sp-1024 rev 1

ABU DHABI MARINE OPERATING COMPANY

Document Ref.:

SP-1024 Control Sheet

ADMA-OPCO STANDARD ENGINEERING DOCUMENTS PAGE

Page 1 of 36

D

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DESIGNATION SP-1024

SPECIFICATION

FOR

CONCRETE WEIGHT COATING OF

SUBSEA PIPELINE

TITLE

AUTHORITY NAME TITLE

B.UNIT

/

DIV

SIGNATURE DATE

TECHNICAL CUSTODIAN

Mohamed Yehia SPE P&E/

DED

TECHNICAL Amr Mohamed Azouz SPETL

P&E/

DED

STANDARDS Khaled Tawfik Hendy ESQASL P&E/

DED

APPROVAL Hisham Awda MDE P&E/

DED

ENDORSEMENT Ali Ghanim Bin Hamoodah SVP-PE P&E

CONTROL STAMP

The soft copy of this document

on ADMA-OPCO Web is

Controlled. When printed, it is considered

Uncontrolled

1 07/2011 Issued for Implementation

Rev. DATE DESCRIPTION/TEXT AFFECTED

SF / General / 001 Rev.0 sheet 1 of 1

COPYRIGHT ABU DHABI MARINE OPERATING COMPANY - ADMA-OPCO

All rights reserved. The information contained in this document is regarded as confidential. Recipient(s) other than ADMA-

OPCO's employees undertake both during the continuance of their services to ADMA-OPCO and after termination to maintain

in safe custody and not to use any such information for any purpose other than a purpose falling within the scope of the

Agreement or Contract under which this document was supplied. Recipient(s) further agree not to dispose of, make copies, in

whole or in part of such information or permit the use or access of the same by any Third Party unless the prior written

permission of ADMA-OPCO Manager Disciplines Engineering is obtained.

1.0 07-11 Issued for Implementation

Rev. Date Description / Text Affected

Specification For Concrete Weight Coating of Subsea Pipeline

ADMA-OPCO SP-1024 PAGE

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Liability for utilization by personnel/organizations outside ADMA-OPCO Whilst every effort has been made to ensure the accuracy of this document, neither ADMA-OPCO nor its employees will assume liability for any application or use outside ADMA-OPCO premises/assets.





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TABLE OF CONTENTS

1. INTRODUCTION ....................................................................................................................... 5

1.1 SCOPE ........................................................................................................................................ 5 1.2 COVERAGE ............................................................................................................................... 5 1.3 EXCLUSIONS ............................................................................................................................ 5 1.4 REFERENCES ............................................................................................................................ 5 1.5 ABBREVIATIONS ..................................................................................................................... 6 1.6 DEFINITIONS ............................................................................................................................ 6 1.7 USE OF LANGUAGE ................................................................................................................ 6 1.8 UNITS ......................................................................................................................................... 7 1.9 LESSONS LEARNED ................................................................................................................ 7 1.10 SITE CONDITIONS & DATA ................................................................................................... 7

2. QUALITY ASSURANCE .......................................................................................................... 8

2.1 QUALITY ASSURANCE SYSTEM .......................................................................................... 8 2.2 QUALITY PLAN ........................................................................................................................ 9 2.3 INSPECTION AND CERTIFICATION REQUIREMENTS ..................................................... 9

3. CONCRETE WEIGHT COATING MATERIALS AND REINFORCEMENT ............. 10

3.1 CEMENT .................................................................................................................................. 10 3.2 AGGREGATES ........................................................................................................................ 10 3.3 WATER ..................................................................................................................................... 11 3.4 CONCRETE MIXING .............................................................................................................. 12 3.5 REINFORCEMENT ................................................................................................................. 12 3.6 CURING COMPOUND ............................................................................................................ 12

4. PROPERTIES OF THE CONCRETE WEIGHT COATING ........................................... 13

4.1 CONCRETE MIX DESIGN ..................................................................................................... 13 4.2 BATCHING PLANT ACCURACY ......................................................................................... 13

5. APPLICATION ......................................................................................................................... 13

5.1 PIPE LENGTH PREPARATION ............................................................................................. 13 5.2 INSTALLATION OF REINFORCEMENT ............................................................................. 14 5.3 PLACING OF THE CONCRETE WEIGHT COATING ......................................................... 15

6. TESTING AND INSPECTION OF CONCRETE ................................................................ 17

6.1 TESTING .................................................................................................................................. 17 6.2 INSPECTION ............................................................................................................................ 20 6.3 QUALIFICATION TESTS ....................................................................................................... 20 6.4 INSPECTION AND TEST PLAN ............................................................................................ 20

7. REPAIRS AND CAUSES OF REJECTION ......................................................................... 21

7.1 REPAIR OF SPALLING .......................................................................................................... 21 7.2 CRACKING .............................................................................................................................. 21 7.3 CAUSES FOR REJECTION ..................................................................................................... 22

8. DOCUMENTATION AND REPORTING ............................................................................ 23

8.1 PRODUCTION AND TEST REPORTS ................................................................................... 23





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9. MARKING OF CONCRETE WEIGHT COATED PIPE .................................................. 24

9.1 COLOUR IDENTIFICATION .................................................................................................. 24

10. STORING AND HANDLING CONCRETE WEIGHT COATED PIPE ......................... 24

10.1 HANDLING OF PIPE AFTER COATING .............................................................................. 24 10.2 HANDLING OF PIPE FOR LOAD-OUT ................................................................................ 24 10.3 PIPE HANDING OVER CERTIFICATION ............................................................................ 24

