Concrete Weight Coating

PETRONASCARIGALISDNBHDPROVISIONOFFRONTENDENGINEERINGDESIGN(FEED)AND

ENGINEERING,PROCUREMENT,CONSTRUCTION,INSTALLATION&COMMISSIONING(EPCIC)OFSK316DEVELOPMENTPROJECT

(CONTRACTNO.CHO/2012/D316/1000)

Page2of50Area Loc. Typ. Disc. No. Rev.05 SSPL SPC U 0005 0

File 05SSPLSPCU00050.doc

TABLEOFCONTENT1 PROJECTINTRODUCTION............................................................................................................51.1 SCOPEOFDOCUMENT.......................................................................................................................71.2 DEFINITION.........................................................................................................................................71.3 ABBREVIATION...................................................................................................................................72 REFERENCES................................................................................................................................82.1 PROJECTDOCUMENTS.......................................................................................................................82.2 COMPANYSTANDARDS......................................................................................................................82.3 CODESANDSTANDARDS....................................................................................................................82.4 SYSTEMOFUNITS...............................................................................................................................93 GENERALREQUIREMENTS.........................................................................................................104 CONCRETECOATINGMATERIALS..............................................................................................114.1 CEMENT............................................................................................................................................114.2 AGGREGATES....................................................................................................................................114.3 WATER..............................................................................................................................................124.4 ADDITIVES.........................................................................................................................................124.5 REINFORCINGSTEEL.........................................................................................................................124.6 WELDEDSTEELWIREMESH..............................................................................................................134.7 STEELCAGETYPE..............................................................................................................................135 RECEIPT,HANDLINGANDSTORAGEOFBAREPIPES...................................................................146 CONCRETECOATINGAPPLICATION...........................................................................................156.1 VISUALANDHOLIDAYINSPECTIONOF3LAYERPECOATEDPIPES.................................................156.2 PLACEMENTOFREINFORCEMENTSTEEL.........................................................................................157 APPLICATIONOFCOATINGMATERIALS.....................................................................................167.1 PREPARATIONOFTHECUTBACKAREA............................................................................................167.2 FINISHINGOPERATIONSWITHINCONCRETECOATINGPLANT........................................................167.3 CURING.............................................................................................................................................177.3.1 WATERCURING...............................................................................................................................177.3.2 STEAMCURING................................................................................................................................187.3.3 CURINGBYSEALINGCOMPOUNDS.................................................................................................18






7.3.4 CURINGUNDERPOLYETHYLENEWRAPPING...................................................................................187.3.5 FOGCURING....................................................................................................................................198 INSPECTIONANDTESTING........................................................................................................208.1 STACKINGOF3LAYERPECOATEDPIPES.........................................................................................218.2 CONTROL,IDENTIFICATIONANDSEGREGATIONOF3LAYERPECOATEDPIPES.............................228.3 DELIVERYANDSTORAGEOFCONCRETECOATINGRAWMATERIALS..............................................228.4 TESTTOBEPERFORMEDONCONCRETECOATINGMATERIALUPONRECEIPT...............................238.4.1 SIEVEANALYSISANDCLEANLINESSCONTROLOFAGGREGATES....................................................238.4.2 STEELREINFORCEMENTWIRESDIMENSIONALCONTROL..............................................................238.4.3 MIXINGWATERCHEMICALANALYSIS.............................................................................................238.5 VERIFICATIONOFCALIBRATIONOFTHETESTINSTRUMENTS.........................................................248.5.1 HOLIDAYDETECTOR........................................................................................................................248.5.2 PIPEWEIGHINGSCALES...................................................................................................................248.6 VISUALANDHOLIDAYINSPECTIONOFTHE3LAYERPECOATEDPIPES..........................................248.7 CONCRETECOATINGMIXCONTROL................................................................................................258.8 CONCRETECOATINGMIXTEMPERATUREMEASUREMENT.............................................................258.9 WATERCEMENTRATIOCHECK........................................................................................................258.10 REINFORCINGWIREPOSITIONCONTROL.........................................................................................268.11 CONCRETECOATINGAPPLICATIONCONTROL.................................................................................268.12 MEASUREMENTOFEXTERNALDIAMETEROFAPPLIEDCONCRETE.................................................268.13 CUTBACKCONTROL..........................................................................................................................278.14 WEIGHINGOFFRESHLYCONCRETECOATEDPIPE............................................................................278.15 CALCULATIONOFNEGATIVEBUOYANCY.........................................................................................278.16 VISUALINSPECTIONOFAPPLIEDCONCRETE....................................................................................288.16.1 SURFACEFALLOUTS(SPALLING)OFFRESHLYCONCRETECOATEDPIPES......................................298.16.2 CONCRETECOATINGDAMAGESONFRESHANDHARDENEDCONCRETE.......................................298.16.3 CRACKS............................................................................................................................................298.17 ELECTRICALRESISTANCEBETWEENSTEELREINFORCEMENTANDTHEPIPE...................................308.18 CONTROLOFCURINGPROCESS.......................................................................................................308.19 CONTROLOFSTACKINGOFPIPESDURINGTHECURINGPROCESS..................................................30






8.20 CONTROLOFMARKINGONCONCRETECOATEDPIPES...................................................................308.21 CONTROLOFMARKINGONCONCRETECOATINGREPAIR...............................................................318.22 DETERMINATION OF FACTOR ALPHA IN THE FORMULA FOR CALCULATION OF NEGATIVE

BUOYANCY.......................................................................................................................................318.23 COMPRESSIONSTRENGTHTESTCUBES...........................................................................................318.24 COMPRESSIONSTRENGTHCORESAMPLES......................................................................................328.25 DETERMINATIONOFTHETIMEFORSTACKINGOFPIPESINMORETHANONELAYER...................338.26 WATERABSORBTIONTEST...............................................................................................................348.27 ADHESIONBETWEENTHE3LAYERPECOATINGANDCONCRETECOATING...................................348.28 IMPACTTESTING..............................................................................................................................358.29 STACKINGOFCUREDCONCRETECOATEDPIPES..............................................................................368.30 LOADOUTINSPECTIONS..................................................................................................................379 3LAYERPECOATINGREPAIR....................................................................................................3810 CONCRETECOATINGREPAIRANDSTRIPPINGOFCONCRETECOATEDPIPES..............................4011 PIPEMARKING..........................................................................................................................4212 STORAGE,HANDLINGANDTRANSPORTATIONOFCONCRETECOATEDPIPES............................4313 DOCUMENTATION....................................................................................................................4513.1 GENERALREQUIREMENTS................................................................................................................4513.2 TECHNICALDOCUMENTATIONTOBESUBMITTEDDURINGTHEBIDDINGPHASE..........................4513.3 TECHNICAL DOCUMENTS TO BE SUBMITTED AFTER AWARD OF THE CONTRACT TO

SUBCONTRACTOR............................................................................................................................4613.4 FINALTECHNICALDOCUMENTATION..............................................................................................4713.5 CONTENTOFPARTICULARTECHNICALDOCUMENTS......................................................................4813.5.1 CONCRETECOATINGAPPLICATIONPROCEDURE............................................................................4813.5.2 INSPECTIONANDTESTPLAN...........................................................................................................4913.5.3 DAILYPRODUCTIONREPORT...........................................................................................................49






1 PROJECTINTRODUCTIONNC3andNC8aregasfields located inBlockSK316,approximately180kmNorthofBintulu,Sarawakwithwaterdepthrangingapprox.between70m105m.NC8fieldislocatedapproximately7kmSouthEastonNC3field.ThenearbyriserfacilityE11RCislocatedapproximately80kmSouthWestofNC3.TheexistingtrunklineconnectingE11RCtoshoreTL6isavailableandprovisionedforinthisgasfielddevelopment.ThelocationsofNC3,NC8andnearbyfacilitiesareillustratedinFigure11below.

Figure11LocationofProject

GasfromNC3andNC8fieldsarethemainfeedgassupplierintothePETRONASLNGComplexTrain9nearBintuluwhich is expected to be ready for startup inDecember 2015.The scope demarcation betweenupstreamanddownstreamfacilitiesisasdescribedbelowinFigure12.

Figure12UpstreamandDownstreamScopeDemarcation






ThedevelopmentofNC3andNC8fieldsisenvisagedtobeincomplextypeconfiguration.NC3willbecomeahubcomprisingofaCentralProcessingPlatform(CPP)withlivingquartersandabridgelinkedWellheadPlatform(WHP).AnotherWHPistobeinstalledatNC8;itwillbetiedbacktoNC3viaaninterfieldsubseapipeline. Though compressionmay not be required at the beginning of production, the need for gascompressionisanticipatedafterapproximatelyfour(4)years.HencetheprovisionforfuturecompressionfacilitiesandmercuryremovalfacilitiesshallbeconsideredaspartofthisFEEDworkfortheNC3CPP.

Figure13OverallDevelopmentConcept

AnewsubseapipelineconnectingNC3andE11RCwillbe installed todeliver theprocessedgasand thespikeddehydratedcondensate.Duetoincompatibilityofthisgasqualitywiththeexistinggassupplyattheriser,adedicatedmanifoldatE11RCmayberequiredtoaccommodatethistiein.ThisistoensurethatthegasfromNC3andNC8fieldsdonotcontaminatetheentirenetworktoshore.Assuch,modificationwillberequiredtoconverttheexistingTL6tobededicatedforgasfromNC3andNC8.Thefuturetrunkline(TL7)mayberequiredinthefutureshouldTL6nolongerbefitforservice.Theprocessed gas anddehydrated condensatewillbe separated atonshore receiving facilitiesprior tobeingintroducedintoLNGPlantTrain9.






