CW9: PART 3

TECHNICAL SPECIFICATION FOR

CONCRETE COATING OF PIPES
PART 3 - THRUST BORING COATINGS
APRIL 1993
J017 ( Rev 08/98 )
.
CW9: PART 3
J017 ( Rev 08/98 ) - i -
CONTENTS
Page
FOREWORD iii
BRIEF HISTORY iv
1. SCOPE 1
2. REFERENCES 1
3. DEFINITIONS 1
4. MATERIALS 1
4.1 Concrete coating 1
4.2 Reinforcement materials 2
4.3 Curing membrane 2
5. SUITABLE ANTI-CORROSION COATINGS 2
6. DESIGN REQUIREMENTS OF THE CONCRETE COATING 2
6.1 Reinforcement design 2
6.2 Concrete mix 2
6.3 Compressive strength of concrete 3
6.4 Concrete thickness 3
6.5 Butt joints 3
7. CONCRETE COATING PROCEDURE 3
7.1 Anti-corrosion coating 3
7.2 Positioning of reinforcement 4
7.3 Placing of concrete mix 4
7.4 Curing of concrete coating 4
8. STORAGE AND TRANSPORT OF CONCRETE COATED PIPE 5
8.1 Uncured coatings 5
8.2 Cured coatings 5
9. INSPECTION AND TESTING 5
9.1 General 5
9.2 Test voltage for holiday detection 5
9.3 Reinforcement 5
9.4 Electrical isolation tests 6
CW9: PART 3
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Page
9.5 Checking of concrete 6
10. CAUSES FOR REJECTION 7
11. VARIANTS 7
APPENDICES
A LIST OF REFERENCES 9
B REPAIRS TO CONCRETE COATINGS 11
CW9: PART 3
J017 ( Rev 08/98 ) - iii -
FOREWORD
This specification has been adopted by Transco and is an editorial revision of the former British Gas TransCo
specification GBE/CW9: Part 3. It reflects the identity and organizational structure of Transco - a part of BG
plc.
This Transco specification has been approved for use throughout Transco.
Comments and queries regarding the technical content of this Transco specification should be directed to:
Lead Engineer
Transco
Norgas House
PO Box 1GB
Killingworth
Newcastle upon Tyne
NE99 1GB
Further copies of this Transco specification can be obtained from Dataform Print Management using the print
requisition form G004 quoting the Form Number of this Transco engineering document (not the designation)
and your cost code.
Transco engineering documents are revised, when necessary, by the issue of new editions. Users should
ensure that they are in possession of the latest edition by referring to the Transco Register of Engineering
Documents available on the Transco Information Library.
Compliance with this engineering document does not confer immunity from prosecution for breach of statutory
or other legal obligations.
Contractors and other users external to Transco should direct their requests for further copies of Transco
engineering documents to the department or group responsible for the initial issue of their contract
documentation.
DISCLAIMER
This engineering document is provided for use by Transco and such of its contractors as are obliged by the terms
of their contracts to comply with this engineering document. Where this engineering document is used by any
other party, it is the responsibility of that party to ensure that the engineering document is correctly applied.
CW9: PART 3
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BRIEF HISTORY
First published as BGC/PS/CW9: Part 3
Amended issue published as GBE/CW9: Part 3
October 1983
April 1993
BG plc 1993
This Transco specification is copyright and must not be reproduced in whole or in part by any means without
the approval in writing of BG plc.
CW9: PART 3
J017 ( Rev 08/98 ) - 1 -
TECHNICAL SPECIFICATION FOR
CONCRETE COATING OF PIPES
PART 3- THRUST BORING COATINGS
1. SCOPE
This Part 3 of Transco Technical Specification* CW9 deals with the quality of materials, mix and finished
profile of concrete coating applied to pipe used in thrust boring operations. The purpose of such concrete
coatings is to protect the anti-corrosion coating on the pipe during the thrust boring operations.
* Hereinafter referred to as 'this specification'.
The concrete coatings may be applied using factory impingement techniques or on site using guniting or
preformed moulds.
