PDVSA

ENGINEERING DESIGN MANUAL

VOLUME 13I ENGINEERING SPECIFICATION

PDVSA N

TITLE

H213OT

CONCRETE COATING OF SUBMARINE PIPELINES

1 0
REV.

DEC. 98 MAY.89
DATE

GENERAL REVISION FOR APPROVAL

DESCRIPTION DATE

13 13
PAG.

Y.K. J.S.
REV.

A.A. J.G.
APPD. DATE

J.E.R A.O.
APPD.

APPD.BY Alexis Arvalo

DEC. 98 APPD.BY J. E. Rojas

DEC. 98

E PDVSA, 1983

SPECIALIST

ENGINEERING SPECIFICATION

PDVSA H213OT REVISION FECHA

PDVSA
.Men Principal

CONCRETE COATING OF SUBMARINE PIPELINES

Indice manual Indice volumen

DEC. 98

Pgina 2
Indice norma

Index
1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 2.2 3.1 3.2 3.3 3.4 4.1 4.2 4.3 4.4 5.1 5.2 5.3 6.1 6.2 PDVSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Industry Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aggregate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reinforcement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Proportioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressive Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Concrete Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coating Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Curing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anode Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corrosion Coat Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3
3 3

3 MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4
4 4 4 4

4 CONCRETE PROPERTY REQUIREMENTS . . . . . . . . . . . . . . . . . . .

5
5 5 5 5

5 COATING APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5
5 6 7

6 ANODE BRACELET INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .

7
7 8

7 COATING OF PIPE SECTION WITH ANODE BRACELET . . . . . . 8 IDENTIFICATION AND MARKING . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSPECTION AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1 9.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 8 8
8 9

10 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1 Spalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 Cracking Due to Pipe Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10
10 11

11 HANDLING AND STACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11
11 12

ENGINEERING SPECIFICATION

PDVSA H213OT REVISION FECHA

PDVSA
.Men Principal

CONCRETE COATING OF SUBMARINE PIPELINES

Indice manual Indice volumen

DEC. 98

Pgina 3
Indice norma

SCOPE
This specification shall govern the materials, application, inspection, repairs, handling, and other requirements for placing anode bracelets and external concrete weight coating on offshore pipelines. The work includes the furnishing of all labor, materials (except line pipe and anode bracelets, tools, and equipment) and the performance of all operations and incidentals necessary for the coating, handling, storing, and shipping of bare and coated pipe. Contractor shall obtain Owner s written approval for any deviations from the requirements of this specification or the specifications, standards, and drawings referenced herein. This document is not intended to be all inclusive, and the use of the guidelines set forth does not relieve the Contractor of his responsibility to supply a product capable of performing its intended service.

REFERENCES
The following codes, standards and specifications, including applicable addenda, in effect as of the last edition, shall form a part of this specification to the extent specified herein.

2.1 2.2

PDVSA
Inspection Manual

Industry Standards
American Society for Testing and Materials (ASTM) C 31 C 33 C 39 C 150 A 82 A 185 A 641 A 90 Standard Practice of Making and Curing Concrete Test Specimens in the Field Standard Specification for Concrete Aggregates Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens Standard Specification for Portland Cement Standard Specification for Steel Wire Plain for Concrete Reinforcement AASHTO No. M32 Standard Specification for Steel Welded Wire Fabric for Concrete Reinforcement Standard Specification for ZincCoated (Galvanized) Carbon Steel Wire Standard Test method for Weight (Mass) of Coating on (Galvanized) Iron or Steel Articles with Zinc or ZincAlloy Coatings

ENGINEERING SPECIFICATION

PDVSA H213OT REVISION FECHA

PDVSA
.Men Principal

CONCRETE COATING OF SUBMARINE PIPELINES

Indice manual Indice volumen

DEC. 98

Pgina 4
Indice norma

Where conflicting statements exist between the different codes, the most stringent regulations shall apply unless otherwise specified by Owner.

