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Comparison in between 3LPE Coating with Cement Mortar Guniting

The pipe can be manufactured from mild steel plates or HR Coil for required sizes. Mild
Steel has high impact strength due to high ductility. Specials of all kinds can be fabricated
without difficulty. Due to elasticity, MS pipes adopt themselves to changes in relative ground
level without failure and hence suitable for laying in ground liable to subsidence. MS pipe
with flexible joints provides additional safeguard against failure. MS pipes being flexible are
best suited for high dynamic loading. When a pipeline has to be laid over waterway or
railway, MS pipes are most suitable due to their flexibility and their lightweight compared to
other pipeline material. Moreover, MS pipes are cheaper than DI pipe for diameter 500 mm
and above. Also, spirally welded MS pipe provides high strength and leakage proof joints.
Hence, best suitable for water transmission main.
Because of its low resistance to corrosion, MS pipes need protection from corrosion
internally and externally. Hence, the internal lining and external coating are provided in MS
pipe. Skilled manpower is available for laying and jointing of MS pipes. Tapping and repairs
are easy.
Pipe Surface Protection
Protection for internal and external surfaces of mild steel pipelines is provided for the
following purposes:
a) To protect the transmission main against corrosion of internal surface by the flowing
water and of the external surface by the surrounding soil; and
b) To provide a comparatively smooth surface for the water flow that will in turn reduce
the pump head and hence the operating costs through reduced energy consumption.
The various methods for protecting the internal and external surfaces of the pipeline are as
follows:
a) provision of suitable lining for the internal surface of the pipe;
b) provision of suitable coating for the external surface of the pipe;
c) Provision of adequate corrosion allowance, if necessary, while selecting the pipe
thickness.
Internal Lining
Following types of lining are under considerations for the internal surface of the pipe
a) Cement mortar lining
b) Epoxy Lining
Both type of lining is described below and the comparison of various parameters of the
linings is presented in following Table 1.

a)
Cement Mortar lining
Cement mortar has been used as lining material for many Water Supply Projects in India
and is used extensively worldwide for water supply applications. The principal advantage of
cement mortar linings is, it is economical; it provides good corrosion resistance and provides
increased carrying capacity when the pipe is new and to maintain the same as the pipe
grows older. Mortar for the lining shall be composed of cement, sand and water. Indian
standard IS.11906 recommends that the cement mortar shall contain not less than 1 part of
cement to 2 parts of sand, by volume. AWWA standard C602 recommends cement mortar
composition as 1 part of cement to 1-1.5 parts of sand by volume. The cement mortar is
centrifugally cast inside the pipe. The lining can be done either at the manufacturing shop or
in-situ after laying the pipes. In the former case, however, about 200 to 300 mm of the end
portion of the pipe will have to be left unlined and lined in-situ by hand after welding of the
joint. Surface preparation is not very critical and cleaning of surface by brushing is adequate.
Indian standard IS.11906 recommends a minimum of 8 mm lining thickness for pipes having
diameter 350 to 900 mm.
Epoxy Lining
Epoxy linings are used successfully, although careful and skill full application is necessary to
ensure successive coats adhere to each other.
Solvent free epoxy systems are
characterized by non-porous films exhibiting better corrosion resistant qualities when
compared to conventional solvent-containing paints possessing inherent porosity in their
films. The lining process involves surface preparation, primer application, top coats and
proper curing. The thickness of lining is about 0.5 mm. In-situ epoxy linings are not
recommended as quality control during application is difficult in the field. For both factory
applied and in-situ applied linings there is a risk of damage leading to local loss of protection.
High performance protective coatings are now available and are cost effective for enhancing
life of the pipelines. These linings demonstrate varying degrees of physical and chemical
properties to suit specific needs of high tensile strength elongation, impact and abrasion
resistance and impermeability. The high C value due to smooth finish ensures enhanced
efficiency. These linings exhibit better resistance characteristics compared to that of cement
mortar linings.
Table I. Comparison of Internal Linings
Sl.
No

Property

1
2

Lining Thickness (mm)


C Value (Hazen Williams
Roughness Coefficient)
New
Design
Surface preparation
Cost of lining (Rs/Sqm)

a)
b)
3
4

Lining Materials
Cement Mortar

Epoxy

12

0.5

140
130
Hand brushing
400-450

145
140
Sand Blasting
500-600

Recommended Internal Lining

The epoxy lining have many advantages over cement mortar linings. They have high
adhesion to steel surface, resistant to chemical degradation over large pH range, require
less time in application and are more impermeable. However, the initial cost of lining is
higher than cement mortar lining .Epoxy lined pipes are now extensively used in many water
supply projects in India..
Based on the studies carried out, data available in India and practical experience, internal
cement mortar lining is well proven for MS pipes. As per the norms many Water
Boards/Authorities, internal cement mortar lining of minimum 10 mm thick shall be provided
up-to pipe diameter 610 mm (OD) and minimum 12 mm thick shall be provided beyond 610
mm OD.
External Coating
The external surface of buried MS Pipes is to be compared for following two types of coating
methods:
a) Guniting
b) Cold Applied Tapes
a)

b)