2. REFERENCES
This specification makes reference to the documents listed in Appendix A. Unless specified otherwise the
latest editions of the documents, including all addenda and revisions, shall apply.
3. DEFINITIONS
For the purposes of this specification the following definitions shall apply:
Transco: Transco plc.
Contractor: the person, firm or company with whom Transco enters into a contract to which this
specification applies, including the contractor's personal representatives, successors and permitted assigns.
4. MATERIALS
4.1 Concrete coating
4.1.1 General
Concrete coating shall comply with BS 8110 unless superseded by this specification.
4.1.2 Cement
Portland cement used in the preparation of the concrete shall conform to BS 12 and BS 1370.
Sulphate-resisting cement shall conform to BS 4027.
4.1.3 Aggregate
In general, aggregates used shall comply with BS 882.
The aggregate shall be washed and from a natural source. Tests on aggregate shall be in accordance with
BS 812.
4.1.4 Sand
All sand used shall comply with BS 882.
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4.1.5 Water
All water used in the preparation of concrete shall be potable (see also 9.5.2). Water from the intended source
of supply shall initially be tested for purity in accordance with BS 3148. Water from any other source shall
not be used without a test for purity being carried out.
4.2 Reinforcement materials
4.2.1 Reinforcement shall conform to BS 4449 or BS 4483.
4.2.2 Reinforcement spacers shall be non-metallic, non-hygroscopic, electrically insulating and have
sufficient base area to prevent damage to, or penetration of, the anti-corrosion coating.
4.3 Curing membrane
The curing membrane shall conform to either of the following:
a) Polyethylene wrap: thickness of material shall be not less than 500 gauge and overlaps not
less than 50 mm.
b) Spray coating: this shall be applied in accordance with the manufacturer's instructions.
5. SUITABLE ANTI-CORROSION COATINGS
Anti-corrosion coatings on pipes which will be subjected to thrust boring operations need to have a high bond
strength to the pipe. Acceptable coatings include fusion bonded powders or urethane tars applied in
accordance with CW6: Part 2. Additionally, consideration shall be given to the use of anti-slip coatings if
there is a possibility of slip occurring between the anti-corrosion coating and the concrete coating.
6. DESIGN REQUIREMENTS OF THE CONCRETE COATING
6.1 Reinforcement design
Reinforcement shall be to a design specified by Transco.
Reinforcement shall be formed and placed in accordance with BS 8110 and with this specification, where
applicable. The reinforcement shall at all times be adequately supported to prevent contact with the pipe and
correctly located by the use of spacers.
Reinforcement shall be electrically isolated from the pipe.
The cut ends of reinforcement shall not penetrate or damage the anti-corrosion pipework coating or contact the
surface of the steel pipework.
Overlaps shall be not less than 50 mm and shall be securely fixed together using malleable mild steel tying
wire or purpose-made clips.
For concrete coating thicknesses equal to or less than 50 mm, one layer of reinforcement shall be applied and
shall be positioned as near to the centre of the thickness of the final coating as practicable.
For concrete coating thicknesses greater than 50 mm, two layers of reinforcement mesh shall be applied. The
inner wrap shall be positioned 15 mm to 20 mm from the surface of the pipework and the outer wrap shall
have 15 mm to 20 mm cover of concrete coating. The two wraps shall be positioned with the necessary size of
spacer standing independently off the pipework surface prior to the application of the concrete.
6.2 Concrete mix
Transco shall specify the limiting parameters, i.e. density, strength, water to cement ratio.
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The Contractor shall design a mix using materials as specified in clause 4 in order to obtain the required
densities and strengths.
Full details of the following shall be made available to Transco:
a) The properties and densities of the respective dry aggregates.
b) The cement weight per cubic metre of concrete.
c) The volume of water per cubic metre of concrete.
d) The density of the proposed mix.
The proposed composition shall meet the minimum mechanical strengths specified in 6.3 and shall ensure easy
and satisfactory application of the concrete coating. The strength of the concrete mix shall be demonstrated,
prior to production commencing, by tests on cubes from trial batches prepared and tested in accordance with
BS 1881: Parts 108 and 116 respectively.
