20-05 - Concrete Coating of Line Pipe

Chevron Nigeria Limited
20.05 - CONCRETE COATING OF LINE PIPE
November 20; Revision A

11-22-91 CN-2 516-20.05
Specification 20.05
Specification 20.05
CONCRETE COATING OF LINE PIPE
TABLE OF CONTENTS
1.0
SCOPE
2.0
COATING CONTROL DATA AND TOLERANCES
3.0
STANDARDS AND SPECIFICATIONS
4.0
MATERIALS
5.0
PROPORTIONING AND MIXING OF CONCRETE
6.0
EQUIPMENT AND APPLICATION
7.0
CURING
8.0
PERMISSIBLE REPAIRS TO CONCRETE COATING
9.0
CAUSES FOR REJECTION
10.0
CARE, HANDLING, AND STORAGE OF PIPE
11.0
SPECIAL WORK
12.0
IDENTIFICATION OF PIPE JOINTS AND REPORTS
APPENDIX
I
Standards and Codes
ATTACHMENTS
1
Concrete Coating of Line Pipe Data Sheet (3 Sheets)
November 20, 1991; Revision A

11-22-91 CN-2 516-20.05
Page 1 of 15
Specification 20.05
1.0
SCOPE
1.1
General
This specification covers application of concrete coating to line pipe for use
offshore off the coast of West Africa. Contractor shall furnish all materials, labor,
equipment, utilities, supervision, services, and all other items required to perform
the work. Contractor shall make all arrangements and obtain permits required for
his performance of work at the coating application site, whether on property
owned or arranged for by Contractor, by Company, or by Others.
1.2
Slippage Control for FBE Coated Pipe

Contractor shall provide adequate shear strength between the concrete and the
fusion-bonded epoxy (FBE) corrosion coating to prevent slippage of the concrete
during installation.
The required minimum shear strength shall be calculated by Contractor and
approved by Company, and shall be as shown on the data sheet.
Shear strength enhancement shall be achieved by any of the following
techniques:
Application of an intermediate barrier coating between the FBE and

concrete.
Forming of a continuous, raised spiral of epoxy between the FBE and
concrete.
Forming of rough bands of epoxy with embedded flint chips on one end of
the pipe prior to application of the concrete.
Forming of a ring of cementitious epoxy on one end of the pipe prior to
application of the concrete.
Contractor shall demonstrate the ability of the enhancement technique to meet the
required minimum shear strength by means of a full scale push-off test or other
experimental method. The results of the test shall be submitted to Company for
approval of the proposed shear strength enhancement method.
1.3
Intermediate Barrier Coating

For coating application by the impingement method over FBE coated pipe,
Contractor shall apply an intermediate barrier coating to protect the FBE from
damage.

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Page 2 of 15
Specification 20.05
Acceptable intermediate barrier coating are:
FRC Composites Ltd. FRC 80

Active Protective Coatings Ltd. Forton 2000
Alternatively, Contractor may propose other methods of limiting damage to the

FBE such as increasing the FBE thickness and using a fine sieved aggregate.
Prior to Company approval of such methods, Contractor shall perform a field trial
where the concrete shall be applied and then washed back off, and the FBE
reinspected for damage both visually and for holidays according to NACE
Recommended Practice RP-0490-90. The concrete application shall have caused
no significant visual damage to the FBE, in the opinion of Company, and shall
result in no more than five detected holidays.
1.4
Exceptions
Contractor shall obtain written approval of Company for any deviations from the
requirements of this specification.
This document is not intended to be all inclusive, and the use of the guidelines set
forth does not relieve Contractor of his responsibility to supply a finished product
capable of performing its intended service.
2.0
COATING CONTROL DATA AND TOLERANCES
2.1
Coating Control Data

