BSIBV-QP-08-2 QP For CWC Coating DPE Rev. 0

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com
2018.10.09 14:45:54
+04'00'
Site Project Quality Document
BREDEROSHAW INTERNATIONAL B.V., RAK QUALITY PROCEDURE - CWC
Revision History
Rev.
Date Detailed Description of Change Ref. Section
No.
08-Oct-18 0 Issued for Review -
Document No.: BSIBV-QP-08-2 Revision No.: 0 Revision Date.: 08-Oct-18 Page 2 of 44

Table of Contents
1 GENERAL ..................................................................................................................................................................... 4
1.1 PURPOSE ................................................................................................................................................................ 4
1.2 REFERENCES ........................................................................................................................................................... 4
1.3 ABBREVIATIONS AND DEFINITIONS ............................................................................................................................. 5
1.3.1 Abbreviations ................................................................................................................................................. 5
1.3.2 Definitions ...................................................................................................................................................... 6
1.4 PROCESS FLOW DIAGRAM ........................................................................................................................................ 7
1.5 RESPONSIBLE PARTIES ............................................................................................................................................ 8
2 COATING SYSTEM REQUIREMENTS ........................................................................................................................ 9
2.1 GENERAL ................................................................................................................................................................. 9
2.2 CALIBRATION ........................................................................................................................................................... 9
2.3 MATERIALS .............................................................................................................................................................. 9
2.3.1 Aggregates (Silica type Washed Sand, Slag & Iron Ore) .............................................................................. 9
2.3.2 Cement ........................................................................................................................................................ 10
2.3.3 Reinforcement Wire ..................................................................................................................................... 10
2.3.4 Water............................................................................................................................................................ 10
2.4 PIPE RECEIPT AT STATION ...................................................................................................................................... 10
2.5 ANODES ................................................................................................................................................................ 10
2.6 MATERIAL MIXING .................................................................................................................................................. 11
2.7 CONCRETE APPLICATION ........................................................................................................................................ 11
2.7.1 Anode Retrofit Process Pipes ...................................................................................................................... 12
2.8 PIPE MARKING ....................................................................................................................................................... 12
2.9 CONCRETE REPAIRS .............................................................................................................................................. 13
2.9.1 Spalling ........................................................................................................................................................ 13
2.9.2 Cracking ....................................................................................................................................................... 13
2.9.3 Gaps............................................................................................................................................................. 13
2.9.4 Concrete Repair Method .............................................................................................................................. 13
2.9.5 Concrete Repair - Hand ............................................................................................................................... 14
2.9.6 Concrete Repair – Gunnite Application ....................................................................................................... 14
2.9.7 Removal of Green and Cured Concrete ...................................................................................................... 14
3 CONCRETE INSPECTION/TESTING ......................................................................................................................... 14
3.1 VISUAL INSPECTION................................................................................................................................................ 15
3.2 PLANT BREAK DOWNS (IF ANY) ............................................................................................................................... 15
3.3 TESTING SAMPLES ................................................................................................................................................. 15
3.4 CONCRETE DENSITY TESTING ON CORES ................................................................................................................ 15
3.5 W ATER ABSORPTION TESTING ON COUPONS ........................................................................................................... 15
3.6 CONCRETE COMPRESSIVE STRENGTH..................................................................................................................... 15
3.7 DETERMINATION OF UNSATURATED COATED PIPE W EIGHT ...................................................................................... 16
3.8 DETERMINATION OF SATURATED COATED PIPE W EIGHT........................................................................................... 16
3.9 ELECTRIC ISOLATION / CONTINUITY ......................................................................................................................... 17
3.10 FRESH CONCRETE ANALYSIS .................................................................................................................................. 17
3.11 INSPECTION RELEASE NOTE (IRN) .......................................................................................................................... 17
4 HANDLING, TRANSPORTATION AND STORAGE .................................................................................................. 17
4.1 HANDLING.............................................................................................................................................................. 17
4.2 TRANSPORTATION .................................................................................................................................................. 17
4.3 STORAGE .............................................................................................................................................................. 17
5 LABORATORY QUALITY CONTROL TESTING ON INCOMING RAW MATERIAL ................................................ 18
APPENDIX 1: TEST METHODS ......................................................................................................................................... 18
APPENDIX 2: DOCUMENTATION – REPORT FORMS .................................................................................................... 23

1 General
1.1 Purpose
This Procedure defines the application, inspection, repair, handling and storage requirements of factory
applied concrete weight coating by the impingement method. The coating system can be applied to CS
Pipes longitudinal welded, spiral welded and to seamless pipe for the construction of buried or
submerged pipelines.
This document is written with the intention of being a working instruction for BSIBV personnel by detailing
the standard of workmanship and acceptance criteria throughout each phase of the process.
1.2 References
Document Number Document Title
DP-PL- 17, Rev. 10 Pipeline Weight Coating - Standard Specification

DP-PL-11, Rev. 06 Receiving, Handling and Storing of Uncoated Pipes - Standard
Specification
Petroleum and natural gas industries - External coating for buried
ISO 21809-5 or submerged pipelines used in pipeline transportation system –
Part 5 External Concrete Coatings.
ASTM A82 Specification for Steel Wire, Plain, for Concrete Reinforcement
Specification for Steel Welded Wire, Fabric, Plain, for Concrete
ASTM A185
Reinforcement
Standard Specification for Zinc-Coated (Galvanized) Steel Pipe
ASTM A810
Winding Mesh
Standard Specification for Zinc-Coated (Galvanised) Carbon
ASTM A 641
Steel Wire
ASTM C33 Specification for Concrete Aggregates
Test Method for Obtaining and Testing Drilled Cores and Sawed
ASTM C42
Beams of Concrete
ASTM C150 Specification for Portland Cement
Test Method for Specific Gravity, Absorption, and Voids in
ASTM C642
Hardened Concrete
BS 1881:108 Method for making test cubes from Fresh Concrete
Method for Determination of Compressive Strength of Concrete
BS 1881:116
Cubes
Method for Determination of the Compressive Strength of
BS 1881: 120
Cured Cores.
Mixing water for concrete. Specification for Sampling, Testing
and Assessing the
BS EN 1008 Suitability of Water, including Water Recovered from Processes
in the Concrete
Industry, as Mixing Water for Concrete
BS 882 Specification for Aggregates from Natural Sources for Concrete.
Method of Sampling and Testing of Mineral Aggregates, Sands,

