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Concrete Coating of Line Pipe
Impingement Method PPL-SU-2014
CONTENTS
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Concrete Coating of Line Pipe
Impingement Method PPL-SU-2014
1.0 SCOPE
This specification defines the minimum requirements for materials, application, inspection and
testing of concrete weight coatings to provide negative buoyancy for pipeline at water crossings,
marshy areas and submarine applications.
2.0 REFERENCES
1. The following documents are referenced herein and are considered part of this specification.
2. Use the edition of each referenced document in effect on the date of the publication of this
specification.
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Concrete Coating of Line Pipe
Impingement Method PPL-SU-2014
3.0 GENERAL
1. Any and all exceptions to Purchaser specifications shall be submitted in writing with the
quotation. Exceptions shall be subject to Purchaser review and agreement.
2. Concrete weight coating shall be applied by the impingement method.
3. Concrete weight coating shall be applied over a corrosion resistant coating of fusion bonded
epoxy (FBE) in accordance with COM-SU-4042.
4. Weight of Concrete Coated Pipe Joint
The weight of any concrete coated pipe joint shall not vary from the calculated weight for
specified density and thickness by more than the tolerances specified in Section 6.1 item 3.
Applicator shall weigh each concrete coated pipe joint immediately after coating.
The calculated weight for the pipe joint, in pounds, shall be:
(Joint Weight)calc = (L x Wp) + [(L - 2h) x Wc]
Where:
Wp = Nominal weight of corrosion protective coated pipe, lb/ft (without concrete
coating)
L = Length of joint, ft
h = Hold back length at each end of joint, ft
Wc = concrete coating weight, lb/ft, as specified on the Data Sheet.
4.0 MATERIALS
4.1 Concrete
1. Cement shall comply with ASTM C150/C150M, Type I/Type II. Cement materials shall be
stored and handled in accordance with Section 2 of ACI 304R.
2. Sand and gravel shall comply with the requirements of ASTM C33/C33M for fine aggregate.
3. Heavy aggregate shall be well graded, clean, and free from salt, alkali, and other harmful
substances and organic impurities. It shall comply in all respects with aggregate as defined in
ASTM C29/C29M.
4. Concrete density shall be as specified on data sheet PPL-DS-2014.
5. Prior to commencement of production coating, applicator shall have compressive strength test
specimens of the design mix prepared and tested in accordance with ASTM C39/C39M.
a. Test specimens shall be tested after a period of 24 hours and shall have a minimum
compressive strength of 1000 psi.
b. 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.
c. Testing shall be by an independent agency agreed to by Purchaser and test results shall be
submitted to Purchaser.
d. No coating shall commence until Purchaser has accepted all design mixes.
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Concrete Coating of Line Pipe
Impingement Method PPL-SU-2014
4.2 Water
1. Water shall be clean and free from injurious amounts of oil, acid, alkali, salt, organic material
or other deleterious substances as required by ASTM C94/C94M.
2. Water shall not contain more than 250 ppm of chlorides.
5.0 APPLICATION
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Concrete Coating of Line Pipe
Impingement Method PPL-SU-2014
5.3 Concrete
1. Primary mixed concrete shall be placed within a time-temperature controlled period such that
it will produce a homogenous cohesive grout.
2. Concrete materials shall be accurately proportioned and mixed in a machine that will ensure a
thorough intermingling of all materials in the concrete.
a. Metering and feed systems shall be initially calibrated by weight before the start of the
concrete application.
b. 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.
3. If applicator proposes 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 and shall be subject to Purchaser for agreement prior to
beginning of coating.
4. Any mixed concrete that has not been placed within 30 minutes after the introduction of the
water into the mixture is unacceptable and shall be disposed of by applicator.
5. Each joint of pipe shall be rotated and coated in a continuous operation such that the required
total thickness of coating is applied uniformly and is free from abrupt irregularities, cold
joints, or excessive variations in thickness.
6. Concrete coating shall terminate to provide the holdback distance from the end of the pipe as
specified on data sheet PPL-DS-2014 or 3 inches (76 mm) short of the end of the previously
applied corrosion protective coating, whichever provides the greater holdback.
a. Coating edge shall be perpendicular to the axis of the pipe and the steel reinforcement wire
shall not protrude through the concrete coating edge.
b. 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.
c. Pipe ends shall be capped prior to concrete application.
7. Concrete shall not be applied if the ambient temperature or the surrounding temperature at the
curing station is 40°F (4.4°C) or less.
8. If temperature goes below 40°F (4.4°C) during the coating period, the coating shall be
protected.
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Concrete Coating of Line Pipe
Impingement Method PPL-SU-2014
Where:
Wp = Nominal weight of corrosion protective-coated pipe, lb/ft (without concrete
coating)
L = Length of joint, ft
h = Hold back length at each end of joint, ft
Dc = Average outside diameter of concrete-coated pipe, in.
Ap = Cross-section area of protective-coated pipe, ft2
The “as-applied” density shall be calculated immediately after weighing and measuring
diameter for at least every fifth joint coated.
