You are on page 1of 10

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 The aggregate shall be of a type approved by the
specifications. COMPANY.

3.1 Cement Well graded iron or barium ore shall be added to
the aggregates to achieve the required
Cement shall conform to ASTM C150, Type II, or density.
approved equal and shall be stored in a manner
thatwillsatisfactorilyprotectitfromtheelements. Concreteaggregatesshallbeclean,soundandfree
Cement that has hardened, partially hardened, or from injurious amounts of salt, alkali, organic
becomelumpyshallnotbeused.Testcertificates impuritiesorotherdeleteriousmatter.Aggregates
fromthecementmanufacturershallbepresented shall meet the requirements of ASTM C33. The
totheCOMPANYforallcement. aggregates shall be well graded to the following
sievesizes:
3.2 Water
U.S.Standard %
Water shall be clean and free from injurious SieveSize Passive
amountsofoil,acid,alkali,salt,organicmaterialor
other deleterious substances. Seawater or water 3/8in. 100
fromstagnantswampsorexcavationsshallnotbe No.4 8090
used.TheCOMPANYreservestherighttorequire No.16 4070
the CONTRACTOR to test the water and have the No.50 1030
resultsapprovedbytheCOMPANYpriortoitsuse No.100 010
intheconcretemixture.
Theaggregatesshallbestoredinasuitablygraded
3.3 Sand(SilicaType) area to ensure satisfactory draining of the
stockpipe.
Sand used shall be round grained and shall be
obtained by sieving. It shall be free of injurious 3.5 ReinforcingSteel
amounts of salt, alkali, deleterious substances or
organic impurities. Suitability of the natural sand The reinforcement shall consist of a woven or
for making concrete shall be determined in welded wire mesh. Woven wire mesh shall be of
accordance with the requirements of ASTM C33. the hexagonal type with extra longitudinal wires.
Thesandshallbewellgradedtothefollowingsieve Sizeofhexagonalmeshopeningsshallbe1.5inches
sizes: across the minimum dimensions. Welded wire
meshshallhaveopeningsof1inchby2inch.
U.S.Standard %
SieveSize Passive The wire mesh shall be galvanized and the
materials shall conform to ASTM A82, A90, A185
4 100 andA641asapplicable.
8 80100
16 5080 Theminimumwirediametershallbe14gage.
30 2555
50 530 4.0 EQUIPMENTANDLABOR
100 010
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
3.4 Aggregate equipmentshallprovideforeitherthebatchingof
SpecificationforConcreteWeightCoating 4of10
materialbyweightorcontinuousmixing,whereall
feedsareaccuratelycontrolledandpercentagesof 5.4 WaterAbsorption
mixarecalibratedbyweight.Batchingscalesshall
be maintained in good condition. Any equipment The water absorption after 48 hours, as
thattendstoseparatetheingredientsshallnotbe determined from tests outlined in Section 7.3.2 is
used. not to exceed four percent of the dry concrete
weightinair.
5.0 CONCRETECOATINGMIX
5.5 Density
5.1 MixDesign
The density of the concrete shall have a nominal
TheCONTRACTORshalldesignthemixesusingthe valueof190pcf.Thetoleranceofthedensityshall
approved aggregates and shall determine the beplusorminus5percentasdeterminedfromthe
proportions which will give the required concrete testsoutlinedinSection7.3.2.
density and strength. All mix designs shall be
agreedwiththeCOMPANYbeforecommencement 5.6 Thickness
ofcoating.Allconcretemixesshallbedesignedto
minimizedryingshrinkage. Theconcretecoatingshallbeofuniformthickness
aroundthecircumferenceandalongthelengthof
FulldetailsshallbeprovidedbytheCONTRACTOR thepipe.Aroundthecircumference,thethickness
withregardto: shall not vary more than inch between the
highest and lowest points at any given cross
a. The proportions and weights of the section. Along the length, the thickness shall not
respectivematerialsusedinthemix. varymorethaninchbetweensuccessivehighand
b. Thewater/cementratio. lowpoints.
c. Thegradingsofthevariousaggregateswith
combinedcurvesasnecessary. The overall average thickness (as determined by
d. Laboratory test results for compressive averaginggirthmeasurementsat5equallyspaced
strengthandunitweightofconcrete. locationsalongthelength)shallnotvarymorethan
+inchfromthenominalspecifiedthickness.
5.2 CompressiveStrengthRequirements
5.7 ConcreteCutbackEndTaper
Theminimumcompressivestrengthasdetermined
fromtestsoutlinedinSection7.3.1shallnotbeless The concrete coating shall be cutback from the
than 3,500 psi after 7 days and 4,650 psi after 28 ends of the pipe joints and no concrete shall be
days. appliedforadistanceof12inchesfromtheends.
Attheends,theconcretecoatingshallbetapered
5.3 WeightRequirements ata60slopewithrespecttothelongitudinalaxis
ofthepipe.Thebaseofthetapershallbenocloser
The nominal weightperfoot of coated pipe shall than12inchesandnofurtherthan14inchesfrom
beasspecifiedintheCONTRACT.Theweightper therootfaceofthebeveledends.
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.
6.0 CONCRETECOATINGPROCEDURES
Inaddition,theaverageweightperfootinairof5
successively coated joints shall be greater than or 6.1 ConcreteApplication
equaltotherequiredweightperfootinair.
SpecificationforConcreteWeightCoating 5of10
The concrete weight coating shall be applied by
either the high impact velocity method or by the For concrete thicknesses greater than 2 inches,
compression method. The concrete shall be two layers of reinforcement shall be used.
appliedonjointsofpipethathavebeenpreviously Reinforcement layers shall be placed equidistant
coated with coaltar enamel as per COMPANY from the pipe, the outer surface of the concrete
Specification2136600SP018. andeachother.Aminimum3/4inchofcovershall
be maintained between the outer layer of the
Noconcreteshallbeappliedwhenthesurrounding reinforcementandtheoutsideoftheconcrete.
temperature at the curing station is 40F. At any
phase of the coating, if the temperature can go The reinforcing steel shall not be in electrical
below 40F the CONTRACTOR shall submit his contactwiththepipe.Atthebeginningofcoating
procedureforweightcoatingbelow40F.Ifduring for each pipe diameter/concrete thickness
the coating period the temperature goes below combination, a joint randomly selected by the
40F, the coating shall be protected according to COMPANY shall be checked with electric power
theapprovedprocedure. sourceandmeter.Thischeckshallberepeatedat
random approximately every 100 joints. Any
All mixed concrete which is not placed within 45 concrete removed to make the test shall be
minutesaftertheinitialintroductionofwaterinto repaired.
themixtureshallberejectedandshallnotbeused
tocoatthepipe. Reinforcingwireshallnotbeexposedattheendsof
theconcretecoating.
Each joint of pipe shall be coated in a continuous
operation. Where practical, the total thickness of 6.3 AnodeJoints
coatingshallbeappliedinasinglepass.Nomore
than 30 minutes shall be allowed between passes Anodesshallbeinstalledonthepipeinaccordance
inanycase. withCOMPANYSpecification2136600SP016.For
anode joints, care shall be taken to ensure that
The uncoated portion of the pipe ends and the there is no contact between the anode and the
bevels shall be kept clean and free from concrete reinforcing wire. A minimum 2inch separation
spatter,oil,grease,etc. shall be maintained between the anode and
reinforcingwire.Concreteweightcoatingshallbe
If kraft paper has been placed on the joint to applieduptoeachsideoftheanodeandtapered
protect the corrosion coating, the paper shall be to the outer diameter of the anode. Following
completely removed before the joint is concrete installationoftheweightcoating,theoutersurface
coated. of the anode shall be brushed cleaned for any
concrete or other materials, and the
6.2 ReinforcingandForming anode/reinforcing wire shall be meter tested to
assureisolationoftheanode.Anodejointsshallbe
The reinforcing steel shall be applied in such a cured and stored separately from other weight
mannerastoprovidecontinuityofreinforcement. coatedjoints.
All circumferential and longitudinal reinforcing
splicesshalloverlapnolessthan6inches. 6.4 Curing