BS 812 2
and fillers

DNV – OS-F101 Submarine Pipeline Systems.
ISO 9001 Quality Management Systems – Requirements
BSIBV-ITP-08-2 Inspection and Test Plan - Concrete Weight Coating

Receipt, Dispatch, Handling and Storage of Tubular Goods –
BSIBV-QP-01
Quality Procedure/Plan
Global Product Specification for Impinged Concrete Weight
BS GPS CWC Global
Coatings – Bredero Shaw
1.3 Abbreviations and Definitions
1.3.1 Abbreviations
Abbreviation/
Description
Acronym
Three Layer Polypropylene coating consisting of a primer layer, adhesive layer
3-LPP
and outer Polypropylene layer.
3LPE Three Layer Polyethylene coating consisting of a primer layer, adhesive layer and
outer Polyethylene layer.
API American Petroleum Institute
BSIBV Bredero Shaw International B.V., Ras Al Khaimah
CS Pipe Carbon Steel Pipes
CWC Concrete Weight Coating
DMP Daily management process
FBE Fusion Bonded Epoxy
ISO International Organization for Standardization
ITP Inspection and Test plan
MFG Manufacturer
MSDS Material Safety Data Sheet
OD Outer Diameter
PE Polyethylene
PP Polypropylene
PQT Procedure Qualification Trial
QP Quality Plan / Procedure
SMS ShawCor Management System

1.3.2 Definitions
Term Meaning
COMPANY Dubai Petroleum Establishment
CUSTOMER TechnipFMC
A 'Start-up' is defined as a modification of production parameters according to the
START UP
manufacturing control procedure or a stop of the coating line
A representative of the Quality Control department whose function is to witness,
verify and document one or more aspects of the process and to ensure that the
QC INSPECTOR
minimum specified requirements are complied with. The term QC Inspector
throughout this document shall be understood to mean ‘Quality Control Inspector.
Designee is a person who is designated to carry out the assignment on behalf of
DESIGNEE the responsible person. The designee shall be a trained and competent person,
who shall be able to carry out the assigned task.
OPERATIVES Personnel charged with responsibility to complete tasks.
CS Pipes provided by the Customer for the purpose of application or installation
CUSTOMER
of coating or any other service as may be provided by BSIBV and throughout this
SUPPLIED
document.
MANUFACTURER Manufacturer of raw materials associated with the coating process.
The Party, which manufactures and/or supplies material, equipment and services
SUPPLIER
to perform the duties as specified in the scope of supply.
A method by which contaminants are removed from the pipe surface by washing
ACID WASH
the pipe with Company approved equivalent phosphoric acid shall be used.
The negative log to the base 10 of the hydrogen ion concentration. i.e being either
pH
acidic or alkaline in nature.
Applying heat to the pipe before a necessary process step, when increased pipe
PRE-HEATING
temperature will serve a useful purpose.
A coating defect penetrating through the coating, to the steel pipe surface of such
HOLIDAY
as dimensions that it is detectable using a high voltage search electrode.
SHIFT HOURS A production shift shall not be more than 12 hours.
Clause revision shall be identified by,
REVISION
STATUS • Revision number in brackets adjacent to the clause, or
• A vertical line to the right of the revised text.

1.4 Process Flow Diagram
1 Transportation of anti-corrosion coated pipe from Three Layer Plant or stockpile to Coating Plant
Overhead Transfer
Pipe Conveyed to Holiday station of Coating Plant 3
2 to Coating Buggy
I
1.1.1.4.1.1.1.2
Concrete Wire Reinforcement
Concrete Mixing Application
4
Cement
Water
Silo
5
Pugmill
Mixer
Aggregate Stockpiles Material Transfer
Overhead Transfer to Weigh Bridge Girth Measurement Cutback Cleaning Transfer to Fog Cure Area
8
and Weighing
6 7
1.1.1.4.1.1.1.1 I
9 10 Post Cure Inspection, Repair & Priming Transportation to Stockpile
Concrete Curing
on pipe ends 11
Canvas
Cover
Sand
Berm I
I Inspection Point
1.1.1.1 K 1.1.1.4 P 1.1.1.3 Directi 1.1.1.2 Inspe
E r on of ction
Y o Flow Point
: c
e
s
s

