PPL-SU-2005

CONCRETE COATING OF LINE PIPE—

COMPRESSION METHOD

APPLICATION: ONSHORE, TOPSIDES, SUBSEA

This document is the confidential property of Chevron U.S.A. Inc. Neither

the whole nor any part of this document may be disclosed to any third
party without the prior written consent of Chevron U.S.A. Inc. Neither the
whole nor any part of this document may be reproduced, stored in any
retrieval system, or transmitted in any form or by any means (electronic,
mechanical, reprographic, recording, or otherwise) without the prior
written consent of Chevron U.S.A. Inc.

Rev Date Description Author Sponsor

06/06 Initial release JROF JROF
03/12 Reaffirmation only. Document number changed GWBR SMIS
from PPL-SU-20.05 No technical content
changes made.

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CONTENTS

1.0 Scope ..........................................................................................................................3

2.0 References ..................................................................................................................3
2.1 Purchaser Documents ......................................................................................3
2.2 Industry Codes and Standards .........................................................................3
3.0 Definitions ...................................................................................................................4
4.0 General ........................................................................................................................4
5.0 Materials ......................................................................................................................4
5.1 Concrete ...........................................................................................................4
5.2 Water ................................................................................................................5
5.3 Reinforcing Steel ..............................................................................................5
5.4 Admixtures .......................................................................................................5
5.5 Shear Bonding (Non-slip) Adhesives ...............................................................5
5.6 Storage of Materials .........................................................................................5
6.0 Application ..................................................................................................................5
6.1 Corrosion Resistant Protective Coating ...........................................................5
6.2 Reinforcing Steel ..............................................................................................5
6.3 Concrete ...........................................................................................................6
6.4 Concrete Coating Density as Applied ...............................................................7
6.5 Curing ...............................................................................................................7
7.0 Inspection and Testing ..............................................................................................7
7.1 Testing ..............................................................................................................7
7.2 Inspection .........................................................................................................8
8.0 Repairs ........................................................................................................................8
9.0 Causes for Rejection .................................................................................................9
10.0 Care, Handling, Storage, and Transportation of Pipe .............................................9
11.0 Documentation .........................................................................................................10
12.0 Identification and Marking .......................................................................................11

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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. Unless otherwise specified in Section 2.1 or Section 2.2, use the latest edition of the
referenced documents.

2.1 Purchaser Documents

COM-SU-4042 Single-Layer Fusion-Bonded Epoxy for External Pipeline Coatings
PPL-DS-2005 Data Sheet for Concrete Coating of Line Pipe

2.2 Industry Codes and Standards

American Concrete Institute (ACI)
304R Guide for Measuring, Mixing, Transporting, and Placing Concrete
Manual of Concrete Practice
American Petroleum Institute (API)
RP 5L1 Recommended Practice for Railroad Transportation of Line Pipe
RP 5LW Recommended Practice for Transportation of Line Pipe on Barges and
Marine Vessels
American Society for Testing and Materials (ASTM)
A82/A82M Standard Specification for Cold-Drawn Steel Wire for Concrete
Reinforcement
A185/A185M Standard Specification For Steel Welded Wire Reinforcement, Plain, for
Concrete
A810 Standard Specification for Zinc-Coated (Galvanized) Steel Pipe Winding
Mesh
C29/C29M Standard Test Method for Bulk Density (“Unit Weight”) and Voids in
Aggregate
C31/C31M Standard Practice for Making and Curing Concrete Test Specimens in the
Field
C33/C33M Standard Specification for Concrete Aggregates
C39/C39M Standard Test Method for Compressive Strength of Cylindrical Concrete
Specimens
C94/C94M Standard Specification for Ready-Mixed Concrete
C150/C150M Standard Specification for Portland Cement
C494/C494M Standard Specification for Chemical Admixtures for Concrete
C642 Standard Test Method for Density, Absorption, and Voids in Hardened
Concrete

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3.0 DEFINITIONS
For the purpose of this document, the following definitions shall apply:
Applicator—The party responsible for furnishing or installing the concrete coating system.
Designer—The person or organization in responsible charge of the engineering design.