All concrete work shall be in accordance with BS 8110, except where superseded by this specification.
6.3 Compressive strength of concrete
The concrete coating shall have a compressive strength of not less than:
a) 30 N/mm
2
after seven days;
b) 40 N/mm
2
after 28 days.
The compressive strength of the concrete shall be measured by tests on samples taken directly from the mixer,
in accordance with BS 1881: Part 116. Cores may also be required to be taken from the concrete coating on
the pipe if test cube results should be unacceptable (see 9.5.4). No concrete coated pipe shall be used until the
concrete has achieved its 28 day strength.
6.4 Concrete thickness
The thickness of the concrete coating shall be 50 mm unless greater thicknesses are specified by Transco.
In all cases the tolerance on the coating thickness shall be 10%.
6.5 Butt joints
If butt joints are required in a length of pipe to be thrust bored, it is not essential for the infill to be of
concrete. A suitable procedure, selected from CW5 or CW6, for the protection of the butt weld area is
required.
7. CONCRETE COATING PROCEDURE
7.1 Anti-corrosion coating
Holiday detection shall be carried out on clean, dry, anti-corrosion coated pipes immediately prior to the
positioning of reinforcement in accordance with the relevant Transco coating specification. Detected holidays
shall be repaired and retested. The anti-corrosion coating shall not be damaged as a result of any concrete
coating activity.
When concrete is applied by the impingement or gunite technique, pipes coated with fusion bonded powder
shall be protected by the use of a barrier coating (e.g. cold applied wrapping tapes to CW5) or by increasing
the thickness of the fusion bonded powder coating to a minimum total thickness of 625 m
(see CW6: Part 2).
Other types of barrier coatings may be proposed as a variant for consideration by Transco.
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7.2 Positioning of reinforcement
The positioning of reinforcement shall comply with the requirements of 6.1 and 9.3.
7.3 Placing of concrete mix
7.3.1 The concrete coating shall normally be applied by impingement, guniting, spraying or formed by
means of moulds. Other methods may be proposed as a variant for consideration by Transco provided the
requirements of this specification are met.
7.3.2 The concrete coating shall be applied uniformly over the length of pipe to be coated leaving
400 25 mm at either end completely free for jointing purposes. The parts of the pipe with no coating shall be
kept clean and free from concrete, oil or grease, etc.
7.3.3 The ends of the concrete shall be chamfered smoothly at an angle of 65 15
0
to the pipe surface.
7.3.4 The concrete shall be placed upon the pipe within 30 min of the water being added to the mix.
Concreting shall not take place if either of the following temperature conditions prevail:
a) the temperature of the pipe, anti-corrosion coating, reinforcement or concrete mix is less than
3
0
C or greater than 35
0
C;
b) air temperature in the concrete coating application zone is outside the range of -5
0
C to 30
0
C.
7.3.5 The use of reclaimed rebound material shall not be permitted unless the coating is factory applied
and recovery of rebound material is part of the approved process. The amount of such reclaimed material used
shall only be added in an even flow during a continuous coating operation. Rebound material not re-used
within 30 min of water addition shall be discarded.
7.4 Curing of concrete coating
7.4.1 Approval of curing method
The Contractor shall demonstrate the efficiency of the method of curing, particularly under adverse climatic
conditions.
The curing process shall ensure that no moisture loss occurs for a period of seven days after application.
If a plastics membrane is wrapped around the concrete coating as part of the curing process, this membrane
shall be removed on completion of curing.
7.4.2 Steam curing
If steam curing is to be used as part of the process, the Contractor shall demonstrate that the process will have
no deleterious effects upon the concrete. The temperature shall not be allowed to be such that it would cause
damage to the anti-corrosion coating.
If steam curing is to be applied, it shall be commenced within a period of 2 h to 4 h after concrete application.
During the period prior to steam curing, the concrete on the pipes shall not be subjected to temperatures
outside the range 5
0
C to 25
0
C, nor shall the surrounding relative humidity be outside the range 80% to
100%.