1.5 Responsible Parties
a) Plant Manager is responsible for ensuring that production activities are carried out on time to the
required specification, at the required level of quality and for ensuring that all relevant Managers
/ Dept. heads are implemented company policy and procedures at all times.
b) Project Manager has overall responsibility of the Project. He shall ensure that all services and
coating related materials are available for the successful and timely completion of the project.
The Project Manager shall also communicate to Customer; act as BSIBV interface with the
Customer throughout the duration of the Project.
c) The QA/QC Manager shall supervise and undertake the technical responsibilities of Production.
The QA/QC Manager has the authority to halt production if products have been identified non-
conforming in accordance with this Quality Procedure/ITP. The QA/QC Manager shall develop
recommend and implement Quality Plans/Procedures to ensure that manufactured products are
of acceptable quality and produced in accordance with specifications and company quality
standards. He shall develop initial plan and preparation of QP & ITP of the PQT/Production, the
same shall be submitted for review and approval.
d) The Area QA Manager shall provide general technical support to the projects as and when
required. He/she supervises and undertakes technical responsibility, develop recommend and
implement the Quality department to ensure that manufactured products are process in
accordance with the specifications and company quality standards.
e) The Operations Manager shall be responsible for all workforce and equipment necessary for the
required operation. He shall also ensure that the operations are performed in a safe manner and
that the product meets the requirements specified herein.
f) HSE Manager shall be responsible to ensure that all workers are versed in safety procedures
and all equipment is visually checked, colour coding is used for hooks and slings, workers are
provided with all required PPE.
g) SMS Coordinator shall make sure the Standard Operating Procedure (SOP), Process Failure
Mode Evaluation Analysis report (PFMEA), Control Plan (CP) prior to start of the
PQT/Production. The set parameters shall be recorded and kept for further reference.
h) The QC Supervisor is responsible for organizing the QC Inspectors and coordinating their
activities in conjunction with production and contract requirements. Ensure that the QC
Inspectors inspect and control the quality of the product in accordance with this document. Also,
perform inspection equipment calibration on a Daily basis at the QP/ITP Requirement. He shall
carry out necessary liaison between the Production/Quality Control Department and Customers
site representative.
i) Project Engineer shall ensure that all services and coating related materials are available for the
successful and timely completion of the project. The Project Engineer shall also act as BSIBV
interface (in the absence of the Project Manager) with the material manufacturer throughout the
duration of the project.
j) QA Engineer shall assist QA/QC Manager in preparation and implementation of all relevant
Quality Assurance documentation necessary to maintain the certification of ISO 9001-2008. He
shall monitor Internal Quality Audit Schedule, Quality Objectives and Corrective Actions.
k) QC Foreman shall be responsible for all inspections and documentation required to ensure each
pipe processed complies with specified contract/purchase order requirements. In addition, he
shall train QC Inspectors to be responsible for inspection, documentation and marking required
ensuring full traceability of each pipe.

l) Tally Coordinator shall be responsible for all matters relating to the arrangements of bare pipes,
efficient identification and data input of pipes received, coated and loaded out. The tally
coordinator shall also be responsible for tracking data related to production and quality control
for records and invoicing purpose of pipes, and other related products applicable. The tally
coordinator will also take the responsibility of tracking the entire process data reports and shall
ensure that the same are filed and documented in a proper manner.
m) Senior QC Laboratory Technician shall ensure all laboratory tests are performed in accordance
with approved BSIBV procedures/ITP and COMPANY specifications. Ensure incoming raw
materials meet specification. Test daily production samples to ensure quality according to BSIBV
and relevant standards in accordance with the PQT/Production document.
n) Yard Superintendent shall be responsible for the correct storage and handling of all pipes and
the execution of pipe movement from load in receipt, within the yard, and for dispatch. He shall
also be responsible for the maintenance and upkeep of the storage areas.
2 Coating System Requirements

2.1 General
All the concrete mixing materials such as cement, aggregate, and water shall be stored in accordance
with Manufacturer recommendations (if any). The Reinforcement Wire shall also be stored in
accordance with Manufacturer recommendation.
2.2 Calibration
The QA/QC Supervisor or designee shall calibrate the concrete plant start of PQT and once per week
in accordance with BSIBV calibration method C 040; Calibration result shall be recorded on report form
CF 040. (Appendix 2) Tolerances shall be in accordance with the agreed BSIBV-ITP-08-2. The mix
design shall be made according to the calibration and it will be recorded on form number CF 040.
The QC Inspector shall witness the calibration of the weighbridges in accordance with BSIBV calibration
method C 041 prior to the start of PQT and production or after a questionable result. Calibration results
shall be recorded on report form CF 041 (Appendix 2). The certified weights shall be used.
The weigh bridge shall be calibrated using certified weight with a maximum tolerance of +/-1%.
The QC Supervisor or designee shall calibrate the holiday detector in accordance with BSIBV-ITP-08-
2. Holiday detector voltage shall be 5kV/mm of coating thickness (up to a maximum of 25kV) and
verification of holiday detector with an artificial pinhole shall be carried out. The result shall be recorded
on form QF 500-1.
2.3 Materials
Every shipment of materials delivered for application under the requirements of BSIBV-ITP-08-2 shall
be supplied with manufacturer’s certificates certifying that the material conforms to the requirements of
this BSIBV-ITP-08-2. Manufacturer certificate shall be submitted to the customer. All the concrete mixing
materials such as cement, aggregate, and water shall be stored in accordance with Manufacturer
recommendations (if any). The Reinforcement Wire shall also be stored in accordance with
Manufacturer recommendation.
2.3.1 Aggregates (Silica type Washed Sand, Slag & Iron Ore)
Aggregates shall be stockpiled on a well-drained and compacted area. Sand, Slag and Iron Ore shall
be segregated and stored separately. Aggregates shall be based on standard supplied (ASTMC33 or
BS882) which will meet the required concrete 'as applied' density and compressive strength criteria.

Grading of aggregates shall be checked every three days during production in accordance with ASTM
C 33 or BS882. Washed sand Aggregates shall be monitored and BS 812 controlled for oversize, the
large Iron Ore particle shall not be more than 9.5 mm.
Typical Gradation of Iron Ore Typical Gradation of Sand

(Slag & Iron Ore)
Sieve Size Ideal Passing Sieve Size Ideal Passing
9.50 mm 100 9.50 mm 100
4.75 95-100 4.75 mm 95 – 100
2.36 mm 80 - 100 2.36 mm 80 – 100
1.18 50 - 85 1.18 mm 50 – 85
600 m 25 - 60 600 m 25 – 60
300 m 5 – 30 300 m 5 – 30
150 m 0 - 10 150 m 0 – 10
Sand shall be local wadi/crushed sand complying with the requirements of ASTM C33 excluding
abrasion and soundness tests.
2.3.2 Cement
All cement used for the preparation of the concrete coating shall be ordinary Portland conforming to
Cement shall conform to ASTM C150 Type II with C3A content shall be less than 8% by weight and the
alkali content shall be less than 0.6%. Compliance shall be demonstrated on supplier’s test certification.
Cement shall be blown directly into the storage silos upon delivery and material that has hardened,
partially hardened or become lumpy shall not be used. Certificate of Conformance for the cement shall
be submitted for customer approval for all cement batches.
2.3.3 Reinforcement Wire