4.0 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 compression or form 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 7.1 item 3.
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 PPL-DS-2005.

5.0 MATERIALS

5.1 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 304.
2. Sand and gravel shall comply with the requirements of ASTM C33/C33M and ASTM
C94/C94M 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-2005.
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.

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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.

5.2 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 94.
2. Water shall not contain more than 250 ppm of chlorides.

5.3 Reinforcing Steel

1. Wire reinforcement shall comply with ASTM A185/A185M and be galvanized or comply with
ASTM A810.
2. Wire material shall comply with ASTM A82/A82M.
3. Minimum wire diameter shall be 17 gauge (1.15 mm) and maximum mesh size of 1.5 inches
(40 mm).
4. Mesh shall not be crimped.

5.4 Admixtures
1. Admixtures shall comply with ASTM C494/C494M.
2. Admixtures shall be used only with Purchaser agreement.

5.5 Shear Bonding (Non-slip) Adhesives

1. Shear bonding adhesives shall be 100% solids 1-part liquid epoxy or FBE roughcoat.
2. Shear bonding adhesives shall be applied in a 4-inch (100 mm) spiral for the entire length of
each pipe starting and stopping approximately 12 inches (300 mm) from the concrete holdback
specified on PPL-DS-2005.

5.6 Storage of Materials

All materials shall be stored and handled in accordance with the applicable ASTM specification
and the Manual of Concrete Practice.

6.0 APPLICATION

6.1 Corrosion Resistant Protective Coating

Prior to the application of concrete weight coating, the FBE shall be visually inspected and holiday
tested in accordance with COM-SU-4042 and any temporary protection shall be completely
removed.

6.2 Reinforcing Steel

1. The reinforcement shall be spirally applied simultaneously with the concrete and shall have a
minimum overlap of 1/2 inch (13 mm).
2. One wrap of reinforcing shall be used for concrete thickness up through 2-3/4 inches (70 mm).
a. An additional wrap of reinforcing shall be applied for concrete coating thickness greater
than 2-3/4 inches (70 mm).

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b. The reinforcement shall be placed to provide maximum reinforcing properties to the

coating.
3. There shall be a minimum clearance of 1/2 inch (13 mm) between the protective-coated pipe
and the reinforcement, and a minimum cover of concrete of 1/4 inch (6 mm) over the
reinforcement. The reinforcement shall not protrude at the concrete coating holdback.
4. If cathodic protection anodes are to be installed, applicator shall provide 2-inch (51 mm)
minimum and 3-inch (76 mm) maximum clearance between anode and reinforcement.

6.3 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. 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. Concrete coating shall terminate to provide the holdback distance from the end of the pipe as
specified on data sheet PPL-DS-2005 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. If needed to keep concrete out of the pipe, 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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6.4 Concrete Coating Density as Applied

1. Density of concrete coating shall be as stated on data sheet PPL-DS-2005, and shall not vary
by more than the plus or minus tolerance specified on the data sheet.
2. If the density varies from the specified density by more than the stated tolerance, applicator
shall take corrective measures to obtain specified density, and shall immediately inform
Purchaser Representative of the deviation and corrective measures.
Density of “as-applied” concrete coating shall be determined using the weight and dimensions
of a concrete coated joint, by the following calculation:

 Weight of Joint, lb.  –  L  W P  1

Density in lb. per cubic ft. = -------------------------------------------------------------------------------  ----------------------------------------
2
-
L – 2h 0.00545D – A c p

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.

6.5 Curing
1. Concrete shall be cured for a minimum of 7 days prior to unwrapping.
2. Concrete shall be protected from freezing during the curing period.

7.0 INSPECTION AND TESTING

7.1 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 7.1 item 2.
c. Testing shall comply with ASTM C39/C39M.
d. Concrete shall have minimum compressive strengths of 1000 psi at 24 hours, 3000 psi at
7 days, and 4000 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.

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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. Report entries and calculations required by Section 6.4 and Section 4.0 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.

7.2 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.
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.