A procedure shall be established to ensure that satisfactory conditions prevail until steam curing is applied.
Extreme care shall be given to transporting, moving or lifting pipes until the steam curing is complete.
Steam shall be applied until the concrete has achieved a compressive strength of 10 N/mm
2
. This strength
shall be proven by testing a set of three test cubes which shall be prepared at the same time that the pipes are
coated and cured alongside the pipes. The frequency of cube preparation and testing shall be a part of the
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procedure that ensures correct curing until steam is applied. The temperatures of the pipe and the coating shall
be not higher than 75
0
C at any time during the curing cycle.
The coated pipes in the curing bay shall be supported on the exposed ends of the steel pipes such that all the
concrete coating is subject to the steam cure. Pipes shall be adequately restrained against rolling and shall not
contact each other.
Appropriate thermometers and hygrometers shall be provided and records of readings shall be made available
to Transco.
7.4.3 Controls during curing period
Checks shall be made to ensure that the first seven days of curing takes place in an air temperature range of
3
0
C to 35
0
C. After seven days of curing, the lower air temperature limit may be reduced to -3
0
C. Should
the temperature fall below -3
0
C during the period seven days to 28 days, strength checks shall be carried out.
After 28 days, no ambient storage temperature limits apply.
8. STORAGE AND TRANSPORT OF CONCRETE COATED PIPE
8.1 Uncured coatings
A coated pipe shall not be moved until the concrete coating has achieved its seven day strength. All pipes
shall be carefully handled to avoid damage to the concrete coating. All lifting shall be accomplished from the
steel pipe ends and shall be undertaken at minimum changes of speed so that the coated pipe is not jolted (for
further guidance refer to L3).
Care shall be taken to prevent pipes swinging into obstructions when being lifted. Any means of transport
used shall provide adequate support over the full length of the pipe, so that no damage or disbondment of the
concrete coating occurs. The pipes shall not be vibrated or jolted during transport.
Coated pipes shall be stored individually, supported only at the concrete free ends and avoiding contact with
any other pipe until cured.
Precautions shall also be taken to avoid sudden temperature changes which could cause the concrete to crack.
8.2 Cured coatings
All coated pipes shall be carefully handled to avoid damaging the concrete coating. Fully cured coated pipes
shall not be stored in a manner which may cause damage to the coating or to the steel pipe.
No pipe shall be removed or used until it is fully cured.
9. INSPECTION AND TESTING
9.1 General
Due allowance shall be made by the Contractor to accommodate the necessary inspection and testing
equipment.
9.2 Test voltage for holiday detection
A test voltage in accordance with the relevant coating specification shall be used for holiday detection carried
out in accordance with 7.1.
9.3 Reinforcement
9.3.1 Storage
Reinforcement materials shall be stored under cover and protected against deterioration and damage.
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9.3.2 Positioning
Location of reinforcement on pipe shall be checked throughout production to ensure compliance with 6.1. Any
damage to the anti-corrosion coating during the positioning of the reinforcement shall be repaired before the
concrete coating is applied. Due note shall be taken of the amount of concrete cover over reinforcement
especially at the ends of the coating (see 9.5.5).
9.4 Electrical isolation tests
Electrical isolation tests shall be undertaken to cover the requirements of 6.1 and 9.3 by using a simple
continuity tester, comprising a 6 V or 12 V battery in series with a compatibly rated bulb. The condition of the
battery shall be checked before each test such that the bulb shall emit white light. When the bulb and battery
is connected between the pipe and metal reinforcement, current flow shall not be evident. Any concrete that
has been removed to expose reinforcement shall be repaired in the manner specified in Appendix B.
9.5 Checking of concrete
9.5.1 Cement
The cement being used shall be checked for satisfactory condition and method of storage (see 4.1.1). Relevant
test certificates shall be retained by the Contractor and made available for inspection by Transco.
The cement shall be stored under cover and kept dry. Cement that has deteriorated shall not be used.