MATERIALS
All coating materials shall be furnished by the Contractor and shall include portland cement, aggregate, water, and reinforcing steel. The Owner will furnish line pipe (bare pipe) and anode bracelets. Materials shall conform to the following specifications:

3.1

Cement
Cement shall conform to ASTM C 150 Type I. The cement shall be stored in a manner that will satisfactorily protect it from the elements. Cement that has hardened, partially hardened, or become lumpy shall not be used.

3.2

Aggregate
Aggregate shall be well graded from fine to coarse according to the following sieve sizes:
Sieve Size 1 cm 0.65 cm No. 4 No. 8 No. 16 No. 30 No. 50 Aggregate Passing Percent 100 87100 6485 4560 3050 1035 015

The aggregate shall be clean and free of chlorides alkali, harmful substances, or organic impurities. It shall conform in all respects to ASTM C 33. Owner reserves the right to reject any aggregate not deemed acceptable by virtue or either sources or quality.

3.3

Water
Water shall be clean and free from injurious amounts of oil, acid salt, or organic material and shall be of a quality suitable for drinking.

3.4

Reinforcement
Reinforcing steel shall be welded wire made from high quality steel that is formed into galvanized wire fabric. The wire fabric shall be minimum 14 gage. The

ENGINEERING SPECIFICATION

PDVSA H213OT REVISION FECHA

PDVSA
.Men Principal

CONCRETE COATING OF SUBMARINE PIPELINES

Indice manual Indice volumen

DEC. 98

Pgina 5
Indice norma

chemical and physical properties of the wire shall conform to ASTM specifications listed in Section 2.0.

CONCRETE PROPERTY REQUIREMENTS

The applied concrete shall conform to the following criteria and applicable specifications as listed in Paragraph 2.0.

4.1

Material Proportioning
The Contractor shall obtain Owner s approval to select any proportioning of materials to produce the minimum requirements of material strength, specified density and specified coated pipe weight.

4.2

Compressive Strength
The minimum compressive strength of the concrete, as determined from tests outlined in Paragraph 9.2.1, shall not be less than 211 kg/sq. cm (3000 psi) after seven days and 327 kg/sq cm (4650 psi) after 28 days.

4.3

Density
Tests outlined in 9.2.2, or approved substitute, shall be used to determine the density of the applied concrete. Should the Contractor, upon approval by Owner, plan to rectify lighter than specified coating material with the application of additional concrete, the additional coating shall be applied uniformly along the length and within 30 min. of last application.

4.4

Concrete Thickness
The concrete coating shall be of uniform thickness around the circumference of the pipe and shall not vary more than 6 mm (1/4 in) along any one meter (three foot) length of a coated pipe joint.

COATING APPLICATION
5.1
5.1.1

General
Coating Equipment The Contractor shall provide mechanical equipment capable of applying coating at the specified degree of uniformity with respect to thickness, density, and strength. The Contractor s equipment shall provide for either the batching of materials by weight or continuous mixing, where all feeds are accurately controlled and percentages of mix are calibrated by weight. Any equipment that tends to separate the ingredients shall not be used.

ENGINEERING SPECIFICATION

PDVSA H213OT REVISION FECHA

PDVSA
.Men Principal

CONCRETE COATING OF SUBMARINE PIPELINES

Indice manual Indice volumen

DEC. 98

Pgina 6
Indice norma

5.1.2

Placement In all cases, the concrete shall be placed within 30 min. after the water is first added to the mix.

5.2

Coating Operation
Each joint of pipe shall be coated in continuous operation. Where practical, the total thickness of coating shall be applied on a single pass. If more than one application is required to produce a coating of the specified thickness, then the time allowed between successive applications shall not exceed 30 min. If the time between coats does exceed 30 min., all previous coating shall be removed and the entire joint shall be recoated. The cost of removing coating and recoating shall be at the Contractor s expense.

5.2.1

Coating Limits Concrete coating shall have a 30cm (12in.) cutback on both ends of the pipe. In conjunction with this, the Concrete coating shall terminate 7.5cm (3in.) short of the end of previously applied corrosion protection coating. Except for the 30 cm cutback and anode bracelet areas, the coating shall cover the entire length of pipe section. Coating shall be beveled to a scope of approximately 2:1 and tapered back a minimum 2.5 cm (1 in) from cutback ends.