11. CATHODIC PROTECTION (SACRIFICIAL ANODES) ................................................. 25

11.1 ANODES ................................................................................................................................... 25 11.2 METHOD OF ATTACHMENT ............................................................................................... 25 11.3 TESTING AND INSPECTION ................................................................................................ 26 11.4 STORING, STACKING AND HANDLING OF PIPE WITH ANODES FITTED ................. 26

APPENDIX-A: CALCULATION OF NEGATIVE BUOYANCY .............................................. 27

A1 FORMULA FOR COMPUTING "AS APPLIED" NEGATIVE BUOYANCY FOR CONCRETE FITTED PIPE ............................................................................................................. 27

A2 FORMULA FOR COMPUTING "AS APPLIED" NEGATIVE BUOYANCY FOR ANODE FITTED & CONCRETED PIPES .................................................................................... 29

APPENDIX-B: CONCRETE COATING DATA SHEET ............................................................ 32

APPENDIX-C: ABBREVIATIONS ................................................................................................. 33

APPENDIX-D: DEFINITIONS ........................................................................................................ 34

APPENDIX-E: REFERENCED DOCUMENTS............................................................................ 35





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1. INTRODUCTION

1.1 Scope

This Specification is intended to provide & highlights the minimum basic

requirements for materials and application of uniform concentric reinforced concrete

weight coating for ADMA-OPCO subsea pipelines and shall not relieve the

Contractor of his contractual obligations. Any deviation from this Specification shall

be identified by Contractor and shall require written approval from ADMA-OPCO.

1.2 Coverage

This Specification covers concrete coating application, inspection, repairs, coated

pipes handling and storage at coating plant.

1.3 Exclusions

This Specification excludes coated pipes transportation and any intervention works

outside the coating plant.

1.4 References

1.4.1 General

The latest edition (at the time of the contract award) of the reference documentation

as listed in Appendix-E shall be read as an integral part of this Document.

The latest edition/revision of ADMA-OPCO Standard Engineering Documents as

indicated in Status List SL-001 shall be utilized.

1.4.2 Equivalent Standards

Standard Documents equivalent to those referred to herein shall not be substituted

without written approval from ADMA-OPCO. Approval of equivalent Standard

Documents will not, in any way, release/relieve responsibility from the Contractor to

meet the best practices and/or requirements of the Standard Engineering Documents

referred to herein, in the event of conflict.

Where differences and/or conflicting issues occur between the referenced documents

themselves or the requirements of this document, the requirements of this document

shall overrule unless otherwise advised by ADMA-OPCO. However, major conflicts

shall be reported in writing to the ADMA-OPCO Standards Authority/Technical

Custodian nominated in the front sheet of this document for determination.

The following hierarchy of adherence to standards shall be followed:





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a. Whenever ADMA-OPCO Standard Engineering Documents (SEDs) relevant to the system, service and/or equipment design are available, the same shall be

utilized first.

b. ADMA-OPCO Shareholder SEDs (tailored to suit ADMA-OPCO needs) shall be utilized next in the hierarchy, if the relevant subject is not covered by

ADMA-OPCO Standards.

c. National or International standards (tailored to suit ADMA-OPCO needs) shall

be utilized, if the required subject is not covered either by ADMA-OPCO or

Shareholder SEDs.

The Contractor shall equip himself with copies of all the referenced Standard

Engineering Documents referred in Appendix-E of this Document and shall make

them readily available to all ADMA-OPCO, or nominated representative, personnel

involved in the work.

1.5 Abbreviations

The abbreviations used in this Specification are listed in Appendix-C.

1.6 Definitions

The definitions used in this Specification are listed in Appendix-D.

1.7 Use of Language

Throughout this document, the words will, may/can, should and shall/must, when used in the context of actions by ADMA-OPCO or others, have specific

meanings as follows:

a. Will is used normally in connection with an action by ADMA-OPCO and / or nominated representative, rather than by a Contractor or Vendor.

b. May / Can is used where alternatives / action are equally acceptable.

c. Should is used where provision is preferred.

d. Shall / Must is used where a provision is mandatory / vital.





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1.8 Units

Units shall be in accordance with ADMA-OPCO STD-00, Part-1.

1.9 Lessons Learned

Upon completion of works related to the scope of this document, a descriptive

summary of lessons learned shall be prepared and made available by the

Contractors/Consultants/Job Officer and shall be forwarded to ADMA-OPCO

Lessons Learned System as appropriate.

1.10 Site Conditions & Data

Site Conditions & Data of existing ADMA-OPCO facilities (Umm Shaif and Zakum

fields) shall be in accordance with ADMA-OPCO STD-00, Part-2. For new Fields

development, project specific requirements should be followed or refer to ADMA-

OPCO.





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2. QUALITY ASSURANCE

2.1 Quality Assurance System

2.1.1 All activities and services associated with the scope of this Specification shall be

performed by Contractors/Vendors approved by ADMA-OPCO.

2.1.2 The Contractor/Vendor shall operate Quality Management Systems (QMS) within

his organizations, which ensure that the requirements of this Specification are fully

achieved.

2.1.3 The Contractor/Vendors Quality Management System shall be based on ADMA-OPCO Specification SP-1009 or the latest issue of ISO 9001 Series and accredited by

an international certifying agency.

The Contractors Quality Manual shall provide details for the preparation of a Quality Plan, which shall include provisions for the QA/QC of services activities.

Where an approved Contractor/Vendor revises their Quality Management System

that affect the ADMA-OPCO approved Quality / Inspection and Test Plan, then the

revised Quality Plan / Inspection and Test Plan shall be submitted for ADMA-OPCO

approval before initiating any service activities.

2.1.4 The effectiveness of the Contractors Quality Management System may be subject to monitoring by ADMA-OPCO or its representative and may be audited following an

agreed period of notice.

2.1.5 The Contractor/Vendor shall make regular QA audits on all their Sub-

Contractors/Suppliers. Details of these audits shall be made available to ADMA-

OPCO when requested.