1.1 SCOPEOFDOCUMENTThepurposeofthisdocument istodefinetheminimumrequirementsforconcreteweightcoatingtobeusedforthefollowingoffshorerigidpipelineintheSK316DevelopmentProject: 32OffshorepipelinefromNC3WHPtoE11RCPlatform 32OffshorepipelinefromE11RCPlatformtoOnshoreBeachValveLocation 20OffshorepipelinefromNC8WHPtoNC3WHP(Diametertobeconfirmed)1.2 DEFINITIONCOMPANY PETRONASCarigaliSdnBhdCONTRACTOR SAIPEMSUBCONTRACTOR PartyselectedbyCOMPANY/CONTRACTORresponsiblefor

application of the concrete weight coating on PROJECTpipes in accordance with this specification and othercontractualdocuments

MANUFACTURER Supplier of the raw materials or inspection and testingequipmentrequiredtoperformthework

PROJECT FEED for SK316 Facilities Development of theNC3 andNC8GasFields

1.3 ABBREVIATIONFBE FusionBondedEpoxyN/A NotApplicableNo. NumberOD Outsidediameter(externalpipediameter)PQT PreQualificationTest3LPE 3LayerPolyethylene3LPP 3LayerPolypropyleneCWC ConcreteWeightCoating






2 REFERENCESUnlessotherwisestated,thelatestissueofthebelowlistedPTSCOMPANYSpecifications,Codes,StandardsandRegulationsshallapply.Equivalentalternativesmaybeoffered;theseshallbeidentifiedandmutuallyagreedon.2.1 PROJECTDOCUMENTSDOCUMENT NAME/1/ 05SSPLBODU0001 PipelineAndRiserDesignBasis/2/ TBC InputforPipelineStudy/3/ 05GENBODB0001 ProcessDesignBasis/4/ 05SSPLREPU0001 SteadyStatePipelineSimulationReport/5/ 05GENBODZ0002 CorrosionStudyMemorandum/6/ 05SSPLREPU0002 PipelineTransientAnalysisReport/7/ 05SSPLREPU0003 PipelineRouteSelectionReport

2.2 COMPANYSTANDARDSDOCUMENT NAME/8/ 31.40.00.20 Pipeline&RiserEngineering/9/ 31.40.30.30 Concretecoatingoflinepipe2.3 CODESANDSTANDARDSDOCUMENT NAME/10/ ISO218091 Petroleum and Natural Gas Industries External

CoatingsforBuriedorSubmergedPipelinesUsedinPipelineTransportationSystems Part1:PolyolefinCoatings(3LayerPEand3LayerPP).

/11/ BSEN10288 Steel Tubes and Fittings forOnshore andOffshorePipelines External Two Layer ExtrudedPolyethyleneBasedCoatings

/12/ ASTMC150 StandardSpecificationforPortlandcement/13/ ASTMC33 StandardSpecificationforConcreteAggregates/14/ ASTMA81001 StandardSpecification forZincCoated (Galvanized)

SteelPipeWindingMesh






/15/ ASTMA615M Standard Specification for Deformed and PlainCarbonSteelBarsforConcreteReinforcement

/16/ ASTM18501 Standard Specification for Steel Welded WireReinforcement,Plain,forConcrete

/17/ ASTMA8201 Standard Specification for Steel Wire, Plain, forConcreteReinforcement

/18/ ASTMC30998A Standard Specification for Liquid MembraneFormingCompoundsforCuringConcrete

/19/ ASTMC171 Standard Specification for Sheet Materials forCuringConcrete

/20/ ASTMC39/C39M01 StandardTestMethod forCompressiveStrengthofCylindricalConcreteSpecimens

/21/ ASTMC61798 Standard Practice for Capping Cylindrical ConcreteSpecimens

/22/ BSEN1971 Cement Part 1: Composition, Specifications andConformityCriteriaforCommonCements

/23/ BSEN1008 Mixing Water for Concrete Specification forSampling, Testing and Assessing the Suitability ofWater, IncludingWater Recovered from Processesin the Concrete Industry, as Mixing Water forConcrete

/24/ BS4482 ColdReduced SteelWire for theReinforcementofConcreteProductsSpecification

/25/ BS4483 Steel Fabric for the Reinforcement of Concrete Specification

/26/ BSEN123902 Testing Hardened Concrete Part 2: Making andCuringSpecimensforStrengthTests

/27/ BSEN123903 Testing Hardened Concrete Part 3: CompressiveStrengthoftestSpecimens

2.4 SYSTEMOFUNITSThe InternationalUnitSystem (SI)shallbeutilized throughout theproject,unlessotherwisehighlighted.Anyconversionshallbeprovidedinparenthesiswhereapplicable.






3 GENERALREQUIREMENTSFortestingpurposesspecifiedinthisSpecification,theproductionshiftshallbeconsideredofmaximum12hours depending on the SUBCONTRACTORs internal organization. In case SUBCONTRACTOR intends toworkmorethan12hoursperday,COMPANY/CONTRACTORshallconsiderthatthework isperformed inmorethanoneshiftandtherelevanttestingfrequencyshallberespectedasperthisSpecification.AllSUBCONTRACTORsdocumentsshallcomplywiththelimitationsofthisSpecification.SUBCONTRACTORshallpromptly informCOMPANY/CONTRACTORofanyneedtomakechangestothesedocuments,whichshallhavetobespecificallyacceptedbyCOMPANY,whohastherighttorequireadditionaltestingwithoutadditionalcosts.Any technical deviations to this Specification shall be obtained by SUBCONTRACTOR only through aconcessionrequestformat. Inanycase it isnotallowedto insertanydeviationfromthisSpecification inanySUBCONTRACTORsdocumentpriorthatthisdeviationhasnotbeenpreviouslypresentedseparatelytoCOMPANY/CONTRACTORandapprovedinwrittenbyCOMPANY/CONTRACTOR.Concession requests requireCOMPANYs reviewandapprovalprior to implementationof theproposedchanges.Pipescoatedby implementing the technicalchangesprior to theCOMPANYsapprovalshallberejected.Priortothecommencementoftheproductionandduringtheproduction,COMPANYshallreservetherighttoperformauditsintheSUBCONTRACTORsfacilities.COMPANYandCOMPANYsrepresentativesshallbepermittedbySUBCONTRACTORtheunlimitedaccessto all SUBCONTRACTORs facilities related to the SUBCONTRACTORs scope of work for the PROJECTstartingfromthemomenttheworkhasbeenawardedtoSUBCONTRACTOR untilSUBCONTRACTOR hascompletedalloftheobligationsrelatedtohisscopeofworkinthePROJECT.It ismandatory requirement for SUBCONTRACTORs coating facilities thatallof the inspectionactivitiesaccordingtotheactionpointsspecifiedininspectionandtestplanscanbeperformedbyinspectorsfromall involved Parties in safemanner for all personnel involved in these activities. In case the inspectionactivities cannot be safely performed for all persons involved in inspection (CONTRACTOR,SUBCONTRACTORs, COMPANYs and Third Partys personnel), SUBCONTRACTOR shall stop all of theactivitiesatthatparticularinspectionpointandshallorganizetheworkspaceinamannerthatallactivitiescanbeperformedinsafemanner.AllcostsduetosuchstoppagesshallbeborneonlybySUBCONTRACTOR.






4 CONCRETECOATINGMATERIALSTheconcretecoatingappliedonlinepipesshallhavethefollowingnominaldryandcuredconcretedensityof3044kg/m3.4.1 CEMENTUnlessotherwisespecifiedinthePurchaseOrder,allcementusedforthepreparationoftheconcreteshallbePortlandCementconformingtotherequirementsofoneofthefollowingstandardsdependingontheavailabilityatthelocationwheretheconcretecoatingapplicationshallbecarriedout: ASTMC150TypeIIandV; MS522standard; BSEN1971standard.Allbatchesofcementshallbesupplied toSUBCONTRACTORwith testcertificatestating thecomplianceeither with the ASTM C 150 (Type II and V) or BS 12 or EN 1971 standard which shall thenSUBCONTRACTORsubmittoCOMPANYforreviewpriortoitsuse.The certificatesmust be presented to COMPANYs review to verify that also the followingmandatoryrequirementsaremet: thatthecontentofalkaliis






SamplingandtestingforcleanlinessofaggregatesshallbecarriedoutforeachdeliveryofeachaggregateinaccordancewithASTMC33standardandotherstandardsreferredintheASTMC33standard.Duringproductionthegradingandcleanlinessshallbecheckedat leastonceeverythreedaysfromeachstockpileandeachnewconsignmentforcleanlinessandgrading.ThegradingshallbeasperthenominalvaluesandtolerancesspecifiedbySUBCONTRACTORandverifiedduringthePQT.Thetestforcleanlinessshallmean visual inspection for presence of any foreignmaterial in tested sample beside the testedaggregateitself(wood,shells,oranyothersimilarcontaminant).SUBCONTRACTORshallberesponsibleforproperstorageofaggregatesandallcostsrelatedtotheCOMPANYsrejectionofcontaminatedaggregateshallbebornebySUBCONTRACTOR.Differenttypesofaggregatesshallbestoredseparatelyinbinsorwellpreparedareas,i.e.cobbled,pavedorwellcompactedareasallowingadequatedrainageofmaterials.4.3 WATERWaterusedinconcretecoatingmixshallbefreshandshallcomplywithAppendixAofBSEN1008.Watershallbeofpotablequalityandobtained fromapublicsupplywherepossible.Watershallnotbetakenfromaspring,well,lakeorsimilarsourceunlesstestindicateitssuitability.DuringthebiddingstageofthePROJECTtheSUBCONTRACTORshallpresentthecertificateforthemixingwaterusedinthecoatingplantandtheSUBCONTRACTORshallprovidetheguarantythatthesamewatershallbeusedduringentireSUBCONTRACTORsworkinthePROJECT.4.4 ADDITIVESAdditivescontainingchloridesshallnotbeusedintheconcretemix.Thetotalquantityofchlorideswithintheconcretemix,calculatedasfreeCaCl2,shallnotexceed0.4%oftheweightofthecement.Waterreducingagentsforconcretemaybeusedintheconcretemix.Airentrainingagentsshallnotbeusedintheconcretemix.4.5 REINFORCINGSTEELThereinforcingsteelmaybeusedinthefollowingforms: weldedsteelwiremesh(typeWWCortypeWWNaspertheASTMA81001standard); steelcagetype.Chickenwiremeshandsteelpoultrynettingarenotallowedasthereinforcementmaterial.Thediameterofthereinforcingsteelshallbeselected inamannerthatallofthefollowingrequirementsaremet: theminimumcircumferentialreinforcementshallbe0.5%ofthelongitudinalcrosssectionalareaof

theconcretecoating; theminimumlongitudinalreinforcementshallbe0.08%ofthetransversecrosssectionalareaofthe

concretecoating;






minimumdiameterofthereinforcingwirefortheweldedsteelwiremeshshallbe1.6mm; minimumdiameterforthereinforcingwireinthecagetypeshallbe3mm.4.6 WELDEDSTEELWIREMESHTheweldedsteelwiremeshshallbegalvanized.TheonlyapprovedtypeofthereinforcingsteelwiremeshareTypeWWCandTypeWWNaspertheASTMA81001standard.Thephysicalandchemicalpropertiesofthewireandwiremeshshallbe inaccordancewiththeASTMA641andASTMA81001standard.4.7 STEELCAGETYPEThe reinforcement shall be in the form of spirallywound cages having a continuous hoopwirewith anumberofstraightlongitudinalbarsevenlyspacedaroundthespiralandweldedateachwireintersection.Alternatively, the continuoushoopwiremaybe replacedby single circumferentialhoops. ThematerialusedshallbenharddrawnwiretoBS4482orASTMA615M(deformed),ortoCOMPANY/CONTRACTORapprovedequivalentstandard.TheweldingofmaterialsshallresultinasteelfabricinaccordancewithBS4483orASTMA185.Thediameterofthecircumferentialandlongitudinalbarsshallbecalculatedfromtherequiredpercentageofreinforcing,withaminimumdiameterof3mm.Thespacingofthe longitudinalbarsshallbebetween50and250mmbutnot lessthanfour longitudinalbarsatapproximatelyequalspacingshallbeprovided.Thecircumferentialhoopspacingshallnotbemorethan100mm.Cagesshallhavetwohoopsspaced50mmapartateachpipeend.Thephysicalandchemicalpropertiesofthereinforcingwireandofthewiremeshshallbe inaccordancewiththeASTMA8201(orASTMA615M)andASTMA18501standard.