5.2.2

Preparation If kraft paper has been placed on the joint to protect the corrosion coating, the paper shall be completely removed before the joint is concrete coated.

5.2.3

Reinforcing Steel Application Reinforcing steel may be applied by any method that will provide for the continuity of reinforcing. When reinforcing is spooled on, a minimum overlap of approximately 2.5 cm (1 in) shall result. The reinforcing wrap shall be placed as close as possible to the center of concrete coating. Unless approved otherwise by Owner, the number of steel reinforcement wraps shall be determined by the required thickness of concrete coating as listed below.
Number of Wraps 1 2 3 4 5 6 Concrete Coating Thickness 1 to 1.75 inch 1.75 to 3.0 inch 3.0 to 4.5 inch 4.5 to 6.0 inch 6.0 to 7.5 inch 7.5 to 9.0 inch

ENGINEERING SPECIFICATION

PDVSA H213OT REVISION FECHA

PDVSA
.Men Principal

CONCRETE COATING OF SUBMARINE PIPELINES

Indice manual Indice volumen

DEC. 98

Pgina 7
Indice norma

Steel reinforcement shall protrude beyond the bevel at the ends of the concrete coating for a distance of approximately 1.25 cm (1/2 in). The reinforcing material shall not be in physical or electrical contact with the pipe. Contractor shall check each coated pipe for electrical contact with a suitable power source and meters.

5.3

Curing
During curing, the concrete coated pipe shall be racked on sand ridges or on a flat earthen surface that is free of obstructions. Stacking of coated pipe while curing shall not be allowed. If the joints are placed on sand ridges, they should be so placed as to eliminate any injurious deflection in the pipe. The concrete may be cured by water spray or by application of a curing membrane. The concrete shall not be allowed to dehydrate. All concrete coated pipe shall cure for not less than four days after application of concrete. Waterspray cured coatings shall be kept surfacewet during daylight hours for seven days. Coated pipe shall not be handled or loaded out from the yard until so cured. No deviation from this requirement shall be permitted.

5.3.1

Water Curing Water curing shall commence no later than six hours after coating. It shall consist of keeping the concrete continuously moist for the curing period by means of intermittent watering by either manual or mechanical means.

5.3.2

Membrane Curing Membrane curing shall be of the clear compound whitepigmented compound or plastic membrane type and shall be subject to Companys approval. It shall be applied by mechanical apparatus to the coated surface in sufficient quantity to provide complete coverage in accordance with manufacturer s recommendations. The application of this curing compound or sheet shall take place immediately after coating is completed and preferably before the pipe is removed from the concrete coating apparatus. A slight spray of water applied after concrete application and before applying the curing agent shall be required for the curing compound method.

ANODE BRACELET INSTALLATION

Anodes shall be furnished by the Owner and installed by the Contractor at the center of the individual 12 m pipe joints. Procedures for installation of the anodes to the pipe joints are given in paragraphs that follow.

6.1

Anode Attachment
Prior to installation of the anode, a small area of the pipe corrosion coating shall be removed to bare metal of the pipe joint. Steel surfaces on the anode that will

ENGINEERING SPECIFICATION

PDVSA H213OT REVISION FECHA

PDVSA
.Men Principal

CONCRETE COATING OF SUBMARINE PIPELINES

Indice manual Indice volumen

DEC. 98

Pgina 8
Indice norma

be welded shall also be cleaned to bare metal. The anode shall be placed on the pipe and carefully aligned so that the bonding plates are in contact with the previously prepared bare metal surfaces. After checking the alignment of the two bracelet halves, they shall be welded together. The molded cylindricaltype zinc anode bracelets shall be connected to the pipeline by circumstantially welding Tshaped tabs in four evenlyspaced places for each bracelet (see Fig. 1).

6.2

Corrosion Coat Repair

After the anode has been installed, the weld areas shall be thoroughly cleaned with a wire brush. All steel surfaces, including the pipe, bonding plates, etc., exposed for welding purposes shall be repaired in accordance with PDVSA Inspection Manual. Care should be exercised to prevent the corrosion coat from touching the outer face of the anode. Damage to the pipe corrosion coat for any reason other than welding the bonding plate to the pipeline shall be repaired in accordance with General Specification H212, Coating and Wrapping of Underground Steel Pipe.