9.5.2 Aggregate, sand and water
The grading and purity of sand and aggregate shall be checked twice weekly. The purity of the water shall be
checked before use, in accordance with BS 3148. Test certificates for sand and aggregate shall be retained by
the Contractor.
The sand and aggregate shall be stored on rolled hard core or paved areas.
9.5.3 Proportions of concrete constituents
The Contractor shall demonstrate that the concrete batching and mixing arrangements produce a consistently
high quality of concrete.
The mixing proportions of the concrete constituents shall be checked at least once per day.
The weight of the mix shall be controlled for each operation. The accuracy of measurement shall be checked
at least once per week.
9.5.4 Strength and density of concrete
Inspection and testing during coating operations shall be carried out as follows:
a) Compressive strength and density tests shall be made on test cubes (minimum side of 100 mm)
prepared from samples taken from mixes throughout the day's production.
b) Two sets of three cubes shall be taken every 8 h of production.
c) Cubes shall be tested for density and strength in accordance with BS 1881: Parts 114 and 116
respectively. Testing shall be carried out seven days and 28 days after casting.
d) If low values of compressive strength and density are obtained from the tests on the cubes, the
subsequent course of action shall be implemented and shall be the full responsibility of the
Contractor.
e) Low values of compressive strength and density may be cause for rejection of any day's or part
day's production.
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9.5.5 Concrete coating profile and thickness
Concrete coating shall be applied uniformly over the pipe in accordance with 7.3.2. The thickness of coating
on every pipe shall be checked by a suitable instrument or method. A total of at least 10 check points at four
different radial positions along the length of the pipe shall be selected.
The chamfered ends of the concrete coating shall be checked throughout production for the correct angle, and
reinforcement ends shall terminate within 40 mm to 60 mm of the chamfered end.
9.5.6 Spalling of concrete coating during application
Each length of concrete coated pipe shall be visually checked immediately after the coating operations. Any
spalling or fall out when coating by impingement shall be repaired with a mixture of the same proportions as
the original mix within 8 h of initial coating.
The degree of damage accepted for repair and the repair procedure is specified in Appendix B.
9.5.7 Application and curing
The necessary inspections shall be made to ensure that the concrete application and completed coating is
applied and cured in accordance with the conditions specified in 7.3 and 7.4. Air temperatures, humidity and
general weather conditions shall be recorded and records made available for inspection by Transco.
9.5.8 Defects in concrete coating
Additional checks shall be carried out after seven days for defects in the concrete coating other than curing
defects already detected and repaired.
All coated pipes shall be examined for defects. Voids and bad compaction areas shall be detected by ringing.*
Excessive voids shall be cause for rejection.
* Ringing shall be carried out by using a 1 kg hammer with a minimum striking face of 2000 mm
2
.
Excessive cracking shall be cause for investigation by the Contractor and may be cause for rejection.
Permissible repair procedures for defects are specified in Appendix B.
10. CAUSES FOR REJECTION
Causes for rejection shall include, but not be limited to, the following:
a) Incorrect placement of the reinforcement steel (see 6.1 and 9.3).
b) Inadequate strength of concrete mix (see 6.3 and 9.5.4).
c) Damage to the anti-corrosion coating or unsatisfactory repair of such damage (see 7.1).
d) Coating left in an uncompleted condition for more than 30 min, e.g. due to plant breakdown
(see 7.3.4).
e) Serious damage to concrete coating during handling operations (see clause 8.).
f) Electrical isolation failing to meet specified requirements (see 9.4).
g) Unacceptable thickness measurements of the applied concrete (see 9.5.5).
h) Excessive spalling, voids or cracking (see 9.5.6) when using impingement techniques or
honeycombing; voids or cracking when placing concrete in moulds.
11. VARIANTS
A contractor shall only propose variants to this specification where the text indicates that variants would be
considered by Transco.
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APPENDIX A
LIST OF REFERENCES
This specification makes reference to the documents listed below (see clause 2).
