CW9: PART 2

TECHNICAL SPECIFICATION FOR

CONCRETE COATING OF PIPES
PART 2- SECURITY COATINGS
APRIL 1993
J016 ( Rev 03/99 )
.
CW9: PART 2
J016 ( Rev 0399) - i -
CONTENTS
Page
FOREWORD iii
BRIEF HISTORY iv
1. SCOPE 1
2. REFERENCES 1
3. DEFINITIONS 1
4. MATERIALS 1
4.1 Concrete coating 1
4.2 Reinforcement 2
4.3 Curing membrane 2
5. ANTI-CORROSION COATINGS 2
5.1 General 2
5.2 Painted pipework 2
5.3 Bare pipework 2
5.4 Existing anti-corrosion coatings 2
6. DESIGN REQUIREMENTS OF THE CONCRETE COATING 3
6.1 Reinforcement 3
6.2 Concrete mix 3
7. SITE SAFETY 4
8. COATING PROCEDURE AND OPERATOR PROOF TESTS 4
9. CONCRETE COATING EQUIPMENT 5
10. PREPARATION FOR CONCRETE COATING 5
10.1 Anti-corrosion coating 5
10.2 Control of concrete coating thickness 5
10.3 Placing of concrete mix 5
11. APPLICATION PROCEDURE 5
12. CONTROL OF REBOUND MATERIAL 6
13. CURING OF CONCRETE COATING 6
14. INSPECTION AND TESTING 7
14.1 General 7
Page
CW9: PART 2
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14.2 Anti-corrosion coating 7
14.3 Concrete coating 7
14.4 Causes for rejection 9
15. VARIANTS 9
APPENDICES
A LIST OF REFERENCES 11
B CONCRETE COATING EQUIPMENT 13
C REPAIR REQUIREMENTS AND DEFECT LIMITS FOR CONCRETE COATINGS 15
D TESTS FOR POLYPROPYLENE FIBRE CONTENT IN CEMENT MIX 17
CW9: PART 2
J016 ( Rev 0399) - iii -
FOREWORD
This specification has been adopted by Transco and is an editorial revision of the former British Gas TransCo
specification GBE/CW9: Part 2. It reflects the identity and organizational structure of Transco - a part of BG
plc.
This Transco specification has been approved for use throughout Transco.
Comments and queries regarding the technical content of this Transco specification should be directed to:
Lead Engineer
Transco
Norgas House
PO Box 1GB
Killingworth
Newcastle upon Tyne
NE99 1GB
Further copies of this Transco specification can be obtained from Dataform Print Management using the print
requisition form G004 quoting the Form Number of this Transco engineering document (not the designation)
and your cost code.
Transco engineering documents are revised, when necessary, by the issue of new editions. Users should
ensure that they are in possession of the latest edition by referring to the Transco Register of Engineering
Documents available on the Transco Information Library.
Compliance with this engineering document does not confer immunity from prosecution for breach of statutory
or other legal obligations.
Contractors and other users external to Transco should direct their requests for further copies of Transco
engineering documents to the department or group responsible for the initial issue of their contract
documentation.
DISCLAIMER
This engineering document is provided for use by Transco and such of its contractors as are obliged by the terms
of their contracts to comply with this engineering document. Where this engineering document is used by any
other party, it is the responsibility of that party to ensure that the engineering document is correctly applied.
CW9: PART 2
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BRIEF HISTORY
First published as BGC/PS/CW9: Part 2
Amended issue published as GBE/CW9: Part 2
March 1984
April 1993
BG plc 1993
This Transco specification is copyright and must not be reproduced in whole or in part by any means without
the approval in writing of BG plc.
CW9: PART 2
J016 ( Rev 0399) - 1 -
TECHNICAL SPECIFICATION FOR
CONCRETE COATING OF PIPES
PART 2- SECURITY COATINGS
1. SCOPE
This Part 2 of Transco Technical Specification* CW9 deals with the quality of materials, mix and finished
profile for concrete security coatings applied by pneumatic means to steel pipework. The main function of
such concrete coatings is to protect the pipeline from impact or shock damage from external sources.
* Hereinafter referred to as 'this specification'
2. REFERENCES
This specification makes reference to the documents listed in Appendix A. Unless specified otherwise the
latest editions of the documents, including all addenda and revisions, shall apply.