Contractor shall weigh each concrete-coated pipe joint immediately after coating,
and shall measure the outside diameter of the concrete either on the scale or as
soon as the joint is placed on the curing rack. The outside diameter shall be
measured at a minimum of five points evenly spaced along the length of the pipe
joint. The average of these measurements shall be reported and used in
calculations for coating thickness and concrete density. Report entries and
calculations required by Sections 2.2 and 2.3 shall be made within 30 minutes
after the pipe joint is placed on the curing rack.
2.1.1
Weighing Devices
Weighing devices used to determine the weight of the concrete-coated joints shall
be certified in writing to an accuracy of 0.5%. When specified on the data sheet,
the weighing device shall be calibrated just prior to start of coating by an
independent agency approved by Company. Checking of the weighing devices
shall be done at the beginning of each day's production, and Company shall retain
the option to request a check at any time. The check shall be performed using a
joint of pipe with a known weight, that weighs within plus or minus 25% of the
weight of a concrete-coated pipe joint to be coated.

11-22-91 CN-2 516-20.05
Page 3 of 15
Specification 20.05
2.2
Density
2.2.1
Density of concrete coating shall not vary from the design density by more than
plus 10% or minus 5%.
Density of coating as determined by methods given in Section 2.2.2 for
"as-applied" concrete coating on the pipe, and Section 5.3.2 for 24-hour sample
cylinders, shall be used for control of mix and application during the period of
concrete coating.
If the density varies from the specified density by more than the stated tolerance,
Contractor shall take corrective measures to obtain specified density, and shall
immediately inform Company of the deviation and corrective measures.
2.2.2
Density of "as-applied" concrete coating shall be determined using the weight and
dimensions of a concrete-coated joint, by the following calculation:
Density in lb per cubic foot =
(Weight of joint, lb) - (L x Wp) x
L - 2h
1
0.00545Dc2 - Ap
where:
Wp
L
h
Dc
Ap
= Nominal weight of corrosion protective-coated pipe, lb/ft (without

concrete coating)
= Length of joint, ft
= Hold back length at each end of joint, ft
= Average outside diameter of concrete-coated pipe, in.
= Cross-section area of protective-coated pipe, ft2
2.3
The "as-applied" density shall be calculated immediately after weighing and

measuring diameter for at least every fifth joint coated.
Weight of Concrete-Coated Pipe Joint
2.3.1
The calculated weight for the pipe joint, in pounds, shall be:
(Joint Weight)calc = (L x Wp) + [(L - 2h) x Wc]
where:
Wp, L, and h are as stated in Section 2.2.2, and Wc = concrete coating weight,
lb/ft.

11-22-91 CN-2 516-20.05
Page 4 of 15
Specification 20.05
The total weight of any single pipe joint shall not vary from the total design joint
weights by more than plus 7.5% and minus 5.0%.
The total weight of any 10 consecutive pipe joints shall not vary from the total of
design joint weights for those joints by more than plus 7.5% and minus 0.0%.
2.4
Concrete Coating for Mechanical Protection Only
2.4.1
Coating Control Data

The average outside diameter of each concrete-coated pipe joint shall be
determined as described in Section 2.1 above. Weighing shall not be required.
Calculations for "as-applied" density per Section 2.2 and joint weight tolerances
per Section 2.3 shall not be required.
2.4.2
Concrete Coating Thickness
3.0
Coating thickness shall not vary by more than minus 0 or plus 1/4 inch from the
nominal thickness specified on the data sheet.
STANDARDS AND SPECIFICATIONS
Concrete weight-coating shall conform to the latest edition of the standards and
specifications listed in Appendix I.
4.0
MATERIALS
Materials shall be subject to Company approval. Sand and aggregate certificates
shall be available to Company. The grading and purity of sand and aggregate
shall be checked at least once a week. Company reserves the right to reject any
material not deemed acceptable by virtue of either source or quality.
4.1
Cement
Cement shall be Portland cement conforming to ASTM C-150 Type II.
4.2
Sand
Sand shall be clean and graded. Clayey and schistose sands shall not be
acceptable. Sand shall be free of injurious amounts of salt, alkali, deleterious
material or organic impurities. Suitability of the natural sand for use in concrete
shall be determined in accordance with ASTM C-33.

