Engineer'S Sticker: Contractor'S Sticker

ENGINEER’S STICKER: CONTRACTOR’S STICKER:
2 GA NA BJ 23.12.23
01 FOR APPROVAL as per Transmittal RR-EH-D-0487 GA NA BJ 30.10.23
00 FOR APPROVAL as per Transmittal RR-EH-D-0246 GA NA PH 03.09.20
A FOR APPROVAL GA NA PH 09.07.20
‫تنقيح‬ ‫سبب اإلصدار‬ ‫بواسطة‬ ‫راجعها‬ ‫وافق عليها‬ ‫التاريخ‬
REV. ISSUED FOR PREPARED CHECKED APPROVED DATE
‫المملكة العربيـــة الســـــعوديــــة‬

KINGDOM OF SAUDI ARABIA
‫المؤسسة الـعـامـــة لتحليــة الميـــاه المالحـــــة‬
SALINE WATER CONVERSION CORPORATION (SWCC)
‫رقم المشروع‬
PROJECT NO ‫تنفيذ أنظمة نقل مياه محطات التحلية الصغيرة الجديدة‬
20SWCG00038
New Satellite Plants Water Transmission System
‫المهندس‬ Ayesa Engineering and Architecture, S.A.

ENGINEER
Al-Rashid Trading & Contracting Co.

‫المقـــاول‬
CONTRACTOR
METHOD STATEMENT CEMENT MORTAR LINING
OF STEEL PIPES DIAMETER 28-INCH & LARGER
DOCUMENT NO: Sheet Rev.
1 0 - Z G 5 0 - F - 2 0 1 1 of 28 02
‫المقاول بالباطن‬ RAYMOND INTERNATIONAL CO. LTD

SUBCONTRACTOR
KINGDOM OF SAUDI ARABIA Page: 2 of 28
Saline Water Conversion Corporation
Document Number:
NEW SATELLITE PLANTS WATER TRANSMISSION SYSTEM PROJECT
METHOD STATEMENT CEMENT MORTAR LINING OF
Subject: 10-ZG50-F-201
STEEL PIPES DIAMETER 28-INCH & LARGER
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TABLE OF CONTENTS Page No.
1.0 PURPOSE Page 3

2.0 REFERENCE TO APPLICABLE CONTRACT DOCUMENT Page 3
3.0 SCOPE Page 3
4.0 ABBREVIATIONS / ACRONYMS Page 3
5.0 PROJECT SPECIFICATIONS Page 3
6.0 PROJECT DOCUMENTS Page 3
7.0 CEMENT MORTAR LINING PROCEDURE Page 4
8.0 INSITU LINING OF PIPE JOINTS Page 7
9.0 CEMENT MORTAR MIX DESIGN Page 8
10.0 MIXING AND BATCHING PROCEDURE Page 11
11.0 PIPE AND LINING INSPECTION PROCEDURE Page 12
12.0 CEMENT MORTAR LINING REPAIR PROCEDURE Page 13
13.0 CURING PROCEDURE Page 15
14.0 PIPE HANDLING, STACKING AND TRANSPORT PROCEDURE Page 16
15.0 MEASURING AND TEST EQUIPMENT CALIBRATION Page 17
PROCEDURE
16.0 CEMENT MORTAR LINING QUALITY CONTROL Page 19
PROCEDURES
17.0 POLISHED LINING STRUCTURE Page 22
18.0 NON – COMPLIANCE PROCEDURES Page 22
19.0 QUALITY CONTROL Page 23
20.0 BREAKING AND RELINING Page 25
EXHIBIT I RAYMOND INTERNATIONAL , CO. LTD Q/C FORMS Page 26
EXHIBIT II AL-RASHID TRADING & CONTRACTING CO. FORMS Page 27
EXHIBIT III RAYMOND INTERNATIONAL -SAFETY PROCEDURE Page 28
Final Engineering Contractor Subcontractor

IBG Al-Rashid Trading & Contracting Co. RAYMOND INTERNATIONAL CO. LTD.
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1.0 PURPOSE
To provide method statement for the application of Cement Mortar Lining of steel
pipes for diameter 28 inch and larger as per SWCC (Saline Water Conversion
Corporation) applicable standards.
2.0 REFERENCE TO APPLICABLE CONTRACT DOCUMENT

Reference is made to Contract Document M03 entitled “Shop Applied Cement
Mortar Lining” for the New Satellite Plants Water Transmission System Project.
3.0 SCOPE
This procedure covers the internal cement mortar lining of straight pipes, bends and
fittings in accordance with AWWA C205 (Cement Protective Lining and Coating for
Steel Pipe – 4 Inch (100mm) and Larger – Shop Applied and the internal cement
mortar lining of weld joints after installation and full backfilling in accordance with
AWWA C602 (Mortar Lining of Water Pipelines in Place – 4 Inch (100mm) and
Larger. This procedure is applicable for pipe sizes 28 Inch diameter and larger.
4.0 ABBREVIATIONS/ ACRONYMS
SWCC Saline Water Conversion Corporation

NSPWTS New Satellite Water Transmission System
TPI Third Party Inspector
RI Raymond International
QA Quality Assurance
QC Quality Control
CML Cement Mortar Lining
St2 Thorough Hand and Power Tool Cleaning
MS Method Statement Procedure
ITP Inspection Test Plan
IR Inspection Report
QSD Quality System Documents
CAR Corrective Action Request
NCR Non-Conformance Report
5.0 PROJECT SPECIFICATIONS

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Document Number Document Title

QA10-H-043 M03 Shop Applied Cement Mortar Lining
QC10-H-021 L01 Pipeline Construction
QC10-H-058 M18 Handling, Storage and Transportation of
Line Pipe Material
6.0 PROJECT DOCUMENTS
Document Document Title

Number
10-ZG50-N-201 Inspection and Test Plan for Cement Mortar Lining of
Steel Pipes, Fittings, Bends, Flanges
10-ZG50-F-203 Procedure for Cement Mortar Lining of Steel
Fittings, Bends, Flanges and Welded Joints of Main
Pipeline.
10-ZG50-F-202 Method Statement Cement Mortar Lining of Steel
Pipes 24 Inch and Smaller
10-ZG50-F-204 Procedure for Storage and Handling Cement Mortar
Lined Steel Pipes, Bends and Fittings.
10-ZG50-F-205 Procedure to Maintain Cement Mortar Lining Curing
Condition during Construction Work
7.0 CEMENT MORTAR LINING PROCEDURE
Cement mortar lining of straight pipes will be carried out on sand berms at the pipe
lining and storage yard. The pipes shall be protected during application of cement
mortar lining with sunscreen shade material to protect the pipes from the sun and
other unfavorable environment conditions. Sunscreen shade material shall remain
in position until the end of 28 days curing period.