3. DEFINITIONS
For the purposes of this specification the following definitions shall apply:
Transco: Transco - a part of BG plc.
Contractor: the person, firm or company with whom Transco enters into a contract to which this
specification applies, including the Contractor's personal representatives, successors and permitted assigns.
Engineer: the Engineer appointed from time to time by Transco and notified in writing to the Contractor to
act as Engineer for the purposes of the Contract.
4. MATERIALS
4.1 Concrete coating
4.1.1 General
All concrete coating shall comply with BS 8110 unless superseded by this specification.
4.1.2 Cement
Portland cement used in the preparation of the concrete shall conform to BS 12 and BS 1370.
Sulphate-resisting cement shall conform to BS 4027.
4.1.3 Aggregate
In general, aggregates used shall comply with BS 882.
The aggregate shall be washed and from a natural source. Tests on aggregate shall be in accordance with
BS 812.
4.1.4 Sand
All sand used shall comply with BS 882.
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4.1.5 Water
All water used in the preparation of concrete shall be potable (see 14.3.2). Water from the intended source of
supply shall initially be tested for purity in accordance with BS 3148. Water from any other source shall not
be used without a test for purity.
4.2 Reinforcement
4.2.1 Polypropylene filaments
The reinforcing filaments to be used shall meet the following requirements:
a) mechanically fibrilated from 12 000 denier polypropylene;
b) breaking load of individual strands not less than 57 kg;
c) density not less than 0.92 g/cm
3
.
4.2.2 Steel
The reinforcement shall consist of 50 mm x 50 mm mesh formed from 2.5 mm diameter high tensile steel wire
and shall comply with BS 4483 and be galvanized in accordance with the minimum requirement of BS 729.
4.2.3 Reinforcement spacers
Reinforcement spacers shall be non-metallic, non-hygroscopic, electrically insulating and have sufficient base
area to prevent damage to or penetration of the anti-corrosion coating.
4.3 Curing membrane
The curing membrane shall conform to either of the following:
a) Polyethylene wrap: thickness of material not less than 500 gauge and overlaps not less than
50 mm.
b) Spray coating: this shall be applied in accordance with the manufacturer's instructions.
5. ANTI-CORROSION COATINGS
5.1 General
Concrete security coatings may be applied over the protective coatings used on Transco pipelines but shall not
be applied directly over painted or bare pipework.
5.2 Painted pipework
Painted pipework shall be wrapped with a cold applied self adhesive tape, in accordance with the relevant
supplement to CW5, before the application of a concrete security coating.
5.3 Bare pipework
Bare pipework shall be wrapped with a cold applied laminate tape, in accordance with the relevant
supplement to CW5, before the application of a concrete security coating.
5.4 Existing anti-corrosion coatings
Concrete security coatings may be applied over:
a) Cold applied laminate tapes when applied in accordance with CW5 and the relevant
supplements to CW5.
b) Fusion bonded powder or multi-component liquids when applied in accordance with the
relevant part of CW6.
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c) Brush/spray applied coating or compound when applied in accordance with CW5 and the
relevant supplement to CW5.
In all cases of applying concrete coating over an existing anti-corrosion coating, care shall be taken to ensure
that the anti-corrosion coating is satisfactorily bonded. Any disbonded or damaged anti-corrosion coating
shall be removed and repaired in accordance with the relevant Transco specification.
6. DESIGN REQUIREMENTS OF THE CONCRETE COATING
6.1 Reinforcement
6.1.1 Steel
Reinforcement shall be to a design specified by Transco.
Reinforcement shall be formed and placed in accordance with BS 8110 and with this specification, where
applicable. The reinforcement shall at all times be adequately supported and secured to prevent contact with
the pipework and at the correct location by the use of spacers.
Reinforcement shall be electrically isolated from the pipe.
The cut ends of reinforcement shall not penetrate or damage the pipework anti-corrosion coating or contact the
surface of the steel pipework.
Overlaps shall be not less than 50 mm and shall be securely fixed together using malleable mild steel tying
wire or purpose-made clips.
For concrete coating thicknesses equal to or less than 50 mm, one layer of reinforcement shall be applied and
shall be positioned as near to the centre of the thickness of the final coating as practicable.