2.1.6 The Contractor/Vendor shall maintain sufficient Inspection and Quality Assurance

staff, independent of the service provider management, to ensure that the QMS is

correctly implemented and that all related documentation is available.

2.1.7 Using Sub-Contractors is not allowed for services/functions carried out by a

Contractor without ADMA-OPCO approval.





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2.2 Quality Plan

2.2.1 Contracted activities shall be performed in accordance with an approved Quality Plan

(QP).

2.2.2 The level of detail required in the Quality Plan shall be commensurate with the scope

of services provided.

2.2.3 The quality of works is an essential factor in carrying out all services & activities

covered by this Document.

2.2.4 During services/activities, Quality Assurance/Quality Control issues are the

responsibility of the Contractor, and shall be approved and certified by TPA.

2.2.5 Conflicts between Contractor & TPA shall be reported in writing to ADMA-OPCO

for resolution.

2.3 Inspection and Certification Requirements

Inspection and certification requirements for material shall be certified to ADMA-

OPCO CP-102 and BS EN 10204.





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3. CONCRETE WEIGHT COATING MATERIALS AND REINFORCEMENT

3.1 Cement

All cement used for the preparation of the concrete shall comply with the following

requirements:

a. Certified by the supplier to be in compliance with the requirements of ASTM C150 Type V.

b. The cement shall be adapted for sea water hardening and shall resist the effects of sulphates.

c. Identified with the following information on the certification and delivery documents for each shipment of cement:

c1. Cement producer's name and location,

c2. Product description including type and classification of cement,

c3. Year and month of production.

d. Handled, transported and stored in compliance with the cement manufacturer's recommendations and the applicable standards.

e. No more than six months from the date of manufacture, unless it is retested and proven to be in compliance with the original standard.

f. Cement shall be stored in covered areas or covered by plastic sheeting if supplied in bags. Bulk cement shall be stored in water proof containers.

g. Cement that has hardened, partially hardened or become lumpy shall be rejected.

h. Test certificates from the cement manufacturer shall be supplied for every cement delivery to site.

3.2 Aggregates

3.2.1 Sand (Silica Type)

Sand aggregates used shall be round grained and shall be obtained by sieving. Sand

shall be free of injurious amounts of salt, alkali, deleterious substances, or organic

impurities. Natural sand and aggregate shall conform to BS EN12620 or ASTM C 33

requirements.

Sand grading shall be within the range of values as shown in Table 3.2.1 herein under

Mesh size, as per

ASTM C 33

Per Cent Passing

Minimum Maximum

4.75 mm -- 100

2.36 mm 80 100

1.18 mm 50 100

600 microns 25 60

300 microns 5 30

150 microns 0 10





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3.2.2 Heavy Aggregate

Heavy aggregates made of crushed iron ore or barites shall conform to BS EN 12620

or ASTM C 33 requirements.

A maximum size of 9.52mm aggregate shall be added to the mixture to achieve the

required negative buoyancy after submersion in sea water.

The aggregate gradation shall be within the range of values shown in Table 3.2.2

below:-

Mesh size, as per

ASTM C 33

Per Cent Passing

Minimum Maximum

9.52 mm 100 -

4.75 mm 100 -

2.36 mm 80 100

1.18 mm 50 85

600 microns 10 30

300 microns 5 30

150 microns 0 10

Table 3.2.2 Aggregate Grading

N.B:

a. The heavy aggregate shall be clean and free of clay, organic and deleterious

materials.

b. The cleanliness of the aggregate shall be controlled by screening at the crusher.

c. The aggregate shall be stored on paved area to avoid its contamination.

3.3 Water

Water used in the production of concrete shall comply with BS EN 1008. The water

shall be clean and free from oils, acids, alcohols, salts or organic materials. Water that

is potable does not require further testing for compliance.





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3.4 Concrete Mixing

3.4.1 The total amount of chlorides in the concrete mix, calculated as the free calcium

chloride (CaCl2) shall not exceed 0.15% of the weight of cement.

3.4.2 The total amount of sulphates in the concrete mix, calculated as sulphur trioxide

(SO3) shall not exceed 3.5% of the weight of cement.

3.4.3 The constituent parts of the concrete mix shall be weigh-batched using a weigh-

batching plant of suitable design. The weigh-batcher shall be accurate to within 2%

of the indicated values.

3.4.4 A water gauge accurate to within 3% of the indicated values shall be used for

adding water to the mix.

3.5 Reinforcement

3.5.1 The reinforcement shall be manufactured from high quality billet steel conforming to

ASTM A 810 or approved equivalent, formed into galvanized wire mesh/fabric

reinforced type. The wire shall be galvanized before weaving.

3.5.2 The resultant proportion of reinforcement shall not be less than 0.5% of the cross

sectional area of the weight coat taken in the plane perpendicular to the longitudinal

axis of the pipe and shall be not less than 0.08% of the circumferential axis of the

pipe as given in DNV-OS-F101.

3.6 Curing Compound

The curing compound shall be of a type approved by ADMA-OPCO and shall be

evenly applied over the complete surface of the concrete. The curing compound shall

be prepared and applied in strict conformity with the manufacturer's written

instructions.

The compound performance shall conform with ASTM C 309. Data sheets shall be

submitted for ADMA-OPCOs approval.





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4. PROPERTIES OF THE CONCRETE WEIGHT COATING

4.1 Concrete Mix Design

4.1.1 Concrete mixes shall be carried out in such a way that the required densities and

strengths are obtained. To this end full details shall be furnished as follows:-

a. The proportion and weights of the respective dry aggregates.

b. The cement weight per cubic meter of concrete.

c. The volume of water per cubic meter of concrete.

d. The results of preliminary tests for water absorption.

e. The density of the proposed mix.