Reinforcement steel shall be galvanized and crimped welded wire mesh, conforming to ASTM A810, or
conforming to all three of the following standards: ASTM A82, ASTM A185 and ASTM A641. The
reinforcement shall be 25.4mm x 67.0mm and of sufficient diameter to provide equal to or greater steel-
to-concrete ratio in both the transverse and longitudinal direction. Certificate of conformance shall be
submitted for customer approval prior to commencement of project.
2.3.4 Water
Water used in the mix shall comply with the requirements of BS EN 1008. The water shall be fresh,
clean and shall not contain soluble compounds, acids, alkalis, oils or suspended organic matter or
sewage which would impair the setting of the concrete or reduce its strength. Independent laboratory
test certificate shall be submitted for customer approval prior to commencement of project.
2.4 Pipe Receipt at Station
All the pipe identification marks shall be confirmed; pipes are subject to holiday detection. Holiday
detector shall be calibrated in accordance with the agreed BSIBV-ITP-08-2. The holiday detection
voltage shall be set as listed in the BSIBV-ITP-08-2.
All anti-corrosion coating damaged areas shall be repaired in accordance with the specific BSIBV-ITP-
07-2. All pipes shall have appropriate anti-slip coating (Sinter) applied prior to concrete coating.
2.5 Anodes
Pipe with anode attachments shall have the anode face protected by covering with polyethylene
sheeting to prevent concrete spatter adhering to the anode face during concrete coating application.
After concrete cure and cutting back of the reinforcement wire the area between the concrete and the
anode shall be repaired using a non-conductive sand/gravel/cement mix. The anode face shall be free
of concrete contamination. The anode shall not protrude above the concrete thickness.

2.6 Material Mixing
Aggregates shall be stockpiled on well-drained and compacted surfaces. Aggregates from their
respective stockpile areas are transferred to the material hoppers by front-end loader where they are
screened and oversized particles (above 10mm) are removed.
Moderate sulphate resistant cement shall conform to ASTM C150 Type II; compliance shall be
demonstrated on supplier’s test certificate. Cement is fed from the storage silo by screw onto the drive
conveyor. Aggregate components pass through a gate in their respective hoppers, calibrated to ensure
correct proportioning, onto the drive conveyor, which feeds all the components into a "Pug Mill". At the
end of the mixing cycle, water is added to complete the mix design.
After mixing, the concrete shall be fed onto small feed belts and conveyed to the throwing unit. Concrete
shall be applied within 30 minutes of water being added to the mix. Moisture content, cleanliness and
gradation of aggregates shall be checked in accordance with ASTM C-33 and the agreed BSIBV-ITP-
08-2. Concrete mix design shall be submitted to client representative prior to the start of PQT/
production. The mix design shall at least contain information as mentioned in BSIBV-ITP-08-2. The
weighing accuracies shall be in accordance with BSIBV-ITP-08-2.
2.7 Concrete Application
Concrete coating thickness shall be in accordance with the scope of work and the Purchase Order.
Pipes shall be lifted by means of a circle crane or overhead crane and placed on to the lower in arms.
The lower-in arms position the pipe on the coating buggy, where it is supported on the bare ends by
rotation wheels. The distance between the buggies is adjustable to accommodate varying pipe lengths
(9.5m to 13m). The layers of reinforcing wire shall be in accordance with Para 2.3.3.
With the pipe correctly positioned on the impingement unit, fresh concrete mix is impinged on to the pipe
surface as the pipe is rotated. At the same time pipe travel shall be activated. The thickness of the
coating applied shall be controlled by adjusting the pipe travel/rotation speeds or by varying the concrete
feed rate such that project requirements are achieved.
Reinforcement wire shall be wound and embedded in the concrete with a minimum overlap between
spirals to aid the concrete application to the pipe and to prevent fresh coating from spalling.
• ≤ 50 mm concrete coating thickness - 1 wire mesh reinforcement wrap shall be used.
The minimum reinforcement shall be 0.5% of the cross-sectional area of the weight coat taken in the
plane perpendicular to the longitudinal axis of the pipe and the minimum reinforcement shall be 0.08%
of the cross-sectional area of the weight coat taken in the plane perpendicular to the circumferential
axis.
As the coated pipe travels away from the throwing unit a scraper shall be held against the concrete
surface to trim any high spots and ensure the specified outside diameter range is achieved. Special care
shall be exercised at ends and at anodes. In the event of a breakdown, concrete mix which has lain in
the pug mill for more than thirty- (30) minutes, shall be discarded.
Material that rebounds or is scraped off the pipe during application shall drop into the reclaim system.
The reclaim material shall be mixed with fresh aggregate on a continuous basis such that the concrete
applied to each pipe has been thoroughly mixed and forms a cohesive mixture. The amount of reclaimed
material used shall not exceed 5 percent of total mix by weight.
Once the concrete has been applied, the pipe shall be lifted from the coating buggy by means of a circle
crane and /or by overhead crane and placed on the weighbridge. Whilst on the weight-bridge tally
personnel shall record the pipe identification and outer diameter measurements for input into the pipe

