Doc. No.

:
COATING WEL-Coating
Procedure
PROCEDURE -001

Owner :
Manufacturer:
Purchaser :
Weltech Co., Ltd.
Project : Shuqaiq Desalination Project

TABLE OF CONTENTS

1 Scope

2 Application Specifications

3 Technical Requirements

4 Inspection and testing

5 Attachments

2 29 Mar. 2021 Attachment is included JOSEPH Y.M. CHO

1 24 Mar. 2021 For Approval JOSEPH Y.M. CHO

0 2 Mar. 2021 For Approval JOSEPH Y.M. CHO

Rev. Date Description Written By Approved By

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 Doc. No.:
COATING WEL-Coating
Procedure
PROCEDURE -001

1. Scope

This procedure describes the internal and external linings applied to the steel line pipe, the
water transport system inside the fittings.

Applies to minimum requirements such as material and coating procedures.

2. Application Specifications

The specifications and standards mentioned here use the latest version of code and standards
for detailed design work.

QC10-H-048 M08 Piping Materials for Stations-Rev6

QC10-H-042 M02 Polyethylene Coating Rev6
QC10-H-063 M23 Fusion-Bonded Epoxy Coating-Rev3
QC10-H-060 M20 Fusion-Bonded Epoxy Lining-Rev4
SP-0102 -Specification for HDPE Coating of Pipes
SP-0209 -Specification for FBE Lining and Coating of Station Piping Material
DIN 30670 - Polyethylene Coatings of Steel Pipes and Fitting(KS D 3589)
Requirements and Testing
SSPC-SP-COM - Surface Preparation Specifications
SSPC-SP 10 near-white metal blast cleaning (NACE No. 2)

If the specifications and standards applied do not match the contract requirements, the
contractor shall inform the engineer of the inconsistencies in this specification and
the standards and the contract documents applied to the Fusion-Bonded Epoxy lining.
Exceptions to this specification and reference documents shall be submitted by the contractor
and approved by the engineer in writing.

3. Technical Requirements

3.1 Coating Materials

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Materials shall be handled and stored in accordance with the recommendations of the material
manufacturer, and the material manufacturer shall be able to review at the pipe coating
contractor facility. Coating materials shall be separated by type and batch during storage and
handling. Materials of damaged containers shall be rejected unless agreed otherwise with the
engineer.
At a minimum, all packages of coating materials shall show the following data:
a) Name of manufacturer
b) Complete material identification – trade name, chemical name and type of product details
c) Batch number
d) Date of manufacture
e) Place of manufacture
f) Shelf life/expiry date (if appropriate)
g) Health and safety, and environmental instructions
h) Hazard warnings
i) Storage instructions
j) Quantity
k) Manufacturing standard
Any material not labelled with the above information shall not be used.

3.2 coating application

3.2.1 General
Coating applications shall be in accordance with the material manufacturer's recommendations
and the procedures described below.

3.2.2 Internal/External Coating Application

3.2.2.1 F.B.E internal Lining
3.2.2.2 F.B.E external coating
3.2.2.3 3LPE external coating

3.2.2.1 F.B.E internal Lining(Minimum 350 Microns)

<F.B.E materials>
Item Data Sheet
description Brand Name Technical Name Ref. color

FBE Powder KCC EX-4412 EX-4412 Ral-7032(Pebble grey)

FBE SAMHWA E 5000P - E 5000P - Ral-7032(Pebble grey)
WT(GREY) WT(GREY)

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 The requirements shall be the same as in Sec. 4.4.3 of AWWA C213 supplemented and/or
amended by the following requirements.
The minimum DFT provided shall be at least 350 mic, or by recommendation of supplier,
whichever is higher and shall be applied in one (1) layer only.
Any line pipe and associated fittings having less than the specified minimum dry film thickness
shall be re-blasted and re-lined.
Cutback and bevels shall be temporarily protected against corrosion during storage and
shipment with weldable primer coat.
The cured lining shall be of uniform colour and gloss, and shall be free of blisters, and
fish eyes. Cosmetic sags, runs, and other non-injurious irregularities are acceptable as long as
the area affected is less than 0.5 % of the coated area.
The following lining performance testing shall be done according to Sec. 4.4.3.7 of
AWWA C213:

