achievable: in such case a technical query should be raised and agreed to.
Reinforcement
All reinforcement shall meet the minimum specified % cross sectional area (CSA)
requirements .
There are commonly two methods of reinforcement; rigid preformed cages
(usually manufactured on site using Zublin machines) and wire mesh fabric.
On occasions both methods are used simultaneously. (This usually occurs
where high thickness concrete coatings are required).
Zublin Machine
Typical Zublin made Cage
Where rigid
the pipe preformed
prior to the cage reinforcement
concrete is used,
application the cages
process. are fitted
Wire mesh to
fabric
however, is wound into the concrete during the concrete application
process. .
Cage reinforcement shall normally be required to meet the requirements of

BS 4482, BS4449 or ASTM A615/A615M using wire with typically
diameters of 5 mm for longitudinal and 7-8 mm for circumferential.
Welded wire fabric reinforcement shall normally be required to meet the

requirements of ASTM A82 for zinc coated drawn wires, Typically one layer
of wire is required for concrete thicknesses up to 55 mm above 55 mm

concrete thickness two layers minimum are required.
Potable water
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Responsibilities:
The Incoming Supervisor shall ensure that the incoming holiday detection, reinforcement
installation, fitting of end rings and end plugs are performed correctly. He shall quarantine
pipes that are in need of repair and supervise the repair operation. He is also responsible for
ensuring that all tasks are conducted in the safest possible manner.
The QC inspector/Auditor shall be responsible for the release or quarantining of the incoming
pipe. He shall maintain checks in accordance with function described in an agreed inspection
Test Plan (ITP)
The tally man shall be responsible for maintain pipe traceability and recording the disposition
of rejected and repair pipes.
3.0 Mixing of Concrete
Prior to concrete coating, the batch plant, cement hopper and water feed systems are
calibrated to allow accurate percentages of c onstituent materials to be delivered to the mixer.
Typical constituents of the concrete mix are cement, high-density iron ore, sand and water.
The concrete mix design is dependent on the Specific Gravity of materials being used and is
proportioned accordingly.
Typical Batch Plant Calibration Tolerances
Cement ± 2%
Aggregates ±3%
Water ± 2%
Whole ±3%
Sand/aggregates are typically transported from their respective stockpiles to the Mixing Plant
hoppers using rubber tired front end loaders. From the feed hoppers the sand and aggregate
are metered into the mixer at the mix design quantities. Cement is typically auger fed from
the cement silo into a weigh hopper which weighs off the required amount to meet the mix
design requirement.
Note: where aggregates are stored in outside open areas the working face of the stockpiles
should be regularly turned over to maintain even moisture mix in the material. It is
inadvisable to take the material from the very bottom of stockpiles where moisture is likely to
be exceptionally high,
Typical Batch Plant feed System
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After weighing, the cement is added to the aggregate in the mixer. After a period of dry
mixing, water is metered by volume into the mixer and the batch mixed for the prescribed
mixing time. On completion of the mixing the concrete is conveyed to the short feed hopper.
From the hopper the fresh mix is gravity fed onto a short belt which in turn progresses the
mix to the concrete application head.
Note: Regular samples of the fresh concrete mix shall be taken from the feed belt to enable
moisture content and fresh analyses to be carried out. Also for mix control purposes fresh
mix test cube specimens are prepared.
Cube Making
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Cube Samples
Responsibilities:
The Batch Plant Supervisor shall be responsible for batch p lant calibration and operation. He
is to ensure that the parameters set through batch plant calibration are maintained
throughout production. conveying aggregates to and from the correct holding hoppers
ensuring that the correct amount of water is added to the concrete mix to provide consistent
moisture content of the mix. He shall also be responsible in ensuring that the task is
conducted in the safest possible manner.
The QC laboratory Technician shall be responsible for ensuring concrete mix calibrations are
carried out correctly, taking samples of the concrete mix for analyzing and preparing samples
for testing. He shall also be responsible for consistently reporting test results to the Batch
Plant Supervisor, and for logging all test results.
4.0 COATING PROCESS:
From the impingement incoming rack or indexer, pipes are placed on the concrete coating
line rotation buggy s using an overhead crane using a spreader bar and suitably protected
hooks. On the rotating buggy s the pipes are transported past the impingement coating head
where premixed concrete is applied at high velocity to the pipe using impingement rollers.
The concrete plant operator selects the pipe rotation and forward travel speeds at a setting
that allows for the c oncrete to be applied to the correct concrete coating thickness.
Pipes with anodes fitted are coated as per a plain pipe with the exception that a shadow plate
and plastic wrap covering the anode is utilized to prevent excessive concrete covering the
anode. After processing the plastic wrap shall be removed and the outer surfaces of the
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Anodes shall be cleaned and be free of concrete coating materials.
Diameter or thickness of the concrete coating is controlled by measurement using a girth or
tree tape and is performed at the coating head and again verified at the weigh station.
Note Where wire mesh fabric reinforcement is used, the wire fabric is fed from a spool
tensioning arrangement then travels though guides and onto the rotating pipe as the pipe is
being impinged.
Welded Wire Fabric Feed
5.0 CLEANING AND WEIGHING STATION
Upon completion of the concrete coating, the pipe cutback areas are cleaned, the end plugs
are removed and any debris in the pipe interior is also removed. The OD of the concrete is
again measured: taking six equidistant measurements along the pipe.
Taking Girth Measurements
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Note: The concrete ends shall be finished square to the pipe axis and the crown of the
concrete shall be slightly rounded.
When all redundant material has been removed from the coated pipe, the pipe is weighed
using a calibrated weigh scale or load cell.
Pipes that are out tolerances for thickness and or weight may be flash coated or scraped to
enable correct tolerances to be achieved. This rectification process shall be carried out whilst
the concrete is in a green state and only if agreed to by the client.
At the cleaning station continuity (anode to pipe) and isolation (rebar to anode & pipe) and
reinforcement position checks shall be performed on pipes in accordance with the agreed
inspection frequency included in the Project inspection Test Plan (ITP)
Reinforcement placement check
Note : In the case where welded wire is used for reinforcement, the excess wire on t he finish
end of the pipe is trimmed back to just below the concrete surface to ensure no protruding
wire is on the concrete surface.
Excess Wire Fabric
When accepted the details of the pipe weight and girth measurements are entered into a pre
programmed computer that determines the negative buoyancy (NB) of the pipe.
A typical formula for NB calculation
Weighing devices used to determine the weight of the concrete-coated joints shall be
certified in writing to accuracy of 0.5%. The calibration of weighing equipment shall be
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checked by test weighing method previously approved by contractor unless other procedures
have been agreed and confirmed in writing. Calibration of the weighing equipment shall be
checked daily.
The unsaturated (as applied) submerged weight per metre (N/m) for each pipe shall be
calculated from the pipe weight in air immediately after coating.
The submerged weight, WSubmerged (N/linear metre), shall be calculated using the
following formula:
where:
Mc = Mass of fresh concrete coated pipe including reinforcement kg