For concrete coating thicknesses greater than 50 mm, two layers of galvanized reinforcement mesh shall be
applied. The inner wrap shall be positioned 15 mm to 20 mm from the surface of the pipework and the outer
wrap shall have 15 mm to 20 mm cover of concrete coating. The two wraps shall be positioned with the
necessary size of spacer standing independently off the pipework surface prior to the application of the
concrete.
6.1.2 Polypropylene
Polypropylene fibre shall be used in the proportion of 0.2% by weight of the dry mix.
The correct proportions of chopped polypropylene fibre shall be dispensed into and uniformly distributed
within the mix using specialized equipment.
6.2 Concrete mix
6.2.1 General
Transco shall specify the limiting parameters, i.e. density, strength and water to cement ratio.
The Contractor shall design a mix using appropriate materials as specified in clause 4 in order to obtain the
required densities and strengths.
Full details of the following shall be made available to Transco:
a) The properties and densities of the respective dry aggregates.
b) The weight and properties of the polypropylene.
c) The cement weight per cubic metre of concrete.
d) The volume of water per cubic metre of concrete.
e) The density of the proposed mix.
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The proposed composition shall meet the minimum mechanical strengths specified in 6.2.2 and shall ensure
easy and satisfactory application of the concrete coating. The strength of the concrete mix shall be
demonstrated, prior to production commencing, by tests on cubes from trial batches prepared and tested in
accordance with BS 1881: Parts 108 and 116 respectively.
All concrete work shall be in accordance with BS 8110, except where superseded by this specification.
6.2.2 Compressive strength of concrete
The concrete coating shall be tested to BS 1881: Parts 116 and 120 and have a compression strength of not
less than:
a) 40 N/mm
2
after seven days;
b) 60 N/mm
2
after 28 days.
Tests shall be carried out in accordance with 14.3.5.
6.2.3 Concrete mix proof test
The strength of the concrete mix shall be demonstrated, prior to production commencing, by tests on cubes
and cores from trial batches prepared by spraying on to test panels and tested in accordance with
BS 1881: Parts 116 and 120 respectively.
Before and after compressive testing of cores, they shall visually be checked for uniform dispersion of
polypropylene fibres.
6.2.4 Concrete thickness
The thickness of the concrete coating shall be specified by Transco in the contractual drawings or documents.
In all cases the tolerance on the coating thickness shall be +5%, -0%.
7. SITE SAFETY
The Contractor shall ensure that all his personnel work strictly in accordance with current safety legislation.
Work, including holiday detection which is to take place on an operational site, shall be subject to a 'Permit to
Work', issued by the Engineer responsible for the site. This will stipulate the plant or equipment which may be
used in a specified area and the precautions which must be taken to protect plant, equipment and personnel.
8. COATING PROCEDURE AND OPERATOR PROOF TESTS
Before the commencement of any work, the Contractor shall demonstrate his ability to comply with the
requirements of this specification by applying a coating to test pipework.
The test shall be carried out by the operatives who will be carrying out the work, so that their ability and
experience in applying concrete coating can be assessed.
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9. CONCRETE COATING EQUIPMENT
The concrete coating equipment is required to be of a special impingement type to ensure that the specified
mix is applied in accordance with the requirements of this specification.
The type of equipment and method of application are broadly outlined in Appendix B.
10. PREPARATION FOR CONCRETE COATING
10.1 Anti-corrosion coating
Holiday detection shall be carried out in accordance with the relevant coating specification on clean dry anti-
corrosion coated pipework immediately prior to the positioning of reinforcement. Detected holidays shall be
repaired and retested. The anti-corrosion coating shall not be damaged as a result of a concrete coating
activity. No area of the pipework shall have a coating thickness less than 625 m or greater than 750 m.
10.2 Control of concrete coating thickness
10.2.1 The required thickness of concrete coating shall be achieved by the use of taut and true-to-line
piano wires spaced around the circumference such that the distance between any two wires is not greater than
225 mm for pipes equal to or greater than 450 mm diameter. On pipes of lesser diameter, the wires shall be
spaced at distances not greater than 150 mm. At no position are the piano wires to span greater than 5 m
without being supported securely by collars or other means. Guide wires and their supports shall be removed
after the applied coating has been inspected and found to be satisfactory.