British Standards
BS 12 - Specification for Portland cement
BS 812 - Testing aggregates
BS 882 - Specification for aggregates from natural sources for concrete
BS 1881 - Testing concrete:
Part 108 - Method for making test cubes from fresh concrete
Part 114 - Methods for determination of density of hardened concrete
Part 116 - Method for determination of compressive strength of
concrete cubes
BS 3148 - Methods of tests for water for making concrete (including notes on the
suitability of the water)
BS 4027 - Specification for sulphate-resisting Portland cement
BS 4449 - Specification for carbon steel bars for the reinforcement of concrete
BS 4483 - Specification for steel fabric for the reinforcement of concrete
BS 8110 - The structural use of concrete
Transco specifications
CW5 - Code of practice for the selection and application of field applied
external pipework coatings
CW6 - Specification for external protection of steel pipe and fittings using
resin powder and associated coating systems:
Part 1 - Requirements for coating materials and methods of test
Part 2 - Factory applied coatings
L3 - Code of practice for handling, transport and storage of steel pipes,
bends and tees.
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APPENDIX B
REPAIRS TO CONCRETE COATINGS
B.1 GENERAL
Concrete used for repairs shall contain the same proportions of constituents as the original coating but, for
hand repairs only, a slight increase in water content will be permitted. Prior to application, the defective areas
shall be thoroughly cleaned of loose material and be cut away to ensure a 25 mm minimum thickness of repair
at any point.
The concrete surfaces to receive the repair material shall be well soaked with water complying with 4.1.5.
All repairs shall be carried out within seven days of the application of the concrete coating.
All repairs shall have a seven day cure period and shall meet the full requirements of this Specification.
Damage to the anti-corrosion coating or the pipe during repairs shall result in rejection of the pipe unless such
damage is satisfactorily rectified.
Alternative repair materials may be proposed as a variant for consideration by Transco.
B.2 DAMAGE AFTER TRANSPORT
Areas where the uncured concrete coating has not adhered, or which have been damaged during handling,
shall be repaired provided that the following conditions are satisfied:
a) Repairs shall be satisfactorily completed within seven days of application of the first coating.
b) The area of repair(s) in any 3 m length is not greater than 5% of the concrete surface area of
that 3 m length.
c) Total area of repairs is not greater than 2.5% of the total concrete surface area of the coated
pipe.
B.3 SPALLING OR GENERAL DAMAGE AFTER COATING APPLICATION
Areas where the uncured coating has not adhered or has been damaged shall be repaired by a gunite technique
subject to the following conditions:
a) Spalling repairs shall be satisfactorily completed within three days of application of the first
coating.
b) The area of repair(s) in any 3 m length is not greater than 10% of the concrete surface area of
that 3 m length.
c) Total area of repair(s) is not greater than 2.5% of the total concrete surface area of the coated
pipe.
B.4 VOIDS
Where voids are detected in the concrete coating and do not exceed the following tolerances, they shall be
broken out and repaired:
a) The total area of a void or voids in any 3 m length is not greater than 2.5% of the concrete
surface area of that 3 m length.
b) The total area of all voids in any concrete coated pipe is not greater than 0.5% of the total
concrete surface area of the coated pipe.
Voids greater than the specified tolerances shall be assessed and the coating may be rejected.
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B.5 CRACKING
B.5.1 Where cracks having a width less than 3 mm are detected in a concrete coating, they shall be
investigated to determine if they are associated with any other defect. If there is no association with any other
form of defect, such cracks are acceptable.
B.5.2 Where cracks having a width of between 3 mm and 9 mm are detected, they shall be cut out and
enlarged to a width of not less than 15 mm and to a depth of not less than 25 mm. They may then be repaired
provided that the following conditions are satisfied:
a) For cracks deeper than 25 mm the width of the crack exposed at the bottom of the cut-out shall
be not greater than 3 mm.
b) The repair mix shall be compatible with the original coating mix.
B.5.3 Cracks having a width of between 3 mm and 9 mm and a depth greater than 25 mm which fail to
comply with B.5.2 a) shall be cause for rejection.
B.5.4 Any crack having a width greater than 9 mm shall be cause for rejection.