Dc = Outer diameter concrete coated pipe m. Average of 6 girth measurements
Ds = Outer diameter of steel pipe plus twice the anti-corrosion coating thickness, m
P1 = Density of field joint filing materials (assume 1025 )
I = Cutback of concrete coating from bevelled end, m
L = Mill length of steel pipe, m
Pw = Density of seawater (assume 1025 )
SW = Submerged weight
For anode and crack/buckle arrestor pipes, the specified maximum submerged weight may
be exceeded. Variations in buoyancy shall be ignored and the submerged weight value shall
be adjusted by using an increased weight in air. The Principal shall specify the allowable
weight variations in the Scope of Work.
The results shall be recorded and tabulated against pipe number and presented to the
Principal at the completion of each day s production. The submerged weight of each coated
pipe shall be within the acceptance tolerances stated by the Client in the Scope of Work.
Responsibilities:
The concrete plant supervisor is responsible for ensuring that all equipment and personnel
are adequately organized to carry out concrete batching, placement of reinforcement,
coating, repairing and checking all coating parameters. He is also responsible in ensuring
that the task is conducted in the safest possible manner.
The concrete plant operator is responsible for maintaining the correct mix design, travel and
rotation speeds, placement of reinforcement, end rings and anode protection.
The coating Tally man is responsible for recording the traceability of the coated pipes, the
correct recording of pipe weights, pipe lengths, coating diameter, cutback lengths and
submerged weight (NB) calculation. He will also keep an ongoing log of running (NB)
averages.
The QA inspector/Auditor is responsible for the correct calibration of the weigh scales (NB
station), periodic checking of any repairs to anti corrosion coating, the concrete coating
parameters, including wash out checks of the reinforcement, overlaps for reinforcement and
periodic isolation/continuity checks.
6.0 CONCRETE CURING
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From the cleaning area acceptable coated pipes are lifted by overhead crane onto trucks
having suitable cushioning and supports that protect the green concrete. The pipes are
transported to the curing area where the freshly concrete coated pipes shall be laid out in
single layers approximately 250 mm apart on suitable sand berms using either an overhead
gantry or mobile crane.
Pipes that are to be cured using the Fog Cure method shall be covered as soon as practical
with a tarpaulin and fog water spray shall be introduced via water pipes fitted with fine
misting nozzles under the covers to maintain a high humidity beneath the covers.
The pipes shall remain in the cure bay until the concrete has achieved a minimum stacking
strength of 14 Mpa (as determined by concrete cube strength testing). On completion of the
curing process and prior to stacking the cutback end rings shall be removed and any
concrete contamination shall be re moved from the coating steel cutback and internal bore.
Pipes selected for concrete coupon testing shall be clearly marked and placed on hold in an
area suitable for coupon extraction work to be performed. Coupon holes shall be repaired in
accordance with the approved Concrete Repair Procedure.
Note: Test cube specimens taken from the fresh mix at the batch plant shall be placed in the
curing bay and cured in a manner identical to the pipe.
7.0 REPAIRS