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7.1 INTERNAL PIPE SURFACE PREPARATION

Prior to cement mortar lining the pipes will be internal cleaned to remove scale,
dirt, dust, grease and oil that may prevent the cement mortar lining from adhering
to the pipe wall. The pipe may be internal cleaned by mechanical wire brushing or
by sweep blasting. Sweep blasting material shall be clean, dry and free of
contaments and have less than 0.05 % chloride ion content and less than 0.40 %
sulfate. Acceptance criteria for the steel surface shall be St. 2 finish of ISO-8501-
1:2007 and AWWA C205. When the cleaning operation of a pipe is completed,
the pipe ends shall be closed with plastic end covers that will eliminate debris or
foreign objects from entering the pipe.
Sweep Blasting is a principle of cleaning one surface using jet of sand at high
pressure. The theory involves the use of such fine aggregate of sand or whatever
suits the situation to directly remove dirty and foreign material from body of metal
to ensure base metal surface finish are obtained.
Before and during application of cement mortar lining of a pipe, the temperature of
the steel pipe shall not be allowed to exceed 35 degree Celsius. A cooling plant
shall be employed (when required) using water for mixing and for spraying chilled
water on to the external surface of the pipes.
7.2 MACHINE APPLIED CEMENT MORTAR LINING

The cement mortar lining application will be carried out during the cooler period of
the day or at night when the ambient temperatures are at the lowest.
An operator controlled centrifugal lining machine in one course will apply the cement
mortar lining by traveling the machine from one end to the other end of the pipe
without interruption.
The centrifugal lining machine applies the mortar through a rotating head spraying
the mortar on to the surface whilst traveling.
The rate of mortar discharge and the travel speed of the machine are regulated to
produce a dense and homogenous lining to the specified thickness and tolerances.
The centrifugal lining machine is provided with a mechanical rotating trowel
arrangement that will apply a uniform pressure on the surface of the fresh-sprayed
cement mortar lining producing a smooth and even surface finish.
The mortar is feed to the lining machine by one of the following method:
7.2.1 Mortar hoses in multiple lengths which are fitted together will be
attached to a mortar pump at one end and fixed to the lining
machine hopper.

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7.2.2. Mortar is transported from the batch plant by means of a suitable

machine and discharged into the lining machine hopper.
The lining machine then travels to the far end of the pipe and the lining process
commences.
A sufficient quantity of mortar is batched to ensure that the cement mortar is applied
in one course without interruption.
The wet lining thickness of the fresh cement mortar lining will be checked at each
pipe end by means of a depth gauge inserted at the 12, 3, 6 and 9 o’clock positions.
(See Form No. FM/QC/031 in Exhibit 1)
Nominal Pipe Diameter Lining Thickness Nominal Tolerances

24 to 36 Inch 10 mm - 2.0 mm / + 3.0 mm
Larger than 36 Inch 13 mm - 2.0 mm / + 5.0 mm
Weld Bead - - 1.50 mm / + 1.50 mm
Immediately after applying the cement mortar lining, a cutback of maximum 150mm
in length for pipe diameter 28 inch and larger will be made at each end of the pipe
in the cement mortar lining using a thin edged scriber tool. The cement mortar lining
in the cutback area will remain in place to prevent corrosion until time of welding.
Both pipe ends will be closed immediately after completion of the cement mortar
lining for the initial curing period.
Prior to and during lining the temperature of the pipe must not exceed 35 degrees
Celsius.
7.3 HAND APPLIED CEMENT MORTAR LINING

Pipe bends, fittings, spools, vents and drains which cannot be cement mortar lined
machine will be cement mortar lined manually (hand applied) by experienced hand
finishers. The surface of the fresh cement mortar will be hand worked with steel
trowels to a smooth finish.
Factory made sharp bends shall be applied to the interior of fittings larger than 24
Inch will be reinforced according AWWA C205 with galvanized wire mesh size 13
gauges, 2-inch x 2-inch, or similar suitable mesh fixed to the internal pipe surface
using Hempel SA Knifing filler. The wire mesh is cut to fit the internal circumference
of the fitting wall and is braced and held in position away from the fitting wall with
temporary spacers. The bracing and spacers will be removed when the Hempel
Knifing filler has hardened.
The cement mortar is then applied to the wall of the fitting.

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The cement mortar for handwork shall be of the same materials as the cement
mortar for machine placed lining. The cement mortar lining thickness shall be
checked in the same manner as for machine placed lining.
The cutback will be made the same as for machine-lined pipes.