• Thermal analysis (DSC) Density

• Permanent train (bendability)
• Water Soak
• Impact

3.2.2.2 F.B.E external coating(150 to 250 Microns)

Pipe Coating Contractor shall provide prior application a proven Application Control Plan for
approval by the Engineer. The approval of the said procedure is required prior commencement
of coating.
The coating material shall be applied according to the Engineer approved written application
procedure which incorporates the Manufacturer's recommendations.
Coating operation shall be suspended if the substrate temperature is less than three (3) °C
above the dew point.
The finished coating thickness shall be in the range 305 to 505 micrometers. Pipe-made
fittings are allowed a maximum DFT of 1,000 micrometers.
Any line pipe and associated fittings having less than the specified minimum dry film thickness
shall be re-blasted and coated.
The finished coating shall have a cut back at each end of 150mm (+/-10mm) on all pipes,
measured from end of pipe. Cutback and bevels shall be temporarily protected against
corrosion during storage and shipment with weldable primer coat.

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 3.2.2.3 3LPE external coating(Minimum 3.5mm)

<3LPE Materials>

Item
description Brand Name Technical Name Data Sheet Ref. Ral color

FBE Powder KCC EX4413-L300(S) EX4413-L300(S) Ral-6027

(Light green)
FBE Powder SAMHWA E5000P-WT(blue) E5000P-WT(blue) Ral-5009
(Azure blue)
adhesive Lotte Chemical EM-400 EM-400 White
Polyethylene Lotte Chemical GR4100M GR4100M Carbon Black
Polyethylene KPIC P601HUBL P601HUBL Carbon Black

3.2.2.3.1 Before Coating

A) Phase
The basic steps of pipe coating shall be as follows.
- Exterior (when applying a three-layer polyethylene clad steel tube coating)
• Abrasive blasting
• Application of FBE layer for three-layer polyethylene clad steel pipes
• Apply adhesive layer
• Polyethylene layer applied

B) Abrasive blasting
Abrasive blasting shall be carried out in accordance with the pretreatment procedure.

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 3.2.2.3.2 Applying coating

- FBE 1st layer(200 to 350 Microns)

The FBE shall be applied to a minimum thickness of 200 microns and a maximum of 350
microns. The pipe shall be uniformly preheated in accordance with the FBE manufacturer’s
instructions. This temperature shall have been confirmed during PQT. The surface
temperature shall not exceed 260 °C in accordance with AWWA C213, section “4.4.3.1
Preheating”. Pipe temperature shall be checked periodically using a recording pyrometer. The
pyrometer shall be checked for error not less than every four hours against a calibrated
temperature-measuring instrument.
The coating shall be applied by electrostatic spray with the pipe at earth potential and the
epoxy powder charged to high potential

- Adhesive 2nd layer Coating(150 to 250 Microns)

The adhesive shall be applied to a thickness of 150 to 250 microns.
The adhesive layer shall be applied before gel time of the FBE has expired. Application of the
adhesive shall not be permitted after the FBE has fully cured.
The Pipe Coating Contractor shall establish to the satisfaction of the Engineer that the
adhesive is applied within the gel time window of the FBE and at the temperature
recommended by the adhesive manufacturer. The Pipe Coating Contractor shall state the
proposed minimum and maximum time interval between FBE and adhesive applications at
the proposed pre-heat temperature.

- Polyethylene Layer(Minimum thickness : 3.5mm over the pipe body)

The polyethylene layer shall be applied to a minimum thickness of 3.5 mm over the pipe body
and to a minimum of 3.25 mm over the production welds for pipe diameters greater than 500
mm and to a minimum thickness of 3.0 mm over the pipe body and to a minimum of 2.75 mm
over the production welds for pipe diameters less than 500 mm.
The polyethylene shall be applied over the adhesive within the time limits established during
pre-production testing.
The coating shall be cooled to below 60°C before handling.
Immediately after the coating is fully cured, pipe identification marks shall be re-applied to the
coated pipe using a method approved by the Engineer.
Cut back of Coating
A length of 120 mm +10/-0 mm from the pipe end shall be free from any coating material.
A polyethylene layer cut back of 150 mm (+10/-10 mm) shall be provided at pipe ends.
The FBE layer shall protrude the polyethylene layer by min.10 mm but shall not extend further
than 120 mm from the pipe end.
The ends of the layers shall be chamfered and beveled at 30 to 45°.