Uncoated areas arising from the removal of supports shall be made good with the same mix of coating as
originally applied. Where guide wires cannot be used, the Contractor may propose an alternative method of
achieving and maintaining the required thickness as a variant to be considered by Transco.
10.2.2 Surfaces which are not to receive applied concrete shall be masked with 500 gauge polyethylene
sheeting and adequately taped to avoid all contamination. Particular attention shall be paid to all electrical
equipment and other services.
Vulnerable and delicate equipment shall be physically protected to avoid damage.
10.2.3 Where a run of applied concrete abuts an adjacent surface, due allowance shall be made for
expansion by the use of expansion joint material suitable for use on flat or curved surfaces as appropriate.
This expansion joint material shall be securely fixed prior to work commencing.
10.3 Placing of concrete mix
Concrete shall not be applied to a pipe or component if any required hydrostatic pressure testing of the pipe or
component has not been completed.
The concrete coating applied by a contractor shall be placed by a special purpose pneumatic technique. Other
methods may be proposed as a variant for consideration by Transco and subject to a demonstration that the
requirements of this specification are satisfied.
11. APPLICATION PROCEDURE
Each layer of pneumatically applied concrete shall be built up by making several passes of the nozzle over the
working area. The mix shall emerge from the nozzle in a steady uninterrupted flow. Should the flow become
intermittent for any cause, the nozzle operator shall direct the flow of material away from the work area until
it again becomes constant. Particular care shall be taken to comply with clause 12.
Where more than one layer is to be applied, the first layer shall be allowed to take its initial set without
conflicting with the requirements of clause 13.
If for any reason coating work ceases for longer than 30 min, the conditions of clause 13 shall apply.
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If coating is halted for longer than 24 h, all laitence, loose materials and rebound shall first be removed by
blast cleaning and the surface cleaned with a water spray before coating operations are resumed.
Care should be taken, when applying the concrete, to ensure that a truly homogenous mix and the specified
thickness are achieved. Particular care will be required to meet the specified thickness when the concrete
coating is being applied to bends and irregular pipework, e.g. reducers.
The ends of the concrete shall be chamfered smoothly at an angle of approximately 65 15
0
to the pipework
surface.
The concrete shall be placed upon the pipework within 30 min of the water being added to the mix.
Concreting shall not take place if the following conditions prevail:
a) the temperature of the pipework, anti-corrosion coating, reinforcement or concrete mix is
outside the range 3
0
C to 30
0
C;
b) air temperature is outside the range -3
0
C to 30
0
C;
c) adverse weather conditions which (unless the work face is suitably shielded) would prevent the
final coating from meeting the requirements of this specification.
Should it become necessary to suspend work and form a day joint, the edge of the material shall be run out.
When application is resumed, the new joint shall overlap the existing material to form a scarf joint.
12. CONTROL OF REBOUND MATERIAL
Rebound material shall not be worked back into the construction by the nozzle operator. Rebound material
which has been removed shall not be included in later batches. Any build up of excess material shall be
removed and treated as rebound material.
Cleanliness is essential and no escape beyond the working area of rebound spray or particles of materials
from the workings shall be permitted. All rebound must be completely contained within the working area and
removed by skip, chute or similar method to a tip to be provided by the Contractor. The rebound shall not
cause any contamination of adjacent structures or equipment.
The basic screening necessary to avoid contamination from the application process and the means of disposal
of the rebound material from the working areas shall be provided by the Contractor.
The Contractor shall ensure that the build-up of rebound as waste material on any boarded areas of scaffold is
not greater than 40 mm in depth on any boards or tubes and that all rebound material is removed from the
working areas and the site.
Similarly, all materials employed at the mixer shall be completely contained within the working area of the
mixer and later removed without any contamination of adjacent works.
The delivery equipment including hoses, connections and valves shall at all times be maintained in first class
condition to ensure that there is no leakage whatsoever from the plant.
13. CURING OF CONCRETE COATING
13.1 The Contractor shall demonstrate the efficiency of the method of curing, particularly under adverse
climatic conditions.
13.2 The curing process shall ensure that no moisture loss occurs for a period of seven days after
application. If a plastics membrane is wrapped around the concrete coating as part of the curing process, this
membrane shall be removed on completion of curing.