5.5 Curing
1. Concrete shall be protected from freezing during the curing period.
2. Concrete shall be cured by one of the following methods.
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Concrete Coating of Line Pipe
Impingement Method PPL-SU-2014
6.1 Testing
1. Applicator shall provide Proctor samples of the mixed concrete to determine the compressive
strength of the concrete coating mix.
a. Four samples shall be taken at the beginning and end of each work shift in accordance
with ASTM C31/C31M and stored with coated pipe until testing.
b. Of the four samples, one sample shall be tested after 24 hours, one after 7 days, and one
after 28 days. The fourth sample shall be used for density tests in Section 6.1 item 2.
Density shall be determined twice daily using the samples in accordance with ASTM
C642.
c. Testing shall comply with ASTM C39/C39M.
d. Concrete shall have minimum compressive strengths of 1000 psi at 24 hours, 2500 psi at
7 days, and 3000 psi at 28 days.
2. Density shall be determined twice daily using the samples in accordance with ASTM C642.
Density shall be within +5% of specified density.
3. Applicator shall weigh each concrete coated pipe joint immediately after coating. The weight
of each concrete coated pipe shall be within -5% to +7-1/2% of the theoretical coated weight
in air.
4. Weighing devices used to determine the weight of the concrete coated joints shall be certified
in writing to an accuracy of 0.5%.
a. The weighing device shall be calibrated just prior to start of coating by an independent
agency agreed to by Purchaser by weighing a piece of coated pipe of a known weight.
b. Checking of the weighing devices shall be done at the beginning of each day’s production,
and Purchaser shall retain the option to request a check at any time.
c. The check shall be performed using a joint of pipe weighing within + 25% of the weight of
a concrete-coated pipe joint to be coated under this Contract.
5. Applicator shall measure the outside diameter of the concrete either on the scale or as soon as
the joint is placed on the curing rack.
a. The outside diameter shall be measured by diameter tape at least five points evenly spaced
along the length of the pipe joint and the average of these measurements reported and used
in calculations for coating thickness and concrete density.
b. Concrete coating thickness shall not vary more than 1/4 inch from high to low in any three
linear feet.
c. Report entries and calculations required by Section 5.4 and Section 3.0 item 4 shall be
made within 30 minutes after the pipe joint is placed on the curing rack.
6. All testing shall be at the applicator’s expense and as agreed to by Purchaser.
7. Test results shall be submitted to Purchaser daily.
6.2 Inspection
1. An area of defect or damage of 1 ft2 (305 mm2) or less in any 5-foot (1.5 m) run of pipe for
which the depth is 25% 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.
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Concrete Coating of Line Pipe
Impingement Method PPL-SU-2014
2. Defective or damaged areas exceeding 1 ft2 (305 mm2) or 25 percent deep shall be repaired by
removing the concrete to sound coating material and to expose uninjured reinforcement.
a. Any damaged reinforcement shall be replaced.
b. The edges of the removed area shall be undercut to provide a key lock for the repair
material.
c. Undercut for key lock is not required if original reinforcing mesh remains intact and is
exposed or if replacement reinforcing can be securely attached.
3. Circumferential cracks exceeding 1/16 inch (1.6 mm) in width at the surface and extending
more than 180 degrees shall be repaired.
4. Longitudinal cracks exceeding 1/16 inch (1.6 mm) in width at the surface and in excess of
12 inches (305 mm) in length shall be repaired.
5. Cracks less than 1/16 inch (1.6 mm) in width and less than 25% of the coating thickness deep
need not be repaired.
7.0 REPAIRS
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Concrete Coating of Line Pipe
Impingement Method PPL-SU-2014
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Concrete Coating of Line Pipe
Impingement Method PPL-SU-2014
e. Pipe lots of each coating thickness and weight shall remain segregated and shall be
shipped separately.
f. Applicator shall reimburse Purchaser for any transportation demurrage due to excessive
delay in loading-out.
8. Transportation shall be in accordance with API RP 5L1 or API RP 5LW as applicable.
10.0 DOCUMENTATION
1. Applicator shall provide Purchaser with the following procedures and reports/records:
a. Batching, compressive strength tests, water absorption test, and submerged weight
calculation and test procedures to be submitted as part of the installation procedures.
b. Material receipts.
c. Inspection and repair reports.
d. Current list of qualified personnel and qualification procedures and test results (to be
presented to Purchaser prior to using the personnel).
e. Quality control reports showing rejection rates, discontinuity types, and corrective actions
taken.
2. The following information shall be provided to Purchaser by the applicator referenced to each
pipe mill joint number:
a. Average of three girth measurements on the finished concrete coated pipe, approximately
equidistantly spaced along the pipe.
b. Weight of pipe length after concrete coating.
c. Pipe length.
d. Actual weight of pipe (provided by mill) and calculated weight of corrosion coating before
concrete coating.
e. Date of concrete coating application.
f. Calculated submerged weight for the joint after coating.
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