tracking computer system, which performs the calculations against required theoretical weight. Each
pipe will be weighed after coating and compared against theoretical submerged weight or theoretical
concrete weight tolerance.
Any pipe that is over thick shall be manually scraped down to remove the excess concrete. Any pipe
that is under thickness shall be fed back into the coating system within 30 minutes from the start of the
initial coating process and additional concrete shall be applied.
Any pipe that is overweight shall be manually scraped down to remove the excess concrete, as long as
the minimum specified thickness value is achieved.
Any pipe that is underweight shall be fed back into the coating system within 30 minutes from the start
of the initial coating process and additional concrete shall be applied as long as the final thickness does
not exceed the maximum specified thickness value.
Concrete mix, which has remained in the pug mill for more than 30 minutes after the addition of water,
shall be discarded. The coating thickness and accepted tolerance will be in accordance with the scope
of work.
The concrete cutback shall be formed by the application of low pressure water washing at the pipe end
and either side of the anode.
Each concrete end (cut back) shall be carefully washed to remove any concrete spatter from the bare
steel and anti-corrosion coating areas. The internal surface of the pipe shall be protected with sponges.
Final preparation of the concrete end and the anode areas shall be performed once the concrete is
cured by cutting the reinforcement wire manually, using wire cutters. Visual inspection of each pipe end
shall be performed to ensure these methods do not damage the anti-corrosion coating.
On completion of pipe end cleaning and inspection, and before drying out of the concrete coating, the
freshly coated pipe shall be transported to the “Fog curing” bays by pole/flatbed trailers fitted with wide
sand box bolsters, to provide adequate support during transportation. On arrival at the curing bays,
cranes fitted with padded hooks shall place the pipes onto sand berms in the curing bays. A number
shall identify each bay and the curing start time shall be recorded on Report Form QF 08-5. (Appendix
1) Forms attached.
Once each bay has been filled, a fabric cover shall be used to enclose the pipe in each bay. A fog mist
is released in to the bay through piping and spray nozzles. The resultant curing environment produces
an assimilated atmosphere steam cure, which results in the concrete coating achieving an initial
compressive strength of as mentioned in the ITP. Once the required compressive strength achieved on
24 hours’ cube samples, the cured pipes shall be stacked. To demonstrate this, at the start of production,
cubes will be taken immediately after curing and tested for compressive strength.
2.7.1 Anode Retrofit Process Pipes
If the anodes are to be installed after concrete coating process, the concrete application process shall
be prevented on approximate middle of pipe by using steel plate. The anode installation area will be
covered with polythene sheet to avoid contact of concrete materials on pipe surface.
2.8 Pipe Marking
On completion of cure, the covers are removed from the bays and a final visual inspection shall be
performed on the coated pipes. On completion of visual inspection, pipes are transported to the end
trimming /repair area. Agreed pipe markings may be applied at the fog cure area prior to transporting
the pipe to the end trimming/repair area and/or applied at the end trimming/ repair area. If required
colour coding shall be carried-out. Marking normally takes the form of full circumferential paint bands
50mm wide (marine paint colour band located at one end of the coating). Anode pipes shall be identified

by one white circumferential paint band. Pipe marking shall be as shown in BSIBV-ITP-08-2.
2.9 Concrete Repairs
2.9.1 Spalling
Spalling due to compression or shearing caused by impact against other objects which causes a loss of
not more than 25% of the total thickness of the coating shall be repaired. An area of less than 0.09 m²
per line pipe where the concrete remaining on the line pipe is sound will be accepted without repairs.
Repairs to spalling damage shall be performed by the following procedures:
• If the damaged area is 0.3 m² or less, remove the damaged concrete.

• If the damaged area exceeds 0.3 m², remove the concrete from around the entire pipe
circumference throughout the length of damaged area.
• Restore the reinforcement steel, if necessary.
• Wet the fresh surface of the remaining concrete coating at the point of coating damage for a
minimum of two hours.
• Place the concrete repair mixture into and through the reinforcing steel until the surface is level
with the coating around the repair.
• Cure the repair.
2.9.2 Cracking
Crack repair is required in following conditions:
• Cracks that are in excess of 1.6 mm in width and extend over 180° circumferentially around the
line pipe.
• Cracks that are in excess of 300 mm in length, along the line pipe irrespective of width.
Crack repair shall be as per below procedure:
• Chisel the crack out to a width of not less than 25 mm throughout the length of the crack, without
damaging the reinforcement steel
• Wet the crack surface for a minimum of two hours
• Fill the crack with concrete repair mixture
• Cure the repair
The repaired area shall be kept moist and allowed to remain undisturbed for a period of not less than
36 hours.
2.9.3 Gaps
Gaps between the pre-coated pipe and the concrete coating in excess of 1.5 mm (0.06 in) extending
more than 150 mm (6 in) from the beginning of the concrete cutback, that have a length of more than
60° around the circumference of the pipe, and which remain for at least 30 minutes after the pipes have
been taken out of stockpile shall be repaired.
2.9.4 Concrete Repair Method

Prior to performing any repair, the concrete coating shall be cut back to the reinforcement to provide an
undercut for the repair.
The area shall be free of loose material and thoroughly wetted for a minimum period of 5 minutes. After
this thorough wetting, the damaged area shall have bonding agent applied to enhance the adhesion
between the parent coating and the repair.
Depending upon the size of the repair, the hand or gunnite method shown below shall be selected.

2.9.5 Concrete Repair - Hand
The hand repair method shall be employed to reinstate the concrete coating at the pipe ends after
concrete curing and also small areas (up to 0.3m2), including core holes.
Mixing of the dry concrete material with water shall be undertaken in a steel vessel until a consistency
suitable for forming the material onto the concrete end or repair area is achieved.
Repaired areas shall be sealed with polythene sheets or wet gunny bags until cure the repaired area.
2.9.6 Concrete Repair – Gunnite Application

The concrete mixture is sprayed pneumatically onto the repair area of coated pipe at a high velocity.
Once gunite has been applied it starts a simultaneous process of consolidation and settling. The gunite
application method shall be used for large repairs, the application will be using same concrete mix from
the plant. The operators shall be followed HSE requirements prior to application.
A portable mixer shall be used to blend the materials. Once mixed the material shall be fed into the
gunite machine. Air and mix feeds shall be adjusted to provide optimum performance. Wet burlaps or
clear polyethylene sheet shall be used to seal the repair until the concrete has cured to required strength
or until a cure time of 24 hours has elapsed.
2.9.7 Removal of Green and Cured Concrete