13.3 Precautions shall also be taken to protect the coating against sudden temperature changes.
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J016 ( Rev 0399) - 7 -
13.4 Checks shall be made to ensure that the first seven days of curing takes place in an air temperature
range of 3
0
C to 35
0
C. After seven days of curing, the lower air temperature limit may be reduced to -3
0
C.
Should the temperature fall below -3
0
C during the period seven days to 28 days, non-destructive strength
checks using a Schmidt hammer shall be carried out to ensure compliance with 6.2.3.
13.5 Concrete coated pipework shall be left undisturbed until the concrete has achieved its 28 days
strength.
14. INSPECTION AND TESTING
14.1 General
Inspection and testing to be implemented by the Contractor shall be as specified in 14.2,14.3 and 14.4.
Records of all tests shall be maintained.
14.2 Anti-corrosion coating
Holiday detection and repair of faulty zones shall be carried out immediately prior to reinforcement cages
being fitted and only when the area is certified 'gas free'. The test voltage shall be in accordance with the
relevant coating specification.
14.3 Concrete coating
14.3.1 Cement
The cement being used shall be checked for satisfactory condition and method of storage. Cement that has
deteriorated shall not be used. Relevant test certificates shall be retained by the Contractor and made
available for inspection by Transco.
14.3.2 Aggregate, sand and water
The grading and purity of sand and aggregate shall be checked twice weekly in accordance with BS 882, and
the purity of the water used shall be checked in accordance with BS 3148. Test certificates for aggregate shall
be retained by the Contractor and be available for inspection by Transco.
The sand and aggregate shall be stored on rolled hard core or other paved areas.
14.3.3 Reinforcement
14.3.3.1 Steel mesh
The steel reinforcement mesh shall be stored under cover and kept dry. Relevant test certificates shall be
retained by the Contractor and made available to Transco on request.
The mesh shall be formed and placed as specified in 6.1.1 and checks made and recorded.
14.3.3.2 Polypropylene fibre
The polypropylene fibre shall be stored under cover and kept dry. Relevant test certificates shall be retained
by the Contractor and made available for inspection by Transco on request.
14.3.3.3 Electrical isolation tests
Electrical isolation tests shall be undertaken to cover the requirements of 6.1.1.
A simple continuity tester shall be used, comprising a 6 V or 12 V battery in series with a compatibly rated
bulb. The condition of the battery shall be such that the bulb shall normally emit white light, but when
connected between the pipework and the mesh reinforcement shall show no visible sign of current flow.
Access to the reinforcement mesh shall be obtained by removing concrete locally. Renovation shall be carried
out in accordance with Appendix C.
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14.3.4 Proportions of concrete constituents
The Contractor shall demonstrate that the concrete batching and mixing arrangements produce a consistently
high quality of concrete.
The mixing proportions shall be checked at least once per day to ensure that they are within the tolerances
allowed.
The weight of the mix shall be controlled for each operation. The accuracy of measurement shall be checked
at least once per day.
14.3.5 Strength and density of concrete
Inspection and testing during coating operations shall be carried out to demonstrate the strength and density of
the concrete as follows:
a) Compressive strength and density tests shall be carried out on test cubes (minimum side of
100 mm) prepared from samples taken from mixes throughout the day's production.
b) Two sets of three cubes shall be taken twice a day for each application machine.
c) Along with preparation of cubes, the Contractor shall apply concrete on to panels by the same
method as the application to the pipework. The concrete shall be the same thickness as the
pipework coating.
d) Testing of cubes shall be carried out seven days and 28 days after casting.
e) If low values are obtained from test cubes, cores shall be taken from the coated panels
associated with such cubes. Three core samples shall be taken in accordance with BS 8110.
Any remedial action shall be the full responsibility of the Contractor.
f) Cubes and cores shall be tested for strength and density in accordance with BS 1881: Parts
116 and 120 respectively.
g) If any repairs are necessary, the previous procedures may be applied. Repairs shall meet the
requirements of Appendix C.
14.3.6 Polypropylene fibres
14.3.6.1 The polypropylene fibre content shall be tested in accordance with one of the methods in
Appendix D.
14.3.6.2 The dispersion of polypropylene fibres shall be visually checked for uniformity in a fractured test
specimen (see 6.2.3).