4.1.2 The component parts of the concrete shall be properly mixed to provide a

homogenous and consistent mix. A number of mixes with different gradings, cement

contents and water ratios shall be tested until the correct mix is attained.

4.1.3 The proposed composition shall meet the minimum mechanical strengths and water

absorption specified and shall ensure easy and satisfactory application of the concrete

coating.

4.1.4 The water/cement (W/C) ratio should not exceed 0.40 and shall not be less than 0.25,

the cement content should not be less than 400 kg/m3.

4.2 Batching Plant Accuracy

The batching plant and water gauge accuracies should be within 3%. Calibration

should be checked weekly during production.

5. APPLICATION

5.1 Pipe Length Preparation

5.1.1 Prior to placing of reinforcements and anode bracelets, the whole anti-corrosion

coating of each pipe length shall be visually inspected and if damages are found, they

shall be repaired to the ADMA-OPCO approved specification before starting the

placing of any concrete.

5.1.2 After repairs, the anti-corrosion coating shall be electrically inspected using a holiday

detector with minimum 20,000 volts.

5.1.3 At the beginning of each work period, the length of the detector's spark shall be

calibrated on sample with a known defect.





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5.1.4 The appropriate output voltage shall be established either by:-

a. Positioning the electrode away from the bare steel, the same distance as the

coating thickness and increasing the voltage until a spark jumps the gap.

b. Using a spark gap setter.

5.1.5 The minimum operating voltage of the detector shall be maintained at or above the

established level throughout the testing works.

5.1.6 The maximum operating voltage for the electrode shall be established such that no

damage to sound coating is caused, and this value shall not be exceeded during the

testing.

5.1.7 Pipes requiring mid-section supports, when so required during concrete placing, shall

be adequately supported to prevent undue flexure during coating.

5.1.8 The installation of anodes shall be performed in accordance with Clause 11.1.2 prior

to the placing of concrete.

5.2 Installation of Reinforcement

5.2.1 The galvanized wire reinforcement shall be carefully placed around the pipe without

causing damage to the anti-corrosion coating.

5.2.2 The resultant proportion of reinforcement shall not be less than 0.5% of the cross

sectional area of the weight coat taken in the plane perpendicular to the longitudinal

axis of the pipe and shall be not less than 0.08% of the circumferential axis of the

pipe.

5.2.3 A minimum overlap of 25 mm is required for the spirally wound reinforcement.

5.2.4 A single wrap of reinforcement can be applied if the concrete coating thickness is

50mm or less. This wrap shall be a minimum of 15mm from the outside surface of the

anti-corrosion coating except at the start of the winding operation. A double wrap of

reinforcement shall be applied if the concrete coating exceeds 50mm.

5.2.5 Additional wraps of reinforcement may be required to be applied for thickness in

excess of 102mm. The number of additional wraps shall be determined in agreement

with ADMA-OPCO according to the minimum cross sectional areas required by this

specification and would be as shown in the Data Sheet, see Appendix-B of this

Specification.

5.2.6 The external wire mesh wrap shall have a minimum of 15mm of concrete cover.

5.2.7 The concrete coated pipe shall be tested with an ohm-meter to ensure that there is no

contact between the wire reinforcement and the pipe or anode.





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5.2.8 Should the Contractor propose alternative reinforcement, then it shall be

demonstrated to the satisfaction of ADMA-OPCO that it provides similar benefits to

the reinforcement specified above. The Contractor shall, specify the alternative type

of reinforcement and the methods to be used to prove the adequacy of the alternative

design, for acceptance by ADMA-OPCO.

5.3 Placing of the Concrete Weight Coating

5.3.1 General Method

a. The concrete coating shall be placed by impingement. In all cases, each pipe joint shall be coated in a continuous operation and in such a manner that the concrete is

applied uniformly throughout the total length and free from any abrupt

irregularities or variations in thickness.

b. If more than one application is required, the total time allowed for the completion of the operation shall not exceed 30 minutes.

c. The application method in all cases, shall ensure that the concrete coating satisfies the minimum requirements of this Specification for:-

c1. Concrete coating sizing and shaping.

c2. Concrete coating specific gravity.

c3. Concrete coating water absorption.

c4. Concrete coating compression strength.

c5. Emplacement of reinforcement.

c6. Negative buoyancy.

5.3.2 Pipe Length with Anodes or Mid-Section Supports

a. The placing of concrete coating on those pipe lengths which have anodes attached or mid-section supports shall be performed in such a way so that the concrete

coating is terminated 30mm from the anode or mid-section support.

b. The procedure for handling this pipe before and after concrete application shall be submitted for ADMA-OPCO approval.

c. The procedure for coating small diameter pipe with mid-section supports shall be submitted for ADMA-OPCO approval.

5.3.3 Time Limitations

In all cases, the time interval from adding water to the mix and final placing of the

concrete shall not exceed 30 minutes.





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Concrete placing shall be completed as quickly as possible and the surface of the

concrete covered to prevent rapid evaporation.

5.3.4 Curing of the Concrete

a. The curing compound shall be applied to the exposed surfaces immediately after concrete application and shall be evenly applied over the complete surface of the

concrete. The curing compound shall be prepared and applied in strict conformity

with the manufacturers written instructions. Number of coats shall be determined and applied as per manufacturers recommendation to ensure complete coverage. Data sheets shall be submitted for ADMA-OPCOs approval.

b. The use of curing membranes, polyethylene sheet wrapping membranes or coatings shall generally be permitted but the Contractor must provide means to

satisfy the water absorption tests specified in Clause 6.1.2.

c. The concrete coated pipe shall be stored in a single layer for a minimum period of 3 days and until a minimum compressive strength of 2100 psi is achieved.

d. All concrete coated pipes shall be cured for a minimum of 10 days and until a minimum compressive strength of 3850 psi is achieved. No concrete coated pipe

shall be skipped from the coating plant without satisfying both conditions unless

otherwise specified by ADMA-OPCO.