GREEN CONCRETE REMOVAL - When the concrete coating is rejected in the green uncured condition,
the complete coating is removed on the application buggy. The pipe is rotated and the reinforcement
wire mesh is unwound, followed by application of the smoothing scraper to remove the concrete
material. After this, the pipe is lifted off the application buggy to a pipe support station where the residual
concrete residue is completely washed off the anti-corrosion coating and steel cutback areas.
CURED CONCRETE REMOVAL - When the concrete coating is rejected in the cured condition, the
pipe is lifted onto a sand berm by crane or front loader. A concrete cutting saw is used to cut through
the concrete along the full length of the coated section at three locations equally spaced around the
circumference. Additional cuts may be made in the circumferential direction also. The concrete shells
will then be prized apart using hydraulic devices or methods. Residual concrete coating shall be
removed by manual hammer and chisel. Prior to cutting, the concrete coating thickness is determined
by OD tape and the depth limiting device is set to ensure the anti-corrosion coating cannot be damaged
during the cutting process.
After concrete removal, regardless of whether it is removed in the green or cured condition, the anti-
corrosion coating shall be visually inspected and holiday detected for ACC damage. Any damage found
shall be repaired in accordance with BSIV-QP-07-2.
3 Concrete Inspection/Testing
The QC Inspector shall measure with a girth tape the outer diameter of all coated pipe in accordance
with BSIBV Test Method TM 26 (Appendix1), Concrete thickness shall measure the outside
circumference of each pipe at six (6) locations in order to calculate the average diameter and the
variation in thickness along the joint length. The Concrete coating thickness shall be 40 mm. Any pipe
that is over thick shall be manually scraped down to remove the excess concrete. Any pipe that is under
thickness shall be fed back into the coating system and additional concrete applied. Result shall be
recorded on report form QF 08-1(Appendix 2).
The QC inspector shall check the placement of the wire reinforcement while removing a coupon from
the wet concrete by water jetting to ensure correct wire size and overlap in accordance with customer’s
requirements. Minimum overlap between spirals shall be respected. One or two layers of reinforcement
may be used based on the concrete thickness.
The wire reinforcement placement shall be in accordance with the criteria listed in the BSIBV-ITP-08-

2: The minimum distance between the reinforcement and the outside surface of the concrete, the
minimum distance between the reinforcement and the corrosion coating, and the minimum spacing
between the layers. Result shall be recorded on report form QF 08-3 (Appendix 2).
3.1 Visual Inspection
The concrete coated pipes shall be subjected to visual inspection for cracks, damages, spalling damage
of concrete coating and exposed reinforcement. The damages shall be repaired in accordance with
section 2.9 of this procedure. The concrete coating cut back shall be measured from the base of the
concrete to the pipe bevel edge in accordance with the BSIBV-ITP-08-2. In additional cut back area
shall be inspected at each concrete end and carefully checked for any concrete spatter on the bare steel
and anti-corrosion coating areas. The internal surface of the pipe shall be clean and there shall be no
visual damage to the coated pipes. The reinforcing steel shall not be exposed at the ends of the concrete
coating.
3.2 Plant Break Downs (If any)
The QC Inspector shall record times of breakdown/halts during production. In the event that the
production stoppage is > 30 minutes, any unused concrete shall be discarded.
3.3 Testing Samples
The concrete sample shall be collected from the concrete mix (pug mill) after material mixing, but
before application. Cubes of 100 mm x 100mm size shall be prepared from the concrete sample. The
cured cubes will then be tested in accordance with BS 1881. Vibration and compaction shall be
applied to have uniform segregation of the concrete mix, eliminate air pockets and ensure the cube
is properly prepared. The cube shall then be filled in layers approximately 1/3 part in depth and each
layer compacted using a vibrator until the top layer is smooth with the top of the mould. Cube samples
shall remain in the mould for a minimum twelve (12) hours covered with a wet cloth. After discharging
from the mould, the cubes shall be cured in a water tank. They shall remain in the water tank until the
required time of testing. Samples shall be towel dried prior to testing.
3.4 Concrete Density Testing on Cores
Density of the concrete shall be tested using cores removed from the cured concrete pipe.
Methods used for sampling, storing and testing of cores shall be in accordance with BS EN 12390-7
in the “as applied” condition.
Testing frequency and Acceptance criteria shall be in accordance with BSIBV-ITP-08-2. Results shall
be recorded on report form QF 08-8 (Appendix 2).
3.5 Water Absorption Testing on Coupons
Water absorption of the concrete shall be tested using coupons removed from the cured concrete
pipe.
Acceptance criteria shall be in accordance with BSIBV-ITP-08-2. Results shall be recorded on report
form QF 08-8 (Appendix 2).
3.6 Concrete Compressive Strength
Compressive strength of the concrete shall be tested using cubes made from the fresh concrete
material and cores removed from the cured concrete pipe.