Both ends of the fitting will be closed with plastic end covers after finishing of cement
mortar lining for the curing period.
Each pipe or fitting will be marked with an identification number and date of cement
mortar lining.
8.0 INSITU LINING OF PIPE JOINTS

Insitu lining of pipe joints will be done after completion of welding, application of
heat shrink sleeves and prior to application of joint lining the backfilling of pipeline
trench has to be completed with access opening at every 500 meters for 28 to 34
Inch pipes, 1,500 meters for 36 Inch pipes, 2,000 meters for 40 to 48 Inch pipes,
2,500 meters for 50 to 60 Inch pipe and 5,000 meters for 62 to 100 Inch pipe. The
steel surface of the joint area to be lined will be cleaned to the same standard as
described in section 5.1 of this procedure.
The mixing, batching, mix proportions and raw materials will be the same as for lining
of straight pipes. Materials will be pre-weighed into bags and delivered to the joint
access point.
The adjacent edges of the existing cement mortar lining will be dampened with clean
potable water and a bonding agent Master Cast or Nitobond SBR will be applied and
allowed to become “tacky”.
The cement mortar will be applied to the joint with a centrifugal joint lining machine
and will be finished smooth by hand troweling to the level of the adjacent cement
mortar lining surface.
The fresh mortar will be delivered to the joint lining machine by a soft wheeled mortar
buggy.
Cement mortar Joints lining in steep areas or sections which cannot be cement
mortar lined by machine will be cement mortar lined manually (hand applied) by
experienced hand finishers. The surface of the fresh cement mortar will be hand
worked with steel trowels to a smooth finish
Joint lining will commence at the farthest joint from the pipeline entry point and work
progressively back applying lining to each joint.
As soon as possible after preset of the joint cement mortar lining, the joints are
sprayed with potable water to keep the surface damp and the relevant pipe sections
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are closed with end covers and water is placed into the pipe section invert to
maintain a moist humid atmosphere.
9.0 CEMENT MORTAR MIX DESIGN
9.1 MATERIALS
9.1.1 CEMENT
Cement will be Type I Ordinary Portland Cement in conformity with the requirements
of ASTM C 150 either supplied in bulk or in 50 kg bags. Storage of bulk cement will
be in silos with direct feed to the batching plant. Storage of cement in bags will be in
a dry sheltered location. Minimum cement content per cubic meter shall be 920 kg.
A manufacturer’s mill certificate for the cement has to be submitted to the
SWCC/Engineer from each shipment or per batch delivery as per M03 clause 2.1.1.
A manufacturer’s Mill certificate for the cement will be submitted to
SWCC/Consulting Engineer for approval prior to commencement of production.
9.1.2 SAND
Sand shall be fine aggregate conforming to the requirements of ASTM C 33. Sand
shall be dry and graded with 100% passing a 1.25 mm sieve and is graded between
1.25 mm and 0.125 mm. The sand shall be free from injurious amounts of dust, clay
lumps, friable particles, mica, loam, oil, alkalis and other deleterious substances.
The stipulations of ASTM C 33 will be applicable.

The sand shall be tested in accordance with the requirements of M03 production
testing. The results of the tests will be submitted to SWCC/Consulting Engineer for
approval.
Clay lumps and Friable Particles max. 1.00 %

Material finer than 75 microns max. 2.00 %
Organic Impurities Higher than standard
Water Absorption max. 1.50 %
Chloride Ion Content (CI) max. 0.05 %
Sulphates (SO3) max. 0.40 %
Magnesium Sulphate Soundness max. 10.00 % (5 Cycles)
Potential Alkali Silica Reactivity Innocuous acc. ASTM C 289
Specific Gravity (Unit Weight) ASTM C 128
9.1.3 MICROSILICA
Microsilica shall comply with the mandatory requirements of ASTM C – 1240.

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Sampling frequency and methods shall be as mandated by the Standard Analysis

Certificates. Each shipment will be accompanied by the Manufacture’s Mill Test
Certificate and will be submitted to SWCC/Consulting Engineer for approval prior to
commencement of production.
Microsilica will be delivered in bulk bags and shall be stored in a dry sheltered
location.The microsilica will then be placed into a silo with direct feeding to the
batching plant.
Compliance is confirmed to mandatory ASTM C – 1240 requirements as follows:

SiO2 Content min. 90.00 %
Moisture max. 3.00 %
Loss of Ignition max. 4.00 %
Alkali Content max. 1.50 %
Accelerated Strength Activity min. 105.00 %
Specific Surface Area min. 15000 m²/kg.
In addition compliance shall be assured to the following parameters:

SO3 max. 2.00 %
MgO max. 5.00 %
Chloride max. 0.10 %
Free CaO max. 1.00%
Free Si max 0.40 %
Fineness (larger 0.045 mm) max. 40.00 %
Grain Size max. 0.10mm
The microsilica powder densified or undensified shall not contain lumps that cannot
easily break down when rubbed in hand.
9.1.4 WATER
Water for mixing and curing will be potable water conforming to DIN 1045 standard
or to the equivalent AWWA standard.
Water shall be clean, colorless and free from objectionable quantities of organic
matter, alkali, salt or other impurities that might reduce the strength, penetration or
other desirable qualities of the mortar.
Water shall not contain substances that negatively influence the water to be
transported through the pipeline when in production. The water will be stored in
water tanks of suitable capacity and be chilled if required.
The water shall comply with the following parameters:
PH 7-8
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Total dissolved Solids max. 2000 ppm

Suspended Solids max. 500 ppm
Chloride as CI ion max. 500 ppm
Sulphates as SO3 max. 1000 ppm
Alkali Carbonates and Bicarbonates max. 1000 ppm
Each month a sample of the water will be send to an Independent laboratory for
testing as per M03 specification. The results will be submitted to SWCC/Consulting
Engineer for approval prior to commencement of production.
9.1.5 ADMIXURES / CONCRETE ADDITIVES
A water reducing / retarding admixture confirming BS EN 480 and BS EN 934 may