5.3.5 Reclaimed/Rebound Material

The amount of reclaimed material used shall not exceed 5 percent of total mix by

weight and shall not be added in an even flow during continuous coating operation.

The reclaimed material is used within less than 10 minutes from the time when it was

originally mixed.

5.3.6 Cutback

The non-concrete coated section "cutback" at the ends of each pipe length shall

typically be 300mm to 330mm, the cutback may extend to 400mm to satisfy the

requirement of welding machine in case of automatic welding. The ends and inside of

the pipe shall be free of concrete debris. The cutback should be square shoulder

section unless otherwise specified by the project requirements.

5.3.7 Tolerances

The concrete coating shall be concentric with the pipe and have a thickness equal to

the nominal thickness calculated from the specified pipe dimensions and required

submerged weight taken from pipeline data sheet.





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6. TESTING AND INSPECTION OF CONCRETE

6.1 Testing

6.1.1 Compressive Strength and Density of the Concrete

a. The concrete coating compressive strength shall be checked by means of test cubes and core samples.

b. Minimum dry densities measured after a minimum of 10 days shall be 3040 kg/m3

(190 lb/cu.ft).

c. The method of determining dry density must be provided for ADMA-OPCO approval.

d. No change will be authorized without the written approval of ADMA-OPCO.

e. The compressive strength shall be a minimum of 3600 psi at 7 days and a minimum of 5000 psi at 28 days. The strength shall be measured on test cubes and

core samples as follows.

e1. Cube Samples

Cube samples shall be taken every 4 hours at every mix change and after every

shutdown period with a minimum of 2 cubes samples taken per occurrence.

e2. Core Samples

e2.1 Where the coating is applied by the impingement or "Compression Coat"

processes the concrete strength shall be determined by removing 1 core from

the coating on one pipe to be selected from every ten pipes by ADMA-OPCO.

The cores shall be extracted using a diamond core cutter modified to ensure

that the core is cut perpendicular to the coating surface. Cores shall be

removed in such positions that the main reinforcement will not be

damaged. Should the main reinforcement be damaged then that section of

weight coating shall be removed and recoated, or repaired by agreement with

ADMA-OPCO. The core cutter shall have a positive depth of cut limit stop

fitted to ensure that the core barrel cannot penetrate to within 8 mm of the

pipe wrapping.

e2.2 At least 2 core samples shall be drilled from the concrete weight coating on

every 20th pipe length.

e2.3 The diameter of core specimens shall be at least 50mm (preferably 75mm). A

single core diameter shall be used throughout the job.





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e2.4 The height to diameter (h/d) ratio shall be, as nearly as practicable, equal to

2.0. A core having a height of less than its diameter (h/d 1.0) after capping

shall not be tested.

e2.5 Evaluation of test results shall be carried out in accordance with BS EN

12504-1 or ASTM C42

e2.6 For samples failing these tests, 2 more samples shall be cored and tested. If

the test on these 2 samples fails, no more samples shall be taken, and the

concrete shall be rejected.

e2.7 All pipe lengths on which such tests indicate that the concrete does not reach

the minimum specified values shall be rejected.

e2.8 The coring procedure and method of evaluation shall be subject to the

approval of ADMA-OPCO. The equipment used must include positive means

to ensure that the depth of cut leaves at least 8mm of undamaged concrete

between the coring tool and the anti-corrosion coating.

e2.9 Core holes shall not be filled without prior inspection by ADMA-OPCO.

e2.10 The method of refilling core holes is subject to the approval of ADMA-OPCO

and shall be in line with the requirements of Clause 6.2.4 of this specification.

6.1.2 Water Absorption Test

a. The water absorption test procedure shall be submitted to ADMA-OPCO for approval.

b. A water absorption test shall be carried out at the beginning of production and subsequently on one pipe in every 150 pipes.

c. Further water absorption tests shall be carried out in the laboratory on cube and core samples.

d. The water absorption shall not exceed 5%.

e. Water absorption exceeding 5% shall result in rejecting all pipe lengths represented by the test.

6.1.3 Location of Reinforcement

a. At the centre of the first pipe of each production shift a water jet shall be used to clear away the freshly placed concrete down to the anti- corrosion coating for an

area approximately 50mm wide and 200mm long in the longitudinal direction.

This exposed area (slot) shall be used to confirm that the reinforcement is

positioned and covered with the concrete as specified.





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b. If the reinforcement is not positioned correctly, the pipe shall be rejected and recoated. Each pipe in succession shall be inspected in this manner until the

position of the reinforcement is acceptable. The repair of the inspection slot shall

be as specified in Sub-section 7.1 of this Specification.

6.1.4 Weight Control

a. Pipe lengths shall be weighed using calibrated load cells. Calibration certificates for weighing equipment shall be provided for approval by ADMA-OPCO.

b. At least once every shift, all weighing equipment used during the concrete coating operations shall be calibrated against a standard test weight of the same order of

magnitude as a concrete coated pipe length.

c. The weighing procedure shall be subject to approval by ADMA-OPCO.

6.1.5 Negative Buoyancy

a. Each pipe length shall be weighed immediately before and after concrete coating. Girth measurements at approximately 5 equidistant locations shall be taken, in

order to calculate the average girth.

b. The maximum permitted tolerances on negative buoyancy are for each pipe length, with or without an anode shall be as follows: -

b1. Single pipe -2 % +10 %.

b2. Shift Production -0 % +5 % calculated on the specified negative buoyancy.

c. The negative buoyancy requirements are based on concrete in the as-applied condition, and not on concrete in a fully saturated condition.

d. The formulae to be used in calculating the "as applied" negative buoyancy is as given in Appendix- A of this Specification.