Repairs to the coatings shall be carried out in accordance with an approved Repair
Procedure. Coated pipes that cannot be repaired shall be rejected, stripped and re coated.
Unacceptable pipe shall be marked up with Red/White hazard tape and recorded on the NCR
system.
After the completion of acceptable repairs the pipe will then be placed in its allocated storage
area. The stacking height for concrete coated pipes shall be in accordance with the approved
handling procedure.
Repairs on freshly applied concrete shall be carried out at the coating plant whenever
appropriate or at the curing bay.
Typical repair procedure
Upon visual examination, concrete coatings that are damaged, are defective or do not meet
with requirements shall be repaired. The circumstances of the damage or defects will dictate
the appropriate method of repair.
Repairs Criteria
If the area is less than 0.8m² in any 3 m length of pipe may be repaired by hand patching
providing that such repairs are carried out within 4 hours of concrete application.
If the area is more than 0.8m² but less than 25% of total coating repairs shall be made using
gunite. The concrete remaining shall be undercut to provide a key lock.
Cracks caused by excessive deflection in handling or s torage, with the following criteria shall
be repaired by chiseling the crack not less than 25mm and repair shall be made using the
same basic material as the coating:-
Cracks in excess of 5mm width and extend over 180° circumferential around the coated pipe.
Cracks which are between 250mm 1000mm in length longitudinally along the coated with
the addition that the ends of each crack shall be drilled with a hole of 10mm nominal
diameter to prevent crack propagation. The bottom of these holes shall be 7 -10mm f rom the
anti-corrosion coating.
Cracks extending halfway through the concrete or penetrated to the cage
Longitudinal surface cracks of any width and less than 250mm in length shall not be
considered a defect but holes of 10mm nominal diameter shall be drilled at the crack tips to
prevent crack propagation. The bottom of these holes shall be 7 -10mm from the
anti-corrosion coating.
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Surface damage shall not be considered a defect if :-
The total surface area of damage per pipe is less than 0.1 m², and
Max depth does not exceed 20% of coating thicknesses, and
The remaining concrete is sound.
Damage at the ends of the concrete coating need not be repaired provided that the damaged
area is less than one third of the circumference for a length less than 200 mm.
Hand Repairs
Damaged areas may be repaired by hand patching in its green concrete state. Patching
shall be carried out by removing the defective area down to underneath the reinforcement
and undercutting the sides to form a key. The cavity formed shall be filled with a mix similar
to that used in the coating process with the addition of just sufficient water to allow hand
application. Polythene wrap shall be used to seal the repair before curing. Maximum
allowable time between concrete coating and repair of green pipe will be 4 hours.
Core Holes
Prior to filling cores holes, each site will be inspected for damage to the anti-corrosion
coating. Damage to this coating will be brought to the attention of QC personnel and the
Customer. Core holes shall be repaired using concrete with the same proportion of
constituents as the original coating.
Core holes may also be repaired using concrete repair material Mapegrout Fast-Set
(manufactured by Mapei) or Certite or similar product. A slight increase in water content
may be considered acceptable to aid cure for some of the materials. The material shall be
trowelled in such that the surface level is continuous with the level of the existing coating
around the repair.
Gunite Repair Criteria
Repair on cured concrete coating and large repair areas shall be rectified using the gunite
method of repair. The size of the gunite repairs shall be demonstrated and witnessed for
suitability as an addendum to the Pre qualification trials for concrete coating. The concrete
mix design used for gunite repairs will be of the same constituent make up as that of the
parent mix material apart from the use of extra water to assist with the application. Curing of
the repairs will be carried out by wrap sealing of polyethylene membrane.
Gunite Repairs
GREEN CONCRETE
Damaged or defective areas shall be prepared by undercutting and exposing the

reinforcement throughout the damaged area a nd removing any loose concrete material. The
area shall then be filled by Gunite application until the entire repair area is reinstated to the
level of the parent material. The completed repair shall be dressed in a manner that allows a
smooth transition to the parent material. Within 30 minutes of the repair completion the green
concrete coated pipe shall be placed in the fog cure.
CURED CONCRETE
Shall be performed as that for green repairs with the addition of a water wetting application to
the cured concrete coating interfaces prior to Guniting. The repair area shall have a curing
membrane tightly affixed and shall stay in place for a minimum of 48 hours to allow sufficient
cure.
Testing
Repair materials used for concrete repairs shall be tested for compressive strength as
determined by 28 day cube strength results. The minimum strength to be achieved shall be
that of the strength specified for the parent coating. The frequency of testing shall be at
start-up, middle and end of project.
Responsibility
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The repair foreman shall be responsible for coating repairs and shall ensure the correct
equipment and repair method is used for coating repair. He shall also be responsible in
ensuring that the task is conducted in the safest possible manner.
QC, Inspector/auditor shall be responsible for checking the preparation and the completed
repair.
All repairs are to be recorded and inspected for compliance to the repair method statements.
8.0 PIPE MARKING AND IDENTIFICATION
The identity of each pipe shall be established and entered into the pipe tracking system such
that traceability is maintained. Accepted pipes will be released for transportation to the
stockpiles or other processes.
Typical Marking Requirements
Pipe no
Length
WT
Heat no.
Date of coating

Responsibilities
Load out Tally man, shall ensure that the correct pipe markings are applied in accordance
with the agreed marking system. He shall also be responsible in ensuring that the task is
conducted in the safest possible manner.
QC, Inspector/Auditor shall be responsible for inspecting that the correct colour banding and
markings are applied.
9.0 SACRIFICIAL ANODE INSTALLATION
Anode are typically fitted to the corrosion coated pipe prior to caging and concrete coating,
however in some circumstances anodes can be retro fitted i.e. after concrete coating.
Process Description
The Coated line pipe shall be positioned on the support racks, over the
anode lifting saddle. The pipe will be positioned until the longitudinal seam
weld (if any) is located around either the 12 or 6 o'clock position or
approximately 150mm of the weld seam. Once positioned the lifting saddle
will raise the lower half shell of anode to the stationary pipe and hold it in
position. The second half shell of anode shall be offered to the pipe and
positioned over the first half shell, by means of crane jib. The two halves
shall be carefully aligned and drawn tightly together using webbing
tensioners, chain come-along or similar.
The centering of the anode along the pipe shall be in a manner that allows
for casing segments to be fed onto the pipes.
Fit Up
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Fillet Welding
Welding will be by metal arc process
Fillet welding shall be carried out continuously around three edges of the
overlapping straps of the anode halves. An insulating material shall be
placed under the weld area to guard against heat damage to the anti
corrosion coating.
Thermit Weld
Fillet Weld
Electrode Handling
Welding consumables will be SMAW electrodes for carbon steel.
o o
Electrodes shall be baked for 2 hours at 325 C and held at 150 C in a
suitable holding oven prior to use. Alternatively, follow manufactures
instructions. The Welder shall keep electrodes in an approved quiver during
use and return unused electrodes to the holding oven when not working.
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Pipe Preparation:
Areas of anti corrosion (TLPE) coating are be removed within each gap
between half shells, each area of removal shall be as small as practical to
accommodate the Thermit Graphite Mould
The removal of coating shall be achieved by using a heated knife and / or a

bolster type chisel cutting around the heated area that is to be stripped,
following the removal of the coating the steel substrate shall be power
ground to achieve a bright, clean roughened surface or St 3.
Connecting of Bonding Leads (Electrical Connection):
Each anode is normally manufactured complete with bonding leads; the

bonding leads may be cut to size using a cable cutter or hacksaw to
remove. The cable should be looped (pig tailed) so as not to be taut after
welding.
The end 25mm of PVC/PE sheathing is stripped back to expose clean