Guniting
This consists of 25 mm layer guniting comprising 1:3.5 cement - sand mix with aggregate
and reinforced by means of mild steel reinforcement as per IS 1916 and IS 1566 with a
minimum cover to pipe surface. The application is done prior to laying by spinning method
and for field joints the application is done in-situ. Guniting apart from providing protection for
pipe against corrosion, it also adds weight to the pipe to counter buoyancy effect and
increases the stiffness of pipe. In steel pipes, the use of internal cement mortar lining and
external guniting reduces the actual deflection to about 50 % of the value that is obtained
without such lining/coating. Application of guniting is quite simple and many pipeline
contractors are well equipped and experienced to carry out guniting. The cost of guniting is
about Rs 750 to 800 per sqm. However, curing of this coating consumes considerable time.
Cold Applied Tapes
Cold applied tape system consists of butyl rubber primer, cold applied anti-corrosion pipe
wrap which is supplied in rolls of various lengths and widths. The cold applied anti-corrosive
pipe wrap can be 3 ply or 2 ply. The 3 ply cold applied wrap referred to as inner wrap
consists of polyethylene/polyolefin backing with plastic butyl rubber on both sides. The 3 ply
tape is wrapped spirally on to the pipe with minimum 25 mm overlap. The overlap may vary
depending upon thickness and mechanical property requirements. As per AWWA C214 the
applied coating thickness is 4 mm.
An outer wrap manufactured from 2 ply plastic tapes consisting of Polyvinyl Chloride or
Polyethylene/polyolefin backing with butyl rubber on one side is spirally wrapped over 3 ply
tapes.
3

The installation requires only simple tools. The steel surface has to be sand blasted. On the
clean steel surface the butyl rubber based primer is applied. As primer is not solvent free, the
primer has to dry before cold applied wrap is applied. The cold applied tapes are then
spirally wrapped under tension with minimum overlap of 25 mm or as required using
wrapping machine. Cost of coating is around Rs. 900 to 1100 per square meter.
Cold applied polyethylene coating system combats corrosion and is compatible with cathodic
protection, resists soil stress and abrasion especially during transport and installation. Also
coating system is applied at ambient temperatures and hence there is no coating shrinkage.
This ensures superior field joint coating. This type of coating does not have proven track
record in India.
Corrosion Allowance
No extra thickness will be provided for corrosion allowance in the MS transmission main as
these pipes will be provided with internal lining and external coating.
Poly Ethylene coating outside pipe surface is already well experienced by GWIL. In compare
to Guniting, PE coating requires significantly less time with good performance, therefore,
reduces the construction period. As per GWILs practice, the internal surface of pipe shall be
provided solvent free food grade epoxy painting of about 0.406 mm thickness and external
surface shall be provided 3 mm thick 3 LPE coating.
Conclusion
Above discussions on the pipe coating can be summarized on the following salient points in
the following table:S.N
o

Description of
Item

Land requirement

Additional Weight of
Pipe

Observations
With Guinting
For field guinting of pipes
substantial land is required for
construction facilities for guinting
works and storage of pipes at
sites including land requirements
for curing etc. Substantial time
may
be
required
for
establishment of such facilities at
site.
Due to additional weight of mortar
coating substantial increase in
weight of pipes will be their
resulting
in
additional
transportation cost of pipes from
works to site.
4

With 3 LPE
No additional space is
required as tape coating
activity is to be carried out
at manufacturer's end at
factory.

Only weight of MS pipe is


to
be
taken
into
considerations.

Rate
of
manufacturing
of
Mortar coated pipes

Additional
Crop
Compensation

Quality Control

Coating
continuation
(Holiday) test

Repairing
of
coating
cracks
during
transportation and
laying jointing.

Skilled Manpower

Considering minimum 21 days of


curing of coated pipes the slack
period for post manufacturing of
MS Shells and completed pipes
will be more.
Considering higher weight of
pipes, necessity of deployment of
haulage machineries of higher
capacity may call for additional
damages
to
the
nearby
agricultural
fields
during
transportation and loading and
unloading activities at site.
As these plants are to be located
at remote locations, the day to
day supervision of guinting
activity has to be carried out
which may call for deployment of
additional TPI for the job.
Not adopted

Very difficult to get integrated with


the existing coating and repaired
patch. This may accelerate the
corrosion of pipe due to
entrapment
of
moisture
subsequently.
Comparatively less required.

Very fast process as


wrapping process is to be
initiated at factory end.

Comparatively
these pipes.

less

for

Strict quality process can


be adhered to at the
manufacturer's premises
itself.

Mandatory
at
the
manufacturer's
end,
confirms
continuous
wrapping
of
coating
material with pipe surface.
As shrinkable sleeves are
to be adopted for joint
repairs, holiday test can
once again performed at
site itself to confirm the
continuation of material.
Adequate
trained
manpower has to be
available to carry out
onsite repair of coating.

Recommendations
Looking into above it can be seen that with use of 3 LPE Coating the quality control on the
pipe coating will be more stringent in tape coating as almost all the pipes will be tape coated
at factory prior to dispatch and all necessary testing parameters can be strictly followed at
the factory end.
In case of guinting the Contractor can be inclined to carry out guinting works at site as
substantial pipe weight will be added if guinting is carried out at factory. With increase of
weight the cost of transportation will also be added up which will definitely encourage the
contractor to carry out guinting at site.

As site specific guinting will be having substantial quality control issues for application
process and curing of the coated pipes.
Any compromise with the quality of coating will accelerate the rate of corrosion of pipes as
splitting of mortar from the surface will call for exposure to alternate wet or dry atmospheric
conditions and any fresh repairing of these coating will be having a heterogeneous coating.
There is a substantial difference in thermal coefficient of expansion for metallic pipe material
and mortar used for coating pipes the chances of degradation will be more in pipes having
guinting as coating.

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