14.3.7 Concrete coating profile and thickness
Concrete coating shall be applied uniformly over the pipework. The thickness of coating on all surfaces shall
be checked. A total of at least 10 check points at four different radial positions along the length of the
pipework shall be selected. The chamfered ends of the concrete coating shall be checked for the correct angle
and reinforcement ends shall terminate within 40 mm to 60 mm of the chamfered face.
14.3.8 Defects in concrete coating during application
Each length of concrete coated pipework shall be visually checked immediately after the coating operation.
The degree of damage accepted for repair is specified in clause C.2. The repair procedure is specified in
clause C.1.
14.3.9 Curing
Curing shall be in accordance with the conditions specified in clause 13. Air temperatures, humidity and
general weather conditions shall be recorded and made available for inspection by Transco. Additional checks
shall be carried out after seven days for other defects in the concrete coating.
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14.3.10 Defects in cured concrete coating
All pipework shall be examined for defects. Voids and bad compaction areas shall be detected by ringing*.
Excessive spalling, voids and cracking shall be cause for rejection. Specific limits and repair procedure are
specified in Appendix C.
* Ringing shall be carried out by using a 1 kg hammer with a minimum striking face of 2000 mm
2
14.4 Causes for rejection
Causes for rejection shall include, but not be limited to, the following:
a) Incorrect placement of the reinforcing steel (see 6.1.1 and 10.1).
b) Unacceptable dispersion and density of the polypropylene fibres in the concrete (see 6.1.2 and
6.2.3).
c) Inadequate strength of concrete mix (see 6.2.2).
d) Unacceptable thickness measurements of the applied concrete (see 6.2.4 and 10.2).
e) Damage to the anti-corrosion coating or unsatisfactory repair of such damage (see 14.2).
f) Damage to concrete coating (see 14.3.8).
g) Excessive spalling, voids or cracking (see 14.3.10).
h) Electrical isolation failing to meet the specified requirements (see 14.3.3.3).
15. VARIANTS
A contractor shall only propose variants to this specification where the text indicates that variants would be
considered by Transco.
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APPENDIX A
LIST OF REFERENCES
This specification makes reference to the documents listed below (see clause 2).
British Standards
BS 12 - Specification for Portland cement
BS 729 - Specification for hot dip galvanized coatings on iron and steel articles
BS 812 - Testing aggregates
BS 882 - Specification for aggregates from natural sources for concrete
BS 1370 - Specification for low heat Portland cement
BS 1881 - Testing concrete:
Part 108 - Method for making test cubes from fresh concrete
Part 116 - Method for determination of compressive strength of
concrete cubes
Part 120 - Method for determination of the compressive strength of
concrete cores
BS 3148 - Methods of tests for water for making concrete (including notes on the
suitability of the water)
BS 4027 - Specification for sulphate-resisting Portland cement
BS 4483 - Specification for steel fabric for the reinforcement of concrete
BS 8110 - Structural use of concrete
Transco specifications
CW5 - Code of practice for the selection and application of field applied
external pipework coatings (other than resin coatings).
Supplement to
CW5 - Application instructions for field applied external pipework coatings
CW6 - Technical specification for external protection of steel pipe and fittings
using resin powder and associated coating systems:
Part 2 - Factory applied coatings.
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APPENDIX B
CONCRETE COATING EQUIPMENT
B.1 BATCHING AND MIXING EQUIPMENT
B.1.1 The correct proportions of sand and cement shall be established by weigh batching. The weighing
equipment shall be suitably accurate for the process requirements and any equipment which is not satisfactory
shall be removed from site and replaced. Periodic testing of this weighing equipment shall be carried out at
intervals during any contract to provide proof of its accuracy. Alternatively, cement may be batched by bag,
and aggregate may be batched volumetrically, if periodic checks are made to ensure that the proportions are
maintained within the required tolerances.
B.1.2 The moisture content of the sand shall be such that the sand cement mixture will flow at a uniform
rate (without slags) through the material hose. The optimum moisture content will depend upon the delivery
equipment being used, but it shall be within the range of 3% to 6%. The sand shall be dampened or dried as
required to bring the moisture to a satisfactory level. Fluctuations in moisture content shall be minimized.