5 RECEIPT,HANDLINGANDSTORAGEOFBAREPIPESPipescoatedonlywith3layerpolyethyleneshallbehandled,storedandtransportedinamannerthatthepipesteelandpipecoatingshallnotbedamaged.Allforeignsubstancessuchasexcessivedirt,debrisofcoatingmaterialsoranyotherforeignobjectsshallberemovedfrominternalpipesurfacebeforestackingofpipesorapplicationofconcretecoating.Coatedpipescanbehandledusingslings, liftinghookspaddedwithsoftmaterialwithsuitablespreaderbars, forkliftshaving lifting forkspaddedwithsoftmaterial, front loaderspaddedwithsoftmaterialandvacuum lifting.Chainsorwireropesoranyotherdevicethatmaydamagethepipesteelorpipecoatingshallnotbeused.Whenmorethanonepipeislifted,separateslingsorhooksshallbeusedforeachpipe.Pipesshallbepickedupfromthestackingpointandatnotimeshallbedraggedorrolled.Coatedlinepipeshallnotbesubjectedtojarorimpactandallpipesupportsshallbepadded.Pipesupportsshallbespacedtoavoidbendingoflinepipes.Thecoatedlinepipesshallalwaysbestackedtoavoidsurfacecontactwiththeground.Thepipesshallbestacked on approved supportswhich shall be free of anymaterial that could potentially damage theappliedcoating.The stackingheightof3LPE/3LPP coated linepipes shallbe limited toavoiddamageof the coated linepipesduetotheweightofotherones.Themaximumnumberofstacking layersforthecoated linepipesshallbecalculatedbySUBCONTRACTORandrelevantcalculationshowingcalculationstepsandresultsshallbe submitted to COMPANY/CONTRACTOR for review and approval however, for safety reasons themaximumheightofanystackshallbe3m.IncaseSUBCONTRACTORdoesnotprovideanycalculationnoterelated to stacking of coated pipes acceptable for COMPANY/CONTRACTOR, the coated pipes shall bestackedinmaximum4rows.Thestacksofcoatedpipesshallbeseparatedforeachofthefollowingcombinations: pipenominalODxpipenominalwallthickness.Thelinepipesshallbestackedataslightangletoallowdrainageofanyrainwater.The coated pipes shall not be stacked below and near electrical lines or near any facilitywhichmayincrease residualmagnetism in the pipes (at all times it shall be kept theminimum distance of 30mbetweenthestoredpipesandanyelectricalcablemeasuredfromtheverticalprojectiontothegroundofthenearestelectricalcable).Incase it isdetecteddisbondmentofthe3layerPEcoatingfromthepipeatthecoatingedgeswhenthecoated pipes are stacked either before or during the load out operation, that particular pipe shall berejectedandthe3layerPEshallbestrippedandreappliedatSUBCONTRACTORscost.






6 CONCRETECOATINGAPPLICATION6.1 VISUALANDHOLIDAYINSPECTIONOF3LAYERPECOATEDPIPESPrior toplacementof the steel reinforcementand/orapplicationofconcretecoating, theentire factoryappliedanticorrosioncoatingofthepipeshallbevisuallyinspected.Any foreignmatter shall be removed from the surface of the anticorrosion coating and each detectedcoatingdamageshallberepairedaccordingtotheapprovedprocedurepriortothecommencementoftheconcretecoatingapplication.Then, theentire coated surfaceof thepipes shallbe inspectedusingaholidaydetectoratavoltageofminimum25 kV.Theholidaydetector shallbeequippedwith a visual and an acoustic signallingdeviceclearlyaudibleintheprevailingworkingconditions.Alldamagesdetectedbytheholidaydetectorshallberepaired.6.2 PLACEMENTOFREINFORCEMENTSTEELForconcretethicknessupto50mm,onewrapofreinforcingshallbeused.Forthicknessesofmorethan50mm, two layers should be considered. Additional layersmay be necessary for concrete thicknesses inexcessof120mm,butthiswouldthenrequirefurtherCOMPANY/CONTRACTORsapproval,sothenumberofsteelreinforcinglayersshallbeasfollows: concretecoatingthicknessupto50mm1layer; concretecoatingthicknessfrom51mmupto100mm2layers; concretecoatingthicknessfrom101mmupto140mm3layers.According to SUBCONTRACTORs discretion, SUBCONTRACTORmay apply also the combination of thereinforcing steel cage and reinforcing steel welded wire mesh but the above mentioned number ofreinforcinglayersvs.concretecoatingthicknessandtherequirementsforpercentageofreinforcingsteelinconcretecoatingcrosssectionalareasmustberespected.Duringtheapplicationofthereinforcingsteel,atalltimes,thefollowingrequirementsmustbemet: minimum15mmdistancebetweenthereinforcingsteelandthefactoryappliedanticorrosionpipe

coating; minimum10mmdistancebetweenthereinforcingsteelandtheoutersurfaceofappliedconcrete

coating; minimum10mmdistancebetweentwolayersofreinforcingsteel.Incasethereinforcingsteelweldedwiremeshisused,thelongitudinaloverlapofthewiremeshshallbeminimum25mm.Incasethecagetypeofreinforcementisused,thesteelreinforcementshallterminate: 10mm30mmfromtheendofconcretecoating.






7 APPLICATIONOFCOATINGMATERIALSItwillbe the SUBCONTRACTORsdecision to apply the concrete coatingusing impingementmethodorcompressioncoatmethod(extrusion),howeveronlytheapplicationmethodusedduringthesuccessfullypassedandcompletedprequalificationtestshallbeused.Prior to the application of the concrete coating, the temperature of the concrete coatingmix shall bewithintherangebetween+5Cand+35C.Incase the temperatureof theconcretecoatingmix is less than+5C, theconcretecoatingshallnotbeperformeduntilSUBCONTRACTORmanagestoheattheentireconcretemixupto+5C.Incasethetemperatureoftheconcretecoatingmixishigherthan+35C,themixingwatershallbecooledwithiceorasuitablecoolingsystemshallbeprovidedforthemixingwaterinordertoobtaintheconcretemixtemperatureofmaximum+35C.Thefreewater/cementrationshallnotexceed0.45byweight.Theconcretecoatingapplicationmethodshallbesuchthatthecoatingtimeforeachpipedoesnotexceed30minutes (starting from themoment that thewaterwasadded to theconcretemixand theconcretecoatingapplicationstartedonthatparticularpipeuptothecompletionofapplicationofconcretecoatingonthesamepipe)otherwisetheconcretecoatingonthatpipeshallberejected.Useofreclaimed/reboundmaterialmightbeallowedprovidingitisdemonstratedthatitdoesnothaveanydetrimentaleffectonthefinalconcreteproduct.Secondarymixingof the reclaimedmaterialwith freshlybatchedconcretemust follow immediatelyandmustproduceahomogeneouscohesivemixture.Theamountofrecycledmaterialusedshallnotexceed10%ofthetotalmixbyweight.Ifabreakofthisoperation,forwhateverreason,exceeds30minutesanyreclaimedmaterialnotpreviouslyaddedtothemixshallbediscardedandremovedfromthecoatingarea.7.1 PREPARATIONOFTHECUTBACKAREATheconcretecoatingshallberemovedatbothpipeendstakingcarenottodamagepipesteelorfactoryappliedanticorrosioncoating.Thelengthofsuchpreparedconcretecoatingcutbackshallbe380mm(0mm/+20mm).Thecutbackshallbesquarewithrespecttopipeaxis.7.2 FINISHINGOPERATIONSWITHINCONCRETECOATINGPLANTSurface fallouts (spalling)shallbe filledbyguniting.Therepairmixshallbesimilar incompositiontotheoriginalmix.Therepairshallbecarriedoutinaccordancewithapprovedprocedurewithin30minutesafterapplicationoftheoriginalconcretecoatingmix.Surfacedamageonconcretecoatingshallnotbeconsideredasadefect ifallofthefollowingconditionshavebeenmet: damageisnotexposingreinforcingsteel;






damageisnotextendedtomorethan20%ofthenominalconcretecoatingthickness; damagedareaislessthan1000cm2(0.1m2).Incasethetotalareaoffallouts(spalling)ismorethan20%oftheconcretesurface,theconcretecoatingshallberemovedfromthatparticularpipe.The cutbackareaand internalpipe surface shallbe completely free fromany residual concrete coatingmaterialandfromanymaterialsdetrimentaltothewelding,NDTandfieldjointcoatingoperationswhichshallbeperformedbypipelayingCONTRACTORduringthepipelayingoperations.Finally,eachpipeendshallbeprotectedwithendcapandtheexposedsteelandthefirst100mmof3layerPEcoatingshallbewrappedwithpolyethylenesheetthatdoesnotcontainanyadhesiveandwhichshallbefirmlytightenedaroundthispipelocation.7.3 CURINGImmediatelyaftercompletionoftheapplicationofconcretecoatingoperations,theconcretecoatedpipepassingallonlineinspectionsandtestsshallbetransferredtothecuringarea.Duringthecuringperiod,thepipesshallbestackedinasinglelayer.Curingshallbeperformedeitherbyusingwatercuring,steamcuring,curingbysealingcompoundsorbypolyethylenewrapping.Theexposedsurfacesoftheconcretecoatingshallbeprotectedduringthecuringperiodfromanyadverseeffectsofsunshine,dryingwinds,rainorrunningwater.The curingprocess shall continueuntil aminimum compressive strengthof14MPahasbeen achievedwhenthecompressionstrength test isperformedoncoresamplesafterwhichtheconcretecoatedpipecanbe lifted, transported and stacked inmore thanone layerup to themaximum allowednumberofstacking layers. Incase theperiodwhen thepipe reachesminimum14MPaofcompressionstrengthoncoresampleshasnotbeendeterminedbypracticaltests,thepipesshallremainstackedinasinglelayerforminimumsevendays.Locationswhere the core samples shall be taken from the pipe for this purpose shall be selected byCOMPANY/CONTRACTOR.7.3.1 WATERCURINGWatercuringshallconsistofwettingandmoisteningtheconcretecoating,startingnotlaterthan6hoursaftercompletionofconcretecoatingapplication.Theconcretecoatingshallbekeptcontinuouslymoistby intermittentspraying foraperiodofat least7days.Theintervalbetweensprayingshallnotbemorethan24hours.Attheambienttemperaturesbelow+4C,suitableprecautionsshallbetakentopreventdamageduetofreezing.