For concrete thicknesses less than or equal to 2 Followingconcretecoatingapplication,thecoated
inches,onelayerofreinforcementshallbeplaced pipe shall be carefully handled and moved to a
midway between the outer and inner surfaces of curing area. In the curing area, the pipe shall be
theconcrete.Aminimuminchofcovershallbe placedinasinglelayerandsupportedinamanner
maintained between the reinforcement and the that does not damage the concrete or allow the
outsideoftheconcrete. concretetocurewiththepipeinadeflectedshape.

SpecificationforConcreteWeightCoating 6of10
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
Thecoatingthicknessshallbecheckedattheends
7.3.1 CompressiveStrengthTest of the coating to determine if the line pipe is
concentrically placed inside the weight coating
Compressive strength of the mix shall be jacket. The variation in coating thickness around
determinedfromsamplespreparedatthejobsite. the circumference shall not exceed the limits
TestsshallbecarriedoutinaccordancewithASTM definedinSection5.6ofthisspecification.
C39.Aminimumoftwotestcylinders(preparedin
accordance with ASTM C31) shall be taken in the Thediameter(andaveragecoatingthickness)shall
morning,andtwointheafternoonforeachdayof bedeterminedatfivelocationsalongthelengthof
production. These cylinders shall be tested to eachpipejointbytakinggirthmeasurements.The
determine the 7 day and 28 day compressive locations for the girth measurements shall be
strengthoftheconcrete. equallyspacedandshallincludeatlest80%ofthe
coated length. The variation in average coating
7.3.2 Concrete Unit Weight and Water thickness shall not exceed the limits defined in
AbsorptionTests Section5.6ofthisspecification.