copper cable. The cable may be cleaned with a wire brush if required.
Cad welding process as follows:
Clean the conductors and position them in the well dry mould;
Place the metal retaining disc in the bottom of the crucible graphite mould;
Pour the welding metal powder into the graphite crucible, spread starting
powder onto the graphite mould edge;
Open the mould lid and ignite the welding powder using a flint gun by firing
the spark onto the starting powder;
The exothermic welding process takes place inside the graphite mould; and
finally the exothermic connection is finished.
Clean the mould using scraper and brush and proceed to the next
connection cable(s) ready for connection.
After welding, each completed w eld shall be tested for electrical continuity
and mechanical bonding strength (1 blow with a 1 Kg Hammer)
Electrical Continuity using Ohm meter
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Anti corrosion Coating:
Subsequent to the satisfactory completion of anode installation, the

anti-corrosion coating shall be reinstated as follows:
The exposed areas of steel substrate around the Cad weld and anode
straps shall be wire brushed to a clean finish. All bare steel shall then be
coated using SOLVENTLESS 2 PACK EPOXY or other approved repair
material.
Anode Completion:
After final inspection, the Anode completion procedure will be carried out,
consisting of the infilling of the gaps between anode halves with either a
gunite concrete or hot poured marine mastic method.
The reinforcement used during concrete coating shall be trimmed back from
the edges of anode allowing a 25- 50mm gap. Electrical continuity test
shall be carried out to ensure that the reinforcement is electrically isolated
from the anode/pipe.
The gaps between the anode and the parent concrete weight coating
shall in filled with either a concrete mix similar to that of the parent coating
material (by hand or gunite method) Or by other approved in fill methods
(for example moulded hot bitumen) On completion a continuity check
between Anode and the steel pipe shall be performed prior to moving the
pipe to storage.
Inspection control:
Pre-qualification
The anode installation procedure and inspection shall be pre-qualified prior

to the start of production.
The pre-qualification will be limited to anode closure (strap) and Cad welds.
Weld / Welder Qualification
Typically each welder shall perform one fillet weld on a test coupon
sometimes supplied by client. The test coupon shall be macro sectioned
and tested for hardness.
rd
All required tests shall be carried out and reported by credited 3 Party
Inspection Laboratory.
Thermit Weld Qualification
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Typically each production welding operative will be qualified by

demonstrating their capability to perform a series of Thermit welds on a
coupon sample. Each weld shall be mechanically tested by a single blow
from a 1kg hammer, aimed at 90 degrees to the sample surface - no lifting
or fracturing shall result. Electrical continuity test shall be carried out
between pipe and anode
The test welds and coupons shall be sectioned and tested for copper penetration by a third
party inspection house
The macro sectioned and hardness and penetration tests reports will be
identified by coupon unique numbers. Test results should meet the
following:
Hardness shall not exceed 248 Hv10 when taken at 2mm intervals extending to 10mm either
side of the extreme edges of the weld.
No cracks or penetration of alloying elements along grain boundaries by more than 0.5mm or
any non-metallic inclusions will be detected at 200X magnification.
10.0 OFFLINE TESTING
Specific Density
Sieve Analysis
Moisture Content
Deleterious Substances
Fresh Analysis
Water Absorption
Compressive Strength Cubes

Compressive Strength Cores
Impact Test
Shear Test
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SPECIFIC GRAVITY - BS 812: part 2 1985
Note: This practice may be modified by the requirements of the customer s specification, see
relevant Project Inspection Test Plan (ITP)
Scope
Determination of the Specific Gravity (SG) of Aggregate/Iron Ore
Equipment
Pycnometer
Electronic balance
Gas ring or oven
Procedure
Obtain a sample weighing approximately 2000 grams.Thoroughly wash the sample to
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remove all material finer than No. 200 Sieve (75micron).Dry the retained sample over the gas
ring (or oven) and then allow it to cool to room (ambient) temperature.
Place 500 g of dry aggregate (Weight, A) into the Pycnometer and fill it with water. Whilst
filling rotate the Pycnometer to eliminate all traces of trapped air within the sample material
and allow settling. After settling, top up the Pycnometer with water again to remove any froth
from the surface so that the water level in the hole at the to of the cone is flat and level. Dry
the exterior of the Pycnometer and weigh (Weight, C).
Empty all the contents of the Pycnometer into a tray, making sure that the aggregate is
completely emptied. Refill the Pycnometer to the original level with water (only), dry the
exterior and weigh (Weight, B).
The difference in water temperature between the first and second weighing shall not exceed
2°C.
Carry out the test twice.
Evaluation
Calculate the Specific Gravity of the aggregate as follows:

Specific Gravity (SG) = Weight A / ((Weight A + Weight B) – Weight C))
Report
Record Specific Gravity
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SIEVE ANALYSIS (GRADATION) OF AGGREGATES - ASTM C 33
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Scope
To establish a Sieve Analysis (Gradation) of aggregates using interlocking, circular sieves of
standard aperture sizes
.
Equipment
Nest of certified sieves