be used. The dosage rates will not exceed the limits specified in the manufacturer’s
product data sheet or those of the approved mix design. Admixtures will be delivered
in drums of approximately 210 liter and shall be stored in a sheltered area with the
lid of the drum kept tightly closed to avoid evaporation and crust formation.
The manufacturer’s data sheet of the proposed admixture will be submitted to
SWCC/Consulting Engineer for approval.
9.2 MIX PROPORTIONS
The cement mortar shall be well mixed as per the “mixing and Batching Procedure”
(section 8). The maximum permitted water to cement + micro silica ratio shall not
exceed 0.32 and the proportions of sand to cement shall not exceed 1.5 to 1.0 when
measured by weight. The actual proportions will depend on the characteristics of the
sand that will be used.
Prior to production mix trials will be undertaken to establish the optimum sand to
cement ratio, microsilica content, admixture content, water to cement ratio and the
workability of the cement mortar lining during lining trials. Mix trials shall include
shrinkage test according ASTM C-490. Mix shall be tested for compressive strength,
bending strength is weekly after 28 days of production and shrinkage (once for the
whole project) and for water permeability and chloride permeability after 28 days.
The mix design will be based on the following proportions which have already proven
most successfully in previous SWCC Cement Mortar Lining Projects.
(We will give preference to use the basic mix design already approved as per
previous and ongoing SWCC projects, NEOM Water Transmission System /
Jubail-Riyadh Water Transmission System / Rabigh-Jeddah / Makkah-Al
Mukarrah Water Transmission System / Taif- Turubah/Ranyah/Al Khumrah
WTS / Shuqaiq Phase 2 & 3 WTS / Yanbu Madina Phase-3 & 4 / Riyadh New
City Feeders and Shoaiba – Mina (B) Water Transmission System)
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9.2.1 PARTS BY WEIGHT

0.93 Cement
7% Microsilica
1.20 Sand
0.32 Maximum Water to Cement Ratio
2.13 ml per 1 kg Cement of admixture (The basic
admixture is 2.13 ml. per kg/cement, however the
quantity of admixture per kg cement is dependent
on environmental conditions and adjustable during
cement mortar lining operations without any effect
on the quality of cement mortar lining.
The mix trials of cement mortar will be sampled and tested in accordance with M03
specification, Inspection and Test plan.
SWCC/Consulting Engineer shall be informed about the execution of the mix design
trials tests. The results of the tests will determine which mix design will be approved
for the application of the cement mortar lining.
10.0 MIXING AND BATCHING PROCEDURE
Prior to the start of a shift production, the foreman shall check equipment for
operational readiness and cleanliness. Mixer, pump and cement mortar lining
machine will be cleaned to remove any hardened mortar and worn out parts of any
equipment shall be replaced prior to operations.
The mortar will be mixed in batches as per approved mix design of sufficient size to
ensure that each individual pipe is fully lined in one course by the lining machine
without interruption. The mixer will be a rotating paddle cement mortar mixer.
All materials for use in the mortar mix will be measured by weight to an accuracy of
+ or – 3 %. Water for mixing will be measured by weight or by flow meter. Admixture
will be added in the mix through a dispensing unit together with the water.
The mortar shall be mixed in batches in suitable mixing equipment in due time
according specification, so that the maximum plasticity is reached.
Mixing and sequence of loading material into the mixer is as follows:
1. Sand
2. 30 % Water
3. Micro silica
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4. Cement
5. 70 % Water and Additives
The sequence and mixing time shall be as follows:
1. Sand
2. 30 % Water
3. Micro silica, wet mix 1 + 2 + 3 for 1 ½ minute
4. Cement, wet mix 1 + 2 + 3 + 4 for 1 ½ minute
5. 70 % Water and additives, wet mix for 2 ½ minute
Slump tests in accordance with ASTM C 230 or DIN 1060 are carried prior to
cement mortar lining application and periodically throughout each lining shift.
Maximum permitted temperature of the fresh mortar shall not exceed 32 degree
Celsius.
11.0 PIPE AND LINING INSPECTION PROCEDURE
Cement mortar lining will be applied to pipes which have been received at the lining
yard and which are within the limitations and tolerances as per M01 (Steel Pipes for
Mainlines) and M02 (Polyethylene Coating) specifications. The steel pipes and the
external polyethylene coating of each pipe will be inspected upon arrival at the lining
yard.
Pipes that have incurred damage and/or are considered unfit for cement mortar
lining will be placed in a segregated area. Damage Pipe Work report will be initiated
together with an investigation into the cause and SWCC/Consulting Engineer will be
informed.
The internal surface of the pipes accepted for lining will be inspected by the Q/C
technician prior to lining. The pipes will be cleaned to St 2 finish of ISO-8501-1:2007
and AWWA C 205 as per cement mortar lining procedure and the condition of the
surface will be recorded on the Lining Inspection Report.
The QC technician will check the cement mortar lining application in progress for
each pipe for lining thickness and surface smoothness. The results will be recorded
on the “Wet Lining Thickness Inspection Report”. The wet lining thickness will be
measured immediately after application of the cement mortar lining using a
hardened needle inserted at 12, 3, 6, and 9 o’clock position on both pipe ends.
The cement mortar lining dry thickness and tolerances will be in accordance within
the parameters of the latest edition of AWWA C 205 table 1.

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Nominal Pipe Diameter Lining Thickness Nominal Tolerances

24 to 36 Inch 10 mm - 2.0 mm / + 3.0 mm
Larger than 36 Inch 13 mm - 2.0 mm / + 5.0 mm
Weld Bead - - 1.50 mm / + 1.50 mm
The start time of cement mortar lining of each pipe will be recorded on the “Wet
Lining Thickness Report”.
Any noticeable defects such as voids, lumps and sack pockets which are not within
the parameters of the project specification may be a cause for rejection and the lining
will either be repaired or removed from the pipe.
11.1 LINED PIPE INSPECTION
Immediately after the initial curing period (preset) when the mortar has reached
sufficient strength a visual inspection with lights will be made on every lined pipe to
determine the quality of the lining and to identify the areas to be repaired.
The surface of the cement mortar lining shall be smooth and even. The surface shall
not be flattened at individual spots nor show waves or grooves. Trowel marks, single
waves or grooves are not ground for rejection as long as the minimum or maximum
specified thickness is maintained. Aggregate grains may only sporadically stand out
of the surface.
The absolute roughness value as per Colebrook White formula shall be at the
maximum 0.1 mm or less. Due to inevitable shrinkage of the cement mortar lining
hairline cracks are unavoidable. Hairline cracks and surface cracks will be allowed
up to a maximum width of 0.8 mm. The length of cracks shall not exceed 50% of
pipe length in accordance with M03 specification. The maximum tolerated crack
widths specified apply to the state of the lining along the entire pipeline length when
the whole pipeline or particular section of the pipeline undergoes the prescribed
inspection before the hydrostatic pressure test.
All defects shall be made good subject to the approval of SWCC/Consulting

Engineer in accordance with the standard of acceptability in the project specification.
All repairs will be undertaken by experienced personnel under the supervision of the
QC technician in accordance with the approved repair methods and procedures.
Lining thickness checks on hardened cement mortar lining will be performed on each
pipe by a Non-destructive method using an electromagnetic thickness indicator such
as supplied by Elcometer Instruments. The lining thickness shall be given to an

accuracy of 0.1 mm.