The density of the concrete shall be determined In addition, the surface of the concrete coating
fromhardenedandcuredconcretethatisnotless shall be spot checked to determine that surface
than the 4 days of age, and is taken from the irregularities do not exceed the limits defined in
coating mix as applied in normal coating Section5.6.
operations.Onecylindertypemodelshallbetaken
for each morning and one for each afternoon of 7.3.4 CoatedPipeWeightTests
production to be used for these tests. Water
absorption tests for the concrete shall be carried The coated pipe weightperfoot in air shall be
outinaccordancewiththefollowingrequirements computedusingthefollowingformula:
andASTMC642.
w =[W W
air m steel(LpLc)]/Lc
Asampleshallbeovendriedat210Ftoconstant
weight. When constant weight is attained, a where
sample shall be allowed to cool to room
temperatureandbeweighedtothenearestgram. wair = calculated weightper
The sample shall be submerged in seawater at
room temperature for not less than 48 hours. footinair(lb./ft.)
While submerged in seawater, itshallbeweighed Wm = the measured
to the nearest gram. It shall then be withdrawn weightinair of the
from the water, the excess of surface moisture fully cured weight
removed, and the sample weighed again to the coated joint of pipe,
nearest gram. The weight per cu. ft. and water (lb.)
absorptionshallbecalculatedasfollows: 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
Repairsshallbemadebysatisfactorilyrestoringthe
(centerof taper to
reinforcement (if necessary); removing all cracked
centeroftaper) of
orbrokenconcreteatthepointofcoatingdamage;
theconcretecoating,
wetting the fresh surface of the broken coating;
(ft.)
andtrowelingastiffmixtureofcementwaterand

aggregate (of the same materials and proportions


8.0 REPAIRSANDACCEPTANCE
asthecoating)intoandthroughthereinforcement.

This mixture shall be built up until the surface is


8.1 RepairofPipe
levelwiththecoatingaroundtherepair.Thepipe

shall then be carefully laid in a position where it


CONTRACTOR shall inspect any pipe furnished by
shallbeallowedtomoistcureforaminimumof7
others upon receipt. All flaws discovered in pipe
days.
notfurnishedbytheCONTRACTORandnotcaused

bytheCONTRACTORwillberepairedasapproved
Nopipesshallbeacceptedifspallingextendstothe
bytheCOMPANY.AtCOMPANY'sdiscretion,these
enamellayer.
joints shall be set aside, with no cost to the

CONTRACTOR. The CONTRACTOR shall provide
8.2.2 CrackingDuetoPipeDeflection
storagespaceforandshallhandleallpiperepairs.

Cracksthatareinexcessof1/16inchinwidthand
All damage to the pipe bevels or facing, which
exceeds API5L allowances for bevel or face extend over 180 circumferentially around the
damage,suchasdents,gougesandflattening,shall pipe, or longitudinal cracks over 12inch in length
becutoutandthepiperebevelledandrefacedor, (irrespective of width), shall be repaired. Repair
attheCOMPANY'sdiscretion,shallbesetaside. shallbemadebychiselingthecrackouttoawidth
ofnotlessthan1inchthroughoutthelengthofthe
8.2 CoatingRepairs crack. The crack shall be repaired with materials
similartothatformwhichthecoatingismade.The
After concrete coatings have hardened, damage repairs shall be kept moist and be allowed to
during handling and storage shall be repaired as remain undisturbed for a period of not less 48
describedbelow. hours.

8.2.1 Spalling 9.0 IDENTIFICATIONANDMARKING

Spallingcausedbyimpactwithotherobjects,shall 9.1 PaintStenciling
berepairedasfollows:
The CONTRACTOR shall paint stencil the inside of
i. Damagedareaoflessthan1sq.ft.,where eachjointofpipewiththeinformationasfollows:
depthofdamageddoesnotexposethereinforcing
wire,andwherethesurroundingconcreteissound, a. Concretecoatingthicknessanddensity
shallbeacceptablewithoutrepairs. b. Measuredweightinair(emptypipe)

ii. Damagedareaexceedinganyofthecriteria 9.2 ColorCoding
ofi.,uptoatotaldamagedareaof3sq.ft.,shallbe
undercuttoprovideakeylockforrepairs. Foragivenpipediameter,theCONTRACTORshall
propose a color coding system which uniquely
iii. Damagedareaexceeding3sq.ft.shallhave identifiedeachconcretethickness.
the concrete coating removed around the entire
pipe circumference and for a sufficient length to Eachjointofcoatedpipeshallthenbecolorcoded
includetheentiredamagedportion. accordingly with a 3inch wide band painted
aroundthecircumferenceateachendofthejoint.
SpecificationforConcreteWeightCoating 9of10
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