7.3.2 STEAMCURINGIf the curingprocess involves steamorwarmhighhumidity air, then it shallbedemonstrated that theprocesswillhavenodeleteriouseffectson theconcrete.Undernocircumstances shall thepipewallbeallowedtoreachatemperaturethatwouldcauseanydamagetotheanticorrosioncoating.Curingbysteamshallnotstartsoonerthan3hoursaftercompletionoftheconcretecoatingapplicationcompletion.Concretecoatedpipesshallbeenclosed inplasticorsimilarcoversuitabletomaintainsteamcirculation.Steam circulation shall start at the ambient temperature and shallbe controlled to give a temperaturegradientofapproximately10C/houruptothemaximumsteelorcoatingtemperatureof+60C.Thepipes shallbeheldunder steam curing for at least6hours and then allowed to cool for a similarperiod.SUBCONTRACTORshalldemonstrateduringtheprequalificationtestthatthecuringtimeused issufficienttomeetthespecifiedconcretestrengthlevels.7.3.3 CURINGBYSEALINGCOMPOUNDSSealingcompoundsshallmeetrequirementsofASTMC30998Astandard.Thematerialshallbestored,prepared and applied in accordance with instructions supplied by the MANUFACTURER of sealingcompounds.The compound shall be nontoxic and nonflammable and shall not reactwith any constituent of theconcrete,reinforcement,protectivecoatingorpipesteel.Unless otherwise specified by the compound MANUFACTURERs instructions, membrane sealingcompoundsshallbesprayedover thecompleteconcretesurfacewithin6hoursaftercompletionof theconcrete application and shall remain for aminimum of 7 days. Thematerials shall not be applied attemperatureslessthan+4C.7.3.4 CURINGUNDERPOLYETHYLENEWRAPPINGWrapping inpolyethylene film shallbedoneduring theapplicationofconcretecoating.A light sprayofwater shall be applied before applying the plastic film. The polyethylene film shall have aminimumthicknessof0.2mmandtheoverlapofthesheetshallnotbelessthan25%ofthesheetwidth.ThepolyethylenefilmshallbeinaccordancewithASTMC171standard.Theinterfacebetweentheconcreteandthebaresteelatthepipeendsshallalsobeprotectedinordertoachieveanairtightseal.Thepolyethylenewrappingshallremainonthepipeforminimumsevendaysbutitshallberemovedpriortofinalloadoutofthepipe.






7.3.5 FOGCURINGFresh concrete coating is continuouslymoistened bymist released from fogging tips and coveredwithtarpaulinsheetstoprovideaclosedenvironmentforcuring.Atomizedmist,withhighwetabilityisintroducedgraduallybuildingtoaclosedhighhumidity,nearsaturationambience to facilitatepropercuringenvironment.Thecontinuous introductionofatomizedfog/mist into tarpaulin shall be continued for one shift before the pipe is removed/subject to furtherhandling.






8 INSPECTIONANDTESTINGThePreQualificationTestshallbeperformedonfivefullyconcretecoatedpipesandshallbecompletedbeforethestartofactualproduction inthePROJECT.Thecombinationofpipematerialvs.pipeexternaldiametervs.pipewallthicknessvs.concretecoatingthicknessselectedforPreQualificationTestshallbeagreedbetweenSUBCONTRACTORandCOMPANY/CONTRACTOR.Itismandatorythatallfiveconcretecoatedpipesareconcretecoatedinasequencewithoutanystoppageof the concrete coating plant in order to allow performance of the offline PQT tests. In case thisrequirementisnotmet,thePQTshallberepeated.Allofthe inspectionsandtests listed inthisdocumentshallbeaddressed inthe inspectionandtestplan.Defectsoranomaliesdetectedduring coatingprocess shall start immediate correctiveactions from theSUBCONTRACTOR.All line pipes to be submitted to the inspections and tests shall be selected in agreement with theCOMPANY/CONTRACTORsInspector.Intheeventthataproductionlinepipefailstomeettheacceptancecriteriaforthetestslistedinthetablethetestcanberepeatedonlyshouldthefailurebecausedeitherbyimproperuseofthetestingequipmentorbyerrorinthetestingprocedure.Thefollowinginspectionsandtestsshallbecarriedout:

Inspection/Test Reference PQT ProductionInspectionofthe3layerPEcoatedpipesduringthereceipt

Section6Section8.2

BeforethestartofthePQT. Beforethestartofproduction.

Visual inspectionof the stackingof the3layerPEcoatedpipes

Section8.1 BeforethestartofthePQT. Periodically.

Inspections of the concrete coating materialsduringtheirreceipt

Section8.3Section8.4.1Section8.4.2Section8.4.3

BeforethestartofthePQT.Mixing water certificate tobedeliveredbeforethestartofthePQT.

Each package of received concrete coatingmaterial.

Verification of calibration of the holidaydetector and the concrete coated pipesweighingscale

Section8.5Section8.5.1Section8.5.2

BeforethestartofthePQT. Onceperday.

Visual and holiday inspection of 3layer PEcoatedpipes immediatelybeforeapplicationofconcretecoating

Section8.6

EachPQTpipe. Eachpipe.

Concrete coating mix control (verification ofcalibrationoftheconcretecoatingmixingplant)

Section8.7 BeforethestartofthePQT. Onceperweek.

Concretecoatingmixtemperaturecheck Section8.8 Once. Whentheambienttemperatureiswithintherange from+10Cupto+25C,thetestshallnotbecarriedout.In case the ambient temperature is outsidethe above mentioned range the concretecoatingmixtemperature shall be measured at thebeginning of each working shift and thenevery4hours.

Watercementratiocheck Section8.9 Once. Firstworkingshiftofeachworkingday.






Inspection/Test Reference PQT ProductionVerification of the correct positioning of theconcretecoatingsteelreinforcement

Section8.10 FirsttwoPQTpipes. One pipe concrete coated at the beginningand on one pipe concrete coated in themiddleofeachworkingshift.

Concretecoatingapplicationcontrol Section8.11 EachPQTpipe. Eachpipe.Measurement of external diameter of appliedconcretecoating

Section8.12 EachPQTpipe. Eachpipe.

Cutbackcontrol Section8.13 EachPQTpipe. Eachpipe.Weighingoffreshlyconcretecoatedpipe Section8.14 EachPQTpipe. Eachpipe.Calculationofnegativebuoyancy Section8.15 EachPQTpipe. Eachpipe.Visualinspectionofappliedconcrete Section8.16 EachPQTpipe. Eachpipe.Measurement of the electrical resistancebetweenthesteelreinforcementandthepipe

Section8.17 Reinforcingsteelwiremesh:eachPQTpipe.Steelcage:On thepipeswhere the testforverificationofthecorrectpositioning of the concretecoating steel reinforcementhasbeenperformed.

Reinforcingsteelwiremesh:eachPQTpipe.Steelcage:On thepipeswhere the test for verificationof the correct positioning of the concretecoating steel reinforcement has beenperformed.

Control of the curing process and control ofstacking of concrete coated pipes during thecuringprocess

Section8.18Section8.19

EachPQTpipe. Periodically.

Controlofmarkingonconcretecoatedpipes Section8.20 EachPQTpipe. Eachpipe.Controloftheconcretecoatingrepair Section8.20 EachPQTpipe. Eachpipe.Controloftheconcretecoatingrepair Section8.21 EachPQTpipe. Eachpipeonwhichtheconcretecoating has

beenrepaired.Determination of factor in the formula forcalculationofnegativebuoyancy (performanceofthistestisnotmandatory)

Section8.22 Two PQT pipes notsubmitted to the waterabsorptiontest.

N/A.

Compressionstrengthtestcubes Section8.23 EachPQTpipe. 4 cubes from first pipe at the beginning ofeachworkingshiftandthenevery25pipes.

Compressionstrengthtestoncoresamples Section8.24 EachPQTpipe. 2x3coresfromfirstpipeatthebeginningofeachworkingshiftandthenevery15pipes.

Determinationofthetimeforstackingofpipesinmorethanonelayer(performanceofthistestisnotmandatory)

Section8.25

ThreePQTpipes. N/A.

Waterabsorptiontest Section8.26 TwoPQTpipes. One pipe coated each day during the firstthreeproductiondays.In case all tests had acceptable results thetestshallbeperformedoncepershift.week

Adhesion between the 3layer PE coating andconcretecoating

Section8.27 Onetest. N/A.

Impacttesting Section8.28 WhenRequested WhenRequestedoneperweekStackingofcuredCWCpipes Section8.29 N/A Eachpipe.Loadoutinspections Section8.30 N/A Eachpipe.8.1 STACKINGOF3LAYERPECOATEDPIPESPeriodicalvisualinspectionshallbeperformedintheareadedicatedforstackingofthepipescoatedwith3layer PE awaiting the application of concrete coating in order to verify that these pipes have beenstackedinamaximumallowednumberoflayersandthattheyhavebeenstackedonapprovedsupports.In case of nonconformance with relevant requirements SUBCONTRACTOR shall informCOMPANY/CONTRACTORwhowillbringfurtherdecisionsandCOMPANY/CONTRACTORsdecisionshallbebinding.