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4. Inspection and test

4.1 3LPE coating

4.1.1 Product Test

4.1.1.1 The production test shall be carried out with the frequency indicated below.

4.1.1.2 Products of the internal Epoxy and external 3LP coating shall be tested in
accordance with approved test procedure. Testing performed for a long time or in
a laboratory may be replaced by a material manufacturer's report card.
Property Acceptable Values Minimum
Frequency
Bare steel pipes
On Arrival
Pipe Damage Minor damage/grinding <3 Each Pipe
per pipe

After Cleaning
Chloride 2 µg/cm2 1 per 100 pipe
Oil No contamination 1 per 100 pipe
Salt 3 µg/cm2 1 per 100 pipe
After Abrasive Blasting
Cleanliness ISO-Sa 2.5 Each pipe
Profile 50-100 µm 1 pipe per 100
Contamination No contamination 1 pipe per 100
Pipe Damage See clause 4.2 Each pipe

Pipes with FBE only

FBE Layer
Visual Inspection No surface defects One pipe per day
Thickness Min/max see clause 4.4.2 and one pipe when
Adhesion See clause 5.3.5 FBE batch changes
At each batch
change and at any
Holidays No holidays stop of FBE
application
Pipes with full coating system
Coating Thickness of See clause 5.3.3 Each pipe
Final Coating
(minimum)
Holidays No holidays Each pipe
Visual Inspection
Coating No surface defects Each pipe
Bare steel at pipe ends 120 +10/−0 mm width Each pipe
Protruding FBE 10 to 40mm width, chamfered Each pipe
PE cut backs 150 +10/-10 mm, bevel 30° to Each pipe
45°
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 Adhesion
Peel Test > 100 N/cm at 20°C ±5°C 1 pipe per 100
Cathodic Disbondment Clause 5.3.10 First pipe, last pipe
at Room Temperature and at intervals of
every 350 pipes

The frequency of tests shown in the table above will be for normal production operations.
This frequency of tests is subject to change at the discretion of the Engineer as a result of
change of materials or consistent poor production performance.
Additional after cleaning checks regarding chloride, oil, salt shall be executed after every stop
and start for certain hours.
The Pipe Coating Contractor’s quality control system shall include the following, as a
minimum:
- Monitoring of blasting grit and shot size
- Visual checks, in good light, of the surface of the blasted pipe
- Temperature control of the pipe surface
- Coating testing as detailed in this Specification
- Supervision of the adequate and proper repair of all defects

The following shall be recorded and logged at least once per shift:

- Air temperature (every 4 hours)

- Relative humidity (every 4 hours)
- Surface temperature of steel
- Dew point

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The frequency of the tests shown in the table above is for normal production operations. The
frequency of this test may change at the discretion of the inspector or change of material.

The pipe coating contractor shall control the following:

- Visual inspection of pipe surfaces after pretreatment
- Pipe preheating temperature
- Coating test results

4.1.1.3 Visual Inspection

FBE:
The FBE layer shall undergo a 100 % visual examination, if necessary using optical
instruments. The coating shall not show any signs of blistering, porosity or voids and shall
exhibit a uniform appearance.
Final Coating:
The following external surfaces of the coated pipe shall be carefully inspected in adequate
lighting:
- Adjacent to the longitudinal or spiral welds.
- Adjacent to the cutback at each end of pipe.
- Within the body of the pipe.
The coating shall be black (unless otherwise agreed by the Engineer). The finished coating
shall be blemish-free, with no dust or other particulate inclusions. The coating shall not have
any defects such as blisters, scratches, wrinkles, engravings, cuts, swellings, excess material
thickness, disbonded zones, air inclusions, tears, voids etc.

4.1.1.4 Coating Thickness

FBE:
The FBE coating thickness shall be measured using an electronic device.
The FBE coating thickness shall be measured at 10 locations which shall be evenly spaced
around the pipe circumference and along the full length of the pipe.
Final Coating:

The total coating system shall be applied to the following minimum thickness requirements:
PIPE DIAMETER PIPE BODY OVER THE MANUFACTURING
WELD

< 500mm 3.0 mm 2.75 mm

≥ 500mm 3.5 mm 3.25 mm

The thickness of the cooled polyethylene coating system shall be checked using Engineer
approved equipment in accordance with the requirements of DIN 30670.
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Film thickness shall be measured by use of an electronic thickness gauge. Calibration of this
gauge shall be rechecked every 2 hours. The Pipe Coating Contractor’s proposed thickness
gauge type, manufacturer and model shall be submitted to the Engineer for review and
approval.
At least 3 of the measured points per pipe length shall be on the welds.
Any individual reading less than the values above shall be cause for the coated pipe length
concerned to be quarantined. The pipe shall be held for further review by the Engineer.

4.1.1.5 Holiday Detection

FBE Layer:
Holiday testing of the FBE coating shall be carried out on 100 % of the coated surface with a
pulse type DC holiday detector equipped with audible signalling device. The test shall be
carried out in accordance with NACE RP0490 or equivalent.
Final Coating:
Each fully coated pipe shall be inspected for holidays over 100 percent of its coated surface
using a high voltage DC detector.
The detector shall be a type, which maintains complete contact with the coating. It may be
either constant or pulsed voltage type. If constant voltage type, holiday detection shall be
carried out on a dry coating. The operating voltage between electrode and pipe shall be
checked at least twice per working shift, and shall be maintained at 10 kilovolt/mm of coating
thickness.
The Pipe Coating Contractor shall demonstrate to the Engineer that the setting of the
detector is satisfactory for detecting pinhole defects. This setting shall be checked once every
two hours. The correct travel speed shall be determined by consistent detection of an artificial
pinhole made in a good coating sample but shall not exceed 300 mm/s.
All holidays and other defects shall be marked for subsequent repair and re- testing. On re-
testing, no holidays shall be permitted in the final coating.
The number of holidays for each pipe length shall be recorded. Coated pipe having holidays in
excess of 1 per 1 square meter shall be stripped and re- coated.
If there is an excess occurrence of holidays on successive pipes, the Pipe Coating Contractor
shall immediately stop the coating operation to determine the cause and remedy it.

4.1.1.6 Adhesion (Peel) Test FBE Layer:

With a sharp narrow bladed knife, two incisions (approximately 13 mm long) shall be made,
in the form of an X, through to the metal substrate. At the intersection of the X, an attempt
shall be made to force the lining from the steel substrate with the knife point. The point of
the knife shall be inserted horizontally i.e., the flat of the blade under the lining at the point
of intersection of the X such that the blade point is on the metal surface. Using a levering
action, the flat point shall be forced away from the steel in an attempt to pry off the coating.
Refusal of the lining to disbond from the substrate shall be recorded as a pass. A pass shall
also be recorded where the lining fails cohesively. Partial or complete adhesive failure
between the lining and the substrate shall be recorded as a failure. Disbondment at the point
of the intersection is common due to the action of marking the 'X' cut. Therefore, for 1 mm
away from the tip of the intersection any disbondment shall be ignored.
Final Coating:

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The adhesion for the complete coating shall be determined in accordance with the
requirements for bond strength in DIN 30670. The relevant test temperature and acceptance
criteria for these tests shall be as detailed in 5.2.1 for procedure qualification and 5.3.1 for
production testing. Automatic chart recording equipment shall be used and the average
peeling force shall be recorded.
The failure mode shall be recorded. The failure should occur at the adhesive/polyethylene
interface or adhesive/FBE interface or cohesively in the polyethylene layer. If failure should
occur at the FBE/steel interface this will be considered a total failure of the system.

4.1.1.7 Impact Test

A sample of coated pipe shall be impact tested in accordance with the procedures and
acceptance criteria of DIN 30670.

4.1.1.8 Resistance to Indentation Test (Indentation Hardness)

Once per shift (and when the FBE or polyethylene batch is changed), the indentation
hardness of two coated samples shall be measured (one at 20°C ± 5°C and the other one at
70°C ± 2°C) in accordance with DIN 30670 (Section 5.3.5).
Indentation depth shall not exceed 0.2 mm at 20°C ± 5°C or 0.3 mm at 70°C ± 2°C.

4.1.1.9 Percentage Elongation at Failure

This test shall be conducted in accordance with DIN 30670 on each of the full system pre-
qualification pipes, but at least the coating of three pipes shall be tested for elongation at
failure, from which five test pieces shall be taken. The percentage elongation at failure shall
be at least 200%.-on each of the full system pre-qualification pipes, 2 samples per pipe to the
requirements of DIN 30670.

4.1.1.10 Other DIN 30670 Tests

The Pipe Coating Contractor shall demonstrate, for the same system to be applied for this
order, attainment of DIN 30670 requirements for Coating Resistivity, to Thermal Ageing and
Light Ageing as required by DIN 30670.

4.1.1.11 Cathodic Disbondment Test

Cathodic Disbondment testing shall be conducted:
· as a pre-qualification test - 48 hours duration at 65 +/- 2°C
· as a pre-qualification test - 28 days duration at 23 +/- 2°C
· as a production test - 48 hours duration, at the frequency of one test per 350 coated
pipes at 65 +/- 2°C
The test requirements shall be in accordance with ASTM G 8.
The final unsealed diameter (including the initial holiday diameter of 6.35 mm) shall not
exceed 15 mm. This shall apply to both, the 28 day test at 23 +/- 2 °C and the 2 days test at
65 +/- 2 °C.
The Pipe Coating Contractor may propose alternative cathodic disbondment test standards
provided the essential requirements of this specification are retained. Any such alternatives

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shall be submitted to the Engineer for review and approval.
Every 24 hours the applied voltage and current flow shall be recorded. Any drift from the
specified voltage setting shall be corrected.

4.1.1.12 Destructive Tests

A sufficient length of production pipe shall be cold cut to provide the required number of
samples for conducting the coating destructive tests listed in this specification.
Items that fail individual tests and that cannot be repaired in accordance with Section 5.3.12
shall be rejected. Subject to the approval of Engineer, the rejected coating shall be stripped
and the joint shall be re-blasted and coated in the manner specified for new pipe in this
specification.
Where a test relates to a quantity of coated items, e.g. 1 per 50 items or 1 per 100 items
etc., the quantity of items represented by the item tested (e.g. 50 or 100) shall be considered
to be a batch.
If a test on an item in a batch fails then this item shall be rejected and two further items shall
be randomly selected from the batch for repeat testing. If either of these tests fails then the
whole batch shall be quarantined for review by Engineer. The cause of failure shall be
established and reported to the Engineer and if deemed necessary by the Engineer the
coating procedure shall be amended and re-qualified. The Engineer will decide whether the
whole batch is rejected and sent for re-blasting and re-coating or whether acceptance may be
on the basis of acceptable tests carried out on individual items.

4.1.1.13 Coating Repairs

The Pipe Coating Contractor shall submit detailed coating repair procedures for approval by
Engineer. These shall include procedures for repair of ‘pin-hole’, ‘small area’ and ‘large area’
defects. The minimum and maximum areas for which each type of repair is applicable shall be
stated taking into consideration the below mentioned requirements.
The maximum number of coating defects allowable, before a joint of pipe shall be classed as
rejected and recoated, shall not exceed 1 per 1 square metre (exclusive of damage caused by
testing).
• Repair areas of sizes < 10 mm²
Pinhole damage shall be repaired by cleaning with an emery cloth followed by application of a
two (2) pack epoxy repair kit or an approved hot melt mastic smoothed flush with the
polyethylene surface. If the mastic is used, it shall be spread with the aid of a hot air or a
propane torch.
• Repair areas of sizes 10 mm² up to < 250 mm²
The area shall be swabbed with solvent and abraded with an emery cloth, to ensure that the
surrounding polyethylene is well bonded, the surface shall be roughened for a distance of at
least 25 mm beyond the damage area. An approved hot melt mastic shall be applied to the
damaged area and smoothed flush. The mastic and surrounding area shall be warmed with
hot air or propane torch until the surrounding polyethylene has as slight sheen. An approved
polyethylene patch material shall be applied overlapping the damage but not overlapping the
pre-abraded areas. Torch heat and smoothing pressure shall be applied to fuse the patch and
ensure that no blisters are formed.
• Repair areas of sizes 250 mm² up to 625 mm²
Heat shrink-wrapping pipe sleeves shall be used for repair according to the following
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 procedure:
- Thoroughly clean the area to be coated
- Bevel the extremities of the mill-coating with a rasp
- Pre-heat the area to be coated to a temperature of approximately 70°C.
- Install the sleeve over the area to be coated
- Warm the shrink sleeve to a temperature above 150°C with a propane torch or a warm-
air ring

• Repair areas of sizes exceeding 625 mm²

No single defect shall exceed an area of 625 mm². Pipes with a coating defect exceeding 625
mm² shall be cause for rejection and shall be subsequently reblasted and recoated. All
rejections shall be recorded.
Repairs shall provide a finished coating equal in effectiveness to that of the parent coating.
The limit of the repair area shall be revised.
Each repaired area shall be holiday inspected in accordance with chapter 5.3.4 of this
specification.
The Pipe Coating Contractor shall submit coating stripping procedure for pipes rejected for
coating quality. The rejected coating may be stripped by heating in an oven. Under these
circumstances, the temperature of the pipe joint shall not be allowed to rise above 400 °C.

4.2 Fusion-Bonded Epoxy coating

4.2.1 General

External coating shall be tested in accordance with specification M20 “Fusion- Bonded Epoxy
Lining”, section 5 “Inspection, Testing and Certification” as far as applicable for external
surfaces of steel welded line pipes and pipe-made fittings.

4.2.2 Coating Thickness Test

The coating thickness test shall be executed as defined in M20 “Fusion-Bonded Epoxy Lining”.
All results for the DFT shall be as specified in paragraph 4.6 of this M23 specification, and
shall be recorded.

4.2.3 Bend Test

Once per shift or every one hundred (100) pipe lengths (whichever is the more frequent) and
at the start of using a new batch of powder the flexibility of the coating shall be determined
by a bend test. The powder utilised for the test shall be taken from the plant application fluid
bed.
The test shall be carried out in accordance with AWWA C213. If either of the bend tests fail,
the tests shall be repeated.
If both bend re-tests are satisfactory, the bend test shall be accepted.
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 If either (or both) of the re-tests fail, all the pipe coated since the previous successful bend
test shall be set aside. Further coating with the suspect batch of powder shall be immediately
stopped. Two (2) specimens with the same dimensions as given in this specification shall be
cold cut from the first pipe coated from the suspect batch or since the last successful bend
test, whichever occurred later. The edges of the specimens as necessary shall be chamfered
to remove stress raisers.
If the samples fail the bend test, all pipe that has been coated with the suspect material shall
be blasted off and the pipes shall be re-coated. If the samples pass the bend test, lot
narrowing shall be used until the Engineer is satisfied that all pipes with substandard coatings
have been identified. These pipes shall be re- blasted and re-coated.

4.2.4 RE-CHECK ON COATING MATERIAL QUALITIES

The Engineer at any time may require that the Pipe Coating Contractor prepare a set of test
specimens as defined in the Qualification Procedure (paragraph 4.2.1 in M23), and arrange
for the performance of any or all of the tests covered by Qualification Procedure at a third-
party laboratory.

4.2.5 REPAIRS

4.2.5.1 General
Each length of coated pipe leaving the Pipe Coating Contractor premises shall be free of
holidays and visual coating defects.
Defects shall be repaired in accordance with the criteria and methods below.

4.2.5.2 Small Defects (Areas of damage up to 1,450 mm²)

For small pinholes, metal slivers, or minor damage repair materials shall be as specified under
paragraph 4.2 in M23, and repairs shall be in accordance with the coating Manufacturer's
recommended procedure.
After repair, these areas shall be re-tested in accordance with specification M20, and shall be
holiday free.

4.2.5.3 Large Defects (Areas of damage exceeding 1,450 mm²)

When large repairs are approved by the Engineer, the following procedure shall be followed
using material outlined under paragraph 4.2 in M23. If the total damaged area exceeds 1,450
mm², the pipe shall be re-coated, not re-paired. Hot melt sticks shall not be used.
The pipe surface to be re-coated shall be cleaned to remove all dirt and damaged or
disbonded coating using abrasive blasting or other approved and suitable means. The edges
of the original coatings shall be "feathered out" approximately 50 mm around the specific
area to be coated, and all dust cleaned off before applying the patch coating.
The preferred method for patching large defects shall be to heat the area locally with
induction heating or other heating means and blow on (flock) the same type powder used on
the production coating line.
When equipment is not available for patching by the method described above, the following

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 procedures shall be used:
a) The material for patch coating in the shop shall be catalytically cured epoxy coating
supplied or approved by the Manufacturer of the powder epoxy coating.
b) The repair coating shall be applied by spatula, brush, roller or spray depending on the
size and nature of the damaged area being repaired.
c) The patch coating shall not be applied when the pipe surface temperature is less than
3 °C above the dew point.
Freshly patched coated areas shall be allowed to cure according to the coating Manufacturer's
recommendations prior to handling, and the repaired area shall be holiday tested in
accordance with specification M20.

4.3 Fusion Bonded Epoxy lining

The requirements and the standards of acceptability for inspection and testing shall be the
same as in Sec. 5 of AWWA C213 supplemented and/or amended by the following
requirements.

4.3.1 Inspection

The Contractor shall notify the Engineer not less than thirty (30) days in advance of the start
of each production run. The Contractor shall provide the Engineer with a detailed time
schedule to permit him to witness or monitor all processing and testing phases.
The Contractor shall be responsible for all quality control checking including visual inspection,
thickness measurements, and holiday testing, and shall keep records on the results of all such
inspections in a form suitable to the Purchaser's appointed Inspector.
The Purchaser's appointed Inspector shall have access to each part of the process, and shall
have the right and opportunity to witness or monitor any of the

quality control tests and/or perform such tests himself on a random sampling basis.
The Purchaser's appointed Inspector shall have the right to stop this work pending alterations
or corrections to the process to correct all faults found in the work that result in failure to
conform to this specification.

4.3.2 Testing

4.3.2.1 Calibration of Inspection Equipment

The lining thickness gauge shall be calibrated at the start of production and every three (3)
hours during production, at approximately the mid range of the lining thickness against a
certified or known standard.
The holiday detector shall be calibrated at least twice per eight (8) hour shift against a
suitable calibrated voltmeter and adjusted to ensure that voltage is sufficiently high to detect
an intentional pinhole holiday through the lining on the pipe.

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4.3.2.2 Coating Materials Tests
Shall be done according to Sec. 5.3.1 of AWWA C213.

4.3.2.3 Powder and Coating Systems Tests

Shall be done according to Sec. 5.3.2 of AWWA C213 and shall comprise the following tests:
• Specific gravity
• Sieve analysis
• Gel time – hot steel plate
• Appearance
• Impact
• Bendability
• Shear adhesion
• Penetration
• Abrasion resistance
• Water soak

In addition the “Cleveland Test” shall be done according to ASTM D4585.

The following tests shall be performed as proof that the “Cleveland Test” did not damage the
lining:
- Corrosion creep (DIN EN ISO 4628-8, DIN EN ISO 9227)
- Impact resistance
- Adhesion ( pull off test)

4.3.2.4 Production coated-pipe tests

Shall be done according to Sec. 5.3.3 of AWWA C213 and shall comprise the following tests:

4.3.2.4.1 Electrical inspection for continuity

The holiday detection test shall be carried out according to NACE Standard RP0188 and
supplemented by NACE Standard TM0186 and the following requirements.
l00% of the lined pipe or fittings surface area shall be holiday detected with a hot spark
pulse-type DC detector employing an audible signalling device. The electrode used for
locating holidays shall be designed to ensure direct contact with the lining, (with no visible
gaps). Holiday detection shall not be conducted if the surface temperature of the pipe is
above 88 °C.
The travel rate of the detectors electrode shall not exceed 75 cm/s and shall not be allowed
to remain stationary while the power is on.
Holidays shall be clearly marked for repair.

WELTECH Co., LTD.

4.3.2.4.2 Adhesion Test
The adhesion of the lining shall be determined at one location on a pipe for each of the
following cases:
- the first production joint,
- the first joint after any interruption in production and
- once every hour or twenty pipe lengths, whichever is more frequent.

4.3.2.4.3 Thickness Test

Every pipe shall be checked at least at five (5) equidistant places and fittings shall be checked
in at least five (5) locations. All coating thickness measurements shall be made using a non-
destructive type of thickness gauge, which shall be calibrated as required in section 4.3.2.1
“Calibration of Inspection Equipment”.

4.3.2.4.4 Cure Test

Twice per shift the lining on production pipes shall be tested by Differential Scanning
Calorimeter (DSC) analysis. Failure of the test shall require each piece lined on that day to be
subjected to the test until a total of three (3) tests in a row (three (3) done both before and
after the piece which failed) are satisfactory.

4.3.2.4.5 Test of lined pipe connections and appurtenances

Shall be done according to Sec. 5.3.4 of AWWA C213 and shall comprise the following tests:
• Electrical inspection for continuity
• Thickness

5. Attachments

5.1 Applicable coating report sample

: Please refer to the back page

WELTECH Co., LTD.