Sieve shaker
Calibrated weigh scale
Oven or gas ring
Sampling box
Oven trays
Plastic bucket
Sampling scoop
Procedure
A representative sample of material to be analyzed shall be taken in a proper sapling
method. The sample shall be at least 1500 grams.
The sample shall be weighed and the weight recorded. After weighing the sample shall be
oven or gas ring dried making sure that none of the sample is spilt from the heating tray.
After drying the sample shall be passed through a set of known mesh size sieves, making
sure that all the sample is removed from the heating tray. The sieves shall be interlocked in
order of aperture size, starting with the larges mesh size at the top.
The interlocking sieves (including bottom pan) s hall be agitated sufficiently (normally with the
aid of mechanical vibrator/shaker) for a period of time (usually 4 minutes minimum), to
ensure that the material has completely passed through the respective grade sizes.
The aggregate which is retained in each of the sieves and the bottom pan are then
individually accurately weighed and the weights recorded.
Calculations
After the mass of aggregate retained on each sieve and in the receiver has been determined,
calculations are then carried out. Note that mass retained and mass passing on each sieve
are recorded and percentage passing is eventually calculated from the obtained results.
Visual representation of the particle size distribution is carried out be means of gradation
graph showing the sieve aperture size against the percentage passing that particular sieve
size.
Due to the relative values of the aperture size, it is convenient to plot them to a logarithmic
scale.
On completion of plotting, the points of the plot are joined together with straight lines resulting
in a graph that is termed the gradation curve.
Evaluation of results
The obtained grading curve should be within the envelope limits drawn by the applicator and
approved by the client and/or limits extracted from the ASTM C33 Standard.
Report
The type of aggregate

Results and percentages calculate
Sieve Analysis
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MOISTURE CONTENT OF AGGREGATES
Scope
Determination of the mass of water in an aggregate, expressed as a percentage of the mass

of the oven-dry, sample material.
Equipment The moisture content can be determined by any one of two methods.
An oven or gas ring

A calibrated weigh scale
Oven pan
Speedy moisture content tester (alternative method)
Procedure & Calculation (oven/gas ring dried method)
The sample is weighed, and then, after being oven- dried, it is re-weighed. Weigh the
masses before and after drying W1 and W2, respectively, then:
Moisture content, % = (W1 W2) / W2 x 100
Use of “Speedy ” moisture content tester (use only in case of accelerated test)
This is a proprietary device whose action is based on the very rapid absorption of water by
calcium carbide. Standardized quantities of aggregate and calcium carbide are mixed by a
standard procedure in a hand-held, sealed pressure vessel. Acetylene gas is formed by the
action of the moisture on the calcium carbide, and the pressure of the gas is related to the
quantity of moisture. The vessel is fitted with a pressure gauge calibrated to give a direct
reading of the moisture content.
Note : This test is unsuitable for larger sizes of coarse aggregate.
Report
Moisture Content in %
Moisture Content

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DELETERIOUS SUBSTANCE IN AGGREGATES - ASTM C40-92
Scope
To determine the organic impurities, including silt and clay in the aggregates
Apparatus
Glass bottle, 500ml

Sodium hydroxide solution, 3% NaOH
Reference color standards
Procedure (extract from ASTM C40-92)
Preparation of solution :
Dissolve reagent grade potassium dichromate (K2Cr207) in concentrated sulfuric acid (SG
1.84) at the rate of 0.250 g/ml of acid. The solution must be freshly made for the color
comparison by gently heating, if necessary, to effect solution
.
Fill a glass bottle to the 130ml level with sample of aggregate to be tested.and add the 3%
NaOH solution into the bottle until the volume of the aggregate and liquid after shaking is
about 200ml.
Cork the bottle, shake it vigorously and allow it to stand for 24 hours.afterward fill a fresh
glass bottle to the 75ml level with reference standard color solution prepared not more than 2
hours earlier per the preparation procedure described in Sub-clause B.3.1
Compare the color of the supernatant liquid of the test sample with that of the reference color
solution.
Record the color comparison result to that of the reference standard, e.g. lighter, darker or
same color.
Evaluation
If the color of the supernatant liquid is darker than that of the referenced standard, the
aggregate tested is considered to contain possible traces of injurious organic compounds. As
such perform further tests.
Report
Record
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Deleterious Substances
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FRESH ANALYSIS
Note: This practice may be modified by the requirements of the customer s specification,

see relevant Project Inspection Test Plan (ITP)
Scope
To verify W/C ratio, cement and aggregate content of the concrete mix. This procedure
applies to fresh concrete coating drawn from the batching mixer or feed conveyor to the
application head.
Equipment
Set of test sieves

Mechanical sieve shaker
Calibrated Electronic balance to an accuracy of 1.0g
Gas ring (to accelerate drying)
Bucket
Gunny sacks
Procedure
Prior to carrying out a mix analysis, it is necessary to carry out a gradation on a

representative sample of each aggregate used in the concrete. It is also necessary to know
the nominal mix design in percentage terms.
Obtain a representative sample of at least 2kg of freshly mixed concrete from the feed belt,
place in a suitable bucket , cover the bucket with a damp gunny sack and immediately
transfer the sample to the laboratory. This test shall be carried out without any delays.
Weigh a 500g sample into a tray and determine the moisture content of the sample.
Weigh a further 1,000g into a 150 micron sieve. Wash this sample carefully under a gentle
flow of clean water until the water draining from the sieve is clean and clear. Be very careful
to ensure that no material spills over the side of the sieve.
When washing is complete, transfer the cleaned sample onto a tray, using a further quantity
of clean water to wash all traces of material out of the sieve and into the tray. Carefully drain
off excess water, making sure that no material is lost in the process.
Place the tray over a burner and dry it thoroughly. Ensure that the rate of drying is gentle
enough to prevent material being ejected from the tray as the water vaporises, or alternately
cover the tray with an identical tray to trap any ejected material.
Once the sample is completely dry, remove from the heat and allow it to cool before
transferring to the sieve stack.
When the sample has been placed into the sieve stack close the sieve stack securely and
operate the shaker for five minutes. Remove the stack from the shaker. Carefully separate
the nested sieves and weigh and record the amount of material retained on each sieve,
ignoring the contents (if any) in the sieve pan.
Input the weights into the pre formatted calculation spreadsheet, or alternatively write by
hand on a blank fresh mix analysis form. For manual calculation, the procedure is as follows:
Record the weight on each sieve in turn

Determine the cumulative weight retained on each sieve by adding the weights of all
previous sieves in the stack