8.2 CONTROL,IDENTIFICATIONANDSEGREGATIONOF3LAYERPECOATEDPIPESThe3layerPE coatedpipes shallbe visually inspected forbeveldamages,dents,gauges, flatendsandcoatingdamages.Alsothecontentofagreedpipemarkingrequiredatthisstageofworkshallbeverifiedonthepipe.Incasebeveldamages,significantcorrosion,dents,gouges,laminationorflatendshavebeendetectedonbarepipeportionatthecutbackarea,thepipeshallbemarkedwithcolouredtape,segregatedifpracticaltodo so,andbrought toCOMPANY/CONTRACTORsattentionwhowill instructSUBCONTRACTORaboutactionstobetakenonthispipe.Incasethecoatingdamagehasbeendetected,damagedareashallbemarkedandcolouredtapeshallbeput around that pipewhich shall remain on the pipe until the coating repair has been completed andapprovedbyCOMPANY/CONTRACTOR.Incaseoil,greaseoranysimilarcontaminationhasbeendetectedatthecutbackarea,thecontaminationshallberemovedwithfreshwateranddetergent,solventoranyothersuitablemethod.Incasethemissingor incorrectpipemarkinghasbeendetected,thepipeshallbemarkedwithcolouredtape, segregated ifpractical todo so andbrought to theCOMPANY/CONTRACTORs attentionwhowillinstructSUBCONTRACTORabouttheactionstobetakenonthatpipe.8.3 DELIVERYANDSTORAGEOFCONCRETECOATINGRAWMATERIALSAteachdeliveryofthecoatingrawmaterials,thereceiveddocumentationshallbereviewedagainstthereceivedmaterialpackagesandagainstthePurchaseOrderdocumentsinordertoverifythatthereceiveddocumentsandmaterialsconformtotherequirementsspecifiedinthepurchaseorder.Incaseofanynonconformance,itshallbetheSUBCONTRACTORsresponsibilitytoresolvethisissuewiththe supplier of the nonconforming material. However, the batch of the material delivered inSUBCONTRACTORspremisesnonconformingtotherequirementsofthisspecification,shallnotbeusedinthePROJECT.Periodically,avisualinspectionshallbeperformedinordertoverifythatthecoatingmaterialshavebeenstoredinconditionsasrecommendedbythematerialMANUFACTURER.Thecementshallbestoredinproperwaterproofsilos.The aggregates can be stacked in stockpiles at the open on clean site, free from the possibility ofcontamination.Thegalvanizedwiremeshmaybestoredattheopencleansitefreefrompossibilityofcontaminationbutthewiresusedformanufacturingofsteelcagemustbestoredinclosedstoragefacilityindryplace.Thepolyethylenewrappingthatshallbeusedforcuringofconcretecoatedpipesmaybestoredoutsideincleansitebutitmustbecoveredwithappropriatesheetingtoavoidexposuretotherainandraisedfromthegroundtoavoidflooding.






COMPANY/CONTRACTORreservestherighttorejecttheuseofimproperlystoredmaterialinthePROJECT.8.4 TESTTOBEPERFORMEDONCONCRETECOATINGMATERIALUPONRECEIPT8.4.1 SIEVEANALYSISANDCLEANLINESSCONTROLOFAGGREGATESThegradingandcleanlinessofaggregatesshallbecheckedfromeachstockpileforcleanlinessandgrading.ThegradingshallbeasperthenominalvaluesandtolerancesspecifiedbySUBCONTRACTORandverifiedduringthePQT.Thetestforcleanlinessshallmeanvisualinspectionforpresenceofanyforeignmaterialintestedsamplebesidethetestedaggregateitself(wood,shells,oranyothersimilarcontaminant).In caseof test failure, the test shallbe repeatedondoublednumberof samples taken from the samebatch.Incaseofrepeatedfailure,theaffectedbatchofsuppliedmaterialshallnotbeusedinthePROJECToritshallbecleanedfromallcontaminationasperCOMPANY/CONTRACTORssatisfaction.RelevantinspectionreportshallbepreparedbySUBCONTRACTORrelatedtothisinspectionactivity.Thereportshallcontainthefollowing items:date,shift,testedmaterial,materialsupplier,materialbatchnumberifapplicable,acceptancecriteria,testresults,remarks.8.4.2 STEELREINFORCEMENTWIRESDIMENSIONALCONTROLForeachbatchofreceivedreinforcingsteelsomeofthereceivedrollsofwiremeshand/orthewiresforcagetypereinforcementshallbecheckedbymeasuringthediameteroflongitudinalandstaywireswithacalliper.The measured value shall correspond to the minimum value provided by the reinforcing steelMANUFACTURER required to meet the requirements for reinforcing steel in concrete coating in thisspecification(minimumtolerancespecifiedfirstbyrelevantstandardand ifthisvaluecannotbefound inthestandardthentheminimumtolerancevaluecanbespecifiedbytheMANUFACTURER).In caseof test failure, the test shallbe repeatedondoublednumberof samples taken from the samebatch.Incaseofrepeatedfailure,theaffectedbatchofsuppliedmaterialshallnotbeusedinthePROJECT.RelevantinspectionreportshallbepreparedbySUBCONTRACTORrelatedtothisinspectionactivity.Thereportshallcontainthefollowing items:date,shift,testedmaterial,materialsupplier,materialbatchnumberifapplicable,acceptancecriteria,testresults,remarks.8.4.3 MIXINGWATERCHEMICALANALYSISWaterusedinconcretecoatingmixshallbefreshandshallcomplywithAppendixAofBSEN1008.DuringthebiddingstageofthePROJECTtheSUBCONTRACTORshallpresentthecertificateforthemixingwaterusedinthecoatingplantandtheSUBCONTRACTORshallprovidethewrittenguarantythatthesamewatershallbeusedduringentireSUBCONTRACTORsworkinthePROJECT.






In case the abovementioned requirement is notmet, the chemical analysis ofmixingwater shall becompleted and the certificate submitted to COMPANY/CONTRACTOR two weeks before thecommencementofthePreQualificationTestotherwiseSUBCONTRACTORshallnotbeallowedtostarttheperformance of the prequalification test. In case the quality of mixing water does not meet therequirementsofthisspecification,theconcretecoatingplantshallnotbequalifiedforthework.8.5 VERIFICATIONOFCALIBRATIONOFTHETESTINSTRUMENTSThe verification of calibration shall be verified for the holiday detector and pipeweighing scales eachworkingdaywhile the calibrationofother testingequipment shallnotbeverifiedbut theThirdPartyscalibrationcertificatesshallbeused.The instruments whose accuracy is not meeting the relevant acceptance criteria for each particularinstrument shall not be used in the PROJECT until the instruments accuracy is brought back withinacceptablelimits.RelevantinspectionreportshallbepreparedbySUBCONTRACTORrelatedtothisinspectionactivity.The report shall contain the following items: date, shift, testing equipment, testing equipment serialnumber,acceptancecriteria,testresults,remarks.8.5.1 HOLIDAYDETECTORThevoltageof theholidaydetector shallbe comparedwith thevoltageof the certified calibrationhighvoltage instrument recommendedby theMANUFACTURERof theholiday inspectionequipment for thispurpose.Theholidaydetector shallbe consideredacceptablewhen thevoltageof theholidaydetectorwhen checkedwith thehigh voltage calibration instrument set at25.0 kV shows the valueswithin therangefrom25.0kVto25.5kV.8.5.2 PIPEWEIGHINGSCALESTheverificationofcalibrationoftheweighingscaleswhichshallbeusedfordeterminationoftheweightoffreshlyconcretecoatedpipesshallbeperformedbyweighingoftheminimum11.5m longminimum10diameterpipehavingknownandcertifiedweight.Theweighingbridgeshallbeconsideredacceptableforusewhenthemeasuredvalueoftheknownweightiswithintherange: Nominalweightofthepipehavingknownandcertifiedweight0.3%.shift.8.6 VISUALANDHOLIDAYINSPECTIONOFTHE3LAYERPECOATEDPIPESPrior to thecommencementofapplicationof theconcretecoating, the3layerPEcoatedpipesshallbesubmittedtothevisualinspectionandholidayinspectionat25kV.Thepipesshallhavenomajorsteeldefectsandthepipecoatingshallbewithoutvisibledefects.Thereshallbenoholidaysdetectedafterholidayinspectionat25kV.






The 3layer PE coating shall be repaired in accordance with the SUBCONTRACTORs coating repairprocedureapprovedbyCOMPANY/CONTRACTOR.RelevantinspectionreportshallbepreparedbySUBCONTRACTORrelatedtothisinspectionactivityonlyincaseanynotconformanceoccurred.8.7 CONCRETECOATINGMIXCONTROLPrior to the commencement of the prequalification test and during the production once per week,SUBCONTRACTORshallperformtheverificationthattheirbatchingplantprovidesthecompositionoftheconcretecoatingmixwithinthetolerancesselectedbytheSUBCONTRACTORhimself.Productionshallnotstartifthebatchingplantisnotproperlycalibrated.Within the concrete coating application procedure, SUBCONTRACTOR shall describe in details theverification of calibration of batching plant for determination of percentage of each component in theconcretecoatingmix.8.8 CONCRETECOATINGMIXTEMPERATUREMEASUREMENTWhentheambientairtemperature is lessthan+10Cand it ishigherthan+25C,SUBCONTRACTORshallmeasure the temperatureof the concrete coatingmix at thebeginningofeachworking shift and thenevery4hours.Approximately310kgofconcretemixshallbetakenattheendofthebeltlocatedafterexitofthemixerandputintothebucketoranyothersuitablecontainer.Then,theimmersionprobeofthedigitalthermometershallbeimmersedinthefreshconcretemixandthetemperatureshallbereadfromthedisplayoftheinstrument.Incase the temperatureof theconcretecoatingmix is less than+5C, theconcretecoatingshallnotbeperformeduntilSUBCONTRACTORmanagetoheattheentireconcretemixupto+5C.Incasethetemperatureoftheconcretecoatingmixishigherthan+35C,themixingwatershallbecooledwithiceorasuitablecoolingsystemshallbeprovidedforthemixingwaterinordertoobtaintheconcretemixtemperatureofmaximum+35C.RelevantinspectionreportshallbepreparedbySUBCONTRACTORrelatedtothisinspectionactivity.Thereportshallcontainthefollowingitems:date,shift,acceptancecriteria,testresults,remarks.8.9 WATERCEMENTRATIOCHECKThefreewater/cementratioshallbecheckedatthebeginningofthefirstworkingshiftofeachworkingday.Thewatertocementratioshallnotexceed0.45byweight.In case the acceptance criterion isnotmet, the concrete coatingoperations shallnot start ithasbeenverifiedthatthewater/cementratioiswithinacceptablelimits.