N.B:

a. If the pipe requires additional concrete to increase the weight or thickness, the

additional concrete shall be added within 30 minutes after the first concrete was

applied.

b. If the tolerances and conditions cannot be obtained, the pipe over its full length

shall be stripped and recoated.

c. For each pipe size and concrete thickness negative buoyancy limits based or

pipeline data sheet shall be calculated and submitted for ADMA-OPCO approval.

d. Separate procedure for weighing concrete coated and anode fitted pipes, and

determination of negative buoyancy and density of weight coating shall be

submitted for ADMA-OPCO approval.





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6.1.6 Cleanliness

Testing and inspection shall include regular check of cleanliness and grading of

aggregates e.g. every third day during production.

6.2 Inspection

6.2.1 Every length of coated pipe shall be non-destructively tested, not less than 3 days

after coating, by such means as "ringing" to determine whether any defects are

present.

6.2.2 Where this procedure indicates faulty coating, the Contractor shall remove cores from

the suspected pipe. If these cores indicate defective concrete coating the, Contractor

shall remove the coating by a method agreed with ADMA-OPCO. The coating shall

not be replaced without the agreement in writing of ADMA-OPCO.

6.2.3 Areas where coating has not adhered during placement or has been damaged

subsequently (in particular the ends of the concrete coating), may be patch repaired

by hand where the area of defective coating is not in excess of 0.1 sq. metre in any 1

metre length of coated pipe. Any more extensive damage shall cause that section of

pipe coating to be rejected.

6.2.4 Patching shall be carried out only by removing the affected coating down to at least

the reinforcement level, taking care not to damage the reinforcement, and making

good the cavity using a similar mix to that used in the coating process with the

addition of just sufficient water to allow hand application. A bonding agent or

additive agreed by ADMA-OPCO shall be used, in strict accordance with the

manufacturer's instructions. A similar mix shall be used to fill core holes after

inspection of the holes by ADMA-OPCO.

6.3 Qualification Tests

Qualifications tests shall be performed in accordance with a procedure agreed

between ADMA OPCO and the concrete coating Contractor and witnessed by the

Third Party Agency.

6.4 Inspection and Test Plan

The Inspection and Test Plan shall be developed by the coating Contractor and

approved by the Third Party Agency.





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7. REPAIRS AND CAUSES OF REJECTION

7.1 Repair of Spalling

7.1.1 If spalling, due to impact or from improper application of the concrete is found to be

not more than 25% of the depth of the coated surface. The following repairs shall be

undertaken for each pipe length:

a. If the damage zone is less than 1000 cm 2

no repairs shall be undertaken.

b. If the damage 2 surface is between 1000cm2 and 3000cm

2, the concrete coating

shall be repaired as follows:-

b.l The concrete coating on the damaged area shall be removed until the

reinforcement is visible and shall be undercut to ensure that a key lock is formed.

Sufficient cover to the corrosion protection layer (min. 10mm) shall be

maintained.

b.2 The edges of the damaged zone shall be trimmed square.

b.3 Fresh concrete shall be gunnited into the hole until the surface is at the same level

with the surrounding coating around the repair.

b.4 The repaired area shall be protected and properly cured to prevent rapid

evaporation.

b.5 The pipe shall be allowed to cure for a minimum of 48 hours.

c. If the damage exceeds 3000 cm2, the coating shall be removed down to the

corrosion coating on the entire periphery of the pipe at the damaged area. If

damaged wire reinforcement shall be replaced. The cavity shall be refilled with

fresh concrete of the required density as per the requirements of Sub-section 5.3

of this Specification.

7.1.2 If the depth of the spalled area exceeds 25% of the coating depth and the damage is

less than 500cm2 and does not expose the anti-corrosive coating, then the procedure

in Clause 7.1.b shall be followed. For damaged zones of 500cm2 or more, the

procedure specified in point (c) above shall be followed.

7.2 Cracking

7.2.1 Every effort shall be made to avoid concrete cracking during handling or stockpiling

operations.

7.2.2 The following cracks shall be repaired:

a. Deep cracks exceeding 1.6mm in width and extending for 180 or more

circumferentially around the pipe.

b. Cracks over 30 cm in length longitudinally along the pipe, irrespective of width.





22


7.2.3 Repairs shall be made by chiselling out the crack to a width of at least 2.5cm

throughout the length of the crack. The crack shall then be refilled with fresh concrete

having a density equal to that originally applied. A suitable additive to render the

concrete shrinkage free shall be used. However, the additive type shall be approved

by ADMA-OPCO prior to its use.

The pipe shall then be allowed to cure for a minimum of 48 hours.

7.3 Causes for Rejection

Causes for rejection of the concrete coating shall include, but not be limited to, the

following:-

7.3.1 Negative Buoyancy

Negative buoyancy less than or greater than the tolerances allowed in Clause 6.1.5 of

this Specification.

7.3.2 Concrete

Concrete which does not meet the specified requirements.

7.3.3 Reinforcement

Improper placement of the reinforcement.

7.3.4 Spalling

a. If the damage of the surface extends to the anti-corrosive coating. A holiday

detection shall be made of the anti-corrosion coating before the concrete is re-

applied.

b. If the damaged zone is more than 3000cm2.

7.3.5 Handling

Pipe coating damaged during handling operations shall be treated as per Sub-section

7.1 of this Specification.





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8. DOCUMENTATION AND REPORTING

8.1 Production and Test Reports

The Contractor shall submit to ADMA-OPCO for approval example of all reports

required to document accurately the production, testing and reporting.