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The N.D.E. measurement shall be performed at both pipe ends and in two (2)
sections of the pipe length (1/3 pipe length from each end). Measurement shall be
taken at four points in each section, at 12, 3, 6 and 9 o’clock positions around the
pipe circumference and recorded on the N.D.E. lining thickness report.
When the measurements of these 16 readings are within the tolerances of the
specification no further readings are required. Only if an abnormal surface condition
is apparent should additional readings be taken in the immediate area of the
abnormality.
If the surface abnormality is included in an area within 75 mm of either side of the

weld bead (or directly atop the weld bead) then the following limits shall apply:
Additional tolerance of +/- 1.50 mm is considered acceptable per pipe diameter
nominal cement lining thickness as per section 9.0.
Prior to loading out cement lined pipes from the yard a final visual inspection will be
made on all pipe work by the cement lining specialist.
12.0 CEMENT MORTAR LINING REPAIR PROCEDURE
12.1 Damaged areas that cover the entire circumference of the pipe will be
repaired mechanically if practical. When the damaged area is not more
than 20 % of the lining inside the pipe then the following procedure
shall be applicable:
12.1.1 The rejected lining will be carefully removed from the internal pipe
Surface with hand tools.
12.1.2 The steel surface will be brushed free of any loose mortar debris.
12.1.3 The adjacent cement mortar lining will be dampened with clean potable
water.
12.1.4 The bare steel will be re-sprayed centrifugally with cement mortar
having the same mix design as the adjacent cement mortar lining.
12.1.5 The freshly applied cement mortar repair lining will be water spray
cured.
12.2 Individual points which require cement mortar lining repair by manual
Application:

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12.2.1 The individual points of cement mortar lining which require repair to the
steel surface will be removed from the internal pipe surface with hand
tools.
12.2.2 The steel surface will be brushed free of any loose mortar or debris.
12.2.3 The adjacent cement mortar lining will be dampened with clean potable
water.
12.2.4 A thin coat of approved bonding agent, such as Master Cast 141 or
Nitobond SBR will be applied to the steel surface in accordance with
manufacturer’s recommended quantities and methods.
12.2.5 Fresh mortar will be applied by hand to the area-requiring repair.

Edges will besmoothed in order to insure a uniform transition to the
adjacent cement mortar.
12.2.6 The freshly applied cement mortar lining repair will be water sprayed
after preset.
13.0 CURING PROCEDURE
When the pipes are cement mortar lined, both ends of the pipe will be sealed with
plastic end covers for the initial curing period and pipes are kept stationary on sand
berms at the pipe yard.
After the initial setting period, a visual inspection is performed by QC technician and
cement lining specialist, any repair or touch up (if any) shall be made as described
in Section 10 of this document. After visual inspection cement mortar lining surface
will be sprayed with clean potable water and water is placed in the pipe invert.
Pipes placed on sand berms and cement mortar lined shall be covered during curing
period with sun screen shade material laid over the pipes which shall be kept in
place during the 28 days curing period from date of cement mortar lining.
During the curing period and any further storage in the yard, the water content inside
the pipes shall be monitored by QC technician to ensure a moist and humid
atmosphere is maintained inside the pipe. Additional water will be placed into the
pipe as required.
The plastic end covers will remain in place, damaged or torn end cover will be
replaced.

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14.0 PIPE HANDLING, STACKING AND TRANSPORT PROCEDURE
14.1 HANDLING
For pipe handling and stacking requirements reference is made to specification M18,
Handling, Storage and Transportation of Line Pipe Material.
Pipe handling and stacking of coated unlined pipes and cement mortar lined pipes
will be carried out in a matter at all times that will prevent damage to the external
coating and cement mortar lining and to the distortion of the pipe.
Pipes will be lifted using a crane of suitable capacity fitted with a lifting beam. The
loading of coated unlined pipes will be carried out using special designed aluminum
hooks, which are inserted into the pipe at each end.
The handling of cement mortar lined pipes will be carried out using nylon
nonabrasive belts which will be positioned at one fifth of the pipe length from each
end.
14.2 STACKING
Coated unlined and cement mortar lined pipes will be stacked on suitable bearing
supports (e.g. sand berm with plastic sheet cover) in the pipe yard. The sand berm
will be free from any objects, which may damage the pipe external coating.
The sand berm shall provide ground clearance of minimum 150 mm and be spaced
approximately one fifth of the pipe length from each end of the pipe. Observe
clearance between pipes to prevent external coating damage. The maximum
stacking height of un-lined pipe shall not exceed the limits defined by the pipe
supplier and/or API 5 L standard.
CM lined pipes and pipes which are ready for lining application shall not be stacked
in more than one layer, to avoid ovalization. See below sketch
All diameter, single stack only
____________________________
CM lined pipes and pipes which
are ready for lining application
Single stack