11-22-91 CN-2 516-20.05
Page 5 of 15
Specification 20.05
4.3
Aggregate
The aggregate shall be granite, iron ore, or any other aggregate approved by
Company. The aggregate shall be well graded from fine to coarse.
The aggregate shall be clean and free from salt, alkali, deleterious material or
organic impurities. It shall conform in all respects to ASTM C-33.
4.4
Water
Water shall be clean fresh water, free from oil, alkali, organic matter or other
deleterious matter. Water shall not contain more than 250 ppm of chlorides.
Source of water supply shall be identified, and an analysis of the water supply
shall be furnished when requested by Company.
4.5
Admixtures
Admixtures shall be limited by the requirements of ASTM C-494 and shall be
added only if approved by Company.
4.6
Reinforcement
4.6.1
Reinforcement shall be high quality 1 1/2 by 1 1/2 inch No. 17 American Steel
Wire Gage galvanized woven wire mesh, hexagon weave with reverse twist,
conforming to ASTM A-390.
At the time concrete coating is applied, the wire fabric shall be free from rust,
scale dirt, oil or other coatings that may reduce the bond with the concrete.
4.6.2
Other reinforcement may be used if approved by Company in writing. Wire fabric

shall conform to ASTM-185 with galvanizing per ASTM A-153.
4.7
Storage of Materials
All materials shall be stored and handled in accordance with the applicable ASTM
Specification and the ACI Manual of Concrete Practice.
5.0
PROPORTIONING AND MIXING OF CONCRETE
5.1
Proportioning
5.1.1
Contractor shall select the necessary proportioning of materials to produce the

required strength and density. The proportions of mix to be used shall be
submitted to Company for review. For concrete other than nominal 140 lb/ft3
density, Contractor shall determine the density of the proposed mix, and submit
test method and test results to Company before start of coating.

11-22-91 CN-2 516-20.05
Page 6 of 15
Specification 20.05
5.1.2
Concrete shall have minimum compressive strengths of 1000 psi at 24 hours,

3000 psi at 7 days, and 4000 psi at 28 days.
5.1.3
Prior to commencement of production coating, Contractor shall have compressive

strength test specimens of the design mix prepared and tested in accordance with
ASTM Method C-39 or British Standards Institute Method BS 1881. Test
specimens shall be tested after a period of 24 hours and shall have a minimum
compressive strength of 1000 psi. If more than one design mix is to be used
because of the use of more than one source of any one material for the concrete,
testing shall be done for all design mixes. Testing shall be by an independent
agency approved by Company and test results shall be submitted to Company.
No coating shall commence until Company has accepted all design mixes.
If the mix is changed for any reason after commencement of coating, the new mix
shall be tested, and test results accepted by Company before the mix is used.
5.2
Batching and Mixing
5.2.1
Primary mixed concrete shall be placed within a time-temperature controlled

period so that it will produce a homogenous cohesive grout.
The concrete materials shall be accurately proportioned and mixed in a machine
that will ensure a thorough intermingling of all materials in the concrete. The
metering and feed systems shall be initially calibrated by weight before the start of
the concrete application. The amount of water and the method of its introduction
into the mix shall result in a mixture providing the physical properties stipulated in
this specification.
5.2.2
Should Contractor propose a method other than batching or using sacked and
weighed materials, a description of such method, including the measures to be
taken to assure a coating conforming to the specification, shall be presented to
Company for approval prior to beginning of coating.
5.2.3
For the impingement method of application, the use of reclaimed rebound material
shall be allowed if placed within 30 minutes. Both freshly mixed material and
rebound material shall be placed so that there is no detrimental effect to the final
concrete product.
5.2.4
Any mixed concrete which has not been placed within 30 minutes after the
introduction of the water into the mixture shall be unacceptable and shall be
disposed of by Contractor.