8.0 REPAIRS
1. Defective or damaged areas shall be repaired by removing the concrete to sound coating
material and to expose uninjured reinforcement.
2. Any damaged reinforcement shall be replaced.
a. The edges of the removed area shall be undercut to provide a key lock for the repair
material.
b. Undercut for key lock is not required if original reinforcing mesh remains intact and is
exposed or if replacement reinforcing can be securely attached.

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9.0 CAUSES FOR REJECTION

Causes for rejection of the concrete coating shall include the following:
1. Concrete compressive strength is less than the specified value.
2. Failure to initiate and maintain the concrete control data and testing procedures.
3. Density of concrete coating is not within the tolerance specified.
4. Weight of a concrete-coated pipe joint is not within the tolerance specified.
5. Coating in which the reinforcement is improperly placed.
6. Coating application on a joint is interrupted for more than 30 minutes.
7. Coating that is defective or damaged to such an extent that Purchaser considers satisfactory
repair is impossible.
8. Concrete coating does not fully adhere to the corrosion protective coating.
9. Any failure of the materials employed to comply with the specifications.
10. Any defective condition of equipment, materials, or workmanship which, in the judgment of
Purchaser, would render the coated pipe unsuitable for the conditions and purposes stipulated
in this specification.

10.0 CARE, HANDLING, STORAGE, AND TRANSPORTATION OF PIPE

1. Applicator shall inventory pipe upon receipt and inspect for damage such as dents, flat ends,
end bevel damage, corrosion protective coating condition or damage, etc.
a. Any visible damage shall be noted on the inbound inventory report; damage not so noted
shall be considered applicator’s responsibility.
b. One copy of daily inventory reports shall be given to Purchaser not later than end of day
following day of receipt of pipe.
2. Applicator shall be solely responsible for the condition of the pipe from the time it is received
until after it has been loaded for shipment.
a. Reasonable care shall be exercised while handling pipe to prevent damage to coating,
pipe, beveled ends, etc.
b. Padded forks, canvas slings/belts, relatively soft plastic or rubber-lined hook ends (or all),
etc., should be used.
c. Pipe and protective coating damaged while in the possession of applicator shall be
repaired to Purchaser’s satisfaction at applicator’s expense.
d. Any pipe that cannot be repaired shall be scrapped.
e. Actual invoiced cost of scrapped pipe, including coating and transportation, shall be
deducted from compensation due applicator.
3. Applicator shall inspect the corrosion protective coating on inspection racks prior to concrete
coating, using a holiday detector agreed to by Purchaser.
a. 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.
b. If pipe was wrapped with Kraft paper or similar wrapping, the paper shall be completely
removed before inspection and concrete coating.

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4. Applicator shall repair all defects in protective coating using the method described on the data
sheet or other suitable Purchaser-accepted method.
5. Protective-coated pipe shall be racked in rows and tiers in a manner that will prevent damage
to pipe and protective coating.
6. Concrete-coated pipe shall be handled and stored by applicator so as to minimize cracking or
other injury to the concrete.
a. Concrete-coated pipe can be stacked after curing as a maximum to the number of tiers
shown on data sheet PPL-DS-2005.
b. Concrete-coated pipe joints needing cleaning or repairs shall not be stockpiled until such
time as cleaning and repairs have been completed.
7. Applicator shall load out coated pipe.
a. Purchaser shall give at least 24-hour notice prior to any loading requirement.
b. If Purchaser requests, applicator shall furnish personnel to load or unload pipe outside
normal operating hours at costs shown in Contract Exhibit - Schedule of Compensation.
c. The loading shall be agreed to by Purchaser.
d. Lifting and rigging shall be performed in accordance with applicable procedures.
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.

11.0 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.

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e. Date of concrete coating application.

f. Calculated submerged weight for the joint after coating.

12.0 IDENTIFICATION AND MARKING

1. The pipe mill shall paint a pipe joint number in 3-inch (76 mm) high letters on the inside at
each end of each pipe joint.
a. The 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.
b. This identification shall be located between 1 foot (305 mm) and 5 feet (1.5 m) of both
pipe ends.
2. Special pipe joints such as joints containing buckle arrestors, anodes, or both shall be clearly
marked and the location of the buckle arrestor or anode shall be visible or indicated on the
concrete.

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