Determine the dry weight of the 1,000g sample used for each sieve
Calculate the cumulative weight retained as a percentage of the sample dry weight
For each sieve, calculate the percentage of the dry weight passing that sieve by subtracting
the value from the previous step from 100%
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The preformatted spreadsheet automatically calculates the mix ratios. To do this manually,
the following procedure is used:
Determine the weight of fines ( < 150 micron) particles of each aggregate in the mix sample
by multiplying the percentage of that aggregate passing the 150 micron sieve (from the
aggregate gradation) by the percentage of that aggregate in the mix by the dry weight of the
fresh mix sample.
Example: If 15% of the sand passes the 150 micron sieve in the sand gradation, and the mix
design incorporates 20% sand, and the fresh mix sample weighs 1,000g with a moisture
content of 6%, then the weight of sand fines in the sample is:-
15% x 20% x (1,000 x 94%), or 0.15 x 0.2 x 1000 x 0.94 = 28.2g
Repeat this step for each aggregate, and total the weights determined in this way. This
gives the total weight of fines in the fresh mix sample.
From the fresh mix gradation, calculate the total weight passing the 150 micron sieve by
subtracting the cumulative weight retained on that sieve from the dry weight of the sample.
This is the apparent weight of cement in the sample.
Note, this weight will include fine particles of aggregate. Subtract from it the total fines
weight calculated previously. The result is the corrected weight of cement.
Subtract the corrected weight of cement from the d ry weight of the mix sample. The result
is the corrected weight of aggregate.
Determine the weight of water in the sample by multiplying the sample wet weight by the
moisture content.
The water to cement ratio is given by dividing the weight of water by the corrected weight
of cement.
The aggregate to cement ratio is given by dividing the corrected weight of aggregate by the
corrected weight of cement.
Report
Record
Fresh Analysis
Fresh Analysis
-----------------------------------------------------------------------------------------------------------------------
CONCRETE DENSITY
Scope
To determine concrete density on removed samples (coupons or cores) removed from a
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concrete coating.
Equipment
Balance sensitive to 1.0g

Container suitable for transporting coupons to lab/cure bay
Core drilling equipment (core sampling)
Hand tools to assist in removal of samples
Wire cutters (coupon sampling)
Test specimen
Draw specimen (coupon) at production line taken immediately after coating or from a cure
pipe (core) dependant on the agreed method of sampling.
Procedure (coupon method)
Brush the sample with a fine bristle brush to remove all loose particles from the sample
surface.
Weigh sample and record as Weight A.
Transfer the sample to pipe curing bay with the pipe and allow the sample to cure for the
same period of time as of the coated pipe (a minimum of four (4) days). Sample may also be
oven dried to the constant weight.
Procedure (coupon and core)
After cure i mmerse sample in seawater filled tank at room temperature for not less than 24
hours. Draw sample from tank, let it surface dry or remove excess surface moisture, weigh
and record as Weight B.
Suspend the sample from a wire and weigh it in water and record as Weight C (this is to
check bulk density of concrete).
With the weights determined in accordance with the above procedures, calculate the
following:
a) Water absorption after Immersion, % = (B A) / A x 100

b) Density (Air- dry), Kg/m3 = A / (A C)
c) Density (Saturated), Kg/m3 = B / (B C)
Report
Record
Sample ID
Concrete coating date
Sample type
Calculation and results
Density
Density Test
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------------------------------------------------------------------------------------------------------------------------
COMPRESSIVE STRENGTH OF CUBES

Scope
Preparation and testing samples of concrete for compressive strength properties using the
cube mold method of sampling.
Equipment
100mm Cube Molds

Trowel
Bucket or Container
Vibrating hammer complete with square face (50mm x 50mm) tamping foot
Calibrated Compression Testing Machine.
Procedure
Draw concrete samples of the production working mix from the conveyor during transfer of
concrete from the mixer to the application head. Ensure that only freshly mixed concrete is
used for the sampling.
Place sample material in a bucket and over the bucket with a moist gunnysack to prevent
premature dehydration of the sample.
Prepare the required amount of cubes required for each sampling period plus two extra
cubes to used as spares. Make the test cubes as soon as practicable after sampling to avoid
dehydration.
Fill each test cube mold with concrete in three layers of 50mm. Compact each layer until
refusal using a vibrating hammer equipped with a square faced tamping foot attachment.
On completion of compacting the topmost layer of the sample the surface shall be prepared
level with the top edges of the mold using a square edged trowel. Each sample shall be
marked with it s ID and sample number. Also for day night operations the ID should include
the letters D/S or N/S
Curing of sample
Immediately after the sample preparation, cover the molds with a moist gunny sack and
place the cubes in the fog cure. Check closely that an uninterrupted moist condition exist
throughout the curing period.
After overnight curing, the mold screws are loosened, the mold dismantled and cube sample
is carefully removed and placed in a water tank. The samples shall remain saturated until
required for crushing.
Note : ensure that before placing the samples in the water tank that a correct, legible ID
exists on each sample
f 34 12/12/2013 5:28 PM
Compression Testing
The testing machine shall be capable of applying load manually or automatically at the
specified rate uniformly without shock. It should be annually (or anytime when anomalies in
the results are
observed) be calibrated and certified by 3

rd Party Certifying Agency for compliance.
Prior to testing each sample shall be weighed (in saturated state), in kilograms.The
dimensions of the samples shall be measurement in mm.
Determine the density of each test cube either by obtained weight over cube measure or by
water displacement method.
After weights, measurements and densities have been determined the test cube shall be
placed between the testing machine platens ensuring that all bearing surfaces of the testing
machine platens and the sample are wiped free of any debris.
Carefully center the cube on the lower platen, ascertaining that load will be applied to the two
opposite cast faces of the cube in a correct and even manner.
Without shock, apply and increase the load continuously at a nominal rate within the range of
0.2 - 0.4N/mm per second until no greater load can be sustained.
Record the maximum load applied to the cube.
Calculation and expression of the results
Calculate the cross-sectional area of the cube face f rom the checked nominal or measured
dimensions.
Calculate the compressive strength of each cube by dividing the maximum load by the cross-
sectional area of cube.
Express the results to the nearest 0.5N/mm2 or any otherwise agreed units.
Report
Record
Concrete Compressive Strength (Cube Sample)
NOTE : The drawing and Test on drilled CORES is in accordance with BS1881 Part 120.
Cube: Core Compressive Strength Correlation (if required) is carried out by this standard
Compressive Strength Cubes
--------------------------------------------------------------------------------------------------------------------------
COMPRESSIVE STRENGTH OF CORES - BS1881
Scope
Preparation and testing samples of concrete coating for compressive strength properties
using the extracted core method of sampling.
Equipment
Core drill, support stand and correctly sized core bits