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As per L-01 section 6.1.2, Unlined pipes of diameter 1000 mm and below
may be stacked in three (3) layers. Unlined pipes of diameter 1000 mm and
above may be stacked in two (2) layers. For pipes of diameter 1500 mm and
above, proper stiffeners will have to be inserted to avoid ovality
14.3 TRANSPORT
Measures will be taken to ensure that the pipes are well prepared for transport so
that the cement mortar will not dry out.
In addition to the plastic end covers during transport the pipe ends will be fitted with
heavy canvas end covers (canvas covers supplied by contractor or transport
subcontractor). These covers are fixed to the pipe with canvas/nylon band and
locked in place with a clamp. The canvas end covers will be of sufficient strength to
withstand the wind forces acting on the canvas end covers during transportation.
A sufficient quantity of water will be maintained within the pipe during transportation.
After unloading of the cement mortar lined pipe on the pipeline construction site the
canvas end covers will be removed. The plastic end cover at the pipe ends will
remain in place and the Pipeline Construction contractor to maintain a humid and
moist atmosphere inside the pipe will add additional water in the pipe invert
15.0 MEASURING AND TEST EQUIPMENT CALIBRATION PROCEDURE
The QC Supervisor is responsible for ensuring that all measuring and test
equipment/instruments used in this program shall be calibrated & recorded and
calibration sticker checked by QC Supervisor. Calibration records which shall
include the date of calibration, validity and due dates shall be maintained and
identified to the particular apparatus. A calibrating log indicating equipment shall be
posted in QC office for ready reference.
An Independent approved Laboratory will perform calibration. A certificate of

calibration will be delivered after performance of calibration.
When practical, all equipment is identified with a calibration label which identifies the
next calibration due date (it is accepted that due to usage it is not practical to fix
labels to wet lining thickness gauges and thermometers).
Calibrations are carried out at regular intervals or in accordance with the

manufacturer’s instruction or on detention of any damage or misuse.

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Test equipment/measuring instruments which are found defective or out of

adjustment are re-adjusted or dispatched for re-calibration and replaced with an
instrument of known calibration.
Handling, protection and storage of all equipment/instruments are maintained to

ensure “fitness for use”.
Defective equipment/instruments awaiting repair or replacement are segregated and

clearly labeled “Do Not Use” to prevent inadvertent use.
15.1 MECHANICAL WEIGHT SCALES FOR BULK MATERIALS

FLOW METERS AND ADMIXURE DISPENDERS
Calibration every three months by an external agency to an accuracy of ± 3
% up to the maximum working range.
15.2 THERMOMETERS
Calibration every six months by an external agency to an accuracy of ± 3 %,
alternative thermometers may be replaced every six months.
15.3 MORTAR THICKNESS GAUGES

Wet penetration gauges are purchased new for each project or replaced if
they show signs of inordinate damage or wear.
Electromagnetic thickness indicators are calibrated every three months by an

external agency to an accuracy of + / - 0.1 mm
.
15.4 LABORATORY WEIGH SCALES
Calibration every six months by an external agency to an accuracy of ± 3 %.
15.5 LABORATORY COMPRESSIVE AND FLEXURAL MACHINE

Calibration every six months by an external agency to an accuracy of ± 3 %.
15.6 SLUMP, CUBE AND FLEXURAL STRENTH TEST MOULD

A visual inspection for damage and wear is made every six months.
15.7 WATER AND CHLORIDE PERMEABILITY EQUIPMENT

Calibration every twelve months by an external agency to an accuracy of ± 3
%.

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16.0 CEMENT MORTAR LINING QUALITY CONTROL PROCEDURES
16.1 CEMENT MORTAR LINING QC PROCEDURES
The following standards are applicable to the Quality Control and test Procedures
that will be used in this program. Materials for cement mortar lining, tests on fresh
and hardened mortar and inspection will be as follows.
In case of contradiction between standards and the specification, the statements of
the specification are valid.
STANDARDS DESCRIPTION
ASTM C 29 Standard method for unit weight and voids in

aggregate.
ASTM C 33 Standard specification for concrete
aggregates.
ASTM C 40 Standard test method for organic impurities in
Fine aggregate for concrete.
ASTM C 88 Test method for soundness of aggregates by
use of sodium sulfate or magnesium sulfate.
ASTM C 109 Standard test method for compressive
strength of cement mortar using 50 x 50 x 50
mm cubes.
ASTM C 117 Standard test method for materials finer than 75
micron (sieve 200) in mineral aggregates by
washing.
ASTM C 128 Standard test method for specific gravity and
absorption of fine aggregates.
ASTM C 136 Test method for sieve analysis of fine and course
aggregate.
ASTM C142/DIN 4226.3.6.1 Standard test method for clay, lumps and friable
particles.
ASTM C 150 Standard specification for Portland cement.
ASTM C 230 Standard specification for flow table for use in the
test of hydraulic cement.
ASTM C 289 Test method for potential reactivity of
aggregates (chemical method)
ASTM C 490 Standard practice for use of apparatus for
determining of length (shrinkage) of hardened
cement paste, mortar and concrete.
ASTM C 1240 Standard specification for use of silica fume for
use as a mineral admixture in cement.
AWWA C 205 Cement Protective Lining and Coating for Steel
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Pipe – 4 Inch (100mm) and Larger – Shop Applied.

AWWA C 602 Mortar Lining of Water Pipelines in Place – 4 Inch
(100mm) and Larger
AASTHO T 277 Standard test method for rapid determination of
chloride permeability of concrete.
BS 812 Part 117/DIN-4226,3.6.5 Method for determining of water-soluble salts.
BS 812 Part 118/DIN-4226,3.6.4 Method for determining of sulphate content.
BS 1881 Part 124 Method for analysis of hardened concrete.
BS 5075 Part 1 Specification for accelerating admixtures,
retarding admixtures.
BS 5075 Part 2 Specification for air-entraining admixtures.

BS 5075 Part 3 Specification for super plasticizing admixtures.
DIN 1045 Standard test method for water.
DIN 1048 Part 5 Method of testing concrete for water permeability
(1991 revision)
DIN 1164 Method for storage of test samples.
DIN 1164 Part 7/BS EN 196-1 Method of testing for bending strength of cement
mortar prism using 40 x 40 x 160 mm beams.
A testing laboratory will be established at the lining yard under the control of the QC
supervisor.
An Independent Test Laboratory will carry out tests that cannot be performed at this
laboratory.
The storage of samples for compressive strength, bending-tensile strength, water

and chloride permeability will be at site laboratory in accordance with DIN 1164.
Sufficient duplicate samples will be made to safeguard against incorrect casting.
Shrinkage test to ASTM C 490 on cement mortar lining samples will be performed
during the pre-production mix trials and each P.Q.T. to establish the mix proportions
that give the maximum compressive and bending-tensile strength with the minimum
shrinkage values.
Compressive and bending-tensile strength shall have the following minimum

average values after 28 days according M03 clause 2.2.2 mechanical properties of
the mortar.
COMPRESSIVE STRENGTH BENDING-TENSILE STRENGTH