COATING OF PIPE SECTION WITH ANODE BRACELET

Corrosion protection coating shall be repaired on pipe sections where anode bracelets have been installed. After proper curing of repairs to the corrosion coating, the concrete weight coating shall be applied. The anode shall be protected to insure that no coating contacts the exterior surfaces of the anode bracelet. Wire reinforcing shall terminate a minimum of five centimeters (two inches) from the anode bracelet.

IDENTIFICATION AND MARKING

Each joint of pipe shall be stenciled with paint on the inside pipe surface with the average thickness of concrete coating and the measured weight of the coated pipe. If required by Owner, coated pipe shall be color coded externally. Thickness and weights shall be in metric units.

INSPECTION AND TESTING

9.1 General
The Owner s representative shall have full and free access to every part of the coating yard and to the on/off loading facilities on the Contractor. Contractor shall provide reasonable assistance to Owner s Representative at every stage of inspection. Pipe coating not meeting the requirements outlined herein shall be rejected and recoated by the Contractor without expense to the Owner. Coatings shall be rejected for the following reasons:

ENGINEERING SPECIFICATION

PDVSA H213OT REVISION FECHA

PDVSA
.Men Principal

CONCRETE COATING OF SUBMARINE PIPELINES

Indice manual Indice volumen

DEC. 98

Pgina 9
Indice norma

1. Improper placement of reinforcing steel. 2. Damage during handling or storage considered by the Company to be excessive and beyond repair. 3. Unfinished coatings that have been allowed to remain unfinished for a period of 30 min. or more. 4. Concrete strength below the specified values. 5. Concrete density outside the specified range. 6. Individual coated joint weight outside the specified range or five joint average below the specified coated pipe weight.

9.2

Testing Methods
Daily samples of the concrete mix, as applied during the coating operation, shall be taken to determine the compressive strength and density of the concrete coating. Each joint of pipe shall be weighted and the final coated weight shall be calculated. All testing shall be at the Contractor s expense and as directed by Owner. The testing and methods to be used are outlined in the following paragraphs.

9.2.1

Compressive Strength Compressive strength of the mix shall be determined from the samples prepared at the jobsite in cylindrical Proctortype molds and obtained in accordance with practices outlined in ASTM C31. A minimum of one test cylinder shall be taken in the morning and one in the afternoon for each day of production. These cylinders shall be tested according to procedures outlined in ASTM C39 to determine the 7 and 28day compressive strengths of the concrete.

9.2.2

Density The density of the concrete shall be determined from hardened and cured concrete that is not less than four days of age and is taken from the coating mix as applied in normal coating operations. One cylinder shall be taken for each morning and one for each afternoon of production to be used for these tests. A sample shall be dried at 100 C (212 F) to constant weight. When constant weight is attained, a sample shall be allowed to cool to room temperature and then weighed to the nearest gram. The sample shall be submerged in seawater at room temperature for not less than 48 hrs. It shall then be withdraw from the water, the excess of surface moisture removed, and weighed to the nearest gram. The sample shall then be weighed, while submerged in seawater, to the nearest gram. The weight per cubic meter shall be calculated as follows:

ENGINEERING SPECIFICATION

PDVSA H213OT REVISION FECHA

PDVSA
.Men Principal

CONCRETE COATING OF SUBMARINE PIPELINES

Indice manual Indice volumen

DEC. 98

Pgina 10
Indice norma

Bulk specific gravity = OvenDry Weight x 0.83 kg.cu m Saturated Weight Suspended Immersion Weight

9.2.3

Coated Pipe Weight Tests The weight of a coated pipe joint shall not deviate in excess of plus seven percent (+7%) or minus five percent (5%) from the specified weight in air. In addition, the average weight in air of five successfully coated joints shall be greater than or equal to the required weight in air. The coated pipe weight in air shall be computed using the following formula: Wair Where: Wair Wm Ws = Weightpermeter in air of the coated pipe (kg/m). = Weight of coated joint of pipe measured by Contractor (kg). = Weightpermeter in air of uncoated steel pipe (kg/m). API nominal weights are acceptable. = Pipe length (m). Lp = Length of concrete coating measured between the crowns of Lc the two tapers (m). Scales used for obtaining weights shall have a certified accuracy of plus or minus one percent ($1%). Lengths shall be obtained to the nearest 0.015 m. Testing shall take place after the fourday curing period. = (WmWs) (LpLc) /Lc

10 REPAIRS
After concrete coatings have hardened, damage during handling and storage shall be repaired in accordance with the paragraphs that follow.