B.1.3 The mixing equipment shall be capable of thoroughly mixing the sand and cement so that the sand
particles are thoroughly coated and capable of producing the mix in sufficient quantity to maintain continuity
of placing. The Contractor shall show that the mixing plant he proposes to use is capable of meeting these
requirements.
B.1.4 The mixer shall be self cleaning and capable of discharging all mixed material without any carry-
over from one batch to the next. It shall be inspected and thoroughly cleaned at least once a day.
B.2 DELIVERY EQUIPMENT
B.2.1 The delivery equipment shall be of the pneumatic feed type and shall be of a design and size which
have given proven results. The equipment shall be capable of discharging the sand cement mixture into the
hose under close control and it shall be capable of delivering a continuous smooth stream of uniformly mixed
material at the proper velocity from the discharge nozzle at all heights of the work.
B.2.2 The discharge nozzle shall be equipped with a manually operated water injection system (water
ring) for directing an even distribution of water to the sand cement mixture. The water valve shall be capable
of ready adjustment to vary the quantity of water and shall be convenient for the nozzle man.
B.2.3 The nozzle shall be capable of delivering a conical discharge stream of uniform appearance
throughout. Distortion of this stream or any non-uniform appearance shall be remedied by examination of the
nozzle, and any malfunction rectified by replacement of defective parts before further work is carried out.
B.2.4 The delivery equipment shall be thoroughly cleaned out at least at the end of each shift. Equipment
parts, especially the nozzle liner and water ring, shall be regularly inspected and replaced as required.
B.3 AIR SUPPLY
B.3.1 The Contractor shall ensure that the air compressor he intends to employ is of sufficient capacity to
maintain continuity of placing. The compressor shall maintain a supply of clean dry air adequate to maintain
sufficient nozzle velocity for all parts of the work while simultaneously operating a blow pipe for clearing
away rebound. The compressor capacities given in Table B.1 are recommended but the Contractor shall be
fully responsible for proving the adequacy of his equipment.
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TABLE B.1 - Compressor capacities
B.3.2 The operating air pressure is the pressure driving the material from the delivery equipment into the
hose and shall be measured by a gauge near the material outlet of the delivery equipment. The air pressure
shall be uniformly steady and non-pulsating under operating conditions. The gauge shall cover the range of
pressures produced and shall be graduated in intervals not greater than 0.35 bar.
B.3.3 The information given in Table B.1 is based on a hose length of 46 m with the nozzle not greater
than 8 m above the delivery equipment. Operating pressures should be increased by about 0.35 bar for each
8 m the nozzle is raised above the delivery equipment.
B.3.4 The water pressure at the discharge nozzle shall be sufficiently greater than the operating air
pressure to ensure that the water is intimately mixed with the other materials, forming a homogeneous mix.
The water pressure shall be independent of mains water pressure, uniformly steady and non-pulsating under
operating conditions. Water storage tanks may be used provided adequate supplies for continuity of the work
can be achieved.
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APPENDIX C
REPAIR REQUIREMENTS AND DEFECT LIMITS FOR CONCRETE COATINGS
C.1 REPAIR REQUIREMENTS
C.1.1 Concrete used for repairs shall contain the same proportions of constituents as the original coating,
but a slight increase in water content will be permitted for hand repairs only. Alternative repair materials may
be proposed as a variant for consideration by Transco.
C.1.2 Prior to application, the defective areas shall be thoroughly cleaned of loose material and be cut
away to ensure a 25 mm minimum thickness of repair, at any point.
C.1.3 The concrete surfaces to receive the repair material shall be well soaked with water complying with
4.1.5.
C.1.4 All repairs shall be carried out within seven days of the application of the concrete coating.
C.1.5 All repairs shall be cured in accordance with clause 13 and must meet the full requirements of this
specification.
C.1.6 Damage to the reinforcement, anti-corrosion coating or the pipework during repairs shall result in
rejection of the security coating.
C.2 DEFECT LIMITS
C.2.1 Spalling
Areas where the uncured concrete coating has not adhered or has been damaged during handling shall be
repaired subject to the following conditions:
a) The area of repair(s) in any 3 m length is not greater than 5% of the concrete surface area of
that 3 m length.
b) Total area of repairs is not greater than 2.5% of the total concrete surface area of the coated
pipework.