11-22-91 CN-2 516-20.05
Page 7 of 15
Specification 20.05
5.3
Testing
5.3.1
Compressive Strength
Samples of the mixed concrete shall be taken to determine the compressive
strength of the concrete coating mix. Three samples shall be taken each morning
and three samples each afternoon in accordance with ASTM Method C-31. Of
the sets of three samples, one sample shall be tested after 24 hours, one after 7
days, and one after 28 days. Testing shall be in accordance with ASTM Method
C-39 or British Standards BS 1881.
5.3.2
Density
Density shall be determined twice daily by weighing the samples for the 24-hour
compressive strength test before making the compressive strength test, and
calculating density based on the measured volume.
5.3.3
All testing shall be at Contractor's expense and as approved by Company. Test

results shall be submitted to Company daily.
6.0
EQUIPMENT AND APPLICATION
6.1
Equipment
Contractor shall provide suitable mechanical equipment in good operable
condition, necessary to apply a concrete coating to the corrosion
protective-coated pipe. Accessory equipment includes proper proportioning,
mixing, and handling equipment.
If required, Contractor shall demonstrate to Company by field test that his
application method, equipment and personnel will produce a concrete coating
conforming to this specification without damage to the underlying corrosion
protective coating. In the event of such damage, repairs shall be made to meet
Company requirements.
6.2
Any temporary protection for the corrosion protective coating shall be completely
removed. Maximum bond must be achieved between the corrosion protective
coating and the concrete coating.
6.3
Placement of Reinforcement
6.3.1
The reinforcement shall be spirally applied simultaneously with the concrete and
shall have an overlap of not less than 3/4 inch.

11-22-91 CN-2 516-20.05
Page 8 of 15
Specification 20.05
One wrap of reinforcing shall be used for concrete thickness up through 2

3/4 inches. An additional wrap of reinforcing shall be applied for concrete coating
thickness greater than 2 3/4 inches. The reinforcement shall be placed so as to
provide maximum reinforcing properties to the coating.
There shall be a minimum clearance of 1/2 inch between the protective-coated
pipe and the reinforcement, and a minimum cover of concrete of 1/4 inch over the
reinforcement. The reinforcement shall not protrude at the concrete coating
holdback.
6.3.2
If cathodic protection anodes are to be installed, Contractor shall provide 2 inch

minimum and 3 inch maximum clearance between anode and the reinforcement.
Reinforcement may be applied over bonding cable where the concrete coating
covers the cable.
6.4
Application by the Impingement Method

Concrete shall be applied to the rotating pipe by the high velocity impact method
so as to form a continuous coating. The surface shall be trimmed to give a
uniform thickness of concrete coating concentric with the pipe.
6.5
Application by the Compression Coat Method

Concrete mix shall be extruded onto the rotating pipe, with the required
reinforcement fabric, and shall be simultaneously covered with a plastic sheet
outer wrap under suitable tension to give a smooth surface, with a uniform
thickness concentric with the pipe.
6.6
Holdback and Cleanup

Concrete coating shall terminate to provide the holdback distance from the end of
the pipe as specified on the data sheet, or 3 inches short of the end of the
previously applied corrosion protective coating, whichever provides the greater
holdback. Coating edge shall be perpendicular to the axis of the pipe and the
steel reinforcement wire shall not protrude through the concrete coating edge.
Pipe ends shall be cleaned and examined immediately after removal from the
coating station to ensure the proper holdback distance and to remove any
concrete from the holdback area and the inside of the pipe. Where needed to
keep concrete out of the pipe, pipe ends shall be capped prior to concrete
application.

11-22-91 CN-2 516-20.05
Page 9 of 15
Specification 20.05
6.7
Temperature
Concrete shall not be applied to the pipe when the ambient temperature is less
than 40F unless Contractor has made provisions acceptable to Company to
properly protect the newly applied concrete.
7.0
CURING
7.1
The concrete coating shall be cured for a minimum of 4 days at temperatures of

not less than 40F. During curing, the concrete coated pipe shall be placed on
sand ridge windrows and shall not be stacked. Sand windrows shall be placed in
sufficient number and position to eliminate detrimental deflection in the pipe. The
concrete shall not be allowed to dehydrate. The pipe shall not be transported
until after the minimum 4 days of curing except for the initial transfer of pipe from
the coating machine to the curing area.
7.2
Curing for Impingement Method
7.2.1
Water curing, if used, shall commence as soon as possible but no later than
2 hours after coating. Water spray shall keep the coating continuously moist for
no less than 4 days providing temperatures are above 50F, or no less than
7 days if temperatures are below 50F.
7.2.2
Membrane curing, if used, shall be with a liquid membrane-forming compound

conforming to ASTM C-309. It shall be applied by mechanical equipment to the
coated surface in sufficient quantity to provide complete coverage in accordance
with manufacturer's recommendations. The application of curing compound shall
take place immediately after concrete coating is completed and shall be preceded
by a fine water spray.
7.2.3
Other curing procedures shall be subject to Company approval.
7.3
Curing for Compression Coat Method