Methods used for sampling, storing and testing of cubes shall be in accordance with BS1881. The
test shall be carried out in 24 hrs, 7 days, and 28 days as per BSIBV-ITP-08-2.
Methods used for sampling, storing and testing of cores shall be in accordance with ASTM C-39 and
ASTM C-42 or BS EN 12504-1.
Cores shall be sampled and tested in accordance with BSIBV-ITP-08-2.
Acceptance criteria shall be in accordance with BSIBV-ITP-08-2. Results shall be recorded on report
form QF 08-10 (Appendix 2).
3.7 Determination of Unsaturated Coated Pipe Weight
The dry weight of each pipe shall be measured and the unsaturated submerged weight of each pipe
length shall be calculated from the dry weight by the CONTRACTOR according to the following
method: -
a) Measure dry weight (W) of concrete coated pipe joint.
b) Calculate dry weight of concrete coated section of pipe (W1) according to the following equation:
W1 = W –2. 𝜋. ƿs.(D – t).t.L1
c) Calculate the buoyancy (B) of the concrete coated section of pipe according to the following
equation:
B = (𝜋 /4). ƿw.D1.(L – 2.L1)
d) Unsaturated submerged weight (Ws) of the coated pipe is calculated in accordance with the
following equation:
Ws = (W 1 – B) / (L – 2. L1)
Where,
L = Length of joint (m)
L1 = Length of concrete cutback (m)
WF=Percentage of Water absorption factor (kg/m3)
Lc=(L-2. L1)
D = Outside steel pipe diameter (m)
D1 = Outside pipe diameter including weight coating (m)
t = Steel pipe wall thickness (m)
W = Dry mass of pipe length including weight coating (kg)
W1 = Dry mass of concrete coated section of pipe (kg)
B = Buoyancy of coated section of pipe in seawater (kg)
Ws = Unsaturated submerged weight (kg/m)
ƿs = Mass density of steel (kg/m3), based on linepipe tally sheets
ƿw = Mass density of seawater taken as 1010 kg/m3
The saturated submerged weight of coated pipe shall be calculated from the unsaturated submerged
weight and the percentage of water absorption.
3.8 Determination of Saturated Coated Pipe Weight
The saturated submerged weight of coated pipe shall be calculated from the unsaturated submerged
weight and water absorption factor. The saturated submerged weight (w) of the test pipe joint shall
be within the specified tolerances of the design submerged weight.
W = W s +WF (Note: Terms are defined in the clause 3.7 of this procedure)
Concrete Weight Tolerance shall be in accordance with BSIBV-ITP-08-2.

For anode pipes, the line pipe weight tolerances for individual lengths may be adjusted accordingly
to take into account the difference in weight between anode material and concrete coating. The results
shall be recorded for individual pipe on QF-08-1 (Appendix 2). Rolling Pipes average and shift
variance shall be recorded in the computer database.
3.9 Electric Isolation / Continuity
The QC Inspector shall check electrical isolation or continuity using the calibrated Ohm meter.
Isolation to proven between the reinforcement and pipe/anode. Continuity to be proven between the
pipe and the anode. Both CWC sections will be checked on the anode pipe.
In the event of a failure, the pipe shall have the concrete removed and recoated. Result shall be
recorded on report form QF 08-4 (Appendix 2).
In the event of a failure on the anode installed pipe, the concrete repair next to the anode will be
removed. If necessary, the reinforcing wire will be trimmed, the area shall be repaired and the
resistance rechecked. Result shall be recorded on report form QF 08-2 (Appendix 2).
3.10 Fresh Concrete Analysis
The QA/QC Supervisor or designee shall take a sample of fresh concrete from the pug mill and shall
perform Fresh Concrete Analysis in accordance with BSIBV Test Method TM 24 (Appendix1).
Water/cement ratio shall be in accordance with the agreed BSIBV-ITP-08-2. Concrete Mix Design &
Analysis shall be as mentioned in BSIBV-ITP-08-2. Moisture content of the concrete shall be checked
in accordance with BSIBV-ITP-08-2. In the event that the tests result is not correct additional tests
shall be performed. Result shall be recorded on report form QF 08-7 (Appendix 2).
3.11 Inspection Release Note (IRN)
Upon completion of all works and testing, Customer representative will sign QF 032 Inspection
Release Note (Appendix 2) for pipes which are complete.
4 Handling, Transportation and Storage
The pipe handling, transportation and storage shall be in reference BSIBV-QP-01.
4.1 Handling
Green uncured concrete coated pipe shall be handled using cranes fitted with a spreader bar and
aluminium or padded pipe hooks onto flatbed/pole trailers for transportation to fog cure area. Unloading
at the fog cure shall be by crane fitted with spreader bar with aluminium or lined pipe hooks.
4.2 Transportation
Trailers for transportation of green concrete shall have constructed sand beds to provide adequate
support for the pipe. Green concrete coated pipes shall not be stacked.
For cured concrete, pipes may be transported on flatbed trucks fitted with sand beds, timber supports
or suitable bolster.
4.3 Storage
The Concrete coated pipe storage shall be carried-out in accordance with BSIBV-QP-01 (Receipt &
Dispatch).

Pipe will be stacked with due consideration to impact effects, nested together up to a maximum safe
working height in accordance with BSIBV pipe stacking calculations.
Sand berms shall be reinstated prior to each new batch of pipes being stored.
5 Laboratory Quality Control Testing on Incoming Raw Material
Laboratory testing on incoming raw materials is controlled by BSIBV form RF 062, Test Requirement
Notification Memorandum for Incoming Raw Materials.
Appendix 1: Test Methods
TM 24 Test Method – Cement Content in Concrete*

TM 25 Test Method – Moisture Content of Concrete*
TM 26 Test Method – Concrete Thickness Measurement*
* ISO 21809-5 is shown in the attached test methods for information only.





Appendix 2: Documentation – Report Forms
Note: The attached documents are the current revision report forms; the revision number may vary during
project.
• RF 033 Material received and inspection Report

• QF 08-9 Aggregate Gradation & Moisture Content Test
• QF 08-3 Reinforcing Wire Mesh Placement Report form
• QF 01-3 General Report Form
• QF 08-7 Cement Content in Concrete Test Report
• QF 001 Pipe Incoming Inspection Report form
• QF500-1 Daily Instrumental Calibration Report
• QF 08-1 Concrete Weight Coating Inspection Report
• QF 08-4 Concrete Field Inspection Report
• QF 08-2 Anode/Concrete Isolation Inspection Report
• QF 08-5 Fog Cure Inspection Report
• QF 08-10 Compressive Strength Test Report
• QF 08-6 Concrete Repair Inspection Report
• QF 08-8 Concrete Coupon Density & Water Absorption Test Report
• CF 040 Concrete Theoretical Mix Design Report Form
• CF 041 Weigh Bridge Calibration Report Form
• QF 026 Stripping Report
• QF 08-14 Shear Test Report - Concrete Weight Coating
• QF 032 Inspection Release Note (IRN)