Calibrated Compression Testing Machine.
Facing saw
External calipers
Acetate film
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Capping compound
Bucket, Container or plastic bags
Water & Power source
Procedure
Pipes selected during production for core sampling shall be clearly marked CORE TEST
and the pipe number and date coated shall be entered into the laboratory LOG
After a curing period (minimum 48 hrs) the core test pipe shall be located in the designated
area for core drilling. The c ore drilling equipment shall be checked for good working condition
and properly connected to the power source. The core drill bit shall be of a s ize that will allow
35 45 mm diameter cores to be removed. Core diameters shall remain constant throughout
the project. Only suitably qualified/trained operators shall perform core drilling.
The core drilling rig shall be firmly located on top of the pipe ( 90°) and the core drilled in a
downward direction. Whilst drilling, water shall be used to lubricate the drilling bit and the
core rig shall be fitted with a positive stop system to ensure the core bit does not exceed the
limitation of penetration (being 7 mm from the PE coating). Core samples shall NOT be
taken from the end 300 mm of the concrete coating.
On completion of drilling, the core drill, including core shall be carefully removed from the
concrete coating. The core sample shall then be carefully removed from the drill bit. When
removed, all cores from the test pipe shall have a band of electrical tape fastened around
them on which the pipe number shall be marked using a ball point pen. The cores shall be
placed in unique plastic bag for each test pipe. DO NOT MIX CORES FROM OTHER TEST
PIPES. The bag containing the cores shall also be clearly marked with the test pipe number.
When received at the laboratory the cores shall be removed from their respective bags and
checked for condition and quantity. If more cores are required, advise the core man as soon
as possible. All cores are to be trimmed and left to dry for 24 hours. When dry, the cores shall
be capped (apart from cores that will be used for density and water absorption tests). These
cores will be capped later. When capped, each core top cap shall be identified with the date
coated and with the letters D (day) or N (night) and placed into the storage tank with the
identification facing upward. The same procedure will apply to density and water absorption
samples after tests are complete. Cores will be stored in a water tank maintained at 23 ±
2°C.
Crushing
Specimens shall be removed from the curing tank and shall be in saturated condition when
tested, ideally removed from the tank approximately 30 minutes prior to crushing.
Select appropriate testing machine platens to suit anticipated compressive force. Clean
platen surfaces and ensure absence of extraneous matter. The core-seating rig (if required),
fabricated in accordance with BS 1881, is placed in the centre of the location circle and the
cores inserted.
Apply the load, without shock, at a nominal loading of 0.2 N/mm2/sec. - 0.4 N/mm2/sec. at a
constant rate for cores. Observe the fast advance and ensure seat correctly on the
apparatus. Operate the controls as failure is approached to maintain load rate(s) above as far
as practicable. When failure occurs the maximum load applied shall be recorded.
f 34 12/12/2013 5:28 PM
Report
Record
The specimen ID
Pipe number
Compressive strength to the nearest 0.5 MPa
Core Samples
Core crushing
---------------------------------------------------------------------------------------------------------------------------
WATER ABSORPTI ON
Scope
Determination of water absorption on sample removed from concrete coating (coupon or core)
Determination of water absorption using a fully coated concrete pipe (full-scale method)
Equipment
Test Sample
Calibrated Balance
Container suitable for immersing sample
Fresh concrete sample (at least 500 grams)
Full Scale
Calibrated weighbridge or load cell
Suitable water tank
Crane
f 34 12/12/2013 5:28 PM
Procedure (Sample testing)
Brush the removed sample (coupon or core) with a fine bristle brush to remove all loose
particles
from the sample surface.Weigh dry sample and record as Weight A.
Transfer the sample (coupon) to pipe curing bay with the pipe and allow curing for the
same period of time as the coated pipe.
Immerse sample in seawater tank at room temperature for not less than 24 hours. Remove
the sample from the tank, let it surface dry or remove excess surface moisture before
weighing and record as Weight B.
Suspend the sample from a wire and weigh it in water and record as Weight C (this is to check
bulk density of concrete).
Calculate the water absorption of the sample as follows:
a) Absorption after Immersion, % = (B A) / A x 100
Calculate the bulk density as follows:
b) Bulk Density (Air- dry), Kg/m3 = A / (A C) IF REQUIRED

c) Bulk Density (Saturated), Kg/m3= B / (B C) .. IF REQUIRED
Procedure (Full scale method)
Weigh a fully concrete coated pipe that has been cured record as weight A.
Place the pipe in a water tank filled with seawater at room temperature, if fresh water is used
a
calculation between sea and fresh water shall be used in the calculation process.
Allow the concrete to fully saturate, normally 24 hrs
After 24 h rs remove the pipe from the water tank and allow all free water to drain off. Weigh
the
pipe and record as weight B
Calculate the water absorption of the concrete coated pipe as follows;
Absorption after Immersion, % = (B A) / A x 100
Report
Record
Sample(coupon)
Full scale water immersion
Water Absorption sample
Water Absorption test
f 34 12/12/2013 5:28 PM
-------------------------------------------------------------------------------------------------------------------------
IMPACT TESTING OF CONCRETE
Scope
This procedure applies to concrete coated pipe subjected to repeated Impact simulating the
pipe movement during transportation and handling at lay barge during installation. It is
carried out to determine concrete integrity when subjected to high impact energy.
Equipment
Impact testing rig