As a minimum, the following shall be recorded for each and every pipe length:

a. Serial number.

b. Length meters.

c. Condition of end bevels and surface receipt.

d. Weight (bare) (kg).

e. Weight after concrete coating (kg).

f. Fitted with anode if applicable.

g. Date and time of placement of coating.

h. Calculated fully saturated negative buoyancy.

i. Details of water absorption test.

j. Concrete details including;

j.l Quantity and type of cement, sand & aggregate,

j.2 Quantity of water and density of mix,

j.3 Crushing strength,

j.4 Thickness of coating.

k. Conditions of end bevels on shipping.

l. Colour Code.





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9. MARKING OF CONCRETE WEIGHT COATED PIPE

9.1 Colour Identification

Contractor shall propose the colour coding requirements.

It shall be necessary to ensure that every concrete coated pipe has at one end indelibly

marked circumferential band to show the specific gravity.

10. STORING AND HANDLING CONCRETE WEIGHT COATED PIPE

10.1 Handling of Pipe after Coating

10.1.1 After completion of the concrete weight coating the pipe shall be carefully handled

during removal from the coating machine to the curing yard.

10.1.2 The pipe shall remain in a single layer for a minimum of 3 days before being removed

from the curing yard and until a minimum compressive strength of 2100 psi is

achieved.

10.1.3 The maximum allowable stacking heights of concrete weight coated pipe shall be

determined so that no pipe is overstressed and coatings are not damaged.

10.1.4 Pipe with anodes fitted shall always be stacked on the top of the stockpile, without

exception.

10.2 Handling of Pipe for Load-out

The procedure for handling concrete weight coated pipe to an appointed load-out

location and loading onto trucks, barges or supply boats shall be subject to prior

approval by ADMA-OPCO.

10.3 Pipe Handing Over Certification

It shall be necessary on completion of all load-outs, to issue, in respect to each and

every pipe, a "Pipe Handing Over" certificate.





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11. CATHODIC PROTECTION (SACRIFICIAL ANODES)

Cathodic Protection shall be in accordance with ADMA-OPCO Specification SP-1053 and

the following:-

11.1 Anodes

11.1.1 Number and Location

When a single anode is to be installed, it shall be placed approximately at the mid

point of the pipe.

Where two anodes are to be installed on a pipe they shall be placed at approximately

1/3 of the pipe length from each pipe end.

11.1.2 Installation

Each anode must be securely attached so that it cannot be rotated and no damage

should be inflicted to the corrosion coating. After bolting the straps must be

tackwelded to insure continuity. The anode external diameter should be the same as

the concrete coating and must not protrude beyond the weight coating thickness.

11.2 Method of Attachment

11.2.1 Electrical Connections

Connections shall be made by connecting strips, which are to be bolted or welded

between the 2 halves of the anode bracelet.

Each half bracelet shall be attached to the pipe by two 16mm2 diameter double layer

PVC insulated copper cables.

Connections shall be made to the ADMA-OPCO approved thermo weld method.

11.2.2 Coating of Anodes and Connections

After completion of the connections and testing of the electrical continuity, two pack

patching compound / paint shall be applied, to the connecting strips.

11.2.3 Concrete Weight Coating Application

Concrete weight coating shall be applied in the same manner as for the pipe without

bracelets, except that the concrete coating is terminated 30mm from each side of the

anode. The gap shall be filled with HDPUF infill material to same diameter of

Concrete Coating. Same concrete mix may be used as a filler material between the

anode and the concrete coating after ADMA OPCOs approval.





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11.3 Testing and Inspection

11.3.1 An electrical continuity test shall be performed prior to the coating of the connection

strips.

11.3.2 On completion of concrete weight coating, a further electrical continuity test shall be

performed to confirm that there is no contact between the reinforcement wire and the

anodes.

11.4 Storing, Stacking and Handling of Pipe with Anodes Fitted

11.4.1 Storing & Stacking

a. Stacking calculations shall be provided for ADMA-OPCOs approval.

b. Concrete coated pipe shall be stacked only after the concrete has attained the minimum required design strength.

c. The pipe shall be stacked on a minimum of two loose graded sand windrows at least 15 cm deep and not less than 2 m wide (each), approximately 7 m apart, and

shall not be separated by bearers.

d. The pipe shall be carefully lowered to limit impact effects and stacked in such a way that water, mud and sand cannot accumulate within the pipe.

e. Pipe with anodes fitted shall be carefully removed from the curing yard and stacked on top of the stockpipe.

11.4.2 Handling

In the case of small diameter pipe, it shall be necessary to utilize a three point lifting

system. Contractor shall submit to ADMA-OPCO all calculations related to the

number of lifting points to utilize.





27


APPENDIX-A: CALCULATION OF NEGATIVE BUOYANCY

A1 Formula for Computing "As Applied" Negative Buoyancy for Concrete Fitted

Pipe

Definitions

L = Length of the Pipe Joint, m.

Ll = Length of the cutback, mm (assumed same for anti-corrosion

coating and weight coating).

D = Outside pipe diameter, mm

Dl = Outside pipe diameter, including anti-corrosion coating, mm.

D2 = Outside pipe diameter, including weight coating, mm.

W = Weight of the pipe joint, including anti-corrosion coating, kg.

Wl = Weight of the pipe joint, including weight coating, kg.

B = Buoyancy of the pipe joint in sea water, kg.

Sea = Density of seawater, (1031 kg/m 3).

Conc = Density of weight coating, kg/m 3

NB: Refer to Fig. 6.1.

Computations

1. Dry weight of the pipe joint = Wl.

2. Buoyancy of the pipe joint:

B = Sea D22 (L - 2Ll )+ D2 x 2L1 4 1000 1000 1000 1000

3. "As applied" negative buoyancy:

WSUB = Submerged weight.