Report Form : QF 08-3
BREDERO SHAW INTERNATIONAL B.V
REINFORCING Revision No. : 5
WIRE MESH PLACEMENT INSPECTION Rev. Date : 2-Jul-15
REPORT Sheet No. : of
Project :
Customer :
Date : Shift: D=Day N= Night
Pipe Size: Dia. x W.T. mm
(Record as d/m/y)
Concrete Thickness (mm) : Wire Mesh Size :
Status
Pipe No. Wire Mesh Overlap (mm) (Record Acc for
SL No. Comments
(Record Pipe No. / Piece No.) accept Rej for
1 2 3 4 reject)
Wire Mesh Position (mm)

Status
Pipe No. Second Wire Third Wire Fourth Wire (Record Acc for
SL No. First Wire Comments
(Record Pipe No. / Piece No.) (Distance From (Distance From (Distance From accept Rej for
(Distance From
1 ˢᵗ Wire mesh 2 ⁿ ͩ Wire mesh 3 ͬ ͩ Wire mesh Cover
Coating to 1 ˢᵗ reject)
to 2 ⁿ ͩ Wire to 3 ͬ ͩ Wire to 4 ͭ ͪ Wire
Wire mesh)
mesh) mesh) mesh)
Note: In the event that tw o-w ire mesh reinforcement is to be installed. Record the top mesh distance (mm) from the outer concrete surface Record bottom mesh distance
(mm) from the FBE-coating surface.
Inspected / Recorded By: Checked / Approved By : Witnessed/Reviewed

TPI TPI
BSIBV QC Inspector BSIBV QA/QC Department Customer Representative
DRAWN BY REVISED BY REVIEWED & APPROVED BY DATE

Report Form Format
Tally Dept. Prejith.P Prakash Daniel 2-Jul-15



















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Document No.: BSIBV-QP-08-2 Revision No.: 0 Revision Date.: 08-Oct-18 Page 2 of 44

Document No.: BSIBV-QP-08-2 Revision No.: 0 Revision Date.: 08-Oct-18 Page 3 of 44

Document Number Document Title

DP-PL- 17, Rev. 10 Pipeline Weight Coating - Standard Specification

Method of Sampling and Testing of Mineral Aggregates, Sands,

Document No.: BSIBV-QP-08-2 Revision No.: 0 Revision Date.: 08-Oct-18 Page 4 of 44

DNV – OS-F101 Submarine Pipeline Systems.

ISO 9001 Quality Management Systems – Requirements

BSIBV-ITP-08-2 Inspection and Test Plan - Concrete Weight Coating

1.3 Abbreviations and Definitions

Document No.: BSIBV-QP-08-2 Revision No.: 0 Revision Date.: 08-Oct-18 Page 5 of 44

Document No.: BSIBV-QP-08-2 Revision No.: 0 Revision Date.: 08-Oct-18 Page 6 of 44

Aggregate Stockpiles Material Transfer

Document No.: BSIBV-QP-08-2 Revision No.: 0 Revision Date.: 08-Oct-18 Page 7 of 44

Document No.: BSIBV-QP-08-2 Revision No.: 0 Revision Date.: 08-Oct-18 Page 8 of 44

2 Coating System Requirements

Document No.: BSIBV-QP-08-2 Revision No.: 0 Revision Date.: 08-Oct-18 Page 9 of 44

Typical Gradation of Iron Ore Typical Gradation of Sand

2.3.3 Reinforcement Wire

2.4 Pipe Receipt at Station

Document No.: BSIBV-QP-08-2 Revision No.: 0 Revision Date.: 08-Oct-18 Page 10 of 44

2.7 Concrete Application

• ≤ 50 mm concrete coating thickness - 1 wire mesh reinforcement wrap shall be used.

Document No.: BSIBV-QP-08-2 Revision No.: 0 Revision Date.: 08-Oct-18 Page 11 of 44

2.7.1 Anode Retrofit Process Pipes

2.8 Pipe Marking

Document No.: BSIBV-QP-08-2 Revision No.: 0 Revision Date.: 08-Oct-18 Page 12 of 44

2.9 Concrete Repairs

• If the damaged area is 0.3 m² or less, remove the damaged concrete.

Crack repair is required in following conditions:

Crack repair shall be as per below procedure:

2.9.4 Concrete Repair Method

Document No.: BSIBV-QP-08-2 Revision No.: 0 Revision Date.: 08-Oct-18 Page 13 of 44

2.9.6 Concrete Repair – Gunnite Application

2.9.7 Removal of Green and Cured Concrete

Document No.: BSIBV-QP-08-2 Revision No.: 0 Revision Date.: 08-Oct-18 Page 14 of 44

3.1 Visual Inspection

3.2 Plant Break Downs (If any)

3.3 Testing Samples

3.4 Concrete Density Testing on Cores

3.5 Water Absorption Testing on Coupons

3.6 Concrete Compressive Strength

Document No.: BSIBV-QP-08-2 Revision No.: 0 Revision Date.: 08-Oct-18 Page 15 of 44

Cores shall be sampled and tested in accordance with BSIBV-ITP-08-2.

3.7 Determination of Unsaturated Coated Pipe Weight

3.8 Determination of Saturated Coated Pipe Weight

Concrete Weight Tolerance shall be in accordance with BSIBV-ITP-08-2.

Document No.: BSIBV-QP-08-2 Revision No.: 0 Revision Date.: 08-Oct-18 Page 16 of 44

3.9 Electric Isolation / Continuity

3.10 Fresh Concrete Analysis

3.11 Inspection Release Note (IRN)

4 Handling, Transportation and Storage

The pipe handling, transportation and storage shall be in reference BSIBV-QP-01.

Document No.: BSIBV-QP-08-2 Revision No.: 0 Revision Date.: 08-Oct-18 Page 17 of 44

5 Laboratory Quality Control Testing on Incoming Raw Material

Appendix 1: Test Methods