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Concrete Coating of Line Pipe—
Compression Method PPL-SU-2005
CONTENTS
March 2012 (R) © 2006–2012 Chevron U.S.A. Inc. All rights reserved. 2 of 11
Concrete Coating of Line Pipe—
Compression Method PPL-SU-2005
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.
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Concrete Coating of Line Pipe—
Compression Method PPL-SU-2005
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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Concrete Coating of Line Pipe—
Compression Method PPL-SU-2005
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.
5.4 Admixtures
1. Admixtures shall comply with ASTM C494/C494M.
2. Admixtures shall be used only with Purchaser agreement.
6.0 APPLICATION
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Concrete Coating of Line Pipe—
Compression Method PPL-SU-2005
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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Concrete Coating of Line Pipe—
Compression Method PPL-SU-2005
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.
7.1 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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Concrete Coating of Line Pipe—
Compression Method PPL-SU-2005
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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Concrete Coating of Line Pipe—
Compression Method PPL-SU-2005
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Concrete Coating of Line Pipe—
Compression Method PPL-SU-2005
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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Concrete Coating of Line Pipe—
Compression Method PPL-SU-2005
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