RelevantinspectionreportshallbepreparedbySUBCONTRACTORrelatedtothisinspectionactivity.Thereportshallcontainthefollowingitems:date,shift,acceptancecriteria,testresults,remarks.8.10 REINFORCINGWIREPOSITIONCONTROLOnonepipe concrete coated at thebeginning andononepipe concrete coated in themiddleofeachworking shift, the proper positioning of the reinforcing steelwiremesh shall be verified by opening awindowofapproximatedimensions200mmx75mmpenetratingdowntotheanticorrosionpipecoatingwhiletheconcretecoatingisstillfresh.During this visual inspection it shall be verified that the requirements specified in Section 8.2 of thisspecificationhavebeenmet.Only in case the cage type steel reinforcement isusedby SUBCONTRACTOR,during this test it shallbetestedalso theelectrical resistancebetween thebottom layerof thereinforcingsteeland thepipeend.Oneelectrodeoftheohmmetershallbeinthecontactwiththebottomlayerofthereinforcingsteelofthecageandanotherelectrodeshallbe inthecontactwithbarepipeendatthecutbackarea.Theminimummeasuredresistanceshallbe1000Ohm.Incasetheacceptancecriteriahavenotbeenmet,thetestingshallcontinueuntilitisdeterminedontwoconsecutivepipes concrete coatedbefore andon two consecutivepipes concrete coated after the testfailure,thatthesetestsaresuccessfullypassed.Thepipesnotpassinganysingleofthesetestsshallhavetheconcretecoatingremoved.8.11 CONCRETECOATINGAPPLICATIONCONTROLDuringtheapplicationoftheconcretecoatingthefollowingverificationsshallbecarriedoutoneachpipe: thattheconcretehasbeenappliedreasonablyuniformlythroughouttheentirepipelengthandthat

ithasbeenappliedwithoutanymajorirregularities; thatthespallingisrepairedonthefreshlyconcretecoatingpipemaximum30minutesafteradding

thewaterintheconcretecoatingmixintheconcretebatchingplant; whenthereinforcingsteelintheformofwiremeshisusedthatthepolyethylenewrappinghasbeen

applied immediately after the concrete applicationwithminimum overlap of 25% of the sheetwidth.

Pipesnotmeetingacceptancecriteriashallhavetheconcretecoatingremoved.8.12 MEASUREMENTOFEXTERNALDIAMETEROFAPPLIEDCONCRETETheexternalcircumference/diameterofappliedconcreteshallbemeasuredoneachconcretecoatedpipeusingaflexiblemeasuringtapeatfiveequidistantpointsalongthepipelength.Themeasurements shall notbe taken at first 400mm from the endsof applied concrete coating. Theaverage of fivemeasurements for external diameter of applied coating shall than be inserted in theformulaforcalculationofnegativebuoyancy.






RelevantinspectionreportshallbepreparedbySUBCONTRACTORrelatedtothisinspectionactivity.Thereportshallcontainthefollowingitems:date,shift,pipesequencenumber,pipenumber,pipeexternaldiameter,pipewallthickness,pipenominalconcretecoatingthickness,testresults,remarks.8.13 CUTBACKCONTROLThe cutback length shall be measured on each concrete coated pipe end. The average of twomeasurementsshallbeinsertedintheformulaforcalculationofnegativebuoyancy.Theedgesofconcretecoatingatthecutbackareashallbeperpendicularwithrespecttothepipeaxisandentire concrete coating cutback area shall be free of residual concrete coating and from anymaterialsdetrimentaltothewelding,NDTandfield jointcoatingoperationswhichshallbeperformedbythepipelayingCONTRACTORduringthepipelayingoperations.Theconcretecoatingcutbacklengthshallbe380(0mm/+20mm).Incasetheacceptancecriteriahavenotbeenmet,thepipeshallbequarantineduntiltheremedialworkistakenwhichshallresultinacceptableconcretecoatingcutback.Relevant inspection report specifying cutback lengths shallbepreparedby SUBCONTRACTOR related tothisinspectionactivity.Thereportshallcontainthefollowingitems:date,shift,pipesequencenumber,pipenumber,pipeexternaldiameter,pipewallthickness,pipenominalconcretecoatingthickness,acceptancecriteria,resultofeachcutbacklengthmeasurement,remarks.8.14 WEIGHINGOFFRESHLYCONCRETECOATEDPIPEEachfreshlyconcretecoatedpipeshallbeplacedonaweighingscalewhereitsweightshallbemeasured.Theresultshallbedisplayedandwhenthepipeweighthasstabilized.Theresultofmeasurementshallbeinsertedintheformulaforcalculationofnegativebuoyancy.RelevantinspectionreportshallbepreparedbySUBCONTRACTORrelatedtothisinspectionactivity.Thereportshallcontainthefollowingitems:date,shift,pipesequencenumber,pipenumber,pipeexternaldiameter,pipewallthickness,pipenominalconcretecoatingthickness,testresults,remarks.8.15 CALCULATIONOFNEGATIVEBUOYANCYThenegativebuoyancyshallbecalculatedoneachpipeasfollows:

NB = negativebuoyancy[kg/m];Wbp = weightofbarepipe,informationsuppliedfromthepipeMANUFACTURER[kg];

W3LPE/3LPP = weightof applied 3layerPE/3layerPPnot includingmassofbarepipe, calculatedusing eithernominaloraverage3layerPEorotherexternalanticorrosioncoatingthickness[kg];






L = lengthofthelinepipetakenthedatafrompipeMANUFACTURER[m];CB3LPE/3LPP = averageoftwomeasurementsofthe3layerHDPE/3layerPPcutbacklength;

theoreticalaverageisalsoallowedforthispurpose[m];CBCWC = averageoftwoactuallytakenmeasurementsoftheconcretecoatingcutback lengthonwhichthe

lengthhasbeenmeasured[m];

= factorof change in theweightof concrete coating fromwetand fresh todryand cured;unlessotherwisedemonstratedduringthePQT,thefactor=0.99[nondimensionalvalue];

WCWC = weightofthepipecoatedwithfreshconcrete,measurementtakenimmediatelyafterapplicationofconcretecoating[kg];

DCWC = externaldiameterof theconcretecoatedpipeobtainedbyaverageof fivemeasurementsof theconcretecoatingcircumferenceasperthisspecificationdividedby[m];

W = densityofseawater.

Theacceptancecriteriafornegativebuoyancyforeachcombinationofpipeexternaldiametervs.pipewallthicknessvs.concretecoatingthicknessshallbeprovidedbyCOMPANY/CONTRACTORinduetime.OnlyunlessotherwisecommunicatedbyCOMPANY/CONTRACTORthefollowingtolerancesshallapply: perworkingshift:nominalvalueofnegativebuoyancy(0%/+4.5%); persingleconcretecoatedpipe:nominalvalueofnegativebuoyancy(0%/+10%).Eachpipenotmeetingacceptancecriteriahavetheconcretecoatingremoved.RelevantinspectionreportshallbepreparedbySUBCONTRACTORrelatedtothisinspectionactivity.Thereportshallcontainthefollowingitems:date,shift,pipesequencenumber,pipenumber,pipeexternaldiameter,pipewall thickness,pipenominal concrete coating thickness,acceptance criteria, test results,remarks.8.16 VISUALINSPECTIONOFAPPLIEDCONCRETEEachfreshlyconcretecoatedpipeshallbevisuallyinspectedfordefects.Surfacedamageonconcretecoatingshallnotbeconsideredasadefect ifallofthefollowingconditionshavebeenmet: damageisnotexposingreinforcingsteel; damageisnotextendedtomorethan20%ofthenominalconcretecoatingthickness; damagedareaislessthan1000cm2(0.1m2).RelevantinspectionreportshallbepreparedbySUBCONTRACTORrelatedtothisinspectionactivity.






Thereportshallcontainthefollowingitems:date,shift,pipesequencenumber,pipenumber,pipeexternaldiameter,pipewallthickness,pipenominalconcretecoatingthickness,testresults,remarks.Thefollowingshallbeconsideredduringvisualinspectionofconcretecoatedpipes.8.16.1 SURFACEFALLOUTS(SPALLING)OFFRESHLYCONCRETECOATEDPIPESIncasethespallingoccurs,itshallberepairedonlyifthemaximum20%oftheconcretecoatingsurfaceisaffectedby it.Thespallingshallberepaired inproduction linewithin30minutesafterapplicationoftheoriginalconcretecoatingmixor incasethistime isexceededbygunitingusingtheconcretecompositionsimilartotheoriginalconcretecoatingmixappliedonthepipe.Afterrepairthepipeshallbereweighedforcalculationofnegativebuoyancy.8.16.2 CONCRETECOATINGDAMAGESONFRESHANDHARDENEDCONCRETEDamages caused by taking of core samples for compression strength test shall be repaired unless theanticorrosionpipecoatinghasbeendamaged.Incasetheanticorrosioncoatinghasbeendamagedduringthecoresamplingprocess,theconcretecoatingshallberemovedfromthatpipe.Incase reinforcingsteelhasbeenonlycutbutnot removed from thepipe, theconcretecoatingcanberepairedandthereinforcingsteelshallbepositionedproperlyduringtherepair.However,ifanyportionofreinforcingsteelhasbeenremovedfromthepipe,theconcretecoatingshallberemovedfromthatpipe.Concrete coating damages resulting also in damage of the 3layer PE coating shall have the concretecoatingremoved.Considering above mentioned limitations, repair of concrete coating damages is allowed when theconcrete coating has been damaged or it has been removed from the pipe for repair purposes up tomaximum20%oftheconcretecoatingsurface(notoftheconcretecoatingvolume.8.16.3 CRACKSCircumferentialsurfacecrackingof theconcretenotexposing reinforcingsteelhavingacrackwidth lessthan5mmshallnotbeconsideredasadefect.Circumferentialannularcrackingvisibleatpipeends isgenerallynotacceptableandallpipeshavingsuchcracksintotalcircumferentiallengthgreaterthan200mmshallhavetheconcretecoatingremoved.Allcrackspenetratingdowntothe3layerPEcoatingshallnotbeacceptableandsuchpipeshallhavetheconcretecoatingremoved.Longitudinalsurfacecracks less than250mm in lengthandhavingawidthof8mmor lessshallnotbeconsideredasadefectbutholesof10mmnominaldiametershallbedrilledatthecracktipstopreventpropagationofthecrack.Thebottomoftheseholesshallbe710mmfromtheanticorrosioncoating.Longitudinalcrackshavinga length from250mmup to1000mmshallberepairedbychisellingout thecracktoawidthofatleast25mmthroughoutitslengthtakingcarenottodamageanticorrosioncoating.