10.1

Spalling
Spalling caused by impact with other objects shall be repaired as follows: 1. Damaged areas of less than 0.1 sq. m (one sq. ft.) where depth of damage does not expose the reinforcing wire and where the surrounding concrete is sound, shall be accepted without repairs. 2. Damaged area exceeding any of the criteria of part (1), above, up to a total damaged area of 0.3 square meters (three square feet) shall be undercut to provide a key lock for repairs.

ENGINEERING SPECIFICATION

PDVSA H213OT REVISION FECHA

PDVSA
.Men Principal

CONCRETE COATING OF SUBMARINE PIPELINES

Indice manual Indice volumen

DEC. 98

Pgina 11
Indice norma

3. Damaged areas exceeding 0.3 sq. m shall have the concrete coating removed around the entire pipe circumference and for a sufficient length to include the entire damaged portion. Repairs shall be made by satisfactorily restoring the reinforcing, if necessary, and removing any cracked or broken concrete at the point of coating damage. The fresh surface of the broken coating shall be wetted and a mixture or cement, water, and aggregate in the same proportions as the coating and troweled into and through the reinforcing. This mixture shall be built up until the surface is level with the coating around the repair. The pipe shall then be carefully laid in a safe position and moistcured for a minimum four days.

10.2

Cracking Due to Pipe Deflection

Cracks that are in excess of 2 mm (1/16 in.) wide and extend over 180 circumstantially around the pipe, or where cracks are over 30 cm (12 in.) in length longitudinally along the pipe, irrespective of width, shall be repaired. Repair shall be made by chiseling the crack out to a width of not less than 2.5 cm (1 in) throughout the length of the crack. The crack shall be repaired with materials similar to that from which the coating is made. The repairs shall be kept moist and be allowed to remain undisturbed for a period of not less than 36 hours.

11 HANDLING AND STACKING

The concrete coated pipe shall be handled and stacked in accordance with the following paragraphs and applicable specifications as listed in Paragraph 2.0.

11.1

Handling
Pipe shall be handled in a manner to prevent damage to coating, pipe walls, and beveled ends. Boomers or equivalent load binding members shall always be used in crosscountry, rough road, and sea handling. Adequate strapping and padding shall be provided when loading for transfer to any location. Pipe shall be raised or lowered by using brasslined end hooks inserted in the ends of the pipe, and carried by a wire rope or chain sling with a spreader bar between the lines. All pipe handling shall be with equipment approved by Owner. If the coating or pipe has been damaged due to handling, the Owner may require the Contractor to take immediate corrective action at the Contractor s expense.

ENGINEERING SPECIFICATION

PDVSA H213OT REVISION FECHA

PDVSA
.Men Principal

CONCRETE COATING OF SUBMARINE PIPELINES

Indice manual Indice volumen

DEC. 98

Pgina 12
Indice norma

11.2

Stacking
Contractor shall obtain Owner s approval for stacking heights of bare pipe, corrosion coated pipe, and concrete coated pipe. Stacking height shall be reduced at the Owner s request if deleterious effects to the pipe or its coating due to stacking become evident. Recommended stacking limits are ten layers for bare pipe and five layers for concrete coated pipe. Stacking height limits and number of layers may be affected by the selected pipe sizes and concrete thickness. Any recommendation to adjust stacking height limits is subject to Owner s approval.

ENGINEERING SPECIFICATION

PDVSA H213OT REVISION FECHA

PDVSA
.Men Principal

CONCRETE COATING OF SUBMARINE PIPELINES

Indice manual Indice volumen

DEC. 98

Pgina 13
Indice norma

FIG. 1