C.2.2 Voids
Where voids are detected in the concrete coating and do not exceed the following tolerances, they shall be
broken out and repaired so that:
a) The total area of a void or voids in any 3 m length is not greater than 2.5% of the concrete
surface area of that 3 m length, and
b) the total area of all voids in any concrete coated pipework is not greater than 0.5% of the total
concrete surface area of the coated pipework.
C.2.3 Cracking
C.2.3.1 Hairline cracks equal to or less than 1 mm width, indications of normal shrinkage, will be allowed
provided the frequency of cracks is not greater than one crack for each 250 mm length of concrete coating.
C.2.3.2 Cracks with widths greater than 1 mm but not greater than 3 mm width are tolerable provided there
is no association with any other form of defect, only one crack occurs in any 3 m length and such cracks are
not less than 2 m from one another.
C.2.3.3 Where a crack having a width of between 3 mm and 9 mm is detected in a length of concrete
coating, it may be considered for repair provided that no other crack of any size occurs within the same 10 m
length of concrete coating.
CW9: PART 2
- 16 - J016 ( Rev 03/99 )
The crack shall be cut out and enlarged to a width of not less than 15 mm and to a depth of not greater than
25 mm. It may then be repaired provided that the following conditions are satisfied:
a) For cracks deeper than 25 mm, the width of the crack exposed at the bottom of the cut-out
shall be not greater than 3 mm.
b) No damage to the reinforcement has occurred during evacuation of the crack.
C.2.3.4 Any crack having a width greater than 9 mm shall be cause for rejection of the security coating.
CW9: PART 2
J016 ( Rev 0399) - 17 -
APPENDIX D
TESTS FOR POLYPROPYLENE FIBRE CONTENT IN CEMENT MIX
D.1 GENERAL
The procedures specified in clauses D.2 and D.3 provide alternative test methods for determining the
polypropylene fibre content in the cement mix. The two methods are for measuring the amount of
polypropylene reinforcement in the mix, but do not define its distribution.
D.2 WET METHOD
D.2.1 Take a sample of concrete mix (any convenient weight between say 500 g and 1000 g) from a test
plate that is coated with the same mix and at the same time as the component. A sample representative of each
application is required. (Frequency of sampling is specified in 14.3.6).
D.2.2 Completely fill a suitable size container (the volume of which is known) with the sample mix. A
volume of approximately two litres is suggested.
D.2.3 Immerse the container and contents in clean water of sufficient quantity (five litres is suggested) to
allow the polypropylene fibres to be washed out and to rise to the surface. Pass the resultant slurry through a
5 mm mesh sieve to ensure that any fibres still trapped are collected.
D.2.4 Collect all the polypropylene fibres and carry out any further washing that may be required prior to
drying the collected fibres. Drying may be carried out by first rinsing in methylated spirit and then drying for
approximately 30 min in an oven at not higher than 80
0
C. Alternatively, the washed fibres could be dried out
in a vacuum dessicator.
D.2.5 Establish the volume of the collected fibres using either a weighing/calculation technique or
preferably, if available, using apparatus normally employed in powder metallurgy to measure the volume of
metallic powders.
D.2.6 Calculate the percentage volume of polypropylene fibres as compared with the original sample
volume of mix.
D.3 DRY METHOD
D.3.1 Obtain a specimen that has cured for not less than 12 h, from either a test cube, a core cut from the
coated component or a quantity collected from a test plate at the time of coating. If the coating is applied to
the component in more than one application, collect a specimen representative of each application.
D.3.2 Weigh the sample to an accuracy of 1 g (a specimen size of between 500 g and 1000 g is
suggested).
D.3.3 Reduce the sample to approximately walnut size with a hand hammer, endeavouring to minimize
the fragmentation or loss of polypropylene fibres. A convenient method is to use a steel tray with three side
walls to stop pieces flying out.
D.3.4 Immerse the pulverized mix in dilute hydrochloric solution (1 part HCI to 10 parts H
2
0) and allow
to stand for not less than 12 h. The application of gentle heat may prove beneficial.
D.3.5 Wash the mix (i.e. polypropylene fibres that may have risen to the surface and the sediment) and
dry.
D.3.6 Collect the polypropylene fibres, examining the dry residue for any residual fibres.
D.3.7 Weigh the polypropylene fibres and calculate the percentage weight of fibres compared with the
original dry sample.