Thepreparedareashallbeundercuttoformanadequatekeyforrepairmaterial.Thentheconcreterepairmaterialshallbeinsertedintothepreparedvoiduntilthevoidiscompletelyfilled.Thentherepairmaterialshallbesmoothedwiththeadjacentconcretecoating.Longitudinalcrackshavinga lengthover1000mm shallnotbeacceptableand suchpipe shallhave theconcretecoatingremoved.8.17 ELECTRICALRESISTANCEBETWEENSTEELREINFORCEMENTANDTHEPIPEWhenthesteelreinforcementinaformofwiremeshisusedbySUBCONTRACTOR,theelectricalresistancebetween the reinforcing steel and the pipe end shall be carried out by placing one electrode of theohmmeterconnected to theprotruding reinforcing steelat theconcretecoatingcutbackandbyplacinganotherelectrodeonbarepipeendatthecutbackarea.Theminimummeasuredresistanceshallbe1000Ohm.Thistestshallbeperformedoneachpipe.Allofthepipesnotmeetingacceptancecriterionshallhavetheconcretecoatingremoved.RelevantinspectionreportshallbepreparedbySUBCONTRACTORrelatedtothisinspectionactivity.Thereportshallcontainthefollowingitems:date,shift,pipesequencenumber,pipenumber,pipeexternaldiameter,pipewall thickness,pipenominal concrete coating thickness,acceptance criteria, test results,remarks.8.18 CONTROLOFCURINGPROCESSPeriodically itshallbeverified theconditionsofcuringprocess inorder toverify that thecuringprocessmeetstherequirementsspecifiedinSection8.6ofthisSpecification.Allpipesnotbeingcured inaccordancewithPROJECTdocumentsshallbequarantinedandsubmittedtoCOMPANY/CONTRACTORsdecisionwhoreservestherighttorejecttheconcretecoatingonthesepipesorin case to avoid concrete coating removal to ask additional testing without any extra cost borne byCOMPANY/CONTRACTOR.8.19 CONTROLOFSTACKINGOFPIPESDURINGTHECURINGPROCESSPeriodicalinspectionofpipesstackedincuringareashallbecarriedoutinordertoverifythatthepipeshasbeenstackedinasinglelayerandonapprovedsupports.All pipes not conforming to the PROJECT Specification shall be marked with coloured tape andCOMPANY/CONTRACTOR shall inform the SUBCONTRACTOR about the actions to be taken on nonconformingpipes.8.20 CONTROLOFMARKINGONCONCRETECOATEDPIPESThemarkingappliedonconcretecoatedpipeshallbechecked inordertoverifythatthemarkingand itscontentmeet the requirements specified by COMPANY/CONTRACTOR and that it has been applied inaccordancewithagreedprocedure.






8.21 CONTROLOFMARKINGONCONCRETECOATINGREPAIRWhentherepairofconcretecoatinghasbeenallowed,itshallbeverifiedthattheconcretecoatingrepairmaterialapprovedbyCOMPANY/CONTRACTORhasbeenused, that the repairmaterialcompletely filleddamagedareaand that ithasbeen reasonably smoothedwith theadjacentpreviouslyappliedconcretecoating.Pipesnotconforming to the requirementsof thisSpecification related to the repairofconcretecoatingshall have the concrete coating removed unless repair cannot be redone in accordance with thisSpecification.RelevantinspectionreportshallbepreparedbySUBCONTRACTORrelatedtothisinspectionactivity.The report shallcontain the following items:date, shift,pipenumber,pipeexternaldiameter,pipewallthickness,pipenominalconcretecoatingthickness,descriptionofcoatingdamagesfoundonthepipe,testresults,remarks.8.22 DETERMINATION OF FACTOR ALPHA IN THE FORMULA FOR CALCULATION OF NEGATIVE

BUOYANCYThistestshallbeperformedonlyduringtheprequalificationtest inordertoverifythedifference intheweightbetweenfreshlyconcretecoatedpipeanddryandcuredconcretecoatedpipeinordertocalculatenegativebuoyancymoreprecisely.Incasethistestisnotperformedthefactorshallremain0.99.During theprequalification test it shallbe verified the differencebetween theweight of the concretecoated pipe afterminimum 7 days passed after the application of concrete coating and theweight ofconcrete coated pipe having freshly applied concrete coating. This verification shall be performed onminimumtwoPQTpipesnotsubmittedtothewaterabsorptiontestbyweighingofthepipesimmediatelyafterapplicationofconcretecoatingandatleast7daysafterapplicationofconcretecoatingasfollows:

RelevantinspectionreportshallbepreparedbySUBCONTRACTORrelatedtothisinspectionactivity.8.23 COMPRESSIONSTRENGTHTESTCUBESThecubesshallbetakenatafrequencyofonesampleforevery25pipejointscoated,uptoamaximumofthreetimesperworkshift.Aminimumof4cubes(100x100x100mm)fromeachsampleshallbetaken.Twocubesshallbetestedat7daysageandtheremainingcubesat28daysage.Thetestcubesshallbemade,curedandtestedaccordingtoBSEN123902andBSEN123903,orASTMC39.Thetestcubesshallbetestedfordensityandcompressivestrength,toindicatetheconsistencyoftheconcrete.Theminimumcompressivestrengthshallbeexpressedasequivalentcorestrength.






8.24 COMPRESSIONSTRENGTHCORESAMPLESThe compression strengthon core samples shallbeperformedon the first concrete coatedpipeat thebeginningofeachworkingshiftandthenevery15concretecoatedpipespassingonlinetests;2setsof3corespecimenshallberemovedbypipesusingadiamondcuttertoensurethatthecutisperpendiculartothepipesurface.Coresamplesshallbetakenwithinfourdaysofconcreteapplicationandstoredinacuringtankuntiltestperformance.Thediameterofthecoresampleshallbebetween35mmand44mmandwhentrimmedfortesting,theratiocoresamplediameter/coresample lengthshallbeapproximately1:1. Incase thecappingofcoresamplemustbeperformed,themaximumheightofappliedcappingatanypointshallbe8mmaspertheTable1oftheASTMC61798standard.Threecore samples shallbe takenapproximately500mm from theedgeofconcretecoating frompipeleadend,threecoresamplesshallbetakenfromthecentreofthepipeandthreecoresamplesshallbetakenapproximately500mmfromtheedgeofconcretecoatingfromthepipetailend.Incaseofcagereinforcementtypethecoresampleshallbetakeninamannerthatthereisnoreinforcingsteelincludedincoresample.Onecoresampletakenfromthepipeleadend,onecoresampletakenfromthecentreofthepipeandonecoresampletakenfromthepipetailendshallbesubmittedtothecompressionstrengthtest7daysafterapplicationofconcretecoating (first setofcore samples).The same shallbedonealso forcompressionstrengthtest28daysafterapplicationofconcretecoatingonthatpipe(secondsetofcoresamples).Remainingsetofcoresamplesshallbesparecoresamplesincaserelevantcoresampledoesnotpassthetestandthesparecoresampleshallberetestedinstead(forexample,incaseoftestfailureofcoresampleonpipeleadend,thesparecoresampletakenfromthepipeleadendshallbetested).Onlyincasewhenthereinforcingsteelintheformofweldedwiremeshisusedandthereinforcingsteelisincluded incoresampleandthiscannotbeavoided,SUBCONTRACTORmayusethefollowingnumberofsparecoresamplesduetothenegativeinfluenceofreinforcingsteelincoresampleontestresults: from40mmto45mmnominalconcretethickness:10corestakenfromthepipeleadend,10cores

fromthecentreofthepipeand10coresfromthepipetailend; fornominalconcretecoatingthicknessabove45mm:5corestakenfromthepipeleadend,5cores

fromthecentreofthepipeand5coresfromthepipetailend.Whencagetypeofreinforcingsteelisused,onlyonesparecoresampleforeachlocationisallowed(pipeleadend,centreofthepipeandpipetailend).Foracceptanceorrejectionofthepipe,onlythe28daystestresultshallbeconsideredwhilethe7daystestshallbeperformedonlyforinformation.






The test performance shall be in accordancewith theASTM C39/C39M01 standardwith exception ofrequirementscontradictingthisstandardspecifiedinthisSpecification.Incasetheacceptancecriteriavalidfor28daystesthavebeenachievedafter7days,the28daystestshallnotbeperformedonthatpipe.Thefollowingacceptancecriteriashallapplyfor28daytest: minimumvalueforindividualcore:32MPa; minimumaveragevalueofthreecores(onetakenatthepipe leadend,onetakenatthecentreof

thepipeandontakenatthepipetailend):35MPa.Incaseoftestfailureonfirstsetofcoresamplesandonallowednumberofsparesamplesthefollowingremedialactionsshallbeperformed: allofthepipesconcretecoatedbetweentheprevioussuccessfulcompressionstrengthtestbefore

thetestfailureandafterthefollowingsuccessfulcompressionstrengthtestperformedonthepipecoatedafterthepipeonwhichthetestfailureoccurredshallbequarantined;

then,thecompressionstrengthtestshallbeperformedontwopipesconcretecoated immediatelybefore and on two pipes concrete coated immediately after the pipe onwhich the test failureoccurred.Incaseoftestfailureonanysingleofthesetestpipes,allofthequarantinedpipesshallbeeithersubmittedtothecompressionstrengthtestuntilacceptabletestresultshavebeenfoundonthree consecutive pipes concrete coated before and on three consecutive pipes concrete coatedafterthetestfailure,otherwisethequarantinedpipesshallhavetheconcretecoatingremoved;

thepipesnotmeetingacceptancecriteriashallhavetheconcretecoatingremoved.RelevantinspectionreportshallbepreparedbySUBCONTRACTORrelatedtothisinspectionactivity.Thereportshallcontainthefollowingitems:date,shift,pipesequencenumber,pipenumber,pipeexternaldiameter,pipewall thickness,pipenominal concrete coating thickness,acceptance criteria, test results,remarks.8.25 DETERMINATIONOFTHETIMEFORSTACKINGOFPIPESINMORETHANONELAYERSUBCONTRACTORshalltakecoresamplesfromthreedifferentpipes(threecorestakenpereachpipeasdescribed in previous paragraph) and submit them to the compression strength test considering coresampling and compression strength testing requirements specified in previous paragraph. ThenSUBCONTRACTOR shall decide howmuch time shall pass from the completion of application concretecoatingontestpipeandtestingofcoresample.However, the timeallowed forstackingofpipes inmore thanone layershallbeconsideredas the timewheneachsingletestedcoresampleachievedtheminimumcompressionstrengthof14MPa.Incasethistestisnotperformed,thepipesshallremainstackedinasinglelayerforminimumsevendays.RelevantinspectionreportshallbepreparedbySUBCONTRACTORrelatedtothisinspectionactivity.