Test Pipe with concrete coating
Timer
Tape measure
Striker edge: 10mm radius
Hammer Weight 2,680 Kg and/or 1,840 Kg
Camera
Procedure
The test shall be carried out 90° to pipe axis at one location.
The test shall be supported with a minimum of 2M concrete sections on either side of the
section under test. Impact blows (5 times) shall be directed on the same location. Hammer
should have a vertical drop of 660mm giving a velocity of impact of 3.60 m/second (7 Knots).
After each impact a photograph of the impact a rea shall be taken together with a sketch of
spalled areas including dimensions of cracks (length and width).
Acceptance criteria:- Typically
f 34 12/12/2013 5:28 PM
The anti- corrosion coating shall not be visible after impact (5 blows).
Spalling has not occurred further than 300mm from the impact location.
Report
Record
Impact Testing of Concrete
Impact Test Rig Drawing
---------------------------------------------------------------------------------------------------------------------------
SHEAR TEST OF CONCRETE

Scope
f 34 12/12/2013 5:28 PM
To evaluate the inter facial shear strength between the anti-corrosion and concrete coating
applied to a pipe.
Equipment (typical)
200MT Hydraulic Jack complete with pressure gauge

Supporting fixtures (design to suit testing set-up)
Measuring gauge for displacement of upper platen
Calibrated dial gauge
Procedure
A pre prepared coated section o f pipe shall be selected having concrete pipe sections of
minimum of 500mm test length. The preferred maturity of the coating is a minimum 7-days
after coating.
Oxy cut from a cured concrete coated pipe approximately 900mm concrete coated test pipe.
Cut only one test piece from each individual coated pipe. Alternatively, pipe can be coated
partly at a section length of 0.50 to 0.90 meter located at one end of pipe (proximity to
cutback). This is depending on what fixture is available from the time of carrying out test.
After having cut the test piece, prepare the cross-sectional surface of the concrete at one end
so that it is near perpendicular to the axis along the piece length.
Carefully center the test piece on the lower platen of the Hydraulic Jack (Compression
machine) unit with the concrete section supported by the appropriate supporting fixtures.
Then slowly lower the top platen to just touching the steel pipe end. Without shock, apply and
increase the load continuously at a nominal rate within the range of 0.2N/mm2 per second
until no greater load can be sustained.
Record the maximum load applied and calculate the surface area (SA) of the anti- corrosion
coating surface as follows:
Surface area, mm2 = 3.1416 x d x L
Where,
d = Pipe OD + anti-corrosion coating thickness

L = Length of concrete coating
Minimum required load (Kg-f) = 0.17N/mm2 x SA / 9.81
Report
Record
Shear Testing results
Shear Bond Test
f 34 12/12/2013 5:28 PM
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Dokumen - Tips - Pipeline Coating Process

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8/13/2019 Pipeline Coating Process

Typical Zublin made Cage

Cage reinforcement shall normally be required to meet the requirements of

Welded wire fabric reinforcement shall normally be required to meet the

of wire is required for concrete thicknesses up to 55 mm above 55 mm

3.0 Mixing of Concrete

Typical Batch Plant Calibration Tolerances

Typical Batch Plant feed System

mix test cube specimens are prepared.

4.0 COATING PROCESS:

Anodes shall be cleaned and be free of concrete coating materials.

Welded Wire Fabric Feed

5.0 CLEANING AND WEIGHING STATION

Taking Girth Measurements

Reinforcement placement check

Excess Wire Fabric

A typical formula for NB calculation

Mc = Mass of fresh concrete coated pipe including reinforcement kg

6.0 CONCRETE CURING

Typical repair procedure

Cracks extending halfway through the concrete or penetrated to the cage

Surface damage shall not be considered a defect if :-

Gunite Repair Criteria

Damaged or defective areas shall be prepared by undercutting and exposing the

8.0 PIPE MARKING AND IDENTIFICATION

Typical Marking Requirements

9.0 SACRIFICIAL ANODE INSTALLATION

Welding consumables will be SMAW electrodes for carbon steel.

The removal of coating shall be achieved by using a heated knife and / or a

Connecting of Bonding Leads (Electrical Connection):

Each anode is normally manufactured complete with bonding leads; the

The end 25mm of PVC/PE sheathing is stripped back to expose clean

Cad welding process as follows:

Electrical Continuity using Ohm meter

Anti corrosion Coating:

Subsequent to the satisfactory completion of anode installation, the

The anode installation procedure and inspection shall be pre-qualified prior

Weld / Welder Qualification

Thermit Weld Qualification

Typically each production welding operative will be qualified by

party inspection house

10.0 OFFLINE TESTING

Compressive Strength Cubes

SPECIFIC GRAVITY - BS 812: part 2 1985

Determination of the Specific Gravity (SG) of Aggregate/Iron Ore

Obtain a sample weighing approximately 2000 grams.Thoroughly wash the sample to

Calculate the Specific Gravity of the aggregate as follows:

Record Specific Gravity

SIEVE ANALYSIS (GRADATION) OF AGGREGATES - ASTM C 33

Nest of certified sieves

A representative sample of material to be analyzed shall be taken in a proper sapling

method. The sample shall be at least 1500 grams.

The type of aggregate

MOISTURE CONTENT OF AGGREGATES

Determination of the mass of water in an aggregate, expressed as a percentage of the mass

An oven or gas ring

Procedure & Calculation (oven/gas ring dried method)

Note : This test is unsuitable for larger sizes of coarse aggregate.

DELETERIOUS SUBSTANCE IN AGGREGATES - ASTM C40-92

Glass bottle, 500ml

Procedure (extract from ASTM C40-92)

such perform further tests.