The plastic sheet outer wrap must be kept in place a minimum of 7 days, and
preferably longer.
8.0
PERMISSIBLE REPAIRS TO CONCRETE COATING

Concrete coating with defects or damage or which does not conform otherwise to
this specification shall be promptly repaired to the satisfaction of Company.
8.1
Repairs to defective or damaged concrete coating shall be as follows:

11-22-91 CN-2 516-20.05
Page 10 of 15
Specification 20.05
An area of defect or damage of 1 ft2 or less in any 5-foot run of pipe, for which the
depth is 25 percent or less of the total thickness of the coating, may be accepted
without repair, provided the remaining concrete is sound and the reinforcement is
not exposed.
Defective or damaged areas exceeding 1 ft2 or 25 percent deep shall be repaired
by removing the concrete to sound coating material and to expose reinforcement.
Any damaged reinforcement shall be replaced. The edges of the removed area
shall be undercut to provide a key lock for the repair material. Undercut for key
lock is not required if original reinforcing mesh remains intact and is exposed or if
replacement reinforcing can be securely attached.
A stiff mixture of grout or concrete shall be troweled into and through the
reinforcement, and built up until the surface is even and smooth with the original
coating around the repair. The coating resulting from the repair shall be equal in
strength to the coating originally applied.
The repaired joint shall be carefully laid in a safe position and moist cured or liquid
membrane cured for a minimum of 4 days before further handling.
8.2
Cracks
Hairline cracks less than 1/16 inch in width need not be repaired.
Circumferential cracks exceeding 1/16 inch in width at the surface and extending
more than 180 degrees shall be repaired.
Longitudinal cracks exceeding 1/16 inch in width at the surface and in excess of
12 inches in length shall be repaired.
9.0
Crack repairs shall be made by widening the crack to 1 inch for the necessary
depth and length and packing the prepared crack with the repair material specified
above until level with the existing coating. Pipe joints with repaired cracks shall
remain undisturbed for a minimum of 36 hours.
CAUSES FOR REJECTION
Causes for rejection of the concrete coating shall include but not be limited to the
following:
Concrete compressive strength less than the specified value.

Failure to initiate and maintain the concrete control data and testing
procedures.
Density of concrete coating does not meet the tolerance specified on the
data sheet.
Weight of a concrete-coated pipe joint, or total of 10 consecutive joints, is
not within the tolerances specified on the data sheet.

11-22-91 CN-2 516-20.05
Page 11 of 15
Specification 20.05
10.0
Coating in which the reinforcement is improperly placed.

Coating application on a joint interrupted for more than 30 minutes.
Coating that is defective or damaged to such an extent that Company
considers satisfactory repair is impossible.
Concrete coating does not fully adhere to the corrosion protective coating.
Any failure of the materials employed to conform to the specifications.
Any defective condition of equipment, materials or workmanship which in
the judgment of Company would render the coated pipe unsuitable for the
conditions and purposes stipulated in this specification.
CARE, HANDLING, AND STORAGE OF PIPE

a.
Reasonable care shall be exercised while handling pipe to prevent

damage to coating, pipe, beveled ends, etc. Padded forks, canvas
slings/belts, and/or relatively soft plastic or rubber-lined hook ends, etc.,
shall be used.
b.
Pipe and protective coating damaged while in the possession of Contractor shall be repaired to Company's satisfaction at Contractor's expense.
Any pipe which cannot be repaired shall be scrapped.
c.
Contractor shall inspect the corrosion protective coating on inspection

racks prior to concrete coating, using a holiday detector approved by
Company. The holiday detector voltage shall be appropriate for the
protective coating, but no higher than 80% of the voltage used at the plant
where the protective coating was applied. If pipe was wrapped with kraft
paper or similar wrapping, the paper shall be completely removed before
inspection and concrete coating.
Contractor shall repair all defects in protective coating using a method
approved by the Company.
d.
Protective-coated pipe shall be racked in rows and tiers in a manner that