= Negative buoyancy.

= (W1 - B)/L. kg/m.

If required, the density of "as applied" weight coating and the specific gravity of the

pipe joint can be checked as follows:-





28


Density of weight coating

conc = density of weight coating.

= Wl - W x 4 X 106 x 1 kg/m

3

D22

-Dl2

(L - 2L1)

1000

Specific Gravity of the Pipe

SG = Wl

B

Figure 6.1

Concrete Fitted Pipe





29


A2 Formula for Computing "As Applied" Negative Buoyancy for Anode Fitted &

Concreted Pipes

Definitions

L = Length of the Pipe Joint, m.

Ll = Length of the cutback, mm (assumed same for anti-corrosion coating

and weight coating).

LA = Length of Anode mm.

D = Outside pipe diameter, mm

Dl = Outside pipe diameter, including anti-corrosion coating, mm.

D2 = Outside pipe diameter, including weight coating, mm.

DA = Outside diameter of Anode.

W = Weight of the pipe joint, including anti-corrosion coating, kg.

Wl = Weight of the pipe joint, including weight coating, kg.

B = Buoyancy of the pipe joint in sea water, kg.

sea = Density of seawater, (1031 kg/m3).

Conc = Density of weight coating, kg/m3

NB:

Refer to Fig. 6.2.





30


Computations

1. Dry weight of the pipe joint = Wl.

2. Buoyancy of the pipe joint:

B = Sea D22 (L - 2Ll-LA )+ D2 x 2L1 + DA2 x LA 4 1000 1000 1000 1000 1000 1000

3. "As applied" negative buoyancy:

WSUB = Submerged weight.

= Negative buoyancy.

= (Wl - B)/L. kg/m.

If required, the density of "as applied" weight coating and the specific gravity of the pipe

joint can be checked as follows:-

Density of weight coating

conc = density of weight coating.

= Wl - W x 4 X 106 x 1 kg/m

3

D22

- D12 (L - 2L1-LA)

1000

Specific Gravity of the Pipe

SG = Wl

B





31


Figure 6.2

Concrete /Anode Fitted Pipe





32


APPENDIX-B: CONCRETE COATING DATA SHEET





33


APPENDIX-C: ABBREVIATIONS

Abbreviation Description

ADMA-OPCO Abu Dhabi Marine Operating Company

HDPUF High Density Polyurethane Foam

QA Quality Assurance

QAS Quality Assurance System

QC Quality Control

QMS Quality Management Systems

SI Systeme International dUnites

TPA Third Party Agency





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APPENDIX-D: DEFINITIONS

D.1 General Definition

Term Definition

Contractor Is the Company contracted to undertake the works of a Project and is

accountable to ADMA-OPCO's or its nominated representative.

Quality Assurance

All those planned and systematic actions (QA) necessary to ensure quality

i.e. to provide adequate confidence that a product or service will be fit for

its intended purpose.

Quality Manual A Document setting out the general quality policies, procedures and

practices of an organization.

Quality Plan A document prepared by the Contractor/Vendor setting out the specific

quality practices, resources and activities relevant to a particular project.

Quality

Management

System

The structure organization, responsibilities, activities, resources and events

that together provide organized procedures and methods of implementation

to ensure the capability of the organization to meet quality requirements.

TPA Is the Company contracted to undertake the Third Party Inspection &

Verification Tasks (TPA) on behalf of ADMA-OPCO.

Vendor

Is the named Manufacturer or Supplier in the ADMA-OPCO Purchase

Order. The term Vendor as used herein includes all Manufacturers and sub-suppliers of equipment covered by this Document.





35


APPENDIX-E: REFERENCED DOCUMENTS

Unless otherwise specified, the latest edition of the Standard Engineering Documents listed below

shall to the extent specified herein, represent part of this document.

Designation Title

ADMA-OPCO

CP-102 Third Party Inspection and Certification Requirements for New Equipment

and Materials in Manufacture.

MNL-01 Painting Manual

SL-001 Status List for ADMA-OPCO Standard Engineering Documents.

SP-1009 Requirements for Contractors Quality Systems on Major Projects

SP-1053 Cathodic Protection of Submarine Pipelines

STD-00 Part-1: Measurements Units

Part-2: Site Condition & Data

British Standards Institution (BSI)

BS EN 10204 Metallic Products Types of Inspection Documents.

BS 410 Specification for test sieves.

BS 812 Testing Aggregates

BS EN 1008

Mixing Water for Concrete - Specification for Sampling, Testing and

Assessing the Suitability of Water, Including Water Recovered from

Processes in the Concrete Industry, as Mixing Water for Concrete

Supersedes BS 3148:1980

BS EN 12390 Testing Hardened Concrete

BS EN 12504-1 Testing concrete in structures Part 1: Cored specimens Taking, examining

and testing in compression

BS EN 197-1 CEMENT Composition, Specifications and Conformity Criteria for Common Cements

BS EN 12620 Aggregates for concrete

International Organization for Standardization (ISO)

ISO 9001 Quality Management Systems - Requirements.

ISO 21809-5 External Concrete Coating





36


APPENDIX-E: REFERENCED DOCUMENTS (CONTD)

Designation Title

ASTM

ASTM A 810 Standard Specification for Zinc-Coated (Galvanized) Steel Pipe Winding

Mesh

ASTM C 33 Specification for Concrete Aggregates.

ASTM C 150 Specification for Portland Cement.

ASTM C 171 Standard Specification for Sheet Materials for Curing Concrete

ASTM C 309 Specification for Liquid Membrane-Forming Compounds for curing

concrete.

Det Norske Veritas (DNV)

DNV-OS-F101 Offshore Standard: Submarine Pipeline Systems