8.26 WATERABSORBTIONTESTThe water absorption test shall be performed on one pipe coated each day during the first threeproductiondays.Incasealltestshadacceptableresultsthetestshallbeperformedonceperweek.Thetestshallbeperformedasfollows: freshlyconcretecoatedpipeselectedforthewaterabsorptiontestshallbeplacedinthecuringarea

togetherwithotherpipesbutitshallbemarkedasatestpipeanditshallremaininthecuringareaforminimumsevendaysafterwhichthepipecanbesubmittedtothewaterabsorptiontest;

immediatelypriortotheperformanceofthewaterabsorptiontest,thetestpipeshallbeweighedontheweighing scaleand the resultofmeasurement shallbe recordedandused in the formula forwaterabsorption(W1);

immediatelyafterweighingthepipeshallbecompletelyimmersedeitherinseawaterorinthefreshwateraspertheSUBCONTRACTORsdiscretionandleftconstantlyimmersedforminimum24hours;

afterimmersionofminimum24hours,thepipeshallbeweighedagainontheweighingscale(W2); thewaterabsorptionshallbecalculatedasfollows:

Maximumallowedvalueofthewaterabsorptiontestshallbe5%.Incaseoftestfailureallofthepipescoatedbetweentheprevioussuccessfulwaterabsorptiontestandthenextsuccessfulwaterabsorptiontestperformedafterthetestonwhichthewaterabsorptiontestfailureoccurredshallbequarantined.Thepipeonwhichthetestfailureoccurredshallhavetheconcretecoatingremoved.Then,twopipesselectedfromthequarantinedpipesshallbesubmittedtothewaterabsorptiontest and in case of test failure on any of these test pipes all quarantined pipes shall be submitted toCOMPANY/CONTRACTORs decisionwho deserves the right to ask for additional testing or to reject allquarantinedpipeswithoutanyadditionalcostsbornebyCOMPANY/CONTRACTOR.RelevantinspectionreportshallbepreparedbySUBCONTRACTORrelatedtothisinspectionactivity.Thereportshallcontainthefollowingitems:date,shift,pipesequencenumber,pipenumber,pipeexternaldiameter,pipewall thickness,pipenominal concrete coating thickness,acceptance criteria, test results,remarks.8.27 ADHESIONBETWEENTHE3LAYERPECOATINGANDCONCRETECOATINGDuring thePreQualificationTest,ononeconcretecoatedPROJECTpipe (minimum1m lengthof the3layerPEandconcretecoatedpipepieceisallowedforthispurpose),theadhesiontest(pushofftest)shallbeperformedinordertodeterminetheshearstrengthbetweentheexternalanticorrosioncoatingoflinepipesandconcretecoating.Thetestshallbeperformedinaccordancewithagreedprocedure.






Theminimum valueof the shear strengthbetween theexternalanticorrosion coatingof linepipesandconcretecoatingshallbe0.5MPa.SUBCONTRACTORshallprepareareportrelatedtothistestactivity.8.28 IMPACTTESTINGImpact testingmaybe required todemonstrate suitability foruse inoffshoreapplicationswhere fishingactivitiesoccur.ImpacttestingshallbecarriedoutonqualificationtestpipesselectedbytheCOMPANY/CONTRACTORandon one concrete coated pipe per week or at the COMPANY/CONTRACTOR's discretion until theCOMPANY/CONTRACTOR is satisfied that theconcrete coatingproceduresproducea consistentproductwithacceptableimpactresistance.Theimpacttestingequipmentandprocedurearedetailedbelow.TheexactdetailsofthetestrigshallbesubmittedtotheCOMPANY/CONTRACTORforapprovalandshallincludedetailsofsafetymeasurestobetakentoavoidinjurytopersonnel.Pipessubjecttoimpacttestingshallbescrappedandnotrepairedorincorporatedinthepipeline.The impact test rig is designed to simulate impact by the trawl beam shoes of typical fishing trawlequipmentasusedine.g.theNorthSea.It shall consist of a steel framework onwhich a heavy cylindrical impact 'hammer' is suspended. Thehammershallbesupportedinthehorizontalpositionbytwosetsofwireropesattachedtothesupportingframework.The impacthammershallbedesignedtosimulatethemassandmomentumofa2.68tonnetrawlboardtravellingat7knotsovertheseabed.The'hammer'shallbe300mmlong,havea10mmradiustip,andbeconnectedtoaplateperpendiculartothepipeaxisasshownin(Figure3).Themassofthehammershallbe2.68tonnewiththecapabilityofreducingthemassto1.84tonne.Theverticaldropofthehammershallbe660mmgivingavelocityonimpactof3.60mls(7knots).Note: The aboveindicated values are based on specificNorth Sea trawling equipment, for other areasdifferentvaluesmaybeapplicable.Theconcretecoatedtestpipeshallberigidlysupported fromtherearover its full lengthbymoistsand.Thepipeshallbeheldrigidlyatitsendsbywoodencradlesandwedgestopreventmovementofthepipeunderimpact.Thepointofimpactontheconcreteshallbeatthe3o'clockposition.Thepipeshallbesupportedsothatimpactoftheconcreteismadewhenthehammerisatthelowestpointinitsswing.Testingshallbecarriedoutinthreeways:

1. 90topipeaxisatonelocation(2.68t)2. 90topipeaxisatfivelocationseach300mmapart(2.68t)3. 60topipeaxisatonelocation(1.84t).






Foralltests,recordingofimpactlocationsshallinclude:a)photographaftereachblow;b)diagram(s)ofcrackpatternsandspaliedareasincludingdimensionsofmajorcracks(lengthandwidth);c)dimensionalchanges,ifany,ofthepipe;detectedbyvisualinternalinspectionandsubsequentexternalmeasurement.The concrete area covering crack arrestors shallbe impactedduringqualification tests, for informationpurposes.Test1Thetestpipeshallbesupportedwithaminimumof2mconcretesectioneithersideofthesectionundertest.Impactblowsshallbedirectedonthesamelocationandtheconditionoftheconcreterecordedaftereachblow,untiltheanticorrosioncoatingisexposed.Theanticorrosioncoatingshallnotbevisibleand thesteelpipewallshallnotbe indentedordamagedafter5blows.Spallingshallnotoccuroveranaxialdistancegreaterthan300mmeachsideofthepointsofimpact,after5blows.Test2The testpipeor rig shallbemovedalongat least2mand thena singleblow shallbedirectedon fivelocations,each300mmapart.Theconditionoftheconcreteshallberecordedaftereachblow.Anyspallingshallnotextendfromoneimpactlocationtoanother.Test3Thetestpipeorrigshallbemovedalongatleastanother2mandthepipeimpactedinthe60positiontothe line ofmotion of the hammer. Five impact blows shall be directed on the same location and theconditionoftheconcreterecordedaftereachblow.Theanticorrosioncoatingshallnotbevisibleafterfiveblows.8.29 STACKINGOFCUREDCONCRETECOATEDPIPESPeriodicalinspectionshallbeperformedinstorageareatoverifythattherequirementsspecifiedinSection12ofthisspecificationaremet.All pipes not conforming to the PROJECT Specification shall be marked with coloured tape andCOMPANY/CONTRACTOR shall inform the SUBCONTRACTOR about the actions to be taken on nonconformingpipes.






8.30 LOADOUTINSPECTIONSThefollowinginspectionsshallbeperformedoneachconcretecoatedpipeduringtheloadoutoperation(pipesnot conforming to the requirementsofPROJECT specifications forexternal coating and concretecoatingshallnotbeacceptedforloadout): checkofpipemarking; visualinspectionof3layerPEcoatingattheconcretecoatingcutbackareaand verificationthat3layerPEcoatingdidnotdisbondfromthepipeattheedges; visualinspectionforthepresenceandintegrityofendcapsandpolyethylenesheeting protectingthe3layerPEcoatingcutback; visualinspectionofconcretecoating; checkofresidualmagnetismonbothpipeends(onlywhenrequestedbyCOMPANY/CONTRACTOR).Inspection report shall be prepared only for nonconforming pipes quarantined during the load outinspection.






9 3LAYERPECOATINGREPAIR3layerPEcoatingdamagesandtherelevantexternalcoatingrepairarenotallowedatthecutbackareawheretheexternalcoatinghasbeenbevelled(atthecoatingangle).All coating damages located on the area 100 mm measured from the coating edge after cutbackpreparationtowardscentrepointofthepipeonbothsidesofthepipecanberepairedonly iftherepairmaterialisperfectlysmoothedwithadjacentfactoryappliedcoating.Acceptanceofcoating repairat thisareashallbedoneonlyaccording to theCOMPANY/CONTRACTORsdiscretion(thisrequest is insertedduetothepositioningofthesupportforwelding/NDTequipmentandforapplicationofheatshrinksleevesasthefieldjointcoatingmaterial).Defectsreducingthecoatingthicknessbelowtheminimumallowedtotalcoatingthicknessorexposingtheprimerorbaresteelarenotallowedwhentheyoccurbeforethecompletionofthevisualinspectionofthepipeattherelevantinspectionpointwithinthecoatingplant.Allsuchlinepipesshallberejected,stripped,cleanedandrecoated.Coatingrepairsareallowedonlyforlinepipesdamagedafterthecoatingandquenchingprocessoncethevisualinspectionofthecoatedpipesiscomplete(duetohandlingandstorage).Classificationofcoatingdamages:CoatingdamageClassA:coatingdamagenot reducing the totalcoating thicknessbelow theminimumallowedtotalcoatedthicknessspecifiedinthisSpecification.Coating damage Class B: coating damage reducing the total coating thickness below the tolerancesspecifiedinthisSpecificationbutnotexposingtheprimerorpenetratingdowntothesteel.CoatingdamageClassC:coatingdamageexposingtheprimerorpenetratingdowntothesteel.Maximum10coatingdamagesClassBareallowedoneachlinepipeotherwisethewholelinepipeshallberejected,stripped,recleanedandrecoated.Incaseofanyindividualareagreaterthan50cm2exposingtheprimer/baresteel(coatingdamageClassC)thepipewillhave tobestripped.Amaximumof threecoatingdamagesexposing theprimer/baresteel(coatingdamageClassC)areallowedpereachpipebutthetotaldamagedareashallnotexceed150cm2.Allrepairedareasshallbesubjectedtothefollowingcheckandacceptancecriteria: visualinspectionon100%ofrepairs:nodefects; thicknessteston100%ofrepairs:asperthisspecification; holidaydetectionteston100%ofrepairs:noholidaysat25kV.EachrepairofthecoatingdamageClassBandClassCshallbereportedandtherelevantreportshallinclude: date;





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