will prevent damage to pipe and protective coating.
e.
Concrete-coated pipe shall be handled and stored by Contractor so as to

minimize cracking or other injury to the concrete.
f.
Concrete-coated pipe joints needing cleaning or repairs shall not be stock

piled until such time as cleaning and repairs have been completed.
g.
The loading of pipe shall be approved by Company. Pipe lots of each

coating thickness and weight shall remain segregated and shall be
shipped separately.

11-22-91 CN-2 516-20.05
Page 12 of 15
Specification 20.05
11.0
SPECIAL WORK
11.1
Anode Bracelet Attachment

Anodes shall be attached to the pipe lengths after concrete coating application.
Installation shall comply with Section 7 of this specification, NACE Standard
MR-06-75 "Control of Corrosion on Offshore Steel Pipelines", Company Technical
Requirements, and manufacturer's instructions. If the anode rings are welded,
they shall be insulated from the corrosion protective coating. Bonding cables shall
be welded to the pipe and tested for electrical continuity prior to concrete
application. Steel reinforcing mesh shall not be within 2 inches of the anode. All
welded areas shall be recoated with corrosion protective coating. The gap
between the anode bracelet and the concrete coating shall be filled with a stiff
grout to provide an even surface between the anode and the adjacent concrete
coating.
Concrete shall be smoothly formed at a 1:4 taper to match the anode thickness
when there are differences between anode and weight-coating thicknesses.
Grout shall not be placed until the anode is installed and protective coating repairs
are approved by Company. After completing grouting, an ohmmeter check shall
be made to prove electrical continuity between the pipe and the anode.
12.0
IDENTIFICATION OF PIPE JOINTS AND REPORTS
12.1
The pipe mill shall paint a pipe joint number in 3-inch high letters on the inside at
each end of each pipe joint. Contractor shall indelibly paint this number, or his
own number, on the outside at each end of each weight-coated joint along with
the pipe size, wall thickness, and nominal weight-coating thickness. This
identification shall be located between 1 foot and 5 feet of both pipe ends.
12.2
The following information shall be recorded for each pipe joint and furnished at
least weekly to Company:
1.
Pipe Joint Number
2.
Coating Joint Number (if different)
3.
Date and time of receipt
4.
Defects at receipt
5.
Calculated weight of pipe joint with corrosion protective coating before

weight coating
6.
Date coating applied

11-22-91 CN-2 516-20.05
Page 13 of 15
Specification 20.05
7.
Weight of pipe after weight coating
8.
Percent deviation in weight from calculated weight, plus or (minus)
9.
Measured average outside diameter of concrete-coated pipe
10.
Average weight-coating thickness
11.
Number and nature of concrete coating defects/repairs
12.
Date and time of shipment
13.
Coating and/or pipe defects at shipment

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Specification 20.05
APPENDIX I
STANDARDS AND CODES
1.
INDUSTRY STANDARDS
American Concrete Institute
Manual of Concrete Practice
American Society for Testing and Materials (ASTM)

A-153
Standard Specification for Zinc Coating (Hot-dip) on Iron and Steel

Hardware
A-185
Standard Specification for Welded Steel Wire Fabric for Concrete

Reinforcement
A-390
Specification for Zinc-coated (Galvanized) Steel Poultry Netting

(Hexagonal and Straight Line) and Woven Steel Poultry Fencing
C-31
Standard Method of Making and Curing Concrete Test Specimens in

the Field
C-33
Standard Specification for Concrete Aggregates
C-39
Standard Method of Test for Compressive Strength of Cylindrical

Concrete Specimens
C-150
Standard Specification for Portland Cement
C-309
Standard Specification for Liquid Membrane-Forming Compounds

for Curing Concrete
C-494
Standard Specification for Chemical Admixtures for Concrete
British Standards Institute

BS 1881 Methods of Testing Concrete (British Standards Institute)

11-22-91 CN-2 516-20.05
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