55 N / mm² 6 N / mm²

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The compressive strength shall be the average of 3 sample results. Each

individual result should not differ from the average result of the 3 samples tested
by more than 10 %.
The bending-tensile strength shall be the average of 3 sample results. Each

individual result should not differ from the average result of the 3 samples tested by
more than 20 %.
Maximum value for chloride permeability according M03 clause 2.2.1 shall be
between 100 and 1000 coulombs.
Maximum value for water permeability according M03 clause 2.2.1 shall be below
4.0 mm. This to be accomplished by:
16.1.1 Utilizing a water reducing additive, designed to cut the mortar’s

water cementitious material ratio to 0.32 or below.
16.1.2. Adding silica fume, approximately 5 – 8 % of cement content.
16.2 DETERMINING OF WATER TO SAND CONTENT
During production the water cement ratio and sand cement ratio test will be
performed daily on a sample of fresh mortar from each lining machine/batching
plant. Fifteen minutes on the latest after finishing the application of the cement
mortar lining in a pipe, about 300 grams of fresh mortar shall be taken from one end
of the pipe. The fresh mortar sample shall be separated thoroughly so that one
sample of 100 grams and another sample of 200 grams can be obtained both having
the same mix ratios. The following abbreviations are valid for analysis:
M = S + Z + W (mass unit)
M = Weighted mortar sample
S = Sand
Z = Cement (cement + microsilica)
W = Water
Determination of sand content:
Mortar sample 200 grams known M1, to determine S1

Immediately after the samples have been taken and weighed, the fresh mortar
shall be elutriated on a 0.09 mm test sieve. The sieve residue shall flushed into a
basin and washed out. The residue is dried at a temperature of 100 degree C to
constant weight.
The water content will be determined as follows drying to constant weight:
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The 100 gram sample is weighed and placed in an oven and dried to constant
weight.
After cooling the sample, it shall weigh again. The loss of weight is equivalent to the
water quantity. The calculation for sand – cement ratio and water are as follows:
Sand content (S1) Weight of mortar sample (M1)

Weight of sand content (S1)
Water content (W2) Weight of mortar sample (M2)

Weight of water content (W2)
Sand cement ratio (V) ____________1_________________

M1 X ( 1 - W2 ) - 1
S1 M2
Water cement ratio (W) W2

_____ M2_______
1 - W2 - S1
M2 M1
17.0 POLISHED LINING STRUCTURE
A visual inspection on the cement mortar lining structure will be made on a hardened
lining sample taken out from a pipe end. In the polished section a cementing agent
with no visible pores shall surround the individual grains of sand on all sides.
18.0 NON – COMPLIANCE PROCEDURES
Materials or products deemed not to comply with the Method Statement

Specification will be placed in two categories, either “HOLD” or “RED TAG”
18.1 HOLD STATUS
Materials or products that have deficiencies and which can be corrected within the
parameters of the Method Statement Specification will be placed in a “HOLD” status.
A Corrective Action Request (C.A.R.) report will initiated and all the deficiencies shall
be corrected. All “HOLD” status cement lined pipe sections must be re-inspected
and approved by cement lining specialist before they can be released from “HOLD”
status.

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18.2 RED TAG STATUS
Materials or products that do not comply with the procedure specification and cannot
be corrected within the scope of specification will be given a “RED TAG” and placed
in a separate storage area.
18.3 NON – COMPLIANCE REPORT
For each material or product that is placed in “RED TAG” status, a Non-Compliance
Report (NCR) will be initiated which shall include final disposition of the item when
required.
19.0 QUALITY CONTROL
In compliance with the necessary application of a highly developed technology for

the cement mortar lining process and for the quality control of this work, it shall be
performed under the responsibility of an international reputed well-experienced
specialist. This is especially mandatory for the investigation necessary for
determining the optimal mixing proportions and curing conditions.
For the elaboration of the optimum cement mortar mix for the lining the performance
of shrinkage test, permeability test, compressive and bending test is imperative.
These tests shall be performed prior to commencement of the cement mortar lining
production.
The exact mix ratio as mentioned in section 7.2.1 will be determined during trials
performed prior to the commencement of the cement mortar lining.
The cement-lining specialist shall control all quality aspects of cement mortar lining
activities at the subcontractor’s lining yard and at the pipe construction area during
the project.
The cement-lining specialist chosen for the above-described responsibility must be

an independent expert and must have at least five years’ experience on projects of
equivalent nature and proportions.
The choice of this specialist is subject to approval by SWCC/Consulting Engineer.

Upon successful completion of the mix design and pre-qualification test plan the
specialist can recommend that production commence.
Every pre-qualification test shall be planned in concurrence with SWCC/Consulting

Engineer and cement lining specialist well in advance.

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19.1 PRODUCTION TESTING
During production, tests and inspections SHALL be performed at the times and
intervals given below.
CLAUSE TEST OR INSPECTION FREQUENCY

4.1 Sand, sieve analysis Daily
Sand, temperature reading Daily
Sand, moisture content Daily
Sand, organic impurities Weekly
Sand, clay & silt content Weekly
Sand, soundness Weekly
Sand, sulphate content Monthly
Sand, chloride content Monthly
Sand, unit weight Monthly
Sand, potential alkali silica reaction Monthly
Cement Monthly/per batch
delivery
Water Monthly
Additives Once
Microsilica Per batch delivery
4.2 Water / cement ratio Daily
Sand / cement ratio Daily
Slump test / temperature reading Daily
4.3 Compressive strength Weekly
Bending / tensile strength Weekly
4.4 Lining thickness (wet) Each pipe end
Lining thickness (n.d.e.) Each pipe
4.5 Water permeability Monthly
Chloride permeability Monthly
6.1.2 Pipe ends Each pipe
6.2.1 Surface condition Each pipe
6.3 Lining structure Monthly
19.2 TEST AND PRODUCTION RECORDS
The results of the tests and inspection provided for in this procedure specification
will determine the acceptance of the cement mortar lining. The tests shall be carried
out by the cement mortar-lining subcontractor and checked by the cement lining
specialist. The contractor shall record the test results in orderly form according to
pipe number and keep these records in evidence for 5 year.

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20.0 BREAKING AND RELINING
Pipes cement mortar lined, which is not within the criteria of this procedure, will be
“RED TAGGED” status.
These pipes will be relocated to a segregated area and re cement mortar lined at a
later date.
The rejected cement mortar lining will be removed from the pipe in the following
manner:
20.1 Manual, by chisels and hammers.
20.2 Mechanical, by pneumatic chisels.
20.3. Sand blasting after cement mortar lining is removed.
The steel pipe surface will not be damaged by removal of the cement mortar lining.
The pipe will be internal cleaned again for re-cement mortar lining as per Section
7.1.

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EXHIBIT 1 (Attachment)
RAYMOND INTERNATIONAL KSA BRANCH

Q/C FORMS
- FM/QC/006 SIEVE ANALYSIS REPORT
- FM/QC/016 COMPRESSIVE & BENDING STRENGHT TEST REPORT
- FM/QC/018 CLAY AND SILT & ORGANIC IMPURITIES TEST REPORT
- FM/QC/022 JOINT LINING REPORT
- FM/QC/023 N.D.E. THICKNESS LINING REPORT
- FM/QC/025 POLISHED SECTION REPORT
- FM/QC/027 TEMPERATURE AND SLUMP VALUES REPORT
- FM/QC/028 WATER CEMENT AND SAND CEMENT RATIO REPORT
- FM/QC/031 WET THICKNESS LINING REPORT
- FM/QC/035 CHLORIDE AND WATER PERMEABILITY TEST REPORT
- FM/QC/050 PIPE SHIPPING REPORT
- FM/QC/051 PIPE RECEIVING REPORT

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EXHIBIT 2 (attachment)
AL-RASHID TRADING & CONTRACTING CO.

(RTCC) FORMS
- APPENDIX 1 DOCUMENTATION RELEASE FORM
- APPENDIX 2 RELEASE FORM
- APPENDIX 3 DAILY INSPECTION FORM
- APPENDIX 4 NON-CONFORMITY REPORT
- APPENDIX 5 CORRECTIVE ACTION REQUEST
- APPENDIX 6 WEEKLY REPORT RESULTS CEMENT LINING
- APPENDIX 7 OVERALL EQUIPMENT CALIBRATION LOG
- APPENDIX 8 RECOMMENDATION FOR RELEASE

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EXHIBIT 3
RAYMOND INTERNATIONAL
SAFETY PROCEDURE


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‫المقاول بالباطن‬ RAYMOND INTERNATIONAL CO. LTD

TABLE OF CONTENTS Page No.

1.0 PURPOSE Page 3

Final Engineering Contractor Subcontractor

2.0 REFERENCE TO APPLICABLE CONTRACT DOCUMENT

4.0 ABBREVIATIONS/ ACRONYMS

SWCC Saline Water Conversion Corporation

5.0 PROJECT SPECIFICATIONS

Document Number Document Title

6.0 PROJECT DOCUMENTS

Document Document Title

7.0 CEMENT MORTAR LINING PROCEDURE

Final Engineering Contractor Subcontractor

7.1 INTERNAL PIPE SURFACE PREPARATION

7.2 MACHINE APPLIED CEMENT MORTAR LINING

Final Engineering Contractor Subcontractor

7.2.2. Mortar is transported from the batch plant by means of a suitable

Nominal Pipe Diameter Lining Thickness Nominal Tolerances

7.3 HAND APPLIED CEMENT MORTAR LINING

Final Engineering Contractor Subcontractor

The cutback will be made the same as for machine-lined pipes.

8.0 INSITU LINING OF PIPE JOINTS

9.0 CEMENT MORTAR MIX DESIGN

The stipulations of ASTM C 33 will be applicable.

Clay lumps and Friable Particles max. 1.00 %

Microsilica shall comply with the mandatory requirements of ASTM C – 1240.

Final Engineering Contractor Subcontractor

Sampling frequency and methods shall be as mandated by the Standard Analysis

Compliance is confirmed to mandatory ASTM C – 1240 requirements as follows:

In addition compliance shall be assured to the following parameters:

Total dissolved Solids max. 2000 ppm

9.1.5 ADMIXURES / CONCRETE ADDITIVES

A water reducing / retarding admixture confirming BS EN 480 and BS EN 934 may

9.2 MIX PROPORTIONS

9.2.1 PARTS BY WEIGHT

10.0 MIXING AND BATCHING PROCEDURE

Mixing and sequence of loading material into the mixer is as follows:

The sequence and mixing time shall be as follows:

11.0 PIPE AND LINING INSPECTION PROCEDURE

Final Engineering Contractor Subcontractor

Nominal Pipe Diameter Lining Thickness Nominal Tolerances

11.1 LINED PIPE INSPECTION

All defects shall be made good subject to the approval of SWCC/Consulting

as supplied by Elcometer Instruments. The lining thickness shall be given to an

Final Engineering Contractor Subcontractor

If the surface abnormality is included in an area within 75 mm of either side of the

12.0 CEMENT MORTAR LINING REPAIR PROCEDURE

Final Engineering Contractor Subcontractor

12.2.5 Fresh mortar will be applied by hand to the area-requiring repair.

13.0 CURING PROCEDURE

Final Engineering Contractor Subcontractor

14.0 PIPE HANDLING, STACKING AND TRANSPORT PROCEDURE

All diameter, single stack only

Final Engineering Contractor Subcontractor

15.0 MEASURING AND TEST EQUIPMENT CALIBRATION PROCEDURE

An Independent approved Laboratory will perform calibration. A certificate of

Calibrations are carried out at regular intervals or in accordance with the

Final Engineering Contractor Subcontractor

Sand cement